RAF Tabtronics LLC Overview 2013

www.raftabtronics.com888 876 6424

RAF Tabtronics LLC – OVERVIEW

Creating Cost-Effective Customized Transformers & Inductors for the World’s Leading Power Technology Companies

WHO WE ARE

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VISION: Build the global leader in the custom electromagnetic components industry by leveraging the transformative power of innovation.

QUALITY: We are responsible for, and committed to, delivering reliable products that meet our customer’s delivery, quality, cost and performance objectives with hassle-free service and continuous improvement of our management systems.

TRANSFORMATIVE POWER

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COMPANY HISTORY

Tomter Inc.

Tabtronics Inc.

Chloride Electro Networks (CEN)

RAF Technologies Inc.

RAF Magnetics Inc.

Caledonia Transformer

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• Robert MALKANI, Chairman & CEO

• James TABBI, President & COO

• Susan SCIPIONI, CFO

EXECUTIVE TEAM

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• Victor QUINN, Director of Engineering / CTO

• Dean COX, Supply Chain Manager

• Robert KINDELL, Business Development Manager

• Jason MANN, Quality Assurance Manager

• Glenn MOORE, Plant Production Supervisor (F1)

• Frank SANTUCCI, Plant Production Manager (F2)

LEADERSHIP TEAM

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High-Volume Low Cost SMT Air Coils w/ removable PNP

WHAT WE DO

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OUR SWEET SPOT

• Ultra-high power density magnetic components for high-reliability applications in defense, aerospace, medical, mass-transit and high-grade industrial markets.

Planar Transformer Module for Radar Application

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• Aerospace, Defense & Homeland Security

• Mass-Transit / Commercial Transportation

• Medical Instruments & Devices

• Computer, Electric & Electronic Equipment

• Instruments & Related Equip

• Mining & Exploration

• Industrial Machinery

MARKETS

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Communications SystemsIgnition SystemsControls (Flight, Process, etc.)SensorsLinear & Switch Mode Power SuppliesCurrent & Potential Transformers Radar/SonarVetronicsand many more…

APPLICATIONS

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• F-35 Lightning II (JSF)

• F-22 Raptor

• F-18 Hornet

• F-16 Fighting Falcon

• F-15 Eagle

• F-117 Nighthawk

• B-1 Lancer

• E-3A Sentry (AWACS)

• MRAP

• JLTV

• AIM-9X Missile

• International Space Station

• Space Shuttle

• Boeing SLAM-ER Launcher

• Virginia Class Nuclear Sub

• AEGIS Destroyer

• Comanche Helicopter

• Blackhawk Helicopter

• LAMPS Helicopter System

• Improved Fire Control System (IFCS)

• GE, Rolls-Royce, Pratt & Whitney, BMW & other Jet Engines

HIGH GRADE PROGRAMS

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High Voltage Xfmr for Jet Engine Exciter

High Current Xfmr for Aircraft Power Application

FLORIDA Operations (F1)

• COE for Commercial Aerospace Magnetics

• AS9100C Certified

• J-STD-001 Certified Soldering

• 15,000 sq. ft.

• Glenn MOORE, Plant Supervisor

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ROCHESTER Operations (F2)

• COE for MIL-PRF-27, HV & Hi-Rel Magnetics

• ISO9001 Certified, AS9100C Compliant

• J-STD-001 Certified Soldering

• 30,000 sq. ft.

• 5,000 sq. ft. Encapsulation Facility

• Frank SANTUCCI, Plant Production Manager

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NEAR SHORE OperationsFrank MARTINEZ, Nearshore Operations Quality Engineer

• Central America (F6)

• ISO9001:2008 Certified

• 30,000 sq. ft.

• ~100 direct labor

• ITAR MLA Licensed

• CARIBBEAN (F7)

• Established 2005

• 35,000 sq. ft.,

• ~250 direct labor

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WHO WE SERVE

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CUSTOMER LOYALTY MARKET / PRODUCT

Lockheed Martin 35+ Years Radar, Sonar, Defense Systems

GE Aviation | Unison Industries 30+ Years Jet Engine Exciters/Igniters

HARRIS | RF Communications 25+ Years Secure Communications

ALSTOM | Transport Signaling 25+ Years Rail Transportation Control & Signaling

Moog Inc. 20+ Years Aerospace & Defense Fluid Control

TEKNIC Inc. 15+ Years Machine Automation Systems

GE Aviation | Power Systems 12 Years Aircraft Power & Control

Champion Aerospace 10 Years Jet Engine Exciters/Igniters

BAE Systems EIS 10 Years Defense & Commercial Power Systems

Communications & Power Ind 5 Years Microwave & RF Power Amplifiers

TOP LOYAL CUSTOMERS

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CUSTOMER ENGAGED MARKET / PRODUCT

Wave Technologies IPT 2013 Wireless Charging Technology

Marotta Controls 2012 Power Supply, Conversion and Conditioning

Crane | Aerospace & Electronics 2012 Power Solutions: TWT, TRUs, ATRUs, LVPS

Invensys Rail 2011 Rail Automation & Control Systems

Rockwell Collins 2011 Aircraft Power & Avionics

Parker Aerospace 2010 Aircraft Electronic Controls

Astronics LSI / DME 2010 Aircraft internal, External & Runway Lighting

ITT Exelis | Electronic Systems 2010Defense Electronics / Avionics / Power Systems

DRS Technologies 2010 Defense Targeting, Control & Electronics

IBM / Jabil Singapore 2010 File Server Power Supplies

EXCITING NEW CUSTOMERS

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HOW WE DO IT

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• Dedicated Project Engineer

• Cross-functional Design Review Team

• Flexible, menu based NPD process

• Advanced design tools & methods- 3D Mechanical CAD (Pro-E)

- specialized Magnetics design & optimization tools

- thermal modeling

- simulation

• Sophisticated Process Documentation

• Robust Process Controls

• AS9102 First Article Inspection Reports

ADVANCED DEVELOPMENT PROCESS

3D CAD Model of Transformer in development using Pro-E software.

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• Power supply topologies

- Flyback; Resonant; Buck; Boost; Forward; Bridge

• Winding geometries- planar, annular, hybrid, SESI

- Litz, foil, specialty wire & windings

- conventional

• Magnetic core geometries- all standard shapes & sizes

- custom shapes & sizes

• Magnetic core materials- standard ferrites, powdered iron, MPP, silicon steel, nickel, cobalt alloys, amorphous metals & nanocrystalline

TECHNICAL EXPERTISE

HXMT Planar Transformer for High-Efficiency Solar Array Inverter

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Large Electromagnet (Square Wire on Copper Coil Form)

• HXMT optimizes coil constructions

• Yields optimal configuration to achieve desired functions

• Optimization reduces lost energy within coil

• Transformers operate cooler & more efficiently

• Gives size, weight and cost reduction

• Is based on loss and energy solutions of the diffusion equation for generalized boundary conditions

• Finds hidden value in magnetic components

U.S. Patents: 7506280, 7885787, 7888931

Optimum Thickness Predicted by Hyper-XMT

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

0.00 2.00 4.00 6.00 8.00

Wire Thickness

Watt

HYPER-X MAGNETIC TECHNOLOGY TM

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HIGH GRADE OPTIMIZATION

Conventional Versus HXMTTotal Loss For 12 Turn Winding, 5 δ Thick Limit

Varying Total Layers(results normalized to optimized conventional 1 layer)

0.00

0.20

0.40

0.60

0.80

1.00

1.20

1.40

1 2 3 4Total Layers

Lo

ss

conventional

HXMT

Sum of 10 Harmonics

-2

0

2

0 2 4 6 8

Phase

Am

plitu

de

22% Loss Reduction

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HIGH GRADE ENCAPSULATION

Power Inductor Redesign To Achieve 75 uH @ 300 Adc

0153045607590

105120135150165180

0 50 100 150 200 250 300 350 400 450Bias Current (Adc)

Inc

rem

en

tal I

nd

uc

tan

ce

(u

H)

+118% inductance increase within packageconstraints

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• J-STD-001 certified trainers / solderers– Lockheed Martin Special Process Supplier

• IPC-610 certified inspectors– GE Aviation DSQR

• Hi-grade finishing capabilities– High-vacuum / Pressure Encapsulation

– Impregnation - Special Coatings

– Precision sizing - MIL-Spec Painting

• Hi-grade testing– partial discharge (Corona)

– high-voltage

– thermal shock

SPECIAL PROCESSES

High Voltage (10kV) Transformer for TWT Power Amplifier

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• Military standards- MIL-PRF-27 - MIL-STD-981

- MIL-T-21038 - MIL-STD-1533

- MIL-STD-454 - MIL-STD-83446

• Safety standards- UL, CSA, TUV, VDE, BSI, CE

• Quality & Environmental Standards- AS/ISO, IEC, RoHS

• Technical Data Protection- International Traffic in Arms Regulations

- US/Canada JCP registered

- intellectual property protection

STANDARDS & CONTROLS

UL Listed Commercial Grade Power Supplies for

Motion Control Applications

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• Ongoing collaboration in leading edge Power Electronics• IEEE/APEC Power Technology Roadmap contributor

• Advanced Harmonic Analysis• Coil loss / Core Loss Studies

• Wide band current sensing

• Ultra high operating temperatures• 230 °C, 260 °C, 300 °C +

• High-voltage Planar Magnetics

• Ultra-light high-power Planar Magnetics

• Integrated Magnetics (proprietary)

• Strategic Product Design Partnerships

LATEST INNOVATIONS / CURRENT R&D

SMT 8kW 500kHz PSFB Radar Application

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THE RESULTS

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510-6050: 40 uH INDUCTOR

• Aerospace / Defense• 40 uH Inductor• High Current• Foil Windings• Integrated Heat Sink• Nano-crystalline Tape-Wound

Cores• Proprietary Hi-Temp

Insulation System• MIL-PRF-27 Grade 5

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510-6041: 3-PHASE INDUCTOR ASSY

• Commercial Aerospace• 3-Phase Inductor Assy• Machined Heatsink• Nano-crystalline Tape-

Wound Cores• Designed for minimal size

and weight

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510-6043: SOLAR INVERTER INDUCTOR

• Solar Inverter Inductor• Design Goal: Maximum

Efficiency in given Volume• Bifilar Helical Winding

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C59401: HIGH CURRENT INDUCTOR

• Naval Defense • Multi-filar twisted

windings• High Shock & Vibration

Environment (MIL-S-901)• Anodized Al Heatsinking

Mounts

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568-5220: PLANAR AEROSPACE XFMR

• Aerospace Power Supply • Planar Windings• J-STD-001 Class 3•

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568-6087:Vehicular Power XFMR

• Defense Vetronics • Extremely low

leakage inductance• 5KW, 100 kHz

Bridge XFMR• Planar Geometry

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568-5210: TRAVELING WAVE TUBE XFMR

• Aerospace Defense • High-Voltage TWT

Application• Planar Geometry• 100 kHz

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568-6109: ENERGY TRANSFER XFMR

• Commercial Bus• Contactless

Charging Application• 150 KW 20 kHz

190A• <1000 W

Dissipation• Custom Cores, Coil-

Forms, Terminations, Mounts

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580-6003: 3-PHASE IND/XFMR MODULE

• Defense Missile Launcher Application

• Ultra-High Efficiency• Ultra-Low Weight• Complex

Heatsinking

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599-6012: XFMR/IND ASSEMBLY

• Defense Missile Launcher Application

• Ultra-High Efficiency• Ultra-Low Weight• Complex Heatsinking• Nano-Crystalline Core• Proprietary Insulation

System

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AND MORE…

Railway Sensing Application

Three-Phase Line Filter

Three-Phase High Power Density Aerospace

SMT 8kW 500kHz PSFB Radar Application

High Density Hybrid Planar Transformer

Aerospace Power Supply

High Voltage Medical X-Ray Transformer

High Density SMT Hybrid-Planar Transformer

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• AS9100C & ISO9001:2008 Quality Systems

• Focused, value oriented company

• World-class customers in diverse markets

• Depth of electromagnetic design engineering capability to solve complex customer problems

• Hyper-X Magnetics Technology patents for optimization of magnetic components

• Unique capabilities, expertise, and experience

• Strong technical & management teams

• Strong Business Record

• ITAR & US/Canada JCP registered

• LCC Manufacturing

• MIL-PRF-27 experts

• Commitment to the Customer, first and foremost!

Why RAF TABTRONICS LLC?

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The information in this presentation is proprietary and confidential, and is intended solely for the audience to whom it is delivered. Any disclosure of the information contained in this presentation and in presentation handouts is a violation of

non-disclosure & confidentiality agreements currently in force. © 2010 RAF TABTRONICS LLC 40