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THE MAGAZINE OF TRANSFORMATION IN ELECTRONIC AND OPTICAL TECHNOLOGY

W W W . M I L A E R O . C O M

TRENDS

JULY 2005 VOL. 16, NO. 7

Lead-free processing involves several board issues

Air Force tunes nonlethal directed-energy weapons

Is cooling the central design issue of our time?

JOHN KELLEREditor in Chief

For years now we’ve lived with t h e a s s u m p -

tion that computer processing power —and hence systems capa-bility—doubles about every cou-ple of years. Th is is the essence of Moore’s Law, which has been an electronics maxim for the past four decades.

Few principles in the electron-ics business have been so constant, dependable, and predictable as Moore’s Law, but a sea change in its guidance may be in the offi ng.

Th e problem is heat. Fast elec-tronics and tightly integrated packaging that are typical in em-bedded systems in military and aerospace applications generate substantial amounts of excess heat, and the pace of improve-ments in integrated circuitry is outstripping our ability to remove the unwanted heat. Tightly pack-aged electronics, in fact, are be-coming more commonplace al-most daily.

Gordon Moore, then-director of the Fairchild Semiconductor Research and Development Lab-oratories, fi rst set forth his theory in 1965. He wrote that integrated circuit transistor numbers double every two years. Th at theory holds true today, and has accurately pre-dicted the evolution of micropro-cessors from Intel and many oth-er industry leading lights.

Somehow, circuit designers al-ways have been able to shrink ge-ometries, double the number of transistors on chips, and step up processing power at a rate that val-idates Moore’s Law, despite some naysayers who along the line have insisted that such advancements simply are not possible. Th us far the circuit designers always have proven the skeptics wrong.

Systems designers have come to rely on Moore’s Law in their plan-ning for incremental upgrades. De-signers take it for granted that tech-

Continued on page 42

BY BEN AMESTUCSON, Ariz.—Research-ers with the U.S. Air Force have found a way to deter potentia l at-tackers without shoot-ing or otherwise killing or maiming them.

It is called the Active Denial System, a type of nonlethal, directed- energ y weapon t hat focuses millimeter waves on the skin of a suspicious person. Th e beam causes agonizing pain, but does no lasting damage, they say.

Now Air Force leaders have awarded a $7.5 million con-tract to Raytheon Missile Sys-


BY JOHN KELLERHIAWATHA, Iowa—NASA research-ers seeking to return the space shuttle orbiters to operational sta-tus are looking to Crystal Group Inc. in Hiawatha, Iowa, to supply rugged computer servers for air-borne experiments.

Crystal offi cials are provid-

ing their CS500 servers to fl y in the nose cones of NASA’s WB-57 high-altitude research jet aircraft to collect data from onboard cameras as NASA works toward returning to space with the schedule launch of the Space Shuttle Discovery,

NASA researchers choose Crystal Group rugged servers for fl ight experiments

Continued on page 4

Raytheon integrated the fi rst generation of Active Denial System onto a HUMV, allowing airmen to use the millimeter-wave beam nearly anywhere.

BY KEITH GURNETTAND TOM ADAMSAs worldwide electronics man-ufacturing moves slowly and unevenly into lead-free mate-rials and processes, most at-tention goes to components and the bonding of those com-ponents to the printed wiring board—especially to the ef-fects of the relatively high re-flow temperatures on compo-nents and joints.

Much less attention goes to the printed wiring board itself. Some years ago, when lead-free manufacturing was still more theory than practice, ex-perts oft en assumed that “new” higher-temperature materials would replace FR-4, the green-colored glass-fi ber-epoxy lami-

nate found in most boards. Th e FR refers to “fl ame retardant.”

Engineers who have long ex-perience with FR-4, however, prefer it to expensive higher-temperature materials for many applications. The result is the continuing dominance of FR-4 in the vast majority of lead-free processing being done today.

Th is means that systems de-signers, more or less, are push-ing FR-4 to its thermal limits. Not much research has been done regarding the effects of higher refl ow temperatures on laminates.

Gail Tennant, team leader in regional supplier engineer-ing at electronics manufactur-er Celestica in Toronto, out-lines the situation.

According to Tennant, there is confusion in terms of what processing temperatures the printed wiring board will be subjected to during lead-free soldering. “One of the key things that we’ve seen in the industry is that there are not really any specifi cations on what lead-free means,” she says. “Some sup-pliers think it means a process-ing temperature of 245 degrees Celsius, but other suppliers are testing to 260°C.

“Overall, lead-free means that the thermal window for the processing of boards is much smaller than it was with lead-ed solders,” Tennant continues. “Problem areas extend to re-work, where a higher temper-ature is needed to remove the

bonded joint from the board.”Tennant is part of an indus-

try consortium to establish the ground rules. “We are working to defi ne the tests that will qual-ify laminates for lead-free tem-peratures,” she explains. “The tests will let us compare one laminate to another.”

One problem area is the long-established glass transition tem-perature (Tg) of a material. Th e Tg is less useful for FR-4 lami-nates in lead-free processing be-cause all of the temperatures in-volved are above the Tg.

Instead, Tennant explains, the industry is moving toward a decomposition temperature because such a measurement would more accurately describe

Continued on page 6

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SPECIAL REPORT

NEWS

www.milaero.com MILITARY & AEROSPACE ELECTRONICS July 2005 3

CONTENTS

BY BEN AMESFALLS CHURCH, Va.—In Pentagon plan-ners’ vision of a network-centric battle-field, every electronic component will maintain an Internet link to every other electronic component.

Th at sounds good, but the recipe calls for more security, mobility, and Internet Protocol (IP) addresses than currently exist. Th e solution is simple, they say—Internet Protocol version 6, better known as IPv6.

Two years ago, leaders at the U.S. De-partment of Defense (DOD) announced a policy requiring all Pentagon purchas-es aft er October 2003 to adopt IPv6. At that pace, DOD experts say their entire Global Information Grid (GIG) will be IPv6-enabled by 2008.

Th ere is just one problem—everyone else is dragging their feet. From corporate America to the rest of the federal govern-ment, most computer users say they are

IN BRIEF page 4, 6, 9, 10, 12, 13

HOMELAND SECURITY FOCUS Idaho National Laboratory receives second round of funding for cyber threat reduction program page 20Northrop Grumman, U.S. Coast Guard enhance maritime security of South Florida coast page 20Coast Guard unveils new helicopter page 21

REPORT FROM WASHINGTONNew terrorist challenge: North Korea page 15

OPTOELECTRONICS WATCHPhasebridge gets DARPA contract for photonic radio program page 16Nano-optics: robust, optical devices for demanding applications page 16

TECHNOLOGY FOCUS Power electronics drive next-generation vehiclesEngineers are building power integrated circuits and other power components to match growing current needs and the effi ciencies of unmanned aerial vehicles, manned aircraft, spacecraft, and ocean-going ships, as well as armored combat vehicles. page 28

PRODUCT APPLICATIONS page 33

NEW PRODUCTS page 35

OPINION page 41

Private business lags behind Pentagon in rush to new Internet protocol

Continued on page 7

DHS turns to high tech to control bordersDepartment of Homeland Security offi cials are procuring and developing technology to secure the nation’s borders and prevent terrorists and weapons from getting through. page 22

BY BEN AMESEDINBURGH, Scotland—Designers of mil-itary computing platforms praise field-programmable gate arrays (FPGAs) for their effi ciency with space and power, but they oft en choose competing solutions like digital signal processors (DSPs) because FPGAs are so diffi cult to program.

Now a consortium of computer com-panies is trying to change that.

In May, a group of technology compa-nies and academics launched the FPGA High Performance Computing Alliance (FHPCA). Over the next two years, they will design and build a 64-node, FPGA-based super computer, capable of achiev-ing processing speeds in excess of one trillion fl oating-point operations per sec-ond (1 TeraFLOPS).

“In the FPGA world, there is a grow-ing interesting in military and aerospace, both on the front end for I/O and for high-performance general processing. FPGAs can save space and power com-pared to traditional solutions,” says Al-lan Cantle, chief executive offi cer of Nal-latech in Edinburgh, Scotland, one of the consortium members.

“But FPGAs are not the easiest things

in the world to program. We need to make it eas-ier for the customer to use,” he says.

“The ability to pro-gram these requires a balance between soft ware and hardware expertise; parallel programming. We will educate the mar-ket to see they can make significantly higher per-formance, both in the embedded and the high performance computing (HPC) environment,” Cantle says. “We will provide a system with reference de-signs, so people can experiment them-selves at a relatively low cost.”

The Edinburgh Parallel Computing Centre (EPCC) at the University of Ed-inburgh will own the new supercomput-er. Experts will build the computer using

commercial-off -the-shelf (COTS) technology from alliance members.

To demonstrate the system’s power and fl ex-ibility, the alliance will select and port three existing supercomputer applications from sci-ence and industry in June 2005.

Eventually, visiting researchers will be able to arrange access to the FHPCA system for three-month research pro-grams. Alliance members will then port their appli-cations to the system.

FHPCA group members include: • Xilinx of San Jose, Calif.;• Nallatech of Edinburgh, Scotland;• the Institute for System Level Integra-

tion (ISLI) at the Alba Centre in Liv-ingston, England;

• the Edinburgh Parallel Computing Continued on page 8

The Virtex-4 FX60 from Xilinx is a 90-nanometer FPGA with integrated serial transceivers from 622 megabits per second to 10.3125 gigabits per second. It is for high-speed serial applications such as servers, storage subsystems, commu-nication line cards, and backplanes.

FPGA companies will design supercomputer

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IN BRIEF

NEWS

www.milaero.com

Lockheed Martin to provide Marine Corps missile-defense radar upgrades Officials at the U.S. Marine Corps Systems Command chose Lockheed Martin in Syracuse, N.Y., to upgrade and provide field support for tacti-cal missile-defense radar systems that protect allied soldiers. Lockheed Mar-tin received a $13.8 million contract to provide new electronics—includ-ing transmitters, receivers, and power supplies—for three AN/TPS-59(V)3 radar systems and spares. Th e Marine Corps also awarded the company a $9 million contract to provide fi ve years of post-production support and Con-tracted Engineering Technical Ser-vices (CETS) for 11 AN/TPS-59(V)3 radars. Th e original equipment manu-facturer of the AN/TPS-59, Lockheed Martin has provided periodic updates to the system’s electronics and soft-ware, allowing the Marines Corps to cost-eff ectively deploy state-of-the-art protection for its troops since the mid-1980s. The mobile radar can predict missile launch and impact points, and cue defensive weapons against incom-ing threats. Th e radar can detect sev-eral targets, and detect and track small air-breathing targets like aircraft and cruise missiles. It is designed to oper-ate with missile-defense systems like HAWK and Patriot.

Radstone to open new North American headquartersOfficials at Radstone Embedded Computing in Towcester, England, are expanding their Billerica, Mass., offi ce. Th e company’s U.S. headquar-ters, and the majority of its func-tions, will transfer from Woodcliff Lake, N.J., to Billerica. Th e Wood-cliff Lake offi ce will remain as Rad-stone’s Northeastern sales and cus-tomer support offi ce. Th e Radstone Billerica offi ce opened in November 2004 and is home to Radstone’s Ad-vanced Engineering Design Center. Th e fi rst product Radstone will de-velop in North America is the AXIS Advanced Multi-Processing Inte-grated Software solution. Transfer of the headquarters functions from Woodcliff Lake will be complete by September. For more information visit www.radstone.com.

Continued on page 6

CORRECTIONSThe April 2005 issue of Military & Aerospace Electronics incorrect-ly characterized the U.S. Army’s Manned/Unmanned Common Architecture Program (MCAP), in the story “POSIX: reveling in its popularity.” Boeing Co. will create a new soft ware architecture for the Army’s AH-64 Apache Longbow helicopter using the Green Hills Soft ware Integrity real-time oper-ating system.

A page-one column in the May 2005 issue of Military & Aerospace Electronics incorrectly stated the projected operational date of the future Transformational Satellite Communications system—better known as TSAT. Th e system will be operational in 2016.

NASA from page 1

set for July 13 at the earliest.Crystal’s CS500, a 5U quarter-wide

rack server, will be part of the NASA WB-57 Ascent Video Experiment system, better known as WAVE—the nose cone-mounted on-board video imaging system on the WB-57 jets that will capture de-tailed images of how the space shuttle be-haves as it climbs toward orbit.

Th e WB-57s operate at altitudes high-er than 60,000 feet on missions as long as 6.5 hours. Th e aircraft can cover 2,500 miles at speeds as fast as 410 knots. Th e WAVE system will use Crystal’s servers store images as it tracks the shuttle for about two minutes, from lift off to sepa-ration of the solid rocket boosters.

“Shuttle video captured by the chase vehicles will help us see the launch in greater clarity than ever before,” says NASA project manager Bob Page. “Along with cameras on the ground, and in and on the shuttle itself, this im-aging system will provide an unprece-dented look at shuttle lift off and atmo-spheric fl ight.”

Crystal CS500 server is tested to MIL-STD-810F and MIL-STD-167-1 standards for altitude, humidity, shock, and vibra-tion. It operates in temperatures from 0 to 50 degrees Celsius. Th e computer is based on the 3.06 GHz Pentium 4 microproces-sor, and weighs 10.65 pounds.

For more information contact the Crys-tal Group online at www.crystalpc.com. £

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NEWS

6 July 2005 MILITARY & AEROSPACE ELECTRONICS www.milaero.com

IN BRIEFtems in Tucson, Ariz., to build a porta-ble version.

Engineers at Raytheon have already built an Active Denial System (ADS) integrated onto a High Mobility Multi Wheeled Vehicle, or HUMV. Th e compa-ny delivered that unit—called System 1—to the Air Force Research Lab at Kirtland Air Force Base, N.M., in fall 2004.

Under the new contract, Raytheon engineers at the company’s Rancho Cu-camonga, Calif., facility will build a ver-sion of ADS that fits in a portable, ar-mored container. Airmen can load this version—called System 2—onto a fl atbed truck or into a C-130 turboprop aircraft for easy transport.

When they arrive, they can use it to protect a strategic location, such as an embassy, detention facility, port, or na-val vessel. By comparison, designers built the HUMV-mounted version for battle-field applications, says Alan Fischer, a spokesman for Raytheon Missile Sys-tems. Raytheon is to deliver the new unit by July 2006.

Researchers at the Air Force Re-search Laboratory originally studied

millimeter-wave technology, and staff at the U.S. Department of Defense Joint Nonlethal Weapons Directorate later improved this technology’s application. Together, they have invested $51 mil-lion in the project since 1992, accord-ing to Air Force records.

The Active Denial System focuses a 95-GHz beam of energy that penetrates a person’s skin less than 1/64th of an inch, producing an instant and painful heating sensation. Th e system relies on key technologies including a millimeter-wave source, cooling system, and planar-array antenna.

Engineers in the Air Force’s directed-energy directorate are working on many other types of directed-energy weapons for applications from lasers that shoot down missiles to microwave beams that disable electronics.

Because the weapons are based on directed energy—not kinetic energy—they have a unique ability for applica-tions such as force protection, long-range strike, precision engagement, electronic attack, and control of space assets, says Roy Hamil, technical advisor in the laser division of the AFRL’s directed-energy directorate. Hamil made his comments

at the Military Technologies Conference, sponsored by Military & Aerospace Elec-tronics, in Boston in March.

Th e weapons all move at the speed of light, have very deep magazines (as long as they have sufficient electricity), and can deliver a full range of controlled ef-fects, “from deny to destroy.”

They are more than theoretical. As long ago as 1979, troops were testing an airborne laser, he says. Engineers tested adaptive optics in 1990, high-power micro-waves in 2002, and lasers for aircraft self-protection in 2004. Th ey are even using them in the fi eld; soldiers used laser daz-zlers to dissuade attackers in Somalia in 1989, and a Battlefield Optical Surveil-lance System (BOSS) in Iraq in 2004.

Other troops are using a nonlethal sound-based system called a direct-ed acoustic device. In December, Army leaders awarded a $4.9 million contract to American Technology Corp. of San Di-ego for the Long Range Acoustic Device (LRAD). Soldiers in the 3rd Infantry Di-vision are using it in Iraq for crowd con-trol, area denial, and building-clearing.

Army leaders awarded the company another contract for $846,000 in April to order additional LRAD units for the 3rd Armored Cavalry Regiment, also de-ployed to Iraq.

Th e LRAD generates a focused beam of sound to issue verbal challenges or instructions to a person more than 500 yards away. If the person does not obey, soldiers can crank up the beam to cre-ate a warning tone that is loud enough to dissuade ill intentions.

Sailors on U.S. Navy and Coast Guard vessels use the LRAD in the Persian Gulf to warn small craft to stay away from their vessels, the company says.

Next, designers at American Technol-ogy Corp. plan to release a smaller ver-sion this summer. The Medium Range Acoustic Device (MRAD) will be about half the size and weight of LRAD, to be optimized for land- and vehicle-based op-erations such as urban warfare, shorter-range checkpoints and access denial. £

The next generation of Active Denial System will be stored in a portable container, similar to the original proto type shown here.

Nonlethal from page 1

Northrop Grumman to develop network-management systemLeaders at the U.S. Air Force Elec-tronic Systems Center at Hansom Air Force Base, Mass., selected Northrop Grumman Mission Systems in San Diego to develop the U.S. military’s next generation of joint and coali-tion network-management systems. The Joint Interface Control Officer (JICO) Support System will manage complex tactical networks through an automated toolset and informa-tion repository that enables plan-ning, management, and analysis of communications before, during, and after operations. The contract, in-cluding production options, could be worth as much as $124 million through July 2008. Joint interface control offi cers use the JICO Support System to plan, establish, and operate tactical communications in local or wide-area theaters of operations. Th e ruggedized, transportable system has all the digitized data and voice com-munications capabilities necessary to support JICO functions and can de-ploy rapidly in severe environments. Th e Air Force is the lead acquisition service for this multiservice invest-ment program.

AD Aerospace FlightVu CabinVu certifi ed for Airbus A330The FlightVu Cockpit Door Mon-itoring Systems (CDMS) from AD Aerospace in Manchester, England, earned a Supplemental Type Certif-icate (STC) for retrofit installation on Airbus A330 jetliner aircraft . Th e STC covers the line replaceable units from AD Aerospace and the instal-lation kit designed by Aircraft En-gineering and Installation Servic-es Inc. (AEI), of Orlando, Fla. The FlightVu CDMS is certified for the B737-200/300/400/500/700/800/900, B757-200/300, B767-200/300/400, MD-80, DC-10, Fokker 70/100, and A330. The DO-160D and DO-178B certified FlightVu system provides cockpit door video security that en-ables pilots to directly observe in real time the area outside the fl ight deck door without leaving their seats. Th e FlightVu cockpit door monitoring

from page 4

Continued on page 9

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content with today’s familiar old tech-nology, IPv4.

A recent poll of information-technol-ogy managers across the public and pri-vate sectors found they were struggling with familiar problems, such as poor support for effi ciency, voice-over-Inter-net protocol phones, quality of service, and security.

Yet fewer than 7 percent of the 349 re-spondents saw IPv6 as the solution, ac-cording to the study's sponsor, Jupiter Networks of Sunnyvale, Calif.

“It’s almost like being on a desert is-land with palm trees and coconuts and saying ‘Gee, I'm starving to death’ while the bananas are hanging on the branch over your head,” says Charles Lynch, technical director of the Defense Infor-mation Systems Agency's IPv6 Transi-tion Offi ce in Falls Church, Va.

“The view in the DOD used to be called horizontal fusion; everything talks to everything. Now it is called netcentric-ity; everything is a communicator and everything uses IP packets,” he says. “But networks today are not designed to han-dle that. We really have a kluge, and now we have a chance to do it the right way.

“While the Net is a great thing, it has a lot of mistakes: security, a protocol not built for today’s high-speed networks, and addresses that were given out fi rst-come, first-served as opposed to geo-graphically,” Lynch says.

“Th e lesson we’ve learned from AT&T is when we lay down a network, it should be geographically based; for instance, 703 is the area code for northern Vir-ginia. But on the internet, the IP num-ber means nothing. If 703 exists in sever-al places, you need the next several digits too, and you need a database with many more numbers.”

Instead, when organizers hand out addresses for IPv6, they will use hier-archical aggregation, which means the numbers will be geographical or even geospatial. An IP address in the new sys-tem could indicate its location on a map, or even its altitude at that spot (such as a specifi c story in a building).

Applied to an Air Force example, de-signers could build an F-22 fi ghter jet with an IP address assigned to every electron-ic component and every sensor. Not only would that streamline communication within the aircraft , but also allow those outside the jet to look in, he says.

A logistician could see the entire wing, and a maintenance worker could see if the avionics are faulty, if the plane can’t drop bombs, or if the pilot’s bio-metrics are off . When the plane lands, mechanics will already have the proper

tools handy to turn the aircraft around quickly for new missions.

“And you can use that platform now not just for dropping bombs, but for sur-veillance. Th e J-UCAS can be outfi tted not only with weapon systems but with sensors,” he says, referring to the Joint Unmanned Combat Air System.

IPv6 can supply enough addresses to

build this “network of networks” because it assigns 128 bits of data for every IP ad-dress, compared to the current 32 bits.

The new system promises great re-wards, but most users look at the cur-rent Internet and shrug, “If it ain’t broke, don’t fi x it,” Lynch says.

“People need a reason to migrate and want it to be seamless if they do. Espe-

cially to proceed beyond a dual-stack mode where they’re using both v4 and v6,” says Rod Murchison, senior direc-tor of product management in the Secu-rity Products Group at Juniper Networks in Sunnyvale, Calif.

“The conception is that v6 will put you on a separate island, but backward

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compatibility is built in, so it will still work with v4—v4 will be around a long time,” he says.

In fact, the change will impact back-end services and management far more than the typical user. To accommodate legacy systems, most companies will roll in the transition by building dual stacks that work with both v4 and v6.

Murchison recently attended the Co-alition Summit for IPv6 meeting in Res-ton, Va., to discuss applications for mil-itary and homeland security, such as network-centric warfare, real-time re-sponse, and communications.

“Address expansion will enable the network to identify every sensor and component,” he says. “Operational sim-plicity is what’s going to make it success-ful, from threat mitigation to attack pro-

tection. That will let you detect when something is compromised, whether to trust a faulty sensor, do intrusion-detec-tion, fi nd anomalies, and deploy active response and remediation.”

Universities and government labo-ratories are leading the private sector charge toward IPv6, with projects such as the high-bandwidth Internet2, but typical companies do not move enough data or support enough Internet nodes

to feel constrained by IPv4, so they ques-tion the move.

Th e transition cost for any company will depend on the number of Internet-enabled devices it has, from desktop PCs to voice-over-Internet-protocol (VOIP) phones, networking devices, and even personal electronics. Other electron-ic manufacturers adopting IPv6 will in-clude networking vendors, operating system vendors, and device makers of handhelds, PDAs, and cell phones.

For more information, see www.moonv6.com, www.usipv6.com, or www.ipv6style.jp/en. To download the Juniper study, see www.juniper.net/federal/IPv6. £

Centre (EPCC) at the University of Ed-inburgh;

• Alpha Data of Edinburgh; and• Algotronix of Edinburgh.

Together, they have raised a budget of £3.6 million (equal to US$6.6 million) for the alliance, including £1.345 (US$2.5 million) from Scottish Enterprise.

Th e supercomputer will use DIME talk for control, and RapidIO as the high-speed switched-network fabric to join the FPGAs, says Malachy Devlin, chief tech-nology offi cer at Nallatech.

“PCI Express and StarFabric consume an awful lot of real estate on an FPGA; they take up many gates, taking away crucial silicon we would rather use for computation,” he says.

Nallatech engineers created DIMEtalk, an FPGA connectivity design tool, which shortens development time with a soft -ware application for system communi-cations. It enables developers to design packet-based communications networks across multiple FPGAs. Th e term is an acronym for DSP and image-processing module for advanced FPGAs.

“You always hear that FPGAs can pro-vide any architecture to fi t your problem. Now it is true also on the network level,” Devlin says.

Th e alliance will use FPGA processors solely because they off er so much power. FPGA-based computing is currently used for high-performance applications such as military signal processing, high-speed ma-chine vision, and bioinformatics.

The processing demands of these tasks are diffi cult to meet using conven-tional microprocessor-based technology, but FPGA-based computers are by their nature massively parallel, performing many calculations per clock cycle and achieving very high data throughput. One reason is that FPGA chips are typi-cally able to dedicate many more pins to

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IN BRIEFinput/output than a microprocessor.“FPGA computing is today where con-

ventional microprocessor-based comput-ing was 15 years ago,” Cantle says.

“Th e potential exists to deliver unprec-edented computational capacity using less power in a smaller space; however, to un-leash that potential the industry needs to develop the means to give users low risk access to that power,” Cantle says. “Work-ing with the FHPCA will help industry to begin the process of opening up the tech-nology to a wider range of users and hence

applications through education, the development of standard-

ized tools and providing a platform for large-scale

demonstrations.”The effort is unique, says

Ma rk Pa r-sons, EPCC’s commercial

director. “What’s really exciting about this proj-ect is that no one’s ever tried to build a big supercomputer with these chips before. People are always think-ing up interesting designs, but the supercomputer we’ve come up with is an abso-lutely unique sys-tem. We’re trying to join a whole lot of these high-per-

formance chips together so we can tackle very large and complex problems. It’s a real opportunity for Scotland to take the lead in a hugely exciting area.”

The use of FPGAs in high-perfor-mance computing brings superior per-formance for many important classes of problems, says Patrick Lysaght, senior director of Xilinx Research Labs and the Xilinx University Program.

“Th e key to this improvement is to use arrays of FPGAs instead of older architec-tures based on sequential computers. Th e natural concurrency of the algorithms can be best exploited by mapping them to FP-GAs with all the advantages of highly spe-cialized data paths, customized memory interfaces and optimized interconnection topologies. Th e tremendous fl exibility of Xilinx FPGAs makes it possible to create a custom computing environment for each class of problem.” £

The BenNUEY-PCI-4E is an FPGA-based com-puting card from Nallatech for net-work applications such as intrusion detection, content processing, and data encryption. It can host as many as four Xilinx Vir-tex-II Pro FPGAs, four Gigabit Ether-net ports, a PCI interface, and four RocketIO channels for intercard com-munications.

FPGA from page 8

system has two or three closed- circuit television (CCTVs) cameras linked to one or two LCD monitors mounted in the cockpit pedestal. Th e monitors pro-vide the fl ight-deck crew with clear, for-

ward viewing, real-time video of the area outside the cockpit door and in sur-rounding galley areas. Th e CCTV cam-eras are fl ush mounted to the aircraft in low profi le, unobtrusive, housings. Th e system also includes Infra Red Illumina-tors that allow the area to be viewed even with cabin lights extinguished. For more visit www.ad-aero.com.

KVH fi ber-optic gyros to be used on remote gun turretsRecon/Optical in Barrington, Ill., has chosen DSP-3000 fiber-optic gyro (FOG) systems from KVH Industries in Middletown, R.I., for use in the U.S. Army’s new Common Remotely Oper-ated Weapon Stations (CROWS). The

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IN BRIEF the behavior of boards at higher temper-atures. Th e decomposition temperature is the temperature at which a board, aft er a stated time, loses about 2 to 5 percent of its mass through volatility.

Th e types of damage that an FR-4 lam-inate may experience in the tin-lead pro-cess temperatures are fairly well under-stood from long experience with leaded solders, but the same types of damage are likely to be more frequent or more se-vere under higher lead-free temperatures. Some types of damage can involve little-known mechanisms because of limited experience in volume production with FR-4 at elevated temperatures.

Board assemblers want to pay atten-

tion to six areas. Th e fi rst is separations between layers of the laminate. Delam-inations occur in response to high tem-peratures, and may be enhanced if con-tamination is present within the layers, or if the laminate has picked up mois-ture during previous handling. Moisture can be removed by baking the laminate before refl ow, but baking is too expen-sive for most applications.

One problem with delaminations is the difficulty involved in identify-ing them. Some delaminations, and es-pecially those very close to the surface, cause a visible bubble. Others create no bubble and are not visible optically, but can be found by sectioning the laminate or by using acoustic microscopy.

Delaminations present more of a threat to long-term reliability than some other defects because there may be no electrical signature at the time they oc-cur. More to the point, the delamination may not immediately cause an electri-cal open. During service, however, the delamination is likely to experience mechanical movement and can collect

moisture, making a field failure more likely.

Second, board assemblers must pay attention to distortions in copper bar-rel plating. Temperatures much above the Tg of FR-4 cause the coeffi cient of thermal expansion of the laminate to in-crease dramatically. Because the layered structure of the laminate constrains movement in the x and y dimensions, the greatest movement is in the z dimen-sions. Th is movement can “stretch” the copper barrel plating in drilled holes.

Plating a hole with either electro or electroless copper is inherently diffi-cult because the narrow diameter of the hole limits current f low and chemical reactions. Th is means it is quite a feat to obtain a consistent and even coat-

ing. Whether the copper is plated onto the walls of the hole or grown by chem-ical reaction, the most frequent anomaly happens when the metal thins near the middle of the holes.

At high temperatures this is where rupture of the solder is most likely un-der the stress of thermal coeffi cient of expansion. If a rupture does occur it can be hidden when the faces of the break line come together again when the board cools and contracts. Th us, a hidden po-tential failure point exists.

This type of fault can have two dif-ferent eff ects. First, it can open and close with temperature variations and cause an intermittent failure during the op-erational mode. Th e cause of the inter-mittent failure will be diffi cult to detect without temperature testing—an unusual diagnostic step for laminates. Second, the rupture can cause permanent failure and require replacement of the board.

In boards that use high-density inter-connects, mechanical drills or lasers form the tiny holes. Mechanical drills tend to leave ridges, which create an uneven

thickness down the hole and can accen-tuate rupture eff ects. Th e eff ect is mini-mal in through-holes fi lled with solder, but more pronounced in unfi lled vias.

Th e third concern is conductive an-odic fi lament (CAF) growth. Th is com-plex phenomenon results in the growth or electromigration of a copper fi lament that can cause a short. It is most com-mon in dense multilayer boards, and oc-curs where copper barrel plating meets the glass reinforcement fibers of the glass-epoxy laminate.

The laminate is a mat of fiberglass and epoxy formed and laminated un-der temperature and pressure. Moisture can form an electrolytic cell that leads to copper fi lament growth along the inter-face between the epoxy and the fi bers. “If you disturb the laminate with a de-lamination or other damage, over time you will see it grow a CAF, which creates a path for a short,” Tennant notes.

Th is growth typically bridges two op-positely biased copper conductors. Th e failure can manifest itself in four main ways: through-hole to through-hole, line to line, through-hole to line, and layer to layer. Th e most common failure mode is hole to hole.

Th e bond between epoxy and fi ber-glass in the basic board makeup is the key. If the higher lead-free temperatures degrade this bond, the loose bonds pro-mote ionic migration. The chance of conductive anodic fi lament failure in-creases, and overall assembly reliabili-ty may suff er.

Various factors such as the pH lev-el or the presence of impurities during the manufacturing phase, along with the application of voltage in the operational mode, can accelerate the CAF reaction.

The fourth concern involves micro hardening. This change in material properties, which comes from thermal excursions above the Tg of the materi-als, makes the laminate more brittle. Al-though excess heat soft ens the laminate and makes it somewhat rubbery, the re-turn to temperatures below Tg can cause micro hardening and brittleness.

The effects of micro hardening are not well understood. “We are still inves-tigating the implications of this charac-teristic,” Tennant reports. “However, initial fi nds show that the materials are more brittle. Th is has implications for handling and possibly for reliability.”

The fifth concern involves damage to board finishes, which protect the copper from oxidizing from moisture, grit, abrasion, and dust; create a barri-er to migration; and identify the points to be soldered. Th e material choices in-clude metallic coatings (matte or bright

Lead-free from page 1

CROWS system, already in use in Iraq, enables turret gunners to operate, aim, and fi re the turret weapon from inside the safety of their humvees or other ve-hicles. Two KVH DSP-3000 FOGs are installed in each CROWS system, pro-viding precise stabilization and weap-on recoil control, and ensuring that the weapon maintains its aim on the tar-get. Th is order represents year one of a fi ve-year contract. “Th e KVH DSP-3000 FOGs are at the heart of our sta-bilization system design,” says Steve Sarles, Recon/Optical’s engineering director for CROWS. “The accuracy of the CROWS stabilization system en-ables the gunner to place ‘can’t miss’ rounds on target, greatly multiplying force eff ectiveness while minimizing collateral damage in urban warfare en-vironments.” Recon/Optical teams on the CROWS system with Electro Op-tic Systems Pty Ltd. CROWS units are fi elded on several vehicle types, includ-ing the M1114 up- armored humvee for the military police, the M1116 up-ar-mored humvee for the Air Force, and the M1117 Armored Security Vehicle for the military police. For more infor-mation visit www.fi beropticgyro.com.

LynuxWorks’ LynxOS selected by Thales for airborne communications controllersOfficials at Thales Computers in Raleigh, N.C., selected the LynxOS real-time operating system (RTOS) from LynuxWorks in San Jose, Ca-lif., for the PowerEngine7 single-board computer (SBC) based on the IBM PowerPC 750X processor run-ning at 733 MHz. The integrated subsystem will serve as the basis for airborne communications control-lers for defense applications. Th ales has incorporated LynxOS into a new subsystem, which features the Pow-erEngine7 and predefined third-party I/O cards inside a 2U rug-ged rack. Th e integrated subsystem provides a turnkey system quali-fied under RTCA/DO-160 for use in demanding airborne environ-ments. For more on Th ales Comput-ers visit www.thalescomputers.com. For more on LynuxWorks go online at www.lynuxworks.com.

from page 9


“ Lead-free means that the thermal window for the processing of boards is much smaller than it was with leaded solders. Problem areas extend to rework, where a higher temperature is needed to remove the bonded joint.”


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IN BRIEFMercury teams with Parker Hannifi n for computer cooling systemsOffi cials at Parker Hannifi n signed a co-marketing agreement with Mercury

Computer Systems of Chelmsford, Mass., for an ongoing relationship be-tween Mercury and Parker’s Advanced Cooling Systems (ACS) business unit, part of the Parker Aerospace Group. Parker ACS provides liquid cooling systems that offer customers choices in design, mechanical, and fl uid-sys-tem packaging, and fi eld-maintenance capabilities. According to Jeff O’Reilly, business development manager for Parker ACS, the agreement benefits both companies. “A relationship with Mercury gives Parker high visibili-ty in the military COTS embedded computing market,” he said. “Mercury will benefi t through access to our ad-vanced liquid and spray cooling solu-tions as they apply to the higher power levels and increased heat dissipation demands of COTS-based embedded defense electronics.”

Army fuel-cell truck completes cross-country testTh e U.S. Army’s Tank Automotive Re-search Development and Engineer-ing Center (TARDEC) in Warren,

Mich., said a fuel-cell-powered semi-tractor completed a cross-country trip from California to Washington, D.C. TARDEC’s National Automotive Cen-ter collaborated with SunLine Transit Agency and Southwest Research In-stitute (SwRI) to modify a standard Class 8 commercial truck by using engine electrification and a fuel-cell auxiliary power unit (APU) to com-plete the 2,650-mile journey. “Driv-ing a vehicle of this size cross-country with electric power is truly a remark-able accomplishment,” says Dr. Rich-ard McClelland, director of TARDEC. “Fuel effi ciency is vital for the military. Th is milestone proves the viability of fue-cell technology for heavy-duty ap-plications, and underscores TARDEC’s commitment to work with commercial industry to establish military require-ments for alternative-energy-powered vehicles.” SwRI engineers converted the truck’s water pump, radiator cool-ing fan, air compressor, air-condition-ing compressor, and air-conditioner condenser fan from engine-powered belts and pulleys to electric power. Re-moving these “parasitic” loads from

the engine and powering them electri-cally enables the engine’s full motive power to propel the truck and increas-es the overall effi ciency of the truck.

DRS to help upgrade radar systems on Navy surface shipsEngineers at DRS Technologies Inc. in Parsippany, N.J., are providing the U.S. Navy AN/SPS-67(V)5 Surface Search Radar System modernization kits for installation in the AN/SPS-67(V)3 ra-dar systems on the Navy’s DDG-51 Ae-gis class combatants. Th e contract was issued the Naval Sea Systems Com-mand (NAVSEA) in Washington. DRS will develop and produce back-fi t kits supporting the AN/SPS-67(V)5 radar-systems program. Th e kits will provide performance and reliability improve-ments to existing AN/SPS-67(V)3 radar systems. Th e company’s DRS Surveil-lance Support Systems unit in Largo, Fla., will produce the workload. Deliv-eries are expected to begin in June 2006 and continue through February 2008. Th e AN/SPS-67 radar system is a sur-face surveillance radar that provides

from page 10

tin, tin over nickel, gold over nickel, pal-ladium, palladium over nickel, silver) and organic solderability preservatives (OSPs). Another well-known method is hot air sol-der leveling, or HASL.

These coating methods are being

evaluated for their performance at the higher ref low temperatures of lead-free. Probably the fi nal protective lay-er is the most critical coating as it is this layer that protects the board sur-face from environmental deterioration during its working life. Damage during refl ow may cause breaks, dimpling, and

lift ing that allow moisture ingress and peeling. Although these types of fi nish damage may be visible on open surfac-es, they will remain hidden in areas un-der components.

In the case of HASL the solder will re-fl ow once more during the assembly re-fl ow phase and has the potential to break the fi nal top coating.

Th e fi nal concern is board warping. Tennant says he has already observed this phenomenon as a result of lead-free tem-peratures. Sometimes referred to as “bow and twist,” warping is a signifi cant prob-lem for fi ne-pitch technology where the signal lines are carried out on thin trac-es and the power lines on much thicker traces. Fine-pitch boards are becoming mainstream and inevitably mean multi-layer circuits. Th in traces and the pow-er lines on much thicker traces carry out the signal lines.

Bow and twist can occur even when tin-lead solder is used, but happens more readily at the higher lead-free temper-atures. If the two thick-trace planes are put on one side of the stack they act like a bimetallic strip and cause bow and twist in the board. Th is distortion can unseat components during refl ow.

Design of the board layers can lim-it bow and twist. Using thinner glass fi bers in the glass-epoxy mix can also limit warping, although at somewhat higher cost. £

Lead-free from page 10

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highly accurate detection and tracking of surface targets and low fl ying aircraft , in addition to supporting ships’ naviga-tion requirements.

Lockheed Martin fi nishes JTRS software radio-design reviewRF experts at the Lockheed Martin Em-bedded Processing Laboratory in Cher-ry Hill, N.J., say they completed a major system design review on the Airborne, Maritime, and Fixed Station (AMF) component of the military’s Joint Tac-tical Radio Systems (JTRS) program. Company offi cials say they demonstrat-ed key technologies that comprise the core of their proposed AMF JTRS so-lution, and laid out their planned ar-chitecture and design approach for the system. AMF JTRS is a transformation-al communications program to mod-ernize the communications systems on fi xed- and rotary-wing aircraft , ground installations, and a wide range of war-ships and submarines. Lockheed Mar-tin leads a team of communications, systems, and platform integrators that is competing for the AMF JTRS pro-gram. The team, which includes BAE Systems, General Dynamics, Northrop Grumman, Raytheon, and other sub-contractors, won a $51 million presys-tem design and development contract last September.

BAE Systems test-fl ies Chinook helicopter digital fl ight-control system BAE Systems in Johnson City, N.Y., completed the fi rst fl ight test of the Boe-ing CH-47 Chinook Digital Advanced Flight Control System (DAFCS), which replaces a relatively old f light-control system on CH-47D helicopters. Boe-ing is upgrading 300 of those aircraft to the F-model for the U.S. Army. Its digi-tal design is to improve reliability, main-tainability, and fl exibility, and include a built-in diagnostic system for detect-ing and analyzing system failures and faults. Following fl ight tests, BAE Sys-tems is set to start building the DAF-CS for fi rst deliveries early next year. In addition to about 450 U.S. Army Chi-nooks, military units worldwide oper-ate about 350 CH-47s that are potential candidates for the f light control up-grade, company offi cials say.

Aerospace dominates Russian trade in 2004Russia maintained its position as one of the world’s main exporters of military aviation technology, the press service of FGUP [federal state unitary enterprise] Rosoboroneksport [state-owned arms trader] reported. “The share of aero-space products and services was around

60 percent of the total value of Rosobo-roneksport’s deliveries, which in 2004 reached a record 5.12 billion dollars,” the announcement states. Russian air-craft manufacturers have taken part in nearly all of the largest regional tenders for the procurement of multirole fi ght-er aircraft , as well as of combat, military transport, and multirole helicopters.

“The Russian bids in them have been among the favorites not just in terms of value for money, traditionally Russia’s strong point. Our off set proposals, pro-grams for the transfer of technologies and licenses, and the establishment of aircraft maintenance centers have also begun to gain in competitiveness,” the announcement reads.£

IN BRIEF

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WASHINGTON—While the defense indus-try is struggling to keep pace with one new kind of war that is challenging its ingenuity, another unsettling situation is looming over the horizon—and not far over the horizon: North Korea.

Th e one ostensible common thread in the two situations is the absolute necessity of keeping weapons of mass destruction (WMDs) out of the hands of terrorists. That’s the stated reason why this country committed troops to Iraq, although those WMDs have proved to be illusory.

North Korea’s WMDs are not illusory. Th ey are nuclear warheads—at least 10 of them, by current Pentagon estimates—plus a variety of chemical weapons (mus-tard gas, sarin, and VX nerve agent) and biological weapons (anthrax, botulism, cholera, hemorrhagic fever, plague, small-pox, typhoid, and yellow fever).

Moreover, North Korea has missiles that make Saddam Hussein’s look puny by comparison: a medium-range missile known as the No-Dang believed to be capable of hitting Japan, the 1,200-mile Taepo Dong 1; and an advanced version known as the Taepo Dong 2, which the-oretically could strike the continental United States.

What is to keep this horrible arsenal out of the hands of terrorists? Th e short answer: not much.

Th e only diplomatic barrier is a treaty known as the Agreed Framework signed in 1994 that promises that the United States, South Korea, and Japan will sup-ply light-water nuclear reactors and fuel oil in exchange for North Korea’s freez-ing its nuclear weapons development.

Everybody expected North Korea to cheat on the agreement, and they did. Th e situation is becoming increasingly untenable as the North Korean econ-omy continues its downward plunge, making the sale of contraband WMDs to terrorists increasingly attractive.

Like the Vietnam War, which it so much resembles, the current war in Iraq would be a minor skirmish com-pared to any commitment of ground forces to Korea.

Although the two countries are about the same size, 23 million people in North Korea and 26 million in Iraq, the real dif-ference is the size of the countries’ mil-itary forces. North Korea is believed to have the world’s fifth largest military, with more than 1.2 million active-duty troops and 7 million reservists.

What this means is that the military casualties would far exceed the 1,500-plus experienced to date in Iraq. Pen-tagon experts have estimated that the fi rst 90 days of a confl ict in North Korea would produce 300,000 to 500,000 American and South Korean military casualties in addition to hundreds of thousands of civilian deaths.

Th e costs would also greatly exceed the $200 billion expended to date in Iraq, and the damage to South Korea alone would gravely cripple the glob-al economy. Consider, for example, that the South Korean capital of Seoul is only 35 miles south of the Demilita-rized Zone and therefore a hostage in any North Korean military move.

This crisis is looming at a time when American troops deployed to South Korea are to be drawn down—from 37,500 last year to 25,000 by 2008. This drawdown, pushed through the military bureaucracy by Defense Sec-retary Donald Rumsfeld, makes sense because of the overwhelming U.S. air and naval superiority to defeat a con-ventional attack.

Countering a potential nuclear at-

tack is another matter. For openers, it puts a high premium on intelligence gathering, which was less than satisfac-tory in Iraq. In addition to fi nding the dispersed nuclear sites, air forces will have to fl y many sorties to be sure they have eliminated them.

Once again, the situation looks sev-

eral orders of magnitude more challeng-ing than today’s action in Iraq.

It’s a challenge the United States can ill aff ord to ignore. Th roughout the cold war the whole thrust of nonprolifera-tion was to keep nuclear weapons out of the hands of those outside the nuclear club and therefore considered too irre-sponsible to possess them.

Moreover, Iran and other nations with clandestine nuclear weapons pro-grams of their own will be watching how the United States handles this sit-uation and whether North Korea will be allowed to become an offi cial nuclear power without reprisal.

As a Pentagon reporter for Aero-space Daily during Secretary of Defense Rumsfeld’s fi rst tour of duty at the head of the Defense Department during the closing days of the Vietnam War, I per-haps see too many parallels between that war and the current action in Iraq.

That may also explain my preoc-cupation with Asia, where I think the United States has a major future around the Pacifi c Rim.

I was surprised to read, for exam-ple, in the current issue of the Atlantic

Monthly that the United States still has not signed a peace treaty with North Korea after that country’s invasion of the south in 1950. President Eisenhower fulfi lled a campaign promise by sign-ing an armistice ending the fi ghting in 1953, but it seems reasonable to me that a peace treaty would be in order—and

might help to defuse what is increasing-ly becoming an untenable situation.

At a minimum, it seems to me that we should not let our ongoing opera-tions in Iraq blind us to what may prove to be even more serious challenges in places like North Korea and Iran.

I think our experience in Iraq rais-es serious questions about the validity of another preemptive strike elsewhere. American troops were not greeted with fl owers as liberators, and I don’t think they will be in North Korea either.

In a potential confl ict situation such as this, action is always preferable to re-action. Now is the time to get our allies on board and to make it clear to the re-gime of Kim Jong Il that any military action will trigger a United Nations re-sponse, as it did in 1950.

The defense industry’s role in the meantime will be to put increasing em-phasis on space-borne surveillance as-sets, the so-called national technical means, and to be ready to deliver the necessary force-multiplier assets that will off set with superior electronics the numerical superiority of a rogue regime playing in its own ballpark. £

New terrorist challenge: North Korea

Iran and other nations with clandestine nuclear weapons programs of their own will be watching how the United States handles this situation. JOHN RHEA

REPORT FROM WASHINGTON


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OPTOELECTRONICS WATCH Phasebridge gets DARPA contract for photonic radio program

Nano-optics: robust, optical devices for demanding applicationsBY HUBERT KOSTALOptical systems in defense and security applications must be able to deploy in harsh environments and meet demand-ing requirements for high performance and high reliability. In addition, de-mand continues for optical devices that are small, light, robust, and—to the ex-tent possible—highly integrated.

Most oft en it is the optical portion of an electro-optic circuit or the electro-optic interface that represents the big-gest design challenge for performance, effi ciency, robustness, and cost. Th is is so because photons carry information in a different way than electrons do, and because they are not manipulated or guided the same way.

Conventional optics and optical engi-neering address these issues but have sig-nifi cant physical limitations, not the least of which involve materials; changing the material changes the function, and of-ten can result in undesirable tradeoffs between material properties and optical functionality. Similarly, the mixture of in-dividual optical component technologies that must be used often translates into minimal integration, so circuit designs are limited by component capabilities.

“Nano-optics” provides a new ap-proach to meeting these requirements by creating a new class of optical devic-es with desirable optical eff ects through nanometer-scale structuring of various materials. Selecting appropriate struc-ture designs and functions can yield a broad range of optical functions in a layer as thin as a few microns. Appro-priate structure designs include one-, two-, or three-dimensional, regular or irregular structures. Appropriate ma-terials include dielectrics, metals, and plastics. Possible optical functions in-clude switching, spectral and polariza-tion fi ltering, and phase modifi cation.

Such nanostructure layers can be fab-ricated on a broad range of substrates so that manufacturers either can custom-ize the optic to the application, or fab-ricate it on the surface of another opti-cal component in an optical circuit. Th is

INDUSTRY VIEW

ARLINGTON, Va.—Offi cials at the Defense Advanced Research Projects Agency (DARPA) have selected Phasebridge Inc., to further the development of an opti-cal RF Quadrature Phase-Shift-Keyed (QPSK) technique and analyze its appli-cations in a new generation of ultra-wide-band and frequency-agile military radio systems. Th is technique will be used to imprint data during the frequency syn-thesis process in such “photonic radios.”

Phasebridge specializes in advanced photonic integration technologies includ-ing optical devices and subsystems for

analog radio-frequency (RF) signal pro-cessing and optical-fi ber transmission.

“Under this new contract, we will optimize the implementation of QPSK modulation as it pertains to ultra-wide-band RF photonic heterodyne frequen-cy synthesis and RF photonic frequency conversion,” says Phasebridge Founder and Chief Technology Offi cer Ron Lo-gan. “Th e Photonic Radio system archi-tecture then integrates these frequen-cy synthesis and conversion methods into a system that permits a baseband- frequency terminal to access chan-

nel frequencies over an extremely wide range of microwave through millimeter-wave channel frequencies.”

Th is wide frequency range will reduce the size, weight, and power consump-tion of today's military radio communi-cations by combining the functions of multiple radio systems into one and by replacing heavy copper cable with opti-cal fi ber, thereby improving the porta-bility of military radio communications. Phasebridge offi cials say.

For more information visit www.phasebridge.com. £


Santa Barbara Infrared delivers optical test equipment to U.S. Navy Santa Barbara Infrared Inc. in Santa Bar-bara, Calif., is delivering the RAD9000 spectral radiometer, which its engineers designed for the U.S. Navy. The system helps calibrate projector-level test systems and stand-alone test components such as blackbodies and discrete targets. Company engineers designed the system to conform

to Navy requirements for high thermal sen-sitivity and increased radiometric accura-cy. Navy offi cials are using the RAD 9000 to test and calibrate equipment operating in the mid-wave and long-wave infrared spectral bands. Th e system has an electro-optical module with interchangeable detector and radiometry modules, radio-metric reference module, and reference control module. For more information contact Santa Barbara Infrared online at www.sbir.com.

Army looks to EOIR Technologies for surveillance prototypesEngineers at EOIR Technologies Inc. in Woodbridge, Va., are designing pro-totype surveillance and force-protec-tion technology for the U.S. Army under

terms of a $25 million contract from the Army Night Vision and Electronics Sen-sor Directorate (NVESD) at Fort Belvoir, Va. EOIR is a subsidiary of Markland Technologies Inc. in Ridgefield, Conn. Markland is working on night-vision and advanced-sensor applications, disposable sensors, and other threat-detection sys-tems for NVSED. Many of the products and services being delivered on this con-tract use next-generation electro-optic and infrared sensor technologies that are being used in direct support of U.S. mili-tary combat operations in Iraq, Afghani-stan, and elsewhere. Th e Army’s NVESD has been responsible for key innovations in the fields of optical electronics and thermal imaging for weapons targeting, electronic surveillance and other mission-critical military applications. For more information contact Markland Technol-ogies online at www.marklandtech.com.

Pulse generator is for high-resolution military photonic applications Quantum Composers in Bozeman, Mont., is off ering the 9500 Plus pulse generators to generate and synchronize several puls-es for optoelectronic and process control for research and testing in military and aerospace laboratories. Th e device helps the user multiplex several channel pulses onto one output to create complex pulse trains for flash lamps, Q-switches, shut-ters, cameras, and other imaging appli-cations. It synchronizes as many as eight diff erent events or instruments, and dig-itally controls as many as eight indepen-dent channels for laser timing, automated testing, and precision-pulse applications.

For more information contact Quan-tum Composers online at www.quantumcomposers.com.

KVH to upgrade optical navigation systemsKVH Industries Inc. in Middletown, R.I., will upgrade vehicular navigation sys-tems on deployed military vehicles under terms of $1.9 million order from an un-named defense prime contractor. KVH experts will upgrade KVH’s TACNAV navigation systems already in the field, enabling the navigation system to con-nect with the U.S. Army’s Force-21 Bat-tle Command, Brigade-and-Below sys-tem, otherwise known as FBCB2. KVH’s TACNAV military vehicle navigation sys-tems employ KVH’s digital compass and fi ber optic gyro (FOG) technology as well as proprietary software algorithms to provide uninterrupted navigation, head-ing, and pointing data for vehicle drivers, commanders, and crews. While TAC-NAV complements GPS, its self-con-tained sensors operate independently of GPS, and can provide mission-critical data for troops in the vehicle as well as to the digital battlefi eld system, even if GPS is blocked, jammed, or is otherwise un-available. For more information contact KVH online at www.tacnav.com.

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approach can enable dramatic reductions in overall size and weight. Optical func-tions can be created using a broad range of materials, so manufacturers can select materials with performance under oper-ating environments in mind.

Nanostructure-based opticsNano-optics are optical thin-film struc-tures that derive their physical properties by patterning materials on a subwavelength-scale roughly normal to the incident angle of the illuminating light. For ultraviolet, visible, and near-infrared wavelengths, the critical dimensions of these structures are on the nanometer scale. Th e structural at-tributes that determine the functional per-formance of a nano-optic device include:• the nanopattern and its dimensions;• the material used for the nanopat-

terned layer;• the material used for the fi ll between

the nanostructures;• the formulation of the thin-fi lm layers

on either side of the nanostructure lay-er; and

• the substrate.Th e critical dimensions of nano-optic

structures for ultraviolet, visible, and near-infrared wavelength devices are on the order of tens to a few hundreds of nano-meters, with a sub-ten-nanometer dimen-sional accuracy required in fabrication.

Physically, nano-optic devices derive their optical performance from the unique interactions of light with subwavelength-scale structures—including form birefrin-gence and elimination of higher-order dif-fraction. At a macro level this is high optical performance in a grating layer oft en thin-ner than one micron. Th e optical function of nano-optic devices is the result of a con-volution of material and structural prop-erties, so the same optical function can be achieved using diff erent material choices by making appropriate adjustments in the dimensions of the nanostructures.

Optical functionality that has been demonstrated based on nanostructures includes:• polarization eff ects such as polarizers

and polarization beamsplitters or com-

biners;• phase retardation such as wave plates

and retarders;• spectral selection; and • focal adjustment such as antirefl ection

structures, diffusive layers, lenses, or mirrors.

In general, nano-optic devices can be designed to perform well in harsh en-vironments by trading off material and structure to use the most robust possi-ble material to achieve the desired func-tion and to minimize the eff ect of ther-mal expansion or contraction.

Fabricating nano-optics Nano-optic devices are fabricated using semiconductor-like deposition, lithogra-phy, etching, and coating processes. In general, a lithographic mask is prepared with the desired nanoscale features pat-terned on it. Th e original mask can be pat-terned using e-beam lithography, interfer-ence lithography, or by combining multiple partial mappings and exposures to create spatial variations or arrayed optics. Man-ufacturers can use this mask in a variety of methods to transfer the nanopattern to a target wafer; the specifi c topography of the mask depends on the method.

A fairly simple method is nanopattern transfer lithography, which is closely re-lated to nanoimprint or nanoembossing. Nanopattern transfer uses physical contact to transfer a pattern to a resist layer. Th is approach allows for high fi delity in pattern replication, and avoids interactions between an energy beam and the polymer layer that can reduce the accuracy of the pattern transfer. Th e nanopattern transfer manu-facturing process consists several steps.

First, one or more target wafers are prepared by selecting a substrate material, depositing appropriate thin-fi lm bound-ary layers, and depositing an appropriate thickness of a target material. Th is target material is the layer into which the nano-structure is to be inscribed; usually it is a dielectric or a metal layer.

For each wafer, a thin, pliable, poly-mer resist layer is spun on top of the tar-get layer, then a physical “mold” shaped

This illustration provides a conceptual drawing of a nano-optic device that consists of a nanopatterned layer between two thin-fi lm layers on a substrate; a scanning-electron-microscope photograph of just the nano-patterned layer—in this case, a grating—is shown as well.

Illuminating light

Thin-film overcoat

Grating materialGrating fill material

Thin-film undercoat

Substrate

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with the complement of the desired pat-tern is brought into contact with the re-sist. Th e polymer resist layer is then set using ultraviolet or thermal curing, and the mold removed. This leaves a relief of the desired pattern in the now fi xed polymer resist layer.

Th e fi xed polymer resist layer then acts

as an etching guide to transfer the pattern to the underlying target layer. Aft er etch-ing has been completed, various deposi-tion processes fill the etched areas with a second material and add a thin-film boundary or surface layer. It is important to eliminate any voids and microchannels in this process.

Finally the wafer can be diced to size for applica-tion, or can be used as the base substrate for another deposition and etching cycle to create multilayer, multifunction, nano-optic devices.

Nano-optic integration This semiconductor-like wafer-scale fabrication process facilitates the ap-plication and integration of nano-optic devices into general electro-optic cir-cuits. Th ree types of inte-gration can take advantage of nano-optics.

First of these is inte-gration by assembly. For certain applications, the nano-optic device will be fabricated on a glass or oth-er substrate whose primary role is to act as a holder for the nano-optic structure. By appropriate material and optical design, this struc-ture can be designed to al-low reduced spacing between the nano-optic and adjacent devices to be refl ective or to have a broad tolerance for angle of incidence to reduce or eliminate the ef-fect of general assembly misalignment. One or more of these eff ects can permit the optical circuit to be more robust or smaller in size.

Second is monolithic integration. Nano-optic layers can be interspersed with thin-fi lm layers and confi gured in arrays of optical functions.

Th ird is hybrid integration. In many cases, the nano-optic layer can be applied to other optical materials or to pre-ex-isting surfaces in an optical design. Th is eliminates the need for the substrate for the nano-optic device, allowing reduction in size of the optical circuit. Combining nano-optic layers with appropriate elec-tronically reconfi gurable layers, such as liquid crystal, lithium niobate, or MEMS structures can allow the design of high-ly compact electronically tunable optics, such as variable optical attenuators, opti-cal switches, and tunable fi lters.

Applications of nano-opticsNano-optic devices can be applied to a broad range of optical circuits, such as digital imaging systems, projection dis-play systems, and optical sensors.

For digital imaging systems, nano-optic fi lters can provide increased per-formance and robustness. Applicable nano-optic devices include bandpass fi l-ters, polarizers, waveplates, tunable spec-

tral fi lters, and optical low-pass fi lters. For projection display systems nano-

optic devices can improve picture clarity and contrast in devices such as polariz-ers, polarization beam splitters, band-pass fi lters, and waveplates.

In optical sensors, sample response to single-wavelength or broadband light sources can be used to identify potential threats or contaminants. Applicable nano-optic devices include polarization beam-splitters, polarizers, waveplates, and spec-tral fi lters. Nano-optic tunable fi lters can be considered for hyperspectral sensing.

For all of these applications, mono-lithic or hybrid integration of nano- optic devices can reduce the size and weight of optical circuits.

In general, nano-optics provides a rela-tively new approach to creating optical de-vices with many more degrees of freedom in material selection, performance, and integration than available using classical optics. Th e fl exibility that this aff ords the electro-optic circuit designer oft en permits improved performance, improved reliabil-ity, and reduced size and weight through optical integration. Many of the applica-tions for this technology are just now being considered, so this remains a fertile area for exploration and discovery. £

Hubert Kostal is vice president of marketing and sales at NanoOpto Corp. in Somerset, N.J. For more information contact the com-pany online at www.nanoopto.com.

Thin-film layer

Grating layer

Substrate

Nano-optic array

A more general nano-optic device design can include several nanostruc-tured layers interspersed with thin-fi lm layers. The individual nanostructure layers can contain arrays of nanostructured regions, resulting in different functionality depending on where light passes through the optical chip.

A straightforward application of nano-optics is digital imaging. A stand-alone nano-optic device can be used as an IR cut-off fi lter (IRCF), allow-ing only visible wavelengths to reach the sensor. This design can be evolved by either integrating the IRCF functionality onto a CCD sensor cover plate, or with other optics.

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Bidirectional adaptive-optics laser communications subsystem

AOptix Technologies in Campbell, Ca-lif., is off ering the GT1.0 Communicator bidirectional adaptive-optics method of beam control. It has a range of more than 16 miles with virtually zero probability of intercept or detection, company offi -cials say. Th e device is in a 26-pound 9-by-13-by-13-inch chassis that operates on battery power for more than eight hours of continuous operation. In ground ap-plications, the system enables building-to-building line-of-sight links directly through windows. It provides 800 giga-bits-per-second bandwidth with a fi ber source, and 1-gigabit Ethernet with an appropriate communications interface. For more information contact AOptix online at www.aoptix.com.

Fiber-optic-based multiparameter test kitFISO Technologies Inc. in Quebec City is off ering the Dynamic Multi-Parameter Test Kit based on the Fabry-Perot (FPI) optical-sensor technology. Th e kit has of Fabry-Perot (FPI) fi ber-optic sensors cov-ering applications in laboratories or re-search centers. Th e system includes tem-perature, pressure, strain, and refractive index sensors. Fiber-optic sensors using FPI are desired because of their versatili-ty, their performance and their dynami-cal range. For more information contact FISO online at www.fi so.com.

Stratos Lightwave optical transceivers meet MIL-STD-810E Stratos Lightwave LLC in Chicago is of-fering a family of ruggedized small-form-factor (SFF) optical transceivers that are validated for compliance with MIL-STD-810E for shock, vibration, and other en-vironmental extremes. These transceiv-ers need no additional rework or testing to meet the requirements of military and avionics standards, company offi cials say. Th e Stratos transceivers come in vertical-

cavity surface-emitting-laser (VCSEL) and light-emitting-diode (LED) ver-sions. Th e LED version operates at 1310 nanometers with data rates from 1 to 300 megabits per second, and supports data links as long as 1.2 miles. Th e VC-SEL version operates at 850 nanometers and is for Gigabit Ethernet, Fibre Chan-nel, or InfiniBand, and supports data links as long as 1,600 feet. Both versions operate in temperatures from –40 to 85 degrees Celsius. For more information contact www.stratoslightwave.com.

Blue-violet laser-diode modules Photonic Products Ltd. in Hatfi eld Broad Oak, England, is off ering 405-nanome-ter blue-violet laser-diode modules for applications such as imaging, fluores-cence sensing, spectroscopy, microsco-py, and biomedical imaging. Th e mod-ules produce either an elliptical output beam of 4-by-1.5 millimeter with out-put of 4 milliwatts, or a 2-millimeter cir-cular output beam with output power of 0.9 milliwatts. Th e glass AR-coated optical lens adjusts to produce a colli-

mated beam or focused spot. Operating voltage is from 8 to 12 volts DC at an operating current of 90 milliamps, or 100 milliamps. For more information contact www.photonic-products.com.

Kopin demonstrates tiny high-resolution color displaysKopin Corp. in Taunton, Mass., is dem-onstrating its 0.59-inch color Cyber-Display that off ers resolution of 800 by 600 pixels for mobile applications such as military wearable computers, as well as mobile communications devices. Ko-pin manufacturers these displays with a proprietary color-filter technology and low-voltage interface. The Cyber-Display consumes less than 100 milli-watts of power. Company offi cials say the display is for high-resolution, full-color applications such as mobile vid-eo eyewear, 3-D stereoscopic video, mo-bile computing, and emerging military products. For more information contact Kopin online at www.kopin.com.

from page 16

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HOMELAND SECURITY FOCUS BY JOHN McHALE

Militarized chemical identifi cation system designed for fi rst respondersEngineers at Ahura Corp. in Wilm-ington, Mass., have developed the First Defender SC, a second generation of their First Defender product line op-timized to meet the needs of fi rst re-sponders. Th e First Defender SC is a rugged handheld instrument for the identifi cation of unknown liquids and solids. Th e rapid identifi cation of po-tentially hazardous materials includ-ing toxic industrial chemicals (TICs), toxic industrial materials (TIMs), ex-plosives, and narcotics is becom-ing increasingly critical to civilian fi rst responders. Th e system is entire-ly self-contained, rugged, lightweight, and easy to use. It weighs less than 4 pounds and is easy to use while wear-ing Level A gear. It requires no cali-bration or consumables and is ready to use within seconds of turn-on, compa-ny offi cials say. For more information visit www.ahuracorp.com.

TSA certifi es explosives detection-system upgrade kit Officials at the Transportation Secu-rity Administration (TSA) in Wash-ington have certified an explosives detection-system (EDS) upgrade kit de-veloped by Lockheed Martin in Owego, N.Y., as prime contractor and Analog-ic Corp. in Peabody, Mass. The up-grade kit was developed as part of TSA’s Phoenix Project, and certifi cation qual-ifi es the equipment for additional fund-ing toward projects that will enhance baggage detection systems at U.S. air-ports. “Our team met stringent techni-cal and testing requirements to deliver a solution that improves image clarity while reducing alarm rates,” says Bri-an Tanton, vice president and general manager of Lockheed Martin’s Distri-bution Technologies business. “Our en-hanced detection system provides op-erators with easy-to-identify images, rather than two-dimensional, mono-chromatic images.” Certifi cation cou-pled with System Qualifi cation enables Lockheed Martin, as prime contrac-tor, to negotiate with the TSA to deploy detection systems fi rst on a pilot basis, and then enter into negotiations to sup-ply production upgrade kits for screen-ing systems already installed at U.S. air-ports. Th e two companies focused on automating the movement of bags, im-proving the throughput of bags being scanned, and reducing the false-alarm rates for the screening process.

Idaho National Laboratory receives second round of funding for cyber threat reduction programBY JOHN MCHALE

WASHINGTON—The U.S. Department of Energy's Idaho National Laboratory (INL) received a second round of fund-ing this week from U.S. Department of Homeland Security (DHS) to continue a multiyear cyber security program.

Th e Control System Security Center will receive $11.7 million in 2005 to con-tinue its eff orts to secure the computer-aided control systems that operate the nation’s critical infrastructures. Control systems are the digital au-tomation systems that op-erate infrastructures such as the electric power grid, oil and gas refi neries, and telecommunication sys-tems, DHS offi cials say.

Th e program was initially given $10 million in May 2004. With that fund-ing, INL installed multiple full-scale control-system components; hired em-ployees with expertise in control sys-tems and critical infrastructure in-dustry sectors; hosted an awareness conference for industry, vendors, and government offi cials; conducted train-ing sessions; engaged industry and vendor user groups at conferences and forums; and established partnerships with other national laboratories.

Th e program also renovated an ex-isting facility with state-of-the-art cyber security tools, routers, firewalls, and

testing bays, and signed research and development agreements with other na-tional and international control-system and component vendors.

“Th is year we plan to focus our eff orts on establishing baseline security assur-ance levels and cyber recommendations to increase industry security,” says Julio Rodriguez, INL department manager for Critical Infrastructure Assurance. “We're

at the point where industry is beginning to recognize the potential threats of un-secured control systems and they are more willing to work with government agencies to improve the security of the nation's critical infrastructures.”

“Control systems typically use off-the-shelf operating systems that are more complex and expensive to upgrade, deploy patches for more than tradition-al computers, and oft en lack suffi cient security measures such as fi rewalls and antivirus soft ware,” Rodriquez adds.

DHS selected INL for this project be-cause of its expertise in design, assess-ments, and operational management

of control systems across several in-dustrial sectors, DHS offi cials say. Th e Control Systems Security Center has utilized INL’s management capabilities to establish partnerships with Sandia, Pacifi c Northwest, and Lawrence Liver-more National Laboratories, as well as universities and private industry ex-perts to develop tools and solutions to improve control systems security.

Idaho National Laboratory is one of DOE's multiyear-program national lab-oratories and performs work in each of the strategic goal areas of DOE —energy, national security, science and environment. Th e Laboratory is the na-tion's leading center of nuclear-energy research and development that is man-aged and operated by Battelle Energy Alliance.

Th e U.S. Department of Homeland Se-curity's Information Analysis and Infra-structure Protection (IAIP) Directorate serves as the focal point for intelligence analysis, infrastructure protection opera-tions, and information sharing. £

The Control System Security Center will receive

$11.7 million in 2005 to continue its efforts to

secure the computer-aided control systems that

operate the nation’s critical infrastructures.

BY JOHN MCHALE

RESTON, Va.—Officials at Northrop Grumman Mission Systems and the U.S. Coast Guard installed advanced equipment and soft ware aboard Coast Guard and other law-enforcement ves-sels to enhance maritime security dur-ing the Organization of American States General Assembly in Fort Lauderdale, Fla., last month.

The vessels were linked with the port- and coastal-surveillance system, called “Hawkeye,” which monitors the ports of Miami and Port Everglades, Fla. Hawkeye integrates radar, cameras and automatic-identification technologies with a command, control, and commu-

nications system to detect, track, and analyze vessel traffi c around ports and along nearby coastal areas, Northrop Grumman offi cials say.

Northrop Grumman’s Mission Systems sector installed similar sys-tems for the Coast Guard in Bos-ton and New York for added security during the Democratic and Republi-can national conventions; at the Coast Guard's Joint Harbor Operations Cen-ter in Hampton Roads, Va.; and in the Port of Charleston, S.C., as part of a U.S. Department of Justice pilot proj-ect. Northrop Grumman is also install-ing a variant of the system overseas to support a U.S. Defense Th reat-Reduc-

tion Agency program.Northrop Grumman Mission Sys-

tems and the U.S. Coast Guard Com-mand and Control Engineering Center developed Hawkeye under a program initiated in late 1993 that is now under the authority of the U.S. Department of Homeland Security.

“Th e Department of Homeland Se-curity places a premium on surveil-lance capabilities that can be employed in layered, multi-agency, maritime se-curity operations to identify and inter-cept threats well before they reach U.S. shores,” says Barry Rhine, sector vice president, Northrop Grumman Mis-sion Systems. £

Northrop Grumman, U.S. Coast Guard enhance maritime security of South Florida coast

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Coast Guard unveils new helicopterBY JOHN MCHALE

ATLANTIC CITY, N.J.—Earlier this year, U.S. Coast Guard officials announced the new HH-65C Dauphine helicopters at Coast Guard Air Station in Atlantic City. Th e helicopters will be replacing the HH-65B helicopters as part of the Deep-water Programs modernization and re-capitalization of the Coast Guard.

Air Station Atlantic City is the fi rst air station in the Coast Guard to receive the new helicopters in time for the boat-ing season.

Th e helicopter was upgraded with Tur-bomeca Arriel 2C2 turboshaft engines that provide substantial power, fl ight- control, and fl ight-safety improvements. Th e he-licopter's communication system will be fully interoperable with other Deepwater assets, as well as with agencies assigned to the Department of Homeland Security, the Department of Defense and local fi rst-responders, Coast Guard offi cials say.

Twin-engine HH-65 helicopters are particularly well-suited for search and rescue, fisheries patrols, maritime se-curity, border patrol, monitoring illegal immigration and drug interdiction. Th e modernization eff ort to re-engine all 95 HH-65 helicopters in the fl eet with the upgraded engine includes the provision of kits by American Eurocopter (AEC), a division of EADS North America. Th e conversion kits facilitate installation of extended heat shields, a reconfi gured cockpit, and specialized avionics soft ware needed for shipboard operations.

“Th ese re-engined helicopters are an es-sential improvement in safety and reliabili-ty for our crews,” says Vice Adm. Vivien S. Crea, commander, Atlantic Area and Mar-itime Defense Zone Atlantic. “Th ey are a critical component of our off shore capabil-ity and will allow us to perform more eff ec-tively across all of our missions.”

Th e upgrade of all HH-65’s within the next two years will remedy significant safety and reliability concerns that impact the aging helicopters, but accelerating the HH-65 re-engining project depends upon the availability of funding, conver-sion kits, engines, and suitable produc-tion facilities. Th e modernization process is being conducted by the ICGS team—a joint venture of Lockheed Martin and Northrop Grumman Corp. in partner-ship with the U.S. Coast Guard.

Th e Coast Guard’s HH-65 re-engining facility is currently the Aircraft Repair and Supply Center (ARSC) in Elizabeth City, N.C. A second line at American Eurocop-ter Facility in Columbus, Miss., will pro-vide additional work. £

TSA orders 32 L-3 EDS machines Transportation Security Administration (TSA) officials in Washington ordered 32 new eXaminer 6000 Explosives De-tection System (EDS) machines from L-3 Communications of Woburn, Mass. Th e new order is valued at $28.1 million. Th e machines will support in-line explosives-detection systems currently under con-

struction at several airports. “TSA is cur-rently operating nine checked- baggage explosives-detection in-line systems with eight full and two partial systems under construction,” says Rear Adm. David M. Stone, USN (Ret.), assistant secretary of homeland security for TSA.

In-line baggage-screening systems will replace the large EDS machines now in

airport lobbies and will be installed into the behind-the-scenes baggage- handling conveyor system where the baggage is screened for explosives and automatically sorted. Th is solution increases the effi cien-cy of screening checked baggage and en-ables passengers to drop off their checked baggage at the ticket counter without a separate screening process. £

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DHS turns to high tech

to control bordersDepartment of Homeland Security officials are procuring and developing technology to secure the nation’s borders and prevent terrorists and weapons from getting through.BY JOHN MCHALE

Today’s news is fi lled with stories about how porous the U.S. borders with Canada and Mexico are, and how easy it is for terrorists to slip through where they potentially could wreak havoc.

More than 500 million people cross U.S. borders every year, including 330 million noncitizens. Commerce and in-dustry boost that traffi c, as 11.2 million trucks and 2.2 mil-lion rail cars cross our borders annually.

Th at is just the tally of traffi c through 350 offi cial ports of entry. Between those legal border crossings lie vast expans-es of open space —the U.S. shares 5,525 miles of border with Canada, and 1,989 miles with Mexico.

Th ose vast numbers mean that border agents cannot pos-sibly check every car or every traveler. U.S. Department of Homeland Security (DHS) offi cials, therefore, are relying on new technologies to tighten the country’s borders.

Th e Offi ce of Customs and Border Protection is the main arm of the DHS for border security.

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Experts at the Civitas Group in Wash-ington, a fi rm that specializes as a liaison between the Homeland Security Depart-ment and private businesses, say there are two main types of border security. First is strict border surveillance like the Arizona border, and the second is points of entry like airports and seaports.

Typically, the goal of border security is to prevent entrance to illegal aliens and terrorists, says Rick Gordon, vice presi-dent of the Civitas Group. It is possible to control the borders thoroughly though technology, but political considerations such as the right to privacy can get in the way, Gordon points out.

Points of entry require credential-ing technology such as smart cards, bio-metrics, and risk-management tools that allow operators of security terminals ac-cess to several kinds of biographical or biometric information and compare it to multiple databases such as the FBI’s Au-tomated Fingerprint Identifi cation Sys-tem, or AFIS.

Currently, fi ngerprints are the main biometric choice; however, new pass-ports may have embedded chips that store a digital image of a person’s face in addition to a fi ngerprint, Gordon says. Although this change is still basically the same as a customs agent or security offi -cer checking a regular photograph, even-tually it will lead to some type of facial recognition, he explains.

There is still a 5 percent failure-to- enroll rate with fi ngerprints but no other biometric is as efficient overall, Gordon says. Typically, the DHS offi cials require all 10 fi ngerprints to be taken because the more fi ngerprints, the easier it is to fi nd a match, Gordon says.

Another technology for port of entry is millimeter-wave RF technology, which can see through clothing and can spot concealed weapons, Gordon says.

One of the companies specializing in technology for securing points of entry, Markland Technologies Inc. in Ridge-land Conn., completed repairs and im-provements to the Secure Electronic Network for Travelers’ Rapid Inspection (SENTRI) system at the heavily traveled U.S. border crossing with Mexico in San Ysidro, Calif.

San Ysidro, Calif., across from Tijua-na, Mexico, is less than 20 miles south of downtown San Diego, and is the world’s busiest port of entry. On an average day, more than 40,000 vehicles pass through.

The SENTRI system at San Ysidro processes prescreened vehicles and low-risk travelers from Mexico in an expe-ditious manner through dedicated travel lanes, Markland offi cials say.

Recent work by Markland’s wholly owned subsidiary Ergo Systems includ-

ed the installation of new roadway-em-bedded sensors, tire shredders, and exit gates. Th ese repairs and improvements improved the security and traffic f low of vehicular traffi c entering the United States from Mexico.

The Massachusetts Port Authority (Massport) is using VistaScape’s SiteIQ surveillance platform to protect Lo-gan International Airport and Mass-

port maritime properties located in and around Boston Harbor. Th e announce-ment follows a pilot project at Logan Air-port in May 2003.

Massport selected the ADT Security Services Federal Systems Division, a unit of Tyco Fire & Security based in Boca Raton, Fla., as the prime contractor and systems integrator, responsible for in-stalling the SiteIQ soft ware, surveillance

cameras, and other security infrastruc-ture. ADT’s Federal Systems Division is in Alexandria, Va. Ross & Baruzzini Inc. in St. Louis is providing the architecture design and engineering services for the project.

SiteIQ soft ware provides a graphical display for monitoring activity across an entire area, based on input from surveil-lance cameras and other sensors. Rath-

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er than relying on guards to monitor several video displays, SiteIQ uses geo- enhanced video analytics to plot detect-ed activity in real time on a 3-D world

model. SiteIQ detects, tracks, and clas-sifi es objects onscreen and, if a securi-ty rule is violated, automatically alerts authorities with audible alarms and live

video of the event.“VistaScape’s software extends our

eyes far beyond the reach of conventional surveillance systems,” says Dennis Treece, director of corporate security for Mass-port. “Th is means a more productive and eff ective security staff for Massport, which translates into a higher level of safety and service for our passengers, commercial customers, and the general public.”

Among the camera technologies from ADT is an infrared camera from Hurley & Associates for high-resolution video

imagery at night and in bad weather. In addition to the fi xed camera infrastruc-ture, Massport will receive a deployable detection device that extends coverage to new areas of concern.

Nuclear materials detectionTh e majority of the research coming out of HSARPA and the DHS is for detect-ing and dealing with radioactive threats, Gordon says. It is a top priority for DHS. Some equipment is already in use but not nearly enough, he says.

SiteIQ from VistaScape is a software platform that provides a single, graphi-cal display for monitoring activity across an entire area, based on input from surveillance cameras and other sensors.

Coast Guard signs BAE Systems to provide port security Offi cials at the U.S. Coast Guard’s Research and Development Center selected BAE Systems in Burlington, Mass., to build the SeeCoast Port and Coastal Scene Awareness Prototype and Demonstration System.

The program, valued at $3.3 million including options, is part of the Department of Homeland Security’s (DHS) Advanced Research Projects Agency (HSARPA) Auto-mated Scene Understanding program.

The SeeCoast system will integrate radar track data, video image streams, po-sitioning information from an Automatic Identifi cation System (AIS), and other data inputs, to provide machine understanding of the coastal and port security scene and enhance vessel detection, evaluation, and tracking in support of tactical anal-ysis and intercept decisions.

SeeCoast will leverage existing BAE Systems capabilities in video processing, track correlation and fusion, rule-based alerting, and visualization. It will use ad-vanced learning methods based on human cognitive processing models to enable continuous, on-the-fl y learning of anomalous activities.

SeeCoast will be installed in the DHS Hawkeye test bed at the Portsmouth, Va., and Miami Coast Guard Sector Command Centers during the fi rst 12 months of the contract.

For more information, see www.na.baesystems.com.

iControl wins DHS contract for container security Offi cials at the U.S. Department of Homeland Security awarded a Phase II Marine Asset Tag Tracking System (MATTS) contract to iControl Inc.

MATTS is part of the Future Smart Container initiative, which establishes the architecture and standards necessary to secure shipping containers from the fac-tory to the warehouse. Phase II culminates in the demonstration of iControl’s solu-tion in a global operating environment.

While industry has focused on supply-chain management and “port-centric” communications, iControl’s MATTS solution will provide Homeland Security and fi rst responders with “anytime, anywhere” access to a container’s status, iCon-trol offi cials say.

“Managing the supply chain is not the same as securing the supply chain,” says iControl’s MATTS program manager, Diane Quick. “Terrorists do not fi ll out manifests or use RFID tags on their shipments. A compromised container is a threat not only to ports, but also to urban areas and critical infrastructure it passes while in transit. Securing populations, property, and economies requires continuous container track-ing and monitoring.”

The MATTS architecture consists of container tags, gateways, and a Data Center. iControl’s use of its existing commercial products as a baseline for the MATTS solu-tion substantially reduced cost, risk, and development time, company offi cials say.

“The MATTS program requirements represent a challenging, yet logical exten-sion of our commercial product capabilities,” says Fred Tubb, iControl’s chief execu-tive offi cer. “During Phase II, iControl’s container tracking device will be deployed as a miniaturized System-On-Chip (SOC) design. It provides substantially superior pro-cessing, communication range, and worldwide tracking capability when compared to RFID technologies. Strategically, we have chosen international standards to improve overseas adoption, to speed deployment, and to minimize installation.”

For more information visit www.icontrol-inc.com.

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Th e biggest problem with these devic-es is the number of false alarms, accord-ing to Gordon. Minor radiation from a watch or even from granite particles of-

ten will set it off . A person can become more radioactive in the granite moun-tains of New Hampshire than on a nu-clear submarine, Gordon points out.

DHS Secretary Michael Chertoff an-nounced this spring that the nation’s bus-iest seaports—Los Angeles/Long Beach, Calif.—will have complete radiation por-

tal monitor (RPM) coverage by year’s end. Th ree terminal locations, at Piers 400,

300, and Trans Pacifi c, within the Port of Los Angeles are scheduled to go online by

Offi cials at the U.S. Customs and Bor-der Protection Branch of the Department of Homeland Security successfully fl ight-tested the eNfusion Broadband commu-nications solution from EMS SATCOM in Ottawa, Ontario, earlier this year. Equip-ment tests took place aboard a P3 Orion multimission aircraft.

“EMS SATCOM is able to provide the most bandwidth over the global Inmarsat satellite network, and is ideal for the va-riety of missions that the P3 aircraft per-forms,” says Stephen Newell, director of government sales for EMS SATCOM. “Bandwidth-on-demand provides the most cost-effective use of this system.”

The U.S. Customs and Border Pro-tection P-3 Orion Aircraft, based in Cor-pus Christie, Texas, are primarily used for detection, monitoring, and interdiction of drug traffi cking in Central and South

America. An aircraft equipped with EMS SATCOM’s eNfusion Broadband com-munications system uses the combina-tion of an EMS SATCOM HSD-128 (high-speed data terminal), two HSDX’s, and an AMT-50 Antenna and radome, to pro-duce 256 kilobits per second of commu-nications bandwidth.

A key feature is the system’s ability to automatically turn channels on and off, based on communication requirements—making contact with the command cen-ter virtually seamless, company offi cials say. The single most important advan-tage of the solution is immediate access to information—for better decisions and faster reaction times.

The HSD-128, a broadband commu-nications terminal, provides secure ac-cess to VPNs, and delivers e-mail, video-conferencing, and Internet.

The AMT-50 antenna is a high-gain Aero-H/H+ multichannel antenna that is lightweight, tail-mounted, and reliable. It provides hemispherical coverage, with no keyholes or gaps, EMS offi cials say.

The HSD-X data extension is an add-on module that provides additional speed to the HSD terminal’s throughput. The HSD-400 line will support CNS/ATM and evolving SwiftBroadband services.

EMS’s CNX cabin network accelera-

tor is a special-purpose, aircraft-certifi ed network solution that combines data ac-celeration, routing, inverse multiplexing, ISDN, terminal adapter, Ethernet hub, and telephony support. It increases Sat-com network throughput by as much as 400 percent, providing high-speed con-nectivity to and from the air, company of-fi cials say.

For more information visit www.ems-satcom.com.

P-3 Aircraft uses EMS SATCOM for real-time streaming video.

U.S. Customs and Border Protection selects EMS satellite communications technology for P3 aircraft

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the end of June. A to-tal of 90 RPMs, which will screen all interna-tional container traffi c and vehicles exiting the facility, for nuclear ma-terials or hidden sourc-es of radiation, will be operational by Decem-ber 2005.

RPMs provide U.S. Customs and Border Protection (CBP) of-ficers with a passive, nonintrusive means to screen containers, ves-sels, or vehicles for the pres-ence of nuclear and radiological materials. Th ese systems do not emit radiation but are capable of detecting various types of radi-ation emanating from nuclear devices, dirty bombs, special nuclear ma-terials, natural sources, and isotopes com-monly used in medicine and industry.

“By applying advanced technology, we will soon be able to screen every vehicle and container entering the nation’s bus-iest seaports for nuclear and radiologi-cal materials, without disrupting the free

fl ow of trade. Complete and efficient coverage at the LA/Long Beach seaports is a major step forward for national se-curity and a model for other ports,” Secretary Chertoff says.

DHS implements a multilayered strategy for screening cargo shipped to the U.S. One such lay-er is the installation of RPMs at seaports, land border ports of entry, and crossings nation-wide, including rail crossings, internation-al airports, and interna-tional mail and express consignment courier fa-cilities, in an effort to

screen 100 percent of all incoming goods, people, and conveyances for radiation.

In April, maritime facilities at the Port of Oakland, Calif., became the fi rst sea-port in the country to have complete cov-erage. RPMs at the LA/Long Beach sea-ports will complement existing cargo security measures to include five mo-

bile gamma ray and two x-ray scanners, personal radiation detectors, and isotope identifi cation devices.

Th e LA/Long Beach seaports receive approximately 44 percent of all sea cargo destined for the U.S. More than 4.3 mil-lion foreign cargo containers arrived at the LA/Long Beach seaports last year—an average of one container every seven seconds.

In April DHS officials also extend-ed the department’s contract with the ORTEC business unit of AMETEK to in-clude the fast-track development and de-livery later this year of two prototypes and other related hardware for an Advanced Spectroscopic Portal Monitoring System.

Th e $3.1 million contract extension follows a fi rst-stage contract awarded by HSARPA in January to AMETEK to de-velop the system, which will screen pas-sengers and cargo for potentially harm-

ful shipments of radioactive materials that could be used in a nuclear device or “dirty bomb.”

Th e prototype systems will incorpo-rate arrays of ORTEC high-purity ger-manium detectors coupled with several unique and novel techniques to process and present data collected from possible gamma and neutron radiation emanat-ing from pedestrians, vehicles, or freight containers. Th e systems will be able to quickly determine whether a source is “innocent,” such as naturally occurring radioactive materials and medical iso-topes, or “suspicious” and poses a poten-tial terrorist threat to safety or security.

The greatest biological threat in Gordon’s mind is a terrorist firing a rocket-propelled grenade into a chlorine tank, he says. “Th ey don’t even need an RPG, all they need to do is blow it up,” he adds. £

ObjectVideo in Reston, Va., has won two contracts totaling as much as $3.2 million over the next three years from the Homeland Security Advanced Re-search Project Agency (HSARPA) to develop next-generation capabilities for intelligent video surveillance systems.

HSARPA officials selected Object-Video from more than 50 companies and awarded it two of the four contracts avail-able to study “Automated Scene Under-standing,” ObjectVideo offi cials say.

The public and private sector have deployed sophisticated security net-works that utilize closed-circuit televi-sion (CCTV), specialized video and infra-red cameras, radars, and other sensors to provide physical security and gener-al awareness at critical infrastructure, transportation hubs, borders, ports, harbors, industrial sites, and other key locations. However, these systems can overload operators with data, increas-ing the chances of the systems being ignored, mismanaged, or rendered in-effective, company offi cials say.

HSARPA has contracted with Objec-tVideo to address this problem by en-riching intelligent video surveillance sys-tems with smarter capabilities including automated threat awareness and dy-namic adaptability—capabilities that are useful in a highly dynamic environment, such as an airport or seaport, where planes and freighters are continually moving in and out of the scene and may not appear in the same area twice.

Instead of monitoring an “area of in-terest” on a continual basis, this next-generation system recognizes specifi c mobile assets, understands what rules apply to them, and automatically adjusts

to protect them, no matter where they appear. It does all of this without a sys-tems operator intervening.

The benefi ts of this capability are a much higher level of protection, fewer false alarms, and smarter use of man-power because it frees the operator from having to constantly set and re-set rules to keep up with the variations in movement of mobile assets.

“HSARPA is seeking to amplify the effectiveness of vital security systems by taking a key component of those sys-tems—intelligent video surveillance—to the next level,” says Dr. Alan Lipton, chief technology offi cer of ObjectVideo.

ObjectVideo’s intelligent video-anal-ysis algorithms, based on artifi cial in-telligence called “computer vision,” run all objects in a camera’s view against pre-programmed rules. When an ob-ject violates a rule—for example, a small boat loiters next to a ship, a bag is left unattended in an airport terminal, or a shopper displays characteristics of shoplifting—the software alerts security personnel by phone, pager, e-mail, or an alert console.

Customers of ObjectVideo’s technol-ogy include the Department of Homeland Security’s Customs and Border Protec-tion Bureau, the Department of Defense, the U.S. Air Force, the Department of En-ergy, the Port of Jacksonville, Port Ever-glades, Miami International Airport and a variety of private-sector businesses.

ObjectVideo markets and sells its products through a VIP partner pro-gram of leading security companies on digital signal processor and serv-er platforms. For more information, see www.objectvideo.com.

The Massachusetts Port Authority (Massport) is using VistaScape’s SiteIQ surveillance platform to protect Logan Inter-national Airport.

ObjectVideo wins DHS contract for video surveillance

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TECHNOLOGY FOCUS BY BEN AMES


F rom electric-drive ships to hybrid Humvees, military vehicles that rely on electric motors rather than

internal-combustion engines will soon rely on advanced power electronics to handle huge voltages in their drive trains.

Power components also must stretch to handle extra-low voltages, as comput-er designers demand power below 5 volts for the latest microprocessors. Designers are also using new kinds of power com-ponents for tasks like replacing hydrau-lic fl ight controls with electric motors on commercial aircraft .

At the same time, designers are seek-ing to reduce the size and weight of the components they use in unmanned aerial vehicles and unmanned ground vehicles. Th ey are also trying to shave ounces from the increasing array of electronic gear that U.S. troops will carry onto the future net-worked battlefi eld.

The next great frontierPower electronics always have driven the systems and sensors aboard military ve-hicles. In the next generation of military designs, power electronics will grow to handle the drive train of the entire vehicle. Designers of military vehicles, in fact, see electric power as the next great frontier.

Electric power is already the solution for industrial applications that need tre-mendous torque, such as freight-train locomotives and the huge dump trucks that operate in strip mines.

Th at is the same approach that Boeing engineers plan to use in the “hybrid elec-tric drive architecture” for manned and unmanned vehicles in the Future Combat System family of battlefi eld vehicles, due to be phased into use over the next 10 years.

Now naval architects are designing an all-electric version of the Nimitz-class

aircraft carrier. Electricity would drive everything from the propellers, to air-craft -launching catapults, to deck guns. Other designers are looking to electrici-ty for unmanned aerial vehicles (UAVs) and for ground vehicles powered by hy-brid gas-electric engines or fuel cells.

The trend also applies to civilian air-craft. Engineers at Boeing Commercial

Airplanes in Renton, Wash., plan to elim-inate compressed air and hydraulic-con-trolled actuators for the fl ight controls in next-generation planes like the 787 Dream-liner, says Rick Furtney, vice president of the high-reliability business unit for Inter-national Rectifi er in El Segundo, Calif.

Regardless of the platform, all-electric systems generally call for two types of mo-tors—variable-speed motors for fuel pumps and vehicle drives, or precision-control ac-tuators for gun turrets and fl ight controls. All those electric motors put a tremendous load on a vehicle’s electric system.

Th e future all-electric aircraft carrier will use electricity for more than just its

propellers; it will also launch airplanes and fire guns with electricity. “It will have a huge power plant essentially to run thousands of volts through the en-tire carrier,” Furtney says.

So technicians at International Recti-fi er build 600- and 1,200-volt insulated- gate bipolar transistors (IGBTs) for such applications. IGBTs are voltage-controlled

power transistors that have higher current densities than equivalent high-voltage- power metal-oxide-semiconductor fi eld-eff ect transistors (MOSFETs). Th e compa-ny also makes a hermetically sealed variety of IGBT for military fl ight control.

Hybrid drives Military designers are also driving the move to electric power as a way to achieve better fuel effi ciency.

Oil prices have been rising quickly for domestic consumption, and they are even higher on the battlefield. By the time it reaches the front lines, gasoline can cost $40 to $600 per gallon including

security and transportation, he says. Hy-brid and electric vehicles represent one way to cut those costs.

Electric motors also make less noise than internal-combustion engines. Army leaders are designing a gas-electric hybrid Humvee that can travel nearly 470 miles on a 25-gallon tank—or about 19 miles per gallon—and then drive another 25 miles in silence using battery power alone. Humvee is the military’s nickname for the High-Mobility Multipurpose Wheeled Ve-hicle, or HMMWV.

Another benefi t of electric vehicles is their ability to share power more easily than gasoline-powered trucks can.

“We learned in Iraq we needed genera-tors on the battle frontier, so now we need to make more-robust generators and add them to vehicles,” Furtney says. “All the Humvees can’t be pulling generator trail-ers around, so instead we’re trying to inte-grate the generator into the vehicle.”

Power electronics drive avionicsThe next generation of aircraft will rely more on electric drives and actuation than ever before, which represents a complex challenge for power distribution, whether it is driving a low-power task like a cathode-ray tube or image intensifi er, or a high-pow-er device like a radar, traveling wave tube (TWT), or electronic countermeasures.

In civil aerospace applications, the Boe-ing 787 Dreamliner and Airbus A380 pas-senger jets use variable-frequency power, with increased demand for electric mo-tors and motor controllers as opposed to hydraulic actuation, says Mark Stefanich, business development manager for Air-craft Electrical Power at Crane Aerospace & Electronics in Lynnwood, Wash.

In fact, the 787 needs a total gener-ator capacity of one megawatt—twice what was necessary for predecessors like the 737 and 777, he says.

At the same time, designers are apply-ing lower voltage at the point of load—such as the card or system distribution level—while retaining standard power at the main distribution bus. That means they need to use an intermediate bus ar-chitecture to step the main load down far enough to use commercial off-the-shelf (COTS) products. A typical main bus sup-plies 28 volts, while an intermediate bus drops that to 12 or 5 volts.

Customers are also demanding bet-ter use of generators, he says. Electric air-craft controls need more stringent pow-er quality, and that means increasing the number of solid-state components

Power electronics drive next-generation vehiclesEngineers are building power integrated circuits and other power components to match growing current needs and the effi ciencies of unmanned aerial vehicles, manned aircraft, spacecraft, and ocean-going ships, as well as armored combat vehicles.

Modern avionics design calls for point-of-use modules such as the SMRT space converter (far right), says Crane Aerospace’s Ernie Parker. Also shown is a 6U single slot VME standard power sup-ply (middle) and an AC-DC power converter (left).

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to create high power and low distortion for applications such as head-up displays, radar, and electronic countermeasures.

To meet those demands, Crane engi-neers use solid-state switching and new topologies like three-phase harmonic correction, says Ernie Parker, director of technology development for Crane’s Power Solutions group.

They also design customized pow-er electronics that enable military archi-

tectures to work with COTS parts, since military designers have adopted the trend of using low-voltage processors from the telecommunications server world.

Th e increased demand for custom pow-er solutions also comes from original equip-ment manufacturers (OEMs) pushing inte-gration work to their customers, who then outsource it to companies like Crane.

Customers have also been request-ing help in providing certification for DO 254, the military hardware quality- assurance requirement.

“We are having to create our own stan-dard products that mimic industry solu-tions, such as point-of-load regulators, bus converter modules, and off -the-shelf VME solutions,” Parker says. Military ap-plications have unique demands for input voltage, environmental protection, and process-control (such as verifying design process to agree with DO 254).

“Our customers want to take advan-tage of COTS reliability and cost, but as they move up in complexity, they must make adaptations,” he says. For example, Crane makes a VME card-slot power sup-ply with standard DC-DC converters but

with custom interface circuits. Th e unit can deal with wide-ranging military tran-sient standards as opposed to the more restricted power-input range required by COTS parts.

“It mimics what’s on the commercial market, because the needs are the same, but in a version that maps better to military input ranges and provides process data for DO 254. We provide COTS standards with a military pedigree,” says Parker.

Fighter jets need power effi ciencySize and weight are crucial details for military avionics and satellite design-ers. Th ey look for high power density in a small package, with hermetic seals and broad temperature ranges.

Temperature is a crucial measure be-cause airplane components can get hot sitting on a runway in Saudi Arabia, then quickly become freezing cold in high al-titude during fl ight, says Mike Bosmann, senior vice president of sales and market-ing at VPT in Blacksburg, Va.

Effi ciency is also critical for design-ers of military aircraft , instruments, and satellites. Th at is the goal for VPT’s new

DVCH product line of DC-DC convert-ers, designed to deliver very low pow-er output—1.5 watts and below—over a wide voltage range with hermetic sealing and a broad temperature range.

Th e unit accepts military input volt-ages from 12 to 50 volts input voltage, and off ers single-voltage outputs of 3.3, 5, 5.2, 12, and 15 volts. Until now, design-ers could use VPT’s 5-watt product for those applications, but they paid a price in effi ciency, he says.

“Usually noise and effi ciency are sac-rifi ced for small size, wide input voltage range, and full military operating range,” says Bosmann. “Our technology enables us to deliver a converter that provides a higher power-conversion effi ciency and carries an output ripple that is one-sixth the noise of our closest competitor.”

Customers are also asking for lower voltage parts. So last year, VPT released two product families of triple-output units; one rated at 5 volts and one rat-ed at 3.3 volts.

And in 2003, VPT designers developed the DVSB brand of DC-DC power convert-er for the F-35 Joint Strike Fighter. It uses dual pulse width modulation (PWM) chips to generate split outputs at 3.3 and 5 volts from an input range of 15 to 50 volts. Th is product allowed engineers to use a single component instead of two, saving valuable weight and volume on the aircraft .

Satellites use lower voltageManufacturers of electrical components for space applications face the opposite chal-lenge—whereas voltages are rising on vehi-cle motors, they are dropping on satellites.

A typical satellite bus runs at 100, 50, or 28 volts, depending on the manufac-turer and whether it’s used for commer-cial communications or military im-aging and targeting, says International Rectifi er’s Furtney.

Designers then break that current down to 50 volts and down again to 5 volts to route it through the system. Modern microprocessors on small die sizes use even less voltage, so design-

Current Humvees rely on expensive fuel, so Army leaders are designing a hybrid Humvee with a gas-electric engine for better mileage and silent running.

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TECHNOLOGY FOCUS

ers must step the power down yet again, reaching 3.3, 2.5, or even 1.8 volts.

Th at is crucial in space because satel-lite designers are handling more and more of the processing load on the spacecraft itself, instead of shipping bulky raw data back to Earth on limited bandwidth.

“Now we’re going to point of load reg-ulation, because a single satellite can be running several diff erent voltages,” Furt-ney says. “If you’re running an FPGA at 1.8 volts and a processor at 2.5, the I/O can be at 3.3 and the memory core is usually even lower. Advanced architec-ture oft en needs more diverse voltages, to handle the increased processing in a space environment.”

Space platforms are also using more solid-state power components.

Designers of space-based platforms have always used mechanical relays for radiation-hardened applications. Yet those relays oft en fail because of shock and vibration, hardening of contact lu-bricant in space temperatures, and the increased weight of extra parts to handle low-voltage logic gates.

So designers at International Recti-fi er have launched rad-hard, solid-state relays. Th e RDHA7x series off ers switch-ing speeds comparable to mechani-cal units, but has better performance in shielding electromagnetic and radio-frequency interference, says Alan Task-er, engineering lead for space module products at International Rectifi er HiRel Products LLC in Leominster, Mass.

A typical unit has three main com-

ponents: an input buff er, an optoisolator, and a rad-hard MOSFET. Compared to other solid-state relays on the market, it boasts lower system electrical noise and a direct interface to logic, Tasker says.

Customers ask for rad-hard parts to guard against many scenarios—the slow-and-steady Total Indicated Dose for a long-endurance satellite, the Single Event Eff ect of heavy ions hitting a booster rock-et, or battlefi eld radiation exposure.

Power components land on MarsEngineers who design satellites and space-craft have special demands for electronic parts. Th ey must be radiation-hardened to withstand exposure to radiation as strong as 100 kilorads for long-endurance mis-sions. Th ey also must be effi cient because electric power is scarce in space, generat-ed sporadically by solar panels and stored in batteries.

Engineers at Aerofl ex in Plainview, N.Y., held those demands in mind as they de-signed a radiation-hardened, pulse width

modulation chip called the ACT5031 to meet specifications for the mobile Mars Science Laboratory rover, a NASA project scheduled for launch in 2009. Th at rover will carry sensors from the Russian and Spanish space agencies to fi nd potential habitats for past or present life, and will plan to remain active for one Mars year (equal to two Earth years) aft er landing.

Aerofl ex engineers worked alongside designers from the NASA Jet Propul-sion Laboratory in Pasadena, Calif., and the Applied Physics Lab at Johns Hop-kins University in Baltimore. Th e result is a chip that has low standby power, can operate effi ciently in sleep mode, and com-plements existing radiation-hardened DC-to-DC converters, says Joe Castaldo, direc-tor of sales and marketing for the Aerofl ex microelectronics operation.

Company engineers made the chip efficient by building it with a CMOS process, as opposed to bipolar or non-CMOS. Th ey also enabled the device to tolerate as much radiation as 100 kilo-

U.S. Air Force fi ghter jets use 270 Vin DC-DC micro modules from Vicor for environmental cooling.

When it launches in 2009, NASA’s Mars Science Laboratory will rely on a pulsewidth modulation chip from Aerofl ex.

Absopulse ElectronicsCarp, Ontario 613-836-3511 www.absopulse.com Advanced Linear Devices Inc.Sunnyvale, Calif.408-747-1155www.aldinc.comAdvanced Power TechnologyBend, Ore.541-382-8028www.advancedpower.comAerofl exPlainview, N.Y.516-694-6700http://ams.aerofl ex.comBehlmanHauppauge, N.Y.631-435-0410www.behlmanpower.com Crane InterpointRedmond, Wash.425-882-3100www.interpoint.comDiversifi ed Technology Inc.Ridgeland, Miss800-443-2667www.dtims.comFairchild SemiconductorSouth Portland, Maine207-775-8100www.fairchildsemi.comGaia Converter Inc.Saint Laurent, Quebec888-601-3169www.gaia-converter.caInternational Rectifi erEl Segundo, Calif.310-726-8000www.irf.comIntersil Corp.Milpitas, Calif.408-432-8888www.intersil.com

K&M ElectronicsWest Springfi eld, Mass.413-263-6200www.kandm.com Kepco Inc. Flushing, N.Y.718-461-7000www.kepcopower.com Martek Power Los Angeles, Calif. 310-202-8820 www.martekpowerabbott.comMS Kennedy Corp. Liverpool, N.Y. 315-701-6751 www.mskennedy.com Micro Power Hillsboro, Ore. 503-693-7600 www.micro-power.comNorth Atlantic Industries Bohemia, N.Y. 631-567-1100 www.naii.comPico Electronics Inc. Pelham, N.Y. 914-738-1400 www.picoelectronics.com Pioneer Magnetics Santa Monica, Calif. 310-829-6751 www.pioneermag.com Pivotal Power 902-832-7359 www.pivotalpower.com Powerex Youngwood, Pa. 724-925-7272 www.pwrx.comRantec Power Systems Los Osco, Calif. 805-596-6000 www.rantec.com Richardson Electronics LaFox, Ill. 630-208-2200 www.rell.com

RO Associates Inc. Sunnyvale, Calif. 408-744-1450 www.roassoc.com Semicoa Semiconductors Costa Mesa, Calif. 714-979-1900 www.semicoa.comSolid State Devices Inc. La Mirada, Calif. 562-404-4474 www.ssdi-power.comSolitron Devices Inc. West Palm Beach, Fla. 561-848-4311 www.solitrondevices.comSpectrum Control Fairview, Pa. 814-474-2207 www.spectrumcontrol.com Transistor Devices Inc. (TDI) Franklin, Mass. 508-520-9960 http://tdipower.comTeledyne Technologies Los Angeles, Calif. 310-893-1600 www.teledyne.comTracewell Systems Westerville, Ohio 614-846-6175 www.tracewellsystems.com Transistor Devices Hackettstown, N.J. 908-850-5088 www.tdipower.com Vicor Corp. Andover, Mass. 978-470-2900 www.vicorpower.comVishay Siliconix Malvern, Pa. 402-563-6866 www.vishay.comVPT Inc. Everett, Wash. 425-353-3010 www.vpt-inc.com

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THE POWER MANAGEMENT LEADER

For a simple design approach you can counton, switch to IR’s radiation-hardened (RAD-

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Immune to the failure modes experienced byelectromechanical devices, our compact RAD-Hard solid state relays provide more reliableon/off switching with lower system partcount. These devices use IR’s long establishedRAD-Hard MOSFETS and are designed tosurvive in high reliability environments.

IR Advantage

• Fewer parts:– No contact bounce filters required– Direct interface to logic

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• SEE rated & TID capable to 100 krad(Si)

• 1,000-volt input to output isolation• Available in SMD or flange Mount

package styles

Contact your local IR Hi Rel sales representativeor go to www.irf.com for data sheets,application notes and radiation reports.

New HiRel Short FormCatalog now available! Provides overview of IR’sHiRel product lines, latesttechnologies, testing,screening, nomenclatures,and case outlines.

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Part Package Current Contact Input EMI/RFI Number Rating Configuration Type Control

RDHA710SE10A2Q 8-pin SMD 10 A Dual SPST 5V Logic ControlledNormally Open Buffer Transition Times

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VSLogic + Relay Driver + Mechanical Relay Logic + Solid State Relay

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TECHNOLOGY FOCUS


rads by building it with a 0.6-micron commercial rad-hard process.

When they release the ACT5031 in July, Aerof lex will position it against competing products from Texas Instru-ments in Dallas, Linear Technology in Milpitas, Calif., and SGS-Th omson, now known as STMicroelectronics, in Car-rollton, Texas.

Customers want to buy electronic com-

ponents off the shelf, which is why Aero-fl ex has expanded its family of rad-hard voltage regulators for satellite applica-tions. The company started with the ACT8601 in 1999, built to withstand a total dose of radiation as strong as 100 kilorads. The device offers adjustable output voltage from 1.2 to 37 volts, 1.5-amp output current, hermetic packag-ing, and a temperature range for indus-

trial, military, and space demands.Th e company off ers four related choices:

the 8603 and 04 off er 30-kilorad protection for three-to-six-month missions, while the 8601 and 02 off er full 100-kilorad protec-tion for 10-year endurance.

Customers also demand standard mili-tary drawings (SMDs) craft ed to standards set by the U.S. Army’s Defense Supply Cen-ter Columbus (DSCC) in Columbus, Ohio,

Fighter jets need effi cient power management at low voltage, which is the purpose of the DVCH product line of DC-DC converters, from VPT. This unit accepts input power from 12 to 50 volts, and offers output of 3.3, 5, 5.2, 12 and 15 volts.

and the resulting data sheet. Aerofl ex has submitted these components for approval.

Components shrink to fi t on UAVsWhen military designers need a power converter, they usually choose a DC-DC converter brick. Most COTS applications can use a full-, half-, or quarter-brick, while specialized jobs use one-eighth or one-sixteenth. Now they have another option—the VI Chip from Vicor Corp. in Andover, Mass. Th e chip can replicate the functionality of a full brick in one-fi ft h the space, while off ering better performance in effi ciency, noise, transient response, and cost, says Andrew Hilbert, senior director of product marketing for Vicor.

With its small size and weight, the VI Chip would be a good match for unmanned aerial vehicles (UAVs) and for personal elec-tronics carried by soldiers.

Some engineers combine bricks and chips. They face a challenge of stepping voltage down low enough to power the lat-est processors, so they oft en use a brick up-stream and then a VI Chip to drop power from 5 volts to 3.3 or lower, Hilbert says.

Vicor is also working on a version of the chip that will handle higher voltages, necessary for electric-drive vehicles. Th e current product family serves the 48-volt commercial market, but Vicor engineers plan to release an extension for 300-volt jobs, as well as a family built for the 28-volt COTS market, with an extension for 270-volt high-power jobs.

Military specifications often require unique input voltages and EMI standards, so Vicor engineers can build almost any custom solution, says Keith Nardone, se-nior military product marketing manager.Th at is crucial to serve a military market challenged by parts that become obsolete within a year or two, he says. So Vicor de-signers use the company’s library of DC-DC converters as a menu of standard building blocks, then optimize the part for main circuits, ancillary circuits, ther-mals, and packaging. £

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Behlman COTS Power Products

Battle-proven, from the cold war to the war on terror.For nearly 50 years, Behlman COTS and build-to-print

power products have performed in even the mosthostile environments on the ground, at sea and in

the air. Behlman meets Military requirements forlow-cost, fast-turnaround, ultra-reliable power

solutions, and offers proven expertise inreverse engineering and modernizing

obsolete power supplies.

We meet MIL-STD-461, MIL-STD-704, MIL-S-901, MIL-STD-810 and

other military specifications. For a freeconsultation call 1 800 874-6727, or email

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• AC - AC• Frequency

converters• Inverters• DC - DC• AC - DC• DC - AC • UPS


PRODUCT APPLICATIONSPRODUCT APPLICATIONS

TEST AND MEASUREMENTBAE tests F-35 cables with DCM tools Engineers at BAE Systems in Lancashire, England, needed test and measurement equipment to verify coaxial cable assem-blies for their customer, the F-35 Joint Strike Fighter (JSF) program. They found a solution with the Model HPCC-3000 test system from DCM Industries Inc. in Union City, Calif.,

Technicians with BAE Systems will use the DCM HPCC-3000 System to test the JSF aft fuselage assemblies un-der construction at the Samlesbury De-sign and Manufacturing Centre Aero-drome plant in the United Kingdom.

This system automates vector-net-work-analyzer (VNA) insertion-loss and VSWR testing of high-performance co-axial cables. Untrained testers can use DCM’s graphical user interface com-

bined with an Agilent 20-gigahertz PNA net-work analyzer and the HPCC-3000 system to measure any type and combination of connec-tors and extract adapter errors using built-in de-embedding techniques.

The system includes secure frequency testing capability, extensive data-base and test reporting functions, and VNA cal-ibration management. A specification editor au-tomatically controls VNA operation, instructs VNA which test to perform, compares the results to the test limits, prints test reports, and stores data. The system includes secured classifi ed oper-

ation, with password protection and fre-quency blanking. For more information, see www.dcmindustries.com.

In addition to the United States Air Force, Navy and Marine Corps, F-35 is being de-veloped for the United Kingdom Royal Air Force and Royal Navy, the Canadian De-partment of National Defence and eight other nations. The JSF program is the larg-est defense contract to be awarded in his-tory, with a value of just under $19 billion.

Founded in 1987 in the U.K., Strategic Thought is a technology and services com-pany specializing in mission-critical applica-tion integration and the provision of enterprise risk management software. For more infor-mation, see www.strategicthought.com.

NASA crunches weather data with VisiQuest Engineers at NASA’s Goddard Space Flight Center in Greenbelt, Md., needed a tool to analyze satellite data on global precipitation. They found a solution in VisiQuest software from AccuSoft Corp.

Technicians in the Precipitation Analy-sis Group (PAG) at NASA’s Laboratory for Atmospheres use VisiQuest scientifi c soft-ware to analyze and visualize precipitation data from 13 different satellites.

They use the data to calculate global

The F-35 is a stealthy, supersonic multi-role fighter designed to replace a wide range of aging fighter and strike aircraft.

DISPLAYSLockheed Martin picks Barco for submarine displays Designers at Lockheed Martin Maritime Sys-tems and Sensors in Eagan, Minn., needed displays for the AN/UYQ-70 program. They found a solution in fl at-panel displays from Barco in Kortrijk, Belgium.

Barco will deliver commercial-off-the-shelf (COTS) rugged flat-panel displays, graphics generators, and video frame grab-bers for various U.S. Navy applications. This order is worth $7 million.

Nearly 4,000 Q-70 consoles are in use aboard the Navy’s Virginia, Seawolf, Los An-geles, and Ohio-class submarines, Aegis-equipped cruisers and destroyers, aircraft carriers, E-2C aircraft, and amphibious ships.

Barco will provide Lockheed Martin with 20.1-inch RFD 251S rugged fl at displays and RGB video frame grabbers for AN/UYQ-70 systems. Specific system installations in-clude the COTS Refresh Program for Aegis-equipped Cruiser Conversion, the Ship Self-

Defense System (SSDS) for aircraft carriers, and the airborne P-3 Anti-Surface Warfare Improvement Program (AIP).

Together with the displays, Lockheed Martin also ordered Barco’s AVS 5100 graphics generators and RGB video frame grabbers. The AVS 5100 boards are de-signed to support high-resolution, drawing-intensive software. They provide the fl exibility to generate graphics data in separate over-lay planes, with simultaneous display of ex-ternal video sources.

Furthermore, the boards feature separate buses for video and/or radar data insertion. The additional RGB video frame grabbers will capture and store high-resolution imag-es during mission performance, to be trans-ferred and stored for later analysis on Navy P-3 aircraft. For more information see www.barco.com.

SOFTWARELockheed Martin uses software to manage risk on F-35 projectEngineers at Lockheed Martin Aeronautics Co., Fort Worth, Texas, needed a software tool to manage business risks for the F-35 Joint Strike Fighter program. They found a solution with Active Risk Manager from Strategic Thought, U.K.

Active Risk Manager is a Web-based enterprise risk management system that facilitates the identification and analysis of risks to ensure compliance with proj-ect and operational guidelines, corporate governance requirements, and industry standards. Lockheed Martin and many of its suppliers have been using Active Risk Manager since July 2001.

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fischermilitary

connectors

● Sleek, rugged, and reliable

● IP68 sealing

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● New reduced length plug is ideal for lightweight, low profile applications

www.fischerconnectors.com

Call 800.551.0121 or visit our Web site at

● Integral EMI/RFI shielding

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● Locking, non-locking, and quick-disconnect plugs available

● In use with military forces worldwide

Fischer Connectors provide the highest level of performance, even in the most harsh environments or demanding

applications.Excellent Performance and Proven Reliability

PRODUCT APPLICATIONS

www.milaero.com

rainfall estimates and post them as visu-al images online, at precip.gsfc.nasa.gov. The result is PAG’s newest offering, the global real-time three-hourly Multi-Satellite Precipitation Analysis.

International relief agencies use the data to assess risks to food resources and to de-tect fl oods and landslides. Other research-

ers include forecasters of hurricanes, El Nino effects, and global climate change.

“VisiQuest, with its visual programming interface, enables us to quickly and easily visualize and analyze our data, not just read it,” says George Huffman, technical area project manager at NASA contractor Sci-ence Systems and Applications Inc. of Lan-

ham, Md. The VisiQuest visual programming en-

vironment allows nonprogrammers to build applications by dragging and dropping icons on the screen. Users can create a visualization tool, target-acquisition project, or signal-processing application. For more information, see www.accusoft.com.

EMBEDDED PROCESSINGLockheed Martin uses Mercury computers for Aegis radarEngineers at Lockheed Martin Maritime Systems & Sensors, in Moorestown, N.J., needed a computer for an Aegis radar sys-tem. They found a solution with the Power-Stream 7000 from Mercury Computer Systems in Chelmsford, Mass.

Lockheed Martin tested the Aegis Bal-listic Missile Defense (BMD) system in Feb-ruary using a PowerStream 7000 RapidIO-based multicomputer from Mercury. Sailors aboard the Burke-class destroyer USS Russell (DDG 59) tested the system with their Aegis combat system, including an AN/SPY-1D radar, augmented with the BMD signal processor (BSP).

Mercury supplied the 6U RACE++ Se-ries VME integrated signal-processing system embedded in the BSP. The pro-cessing capability of the Mercury system enabled the SPY-1D radar to achieve real-time detection, tracking, analysis and dis-crimination of several challenging targets in the BSP’s fi rst at-sea participation of a BMD at-sea test campaign.

The PowerStream 7000 enables ex-treme processing density with one TeraFLOPS or more of total process-ing power within an air-cooled, deploy-able chassis. For more information, see www.mc.com/PowerStream7000.

AVIONICSL-3 uses BAE Systems autopilot for P-3 OrionAvionics designers at L-3 Communica-tions, New York, needed an autopilot sys-tem for P-3 Orion aircraft to be used by the Royal New Zealand Air Force. They found a solution in the Digital Autopilot Systems (DAS) from BAE Systems Platform Solu-tions in Johnson City, N.Y.

For this $3 million contract, engineers at BAE Systems will upgrade their existing DAS with a new fl ight director and an up-grade to the autopilot control panel. This award follows the U.S. Navy’s 2004 award of a $41.9 million contract to upgrade 150 P-3 Orion aircraft with the digital autopilot.

The P-3 DAS is a dual-redundant digi-tal autopilot system that offers enhanced safety, high system reliability, and lower op-erating costs. The system provides pilots with enhanced modes of operation, includ-ing control-wheel steering, navigation steer-ing, a broad range of hold modes, and au-tomatic approach to CAT 1 landings. It also provides ARINC 429/MIL-STD-1553 interfac-es that are compatible with current and an-ticipated Global Air Traffi c Management re-quirements. For more information, see www.na.baesystems.com/platformsolutions.

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NEW PRODUCTSNEW PRODUCTS


To submit new products for consideration, contact John Keller by e-mail at [email protected], or by post at 98 Spit Brook Road, Nashua, N.H. 03062. Please include a high-resolution color photo.

» EMBEDDED PROCESSING6U CompactPCI single-board computer Radstone Embedded Computing in Towcester, England, is offering the fi rst member of its PowerPact 6 product family, the CP1A 6U rugged

CompactPCI PowerPC single-board computer (SBC). Based on the PowerXtreme PPC7D VMEbus SBC, the CP1A features the Freescale 7448

PowerPC running at 1.4 GHz and the Marvell Discovery III integrated system controller. The AFIX (additional fl exible interface extension) daughter card offers features via a plug-on module. Initial offerings in the AFIX form factor include AFIX1553 (dual-channel, dual-redundant MIL-STD-1553 interfaces) and AFIXSG (SCSI and graphics accelerator). The CP1A’s also includes as many as six serial ports, up to fi ve USB 2.0 ports, as much as 33 bits of discrete digital I/O, a parallel port, and two PICMG 2.16-compliant Gigabit Ethernet ports. For more information contact Radstone online at www.radstone.com.

Upgrades to low-power Pentium embedded computerThales Computers in Raleigh, N.C., is offering several upgrades to its PENTXM single-board computer (SBC) offering. Thales is introducing

the rugged version of the PENTXM low-power Pentium M SBC operating at 1.2 GHz over a temperature range of –40 to 85 degrees Celsius. It uses a 1.6-GHz processor de-rated to 1.2 GHz for consistent effi ciency over the temperature range. Also, the commercial (SA) version of the PENTXM is now available with a 1.8-GHz build option in addition to the original 1.6-GHz processor speed option. The onboard BIOS allows the user to either fi x the clock rate of the processor to a defi ned value or let the processor determine its frequency according to the die temperature. Both processors have a 400-MHz front-side bus (FSB) as well as 64 kilobytes of primary cache. The 1.6 GHz processor has 1 megabyte of secondary cache, while the 1.8 GHz has 2 megabytes. For more information contact Thales online at www.cetia.com.

Radiation-tolerant 3U CompactPCI single-board computer for space Aitech Defense Systems Inc. in Chatsworth, Calif., is offering a radiation-tolerant, single-slot 3U Compact PCI single-board computer, based on the PowerPC 750FX microprocessor, for manned and robotic space vehicles that must operate in radiation environments. The conduction-cooled embedded computer, called the S950, is for redundant mission computers, fl ight guidance and navigation computers,

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Why use all of these?

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and command- and data-handling computers. The board also has a silicon-on-insulator processor for reduced power consumption, increased processor speed, and radiation tolerance. The S950 can withstand total-dose radiation of 20 kilorads, and has a single-event upset rate of one per 25 years of operation. For more information

contact Aitech online at www.rugged.com.

» MULTICOMPUTER SYSTEMSRuggedized multicomputer approaches 0.5 teraFLOPs Mercury Computer Systems Inc. in Chelmsford, Mass., is offering the conduction-cooled 800-MHz

7447 6U VME multicomputer for applications in extreme environmental conditions. The multicomputer can scale up to as many as 72 PowerPC 7447A compute nodes connected on the Mercury RACE++ communications fabric, for a total of 460 billion fl oating point operations per second (gigaFLOPs). Each module has an MCJ6 motherboard with one or two daughter cards. The

board also accepts high-speed front-panel data port (FPDP) I/O daughter cards. For more information contact Mercury online at www.mc.com.

» SIGNAL PROCESSINGData-capture and processing board with 2-GHz sampling rate Pentek Inc. in Upper Saddle River, N.J., is offering the model 6826 VME A-D converter board with single- or dual-channel data acquisition at 2 million samples per second with 10-bit bit resolution. The board uses the Atmel AT84AS008 A-D converter device and the Xilinx XC2VP100 Virtex-II Pro fi eld programmable gate array (FPGA), and accepts single-ended or differential inputs to preserve signal integrity across many kinds of analog signal sources. The board is for applications in wideband signal analysis, wideband radar processing, and wideband communications processing. The FPGA has a density equivalent of more than 11 million system gates and performs signal processing for the stream of data fl owing from the A-D converters. For more information contact Pentek online at www.pentek.com.

VXS board with fast I/O and FPGA processingTEK Microsystems Inc. in Chelmsford, Mass., is offering the Quixilica Callisto VXS-1 board that combines fi eld-programmable gate arrays (FPGAs) with a digital I/O architecture that moves data as quickly as 230 gigabits per second—20 gigabits through the backplane and 3 gigabits through the front panel, company offi cials say. TEK Micro is releasing the product

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Unmanned Systems: 2005-2006International Opportunities Program (IOP)

• Unmanned Systems International 2005September 8-9 • London, England, UK

• Defence Systems & Equipment InternationalExhibition & Conference (DSEi)September 13-16 • ExCeL, London, England, UKAUVSI-Sponsored Unmanned Systems Pavilion

• Unmanned Systems East Asia 2005October • Seoul, KoreaIn conjunction with the Seoul Air Show 2005

• Seoul Air Show 2005Korea Aerospace & Defense Exhibition 2005October 18-23 • Seoul Airport, Seoul, Korea

• Dubai Aerospace Exhibition 2005November 20-24 • Airport Expo, Dubai, UAEAUVSI-Sponsored UAV Pavilion

• Unmanned Systems Asia-Pacific 2006February 19-20 • SingaporeIn conjunction with Asian Aerospace 2006

• Asian Aerospace 2006February 21-26 • Changi Exhibition Center,SingaporeAUVSI-Sponsored UAV Pavilion

• Unmanned Systems Europe 2006May • Berlin, GermanyIn conjunction with ILA 2006

• Berlin Air Show, ILA 2006May 16-21 • Berlin-Schonefeld Airport, GermanyAUVSI-Sponsored UAV Pavilion

• Farnborough International 2006July 18-23 • Farnborough Airport,Farnborough, England, UKAUVSI-Sponsored UAV Pavilion

• Unmanned Systems North America 2006August 29-31• Orlando, Florida, USA

The Association for

Unmanned Vehicle

Systems International

(AUVSI®) and Flight

International magazine

have partnered to bring

the unmanned systems

community a program

focused on international

growth and exposure.

This unprecedented

annual program offers

comprehensive confer-

ences and exhibitions

in major geographic

regions of the globe.

For more information, contact: AUVSI® • Gretchen Wherry+1.703.845.9671 x203 • [email protected] • www.auvsi.org

NEW PRODUCTS


in partnership with QinetiQ of Malvern, England. VXS describes the VITA-41 high-speed data interconnect. Callisto has as many as fi ve Xilinx Virtex-II Pro Xc2VP50 FPGAs, and is for management, processing, and distribution of large volumes of data from advanced sensors such as radar, mobile communications, and electronic warfare. Callisto can concentrate data streams from as many as 16 VXS payload cards and fan data out to several VXS processor cards in applications that call for a work farm of processing resources. For more information contact TEK Micro online at www.tekmicro.com.

» DATABUSES AND NETWORKINGGigabit Ethernet TCP/IPoffl oad PMC sampling network controller

Data Device Corp. (DDC) in Bohemia, N.Y., is offering the GigExtreme ET-71000 Gigabit Ethernet network controller and TCP/IP offl oad engine (TOE) cards for applications in avionics, vetronics, high-speed video processing, motor control, and sensor interfacing. The ET-71000 offl oads the TCP/IP and UDP-IP protocol stack without modifi cation or recompilation of the network application. It not only supports the protocol stack, but also military system requirements such as traffi c shaping, redundancy management, and information security. The board also is IPv6 capable and supports board-level diagnostics. For more information contact DDC online at www.ddc-web.com.

» DESIGN AND DEVELOPMENT Virtex-4 XtremeDSP development kit for Xilinx DSP system generatorNallatech in Eldersburg, Md., is offering the Virtex-4 XtremeDSP development kit that will enable designers to use the Xilinx

Virtex-4 SX fi eld-programmable gate arrays (FPGAs) in advanced FPGA designs. The kit has a SX35 Virtex-4 FPGA, which has 192 XtremeDSP slices, in which each slice is capable of operating at 400 MHz. The kit also has embedded memory with 3,456 kilobits internal RAM and 15,360 logic slices. This kit is for DSP

designs for 3G wireless, video encoding and decoding, including H.264 or MPEG-4, radar and beam-forming applications. The kit uses Nallatech’s modular DIME-II architecture for FPGA systems, and includes the dual-mode BenONE DIME-II USB and PCI motherboard populated with a BenADDA-V4 DIME-II module.

The new kit is supported by Xilinx System Generator v7.1 software for DSP design tool, which enables designers to model high-performance DSP systems within an FPGA using the MATLAB/Simulink design environments and the Xilinx DSP IP libraries. For more information contact Nallatech online at www.nallatech.com.

Elma Electronic Inc.

Phone:(510) 656.3400

Fax:(510) 656.3783

www.elma.com

e-mail [email protected]

>> E lma R ugged COTS C h a s s i s

VVIRIRTUALLTUALLYY IINDESTRUCTIBLENDESTRUCTIBLE

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VME/VME64X and CompactPCI Backplanes, 2-20 slots

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Complete EMI/RFI integrity via braided gasketing and honeycomb filters

350 - 1400 watt power supplies: 90-240VAC/28VDC inputs, 40-440Hz

MIL Grade components

Tested for shock, vibration, and structural integrity

Designed to meet MIL-STD: 461, 810, 704, 167

Elma’s COTS 12R2 is a high quality and cost-efficient rugged package

for all VME/VME64x and CompactPCI applications. The rugged product

line includes 5U-14U models for both 6U and 9U cards. Shock-isolation

optional. Intended to withstand the demands of a military environment, the

12R2 is designed to meet benchmark military standards.



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38 July 2005 MILITARY & AEROSPACE TECHNOLOGY www.milaero.com

PRODUCT & LITERATURE SHOWCASE

Rugged Computer System with 15" Color XGA TFT DisplayST-8015 standard features includes:★ Rugged 19" rack mount chassis and rack★ 14 slot ISA/PCI passive back plane★ 300 Watt 110/220V AC 50-400Hz power supply★ Pentium III 1GHz CPU card with 256Mb ram★ 15” color TFT display with 1024x768 resolution and true colors★ Shock isolated 1.44Mb floppy and DVD/CD-R/W drives★ 36GB wide SCSI removable and shock isolated drive★ Keyboard with track ball on a slide out tray★ Meets MIL-STD-167-1 vibration★ Meets MIL-STD-901 Light weight Grade A Class 1 shock★ Win 98, NT, 2000, XP or Linux compatibleFor full line of rugged, rackmount and portable systems, please contact:

IBI Systems, Inc.6842 NW 20th Ave, Fort Lauderdale, FL 33309

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Security vulnerabilities in soft ware for military and aerospace systems unfor-tunately can be just as dangerous as the functional problems that industry has developed so many controls to prevent, and systems integrators can bet that soft ware with either type of weakness may not produce the expected results.

A functional soft ware error can oc-cur in a noncritical section of code, and have little to no infl uence on the sys-tem’s safety or success. An error that affects navigation or fuel, however, could have disastrous consequences. When an attacker manages to exploit a soft ware security vulnerability, the unexpected behavior is usually trouble-some. Aft er all, someone attacking a system is typically set on being as ma-licious as possible.

Many of the same techniques used to prevent functional problems can also reduce security vulnerabilities. Buffer overf lows are the most com-mon type of attack to exploit mili-tary and aerospace systems, but com-mon industry best practices like unit testing and coverage analysis can help prevent these attacks.

Buffer overfl owsBuff er overfl ows represent a standard problem that all too often affects ap-plications written in C and C++. Buf-fer overf low attacks occur when a hacker manages to break past an appli-cation’s perimeter security, pass an in-put through all the program’s built-in defenses, and write to the buff er. Th ese attacks only occur if the attacker can fi nd and exploit a memory corruption bug in the application.

Assume, for example, that a C++ application has an array or memory chunk on the stack, and a memory issue enables a hacker not only to write be-yond the array or memory chunk, but also to overwrite the return address of the function. By exploiting this weak-ness, the hacker either can convert the function returns to a hacker-designated function, or alter the function so it exe-cutes a hacker-designated operation.

In fact, some recently discovered buffer overf lows in major operating

systems enable hackers to perform a variety of malicious actions, such as causing the system to fail, installing programs, viewing, changing, and de-leting data, modifying any part of the system, and creating accounts with full privileges.

Developers traditionally try to han-dle these exploits by limiting the size of the input or by verifying the input. However, it is easy to miss cases if the developer has no procedure for iden-tifying all the inputs that need to be checked. To remove the opportunity for these attacks, developers need to pre-vent the memory corruption bugs that allow them to occur.

Changing a function’s return addressTh e most dangerous type of buff er over-fl ow typically overfl ows an array that is allocated on the stack. If the hacker can write beyond an array, he can also over-write the return address of a function; if this occurs, the function can return to a place that the developer did not in-tend. An attacker trying to manipulate the system could exploit this weak-ness by providing inputs that overwrite the function’s return address, have the function return to a place of his choice instead, and then perform operations of his choice.

Unit testing to expose potential vul-nerabilities can prevent this type of buf-fer overfl ow. To do this, the developer takes every routine that allocates arrays on the stack and generates a wide range of test cases for each array. Th e goal is to determine whether any potential ar-gument can overwrite memory on the stack. Soft ware developers can generate these test cases with a unit testing tool or create test cases manually.

To determine whether memory cor-ruption occurs as these test cases exe-cute, developers run the unit tests un-der a runtime error-detection tool that provides memory access checking.

For example, consider the follow-ing code:

static const int stPacketArraySize = 1024;...

ErrorStatus processUserDataStream(int userStreamLength, UserStream& stream){ErrorStatus status = OK; Packet packetArray[stPacketArraySize];

if (userStreamLength >= stPacketArray-Size) // (*){status = BUFFER_TOO_SMALL; }else{ Packet* packet = processPacket(stream);for (int i = 0; packet; i++){ packetArray[i] = packet; packet = processPacket();}}// further process the packetArray...return status;}

Although this function has a legitimate check on the array size, the check (*) will not trigger if the array size does not correspond to the actual stream length or is negative (for example, –1). The result may be a buff er overfl ow. Th is sit-uation is a cause for concern, especially if the user provides the stream length as a part of the stream.

Using unit testing, soft ware develop-ers could identify this critical security vulnerability. For example, testing the function with the typical set of bound-ary conditions for an integer variable (-MAX_INT, -1, 0, 1, MAX_INT) and adding another test condition when the supplied stream length parameter is shorter than the actual would expose this problem.

Once the developer locates the error, an apparent fi x is not only to check the size of the array against the stream length up front, but also to check the array index in the loop where the pro-cessed packets are stored:

for (int i = 0; i < stPacketArraySize && packet; i++){ packetArray[i] = packet;

packet = processPacket();}

By leveraging unit testing for security verifi cation purposes, developers could identify and remove this fl aw as soon as the unit is completed. In this way, the developer would prevent the security vulnerability from ever reaching the integrated application. As study after study shows, the earlier a fl aw is found, the easier, faster, and least expensive it is to correct.

Changing execution pathsEven if an attacker cannot overwrite memory on the stack, he can neverthe-less perform serious damage by altering the expected execution path. Any over-written memory could be dangerous if that memory might aff ect the direction of the program execution.

For instance, say the developer has code with an if/else branch statement and two arrays. Th e values in the sec-ond array infl uence the branch taken.

AccessCode RequestAccess(ResourceID resource, const char* username){ AccessCode permission; char nameBuf[USERNAME_FIELD_LENGTH];bool accessFlags[NUMBER_OF_FLAGS]; // for a bogus username the access fl ags should be set to “deny” RetrieveAccessFlags(username, resource, accessFlags); // nameBuf buffer may overfl ow and spill into the accessFlags // array, overwriting the data there and possi-bly allowing access // to the requested resourcestrcpy(nameBuf, username); if (accessFlags[0] && accessFlags[2]){ permission = DENY_ACCESS; DenyAccessMessage(nameBuf);}else if (accessFlags[3]){ permission = REQUIRE_CONFIRMA-

TION; RequireConfi rmationMessage(nameB

uf);}

Reducing software security vulnerabilities through unit testingBY DR. ADAM KOLAWA

OPINION

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OPINION


else permission = GRANT_ACCESS;}Using username of the maximum

fi eld length will result in a memory over-write by strcpy, as it will need to copy a terminating 0 into the nameBuf as well. Thus, this memory bug allows an at-tacker to alter the branch selection that the program execution will normally take. Assuming that the branch selec-tion statement controls the assignment of security privileges, an attacker could exploit this vulnerability to upgrade his security privileges—without even insert-ing any special instructions into the ex-ploit string passed as a username.

To determine whether overwriting memory is possible in this code, the de-veloper creates unit tests, then runs the unit tests under a runtime error-detec-tion tool that provides memory access checking. Th e goal is to exercise the fi rst array as thoroughly as possible to deter-mine an attacker can possibly write be-yond that array.

For instance, the following simple test case would expose the security vulnera-bility in the previous piece of code:

const char* username = “username of at least the input fi eld length”; RequestAccess(resourceID, username);

On catching the memory error, the fi rst fi x is to size nameBuf properly by increasing it by 1. Then the rules on checking on the length of the string be-ing copied should apply. Preferably, the nameBuf buff er should be sized by using strlen(username):

unsigned int bufLength = strlen(username) + 1; char nameBuf[bufLength];

Additional considerationsAs the developer applies unit testing to expose security vulnerabilities, memory corruption that permits security attacks can go unnoticed if unit tests do not thoroughly exercise the unit. It is critical to monitor the coverage of tests. When performing unit testing in an attempt to expose security vulnerabilities, a goal of 100 percent coverage of each function is desirable and achievable.

This degree of coverage is possible at the unit level because designing in-puts that reach all parts of the function when testing in isolation (apart from the rest of the application) is so much easier than testing at the application level. To-tal coverage may not be possible in all sit-uations, but it is the goal that developers should strive for.

Another important point to consid-er is memory; every instance of memory corruption should be considered a poten-tial security vulnerability. In many cases,

human subjectivity is actually more of a hindrance than a help in evaluating po-tential security vulnerabilities.

For instance, assume that values in an array control the switch statement direc-tion, but the developer does not expect memory to lay out in such a way that this critical array follows the fi rst array. If the developer had these expectations and learned that the first array might overwrite memory, he would probably assume that this overwrite would not af-fect the critical array and decide against correcting the memory corruption.

Th is might be a bad decision, however. If memory layout fails to meet expecta-tions, the code could be vulnerable to security attacks. It is diffi cult to predict how compilers will lay out memory, and different compilers lay out memory in diff erent ways. If the developer can’t be certain how memory lays out, he can’t be certain how writing beyond the bounds of an array will infl uence the application. Th anks to the variation among compil-ers, the exact same code that seems se-cure when compiled on one compiler could be vulnerable to attack when com-piled on another compiler.

Two key lessons are to be learned here. One, because memory layout is compiler-dependent, the developer cannot accu-rately identify potential memory corrup-tion (and the security vulnerabilities they bring) by simply examining or parsing

the source code; it must be compiled, ex-ecuted, and monitored as it executes. Two, the developer can never be too thorough or too paranoid when it comes to iden-tifying and removing the possibility for memory corruption. With soft ware de-signed for use in military and aerospace systems, a security attack can have severe and potentially deadly consequences. To reduce the risk of attackers being able to gain unauthorized control over mission-critical systems, it is crucial that you iden-tify and correct every potential memory corruption in the systems’ soft ware. £

Dr. Adam Kolawa is the cofounder and chief executive offi cer of Parasoft Corp., a provider of automated-error-prevention (AEP) soft-ware, in Monrovia, Calif.

TRENDS from page 1

Opinion from page 41

nology will always be available for them to double computational performance on a reasonably predictable schedule.

Yet aft er such a phenomenal 40-year run, Moore’s Law soon may no longer apply—not because of physical limita-tions to stuffing ever-more transistors on a chip, but because of the industry’s lagging ability to remove heat from chips at the same pace of new processor devel-opment.

More processing power means in-creasing amounts of heat that designers have to remove, and today’s convention-al technologies to cool chips and boards simply are not progressing as fast as processor technologies.

Th e upshot may be, in the not-too-distant future, a technological smash-up in advanced embedded computers for military and aerospace applications that threatens to bring to a screeching halt the rapid upgrades that we’ve all become accustomed to seeing.

Far more so than I can ever remem-ber, electronics designers from the chip to

the platform level are spending far more time and investing far more passion on topics like innovative cooling techniques and improving system effi ciencies.

Some are even starting to discuss actually slowing the performance of systems components such as the latest micro processors and fi eld-programma-ble gate arrays (FPGAs) just so they can stay within their power- and heat-man-agement budgets.

There are many viable options out there, depending on the application. Sometimes today’s cooling techniques are just fi ne. Heat sinks, fans, cold walls, heat-conducting board stiffeners, and other traditional cooling techniques for rugged embedded systems oft en are adequate for even the most advanced processors.

For other applications, simply slow-ing down processor speeds or otherwise compromising system performance also might work. Yet for some requirements, simply putting the brakes on system performance may not be an option.

For those embedded applications that cannot rein-in performance, sys-tems designers are paying increasing attention to new kinds of cooling tech-

niques, such as spray cooling, f low-through liquid cooling, and thermo-electric devices that pump heat away from electronics hot spots.

Some of these approaches are not new. In fact, original plans for what has be-come the U.S. Air Force Lockheed Mar-tin F/A-22 Raptor strike fi ghter called for flow-through cooling for the aircraft’s avionics. Th is approach calls for phys-ically piping cooling fl uid onto printed circuit boards to remove heat quickly.

Other kinds of liquid cooling are also under consideration. Spray cooling from companies like ISR Inc. in Liberty Lake, Wash., bathes hot electronic components in a fi ne spray of inert fl uid, which recir-culates through the system to keep high-performance systems cool.

Other options include thermoelectric device technology, a thin-fi lm superlat-tice material made from a semiconduc-tor alloy that provides heat-pumping devices for hot electronics.

How successful these new cooling techniques prove to be—in terms of cost, size, weight, and effi ciency—un-doubtedly will be telling factors in how electronics development unfolds over

the next several years.Already some engineers are starting to

quip about some of the dilemmas these new cooling approaches may create.

One of my favorites involves the fu-ture “all-electric” aircraft, inwhich de-signers seek to substitute electric motors and actuators for the hydraulic systems that move fl aps, rudders, and other con-trol surfaces.

One of the motivations for the all-electric approach is to reduce subsystem size and weight by getting rid of heavy hydraulic systems, which also are noto-riously leaky and diffi cult to maintain.

Ironically, however, the all-electric air-craft may require the same types of fl uids and piping as those this design approach is intended to replace. Instead of using pipes and circulating fl uid to move con-trol surfaces, the all-electric aircraft just may require pipes and circulating fl uid to cool electric and electronic systems.

I doubt that future design challenges ultimately will be quite that extreme, but it’s clear that thermal experts have a lot of work ahead of them to come to grips with future generations of high-perfor-mance electronics. £

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when you turn to SBS Technologies® for one of our full

line of tightly integrated, rugged computing systems.

Our CompactPCI® and VME systems are built on proven

SBS chassis, single board computers, I/O components as

well as APIs, driver development kits, software libraries

and experienced field application engineers. This

combination is a recipe for success that has delivered,

over and over, for some of the most demanding customers

FREE DEFENSE AND AEROSPACE GUIDE. Go online now and get our free 36-page full color Defense and Aerospace Guide at: www.sbs.com/systems

SBS knows. To find out more, visit us at www.sbs.com or call us at 800.SBS.1553

Our systems are designed to survive the harshest environments.

Including yours.

Conduction Cooled 3U

CompactPCI Ruggedized Chassis

in the business. In some of the most demanding conditions on

the planet. (And off the planet, for that matter.)

With SBS, you have the freedom to build your own

system from the enclosure up, based on our long list of

components. The end result is a highly customized system

that meets your specifi c application needs, yet still delivers

all the benefits of commercial off-the-shelf-hardware.

At SBS, we believe you should think outside the box.

And let us worry about what’s inside of it.

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http://www.qmags.com/clickthrough.asp?url=www.sbs.com&id=11175&adid=PCOVER 3A2

http://www.qmags.com/clickthrough.asp?url=www.sbs.com/systems&id=11175&adid=PCOVER 3A1




Defense Solutions that Soar

©2005 GE Fanuc Automation. All rights reserved.

GE Fanuc Embedded Systems is your single trusted source forthe broadest and most capable defense technologies available- from customized single board computers to the latest in highspeed networking and switches.

With a 30+ year history of loyal service to this market, GE Fanuc Embedded Systems has the experience, stability and commitment you can rely on. When the stakes are thishigh, you need a partner this strong.

Learn more at www.gefanuc.com/embedded

VMIVME-7050IBM® 750FX/GX PowerPC®

VME Single Board Computer• Up to 2 Gbyte DDR SDRAM with ECC• 64.5 Mbyte bootable flash• Dual 64-bit/100 MHz PCI-X PMC sites • Dual Gigabit Ethernet–10/100/1000 BaseT• Dual high performance serial ports• Up to 1 Gbyte Compact Flash• 64-bit PCI connector for PMC and

feature expansion• High speed rear I/O available via P0• Operating system support for VxWorks,

Linux and LynxOS

VMIVME-5565Ultrahigh Speed Fiber Optic ReflectiveMemory with Interrupts• Easy-to-use shared memory network

operating at 2.12 Gbaud• Low latency for real-time applications• Network transfer rates up to 174 Mbyte/s• Data connections up to 10 km

(single-mode fiber)• DMA controller• Operating system and architecture

independent • Ultra low CPU overhead; onboard hard-

ware manages communication protocol

VMIVME-7700Ultra Low Voltage Intel® Celeron®

VME Single Board Computer• Processor speeds up to 650 MHz• Up to 512 Mbyte SDRAM• Single 32-bit/33 MHz PMC site• Dual 10/100BaseTX Ethernet ports• Dual USB 2.0 ports• Dual 16550-compatible serial ports• Front panel SVGA• Up to 1 Gbyte CompactFlash• Extended temperature from 0 to 70 °C• Operating system support for Windows®

2000, Windows XP, QNX, Linux andVxWorks

RM920VME Managed Gigabit Ethernet Switch• Layer 2/3/4 switching• Two product configurations available

– 10 front panel, 2 rear panel (single slot) – 20 front panel, 4 rear panel (dual slot)

• Copper and fiber connection options• Full management support• 802.1p, 802.1Q VLAN, deep packet filter-

ing, link aggregation, Rapid SpanningTree (802.1w, 802.1d), broadcast stormcontrol, port mirroring

GE Fanuc Automation

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