Signal & Data Processing Rack
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This case study illustrates Mistral's design and integration of a custom hybrid signal and data processing (SDP) rack for a defense lab, accommodating VME and VPX architectures while meeting environmental and performance specifications. The project included mechanical design, environmental testing, and the creation of a hybrid backplane, ensuring reliable communication and processing capabilities. Mistral's expertise and partnerships facilitated a complete solution that minimized the customer's development cycle and ensured compliance with industry standards.
Signal & Data Processing Rack
- 1. This case study showcases Mistral’s expertise in the architecture and design of a custom hybrid system that supports two industry standard bus architectures VME and VPX. The Customer The Requirement Solution Provided A leading Defense Lab selected Mistral to design, build and integrate a system capableoffunctioningasaSignalandDataProcessing(SDP)Rack. The customer’s requirement was to design and integrate a solution that met their overall functional/performance criteria and adhered to longevity, product lifecyclemanagementandintegrationnorms. Mistral is a professional design services company with extensive experience in embedded hardware and software development for Mil-Aero applications. This capability, in conjunction with partnerships with leading embedded solution providers like Curtiss Wright Controls Defense Solutions and Wind River Systems, enabled Mistral to provide a complete solution to meet the customerexpectations. : ! ! ! : : : ! ! ! ! ! ! MechanicaldesignoftheSDPRackwithstructuralandthermalanalysis Therackhadtobehousedinashelteredspaceonawheeledvehicle The rack had to be mounted on shock mounts in an air conditioned shelter and an AC vent had to be provisioned on top of the SDP rack to allow circulationofconditionedairtotherackforcoolingpurposes The rack had to be designed in compliance with JSS 55555 and MIL - STD 461 E and would be subjected to environmental and EMI/EMC tests, at thecustomerpremises DesignandFabricationofthehybridbackplane(VPXandVME) Generation of Wiring Charts, Inter Connection Document (ICD) and providing cable harnesses as per the ICD The rack had to be equipped with: Quad Power PC and Intel based processing system Quad channel sFPDP module mounted on VPX board capable of communication using sFPDP protocol VPX based Gigabit Ethernet Switch Provision for Redundant Power Supply Power Supplies for the entire rack. Circuit breakers and protection circuitry to be provided to prevent damage to the electronics housed in the rack The rack had to be mounted with LEDs, to indicate the health of the power supplies and the fans. Introduction TheSignalandDataProcessing(SDP)Rack isoneofthesub-systemsinthe radar network which provides resources for radar signal processing, data capturinganddatarecordingwithotherradarcontrolfunctions. This Case Study highlights Mistral’s expertise in the architecture and design of a custom hybrid system that supports two industry standard bus architectures VME and VPX, to meet the requirements of input /output signals, communication links, processing capability and data transfer capability. Case Study Signal and Data Processing Rack
- 2. Mistral Solutions Inc., solutions 4633 Old Ironsides Drive, Suite 410, Santa Clara, CA 95054 USA Phone: +1-408-705-2240 Fax: +1-408-987-9665 E-mail: usa@mistral .com Branch Offices: INDIA ! Hyderabad ! New Delhi USA ! Dallas, Texas Mistral Solutions Pvt. Ltd., No.60, 'Adarsh Regent', 100 Ft. Ring Road, Domlur Extension, Bangalore - 560 071 Tel: +91-80-3091 2600 Fax: +91-80-2535 6440 E-mail: info@mistralsolutions.com Copyright 2013, Mistral Solutions Pvt. Ltd. All rights reserved. & ...Partners in Real Time are registered Trademarks and Logos of Mistral. All other© Trademarks and Trade names are the property of the respective owners. Mistral developed the SDP Rack, an air-cooled mechanical enclosure system comprisingofthefollowingcomponents: PowerPCbasedVPX processingcards QuadChannelsFPDPModuleforsFPDPinterface VPXbasedDataRecordercard VPXbasedGigabitEthernetSwitch IntelCore2DuobasedVMEprocessingboard FlashPMCmodule TwoportGigabitEthernetPMCModule CustomHybridBackplane SerialtoLANconverter NecessaryPowerSupplies BackplaneChassis The VPX based chassis consists of 6U VPX cards and VME cards. To accommodate this, the chassis was equipped with custom hybrid backplane, designed by Mistral and its solution partner adhering to VPX and VME standards.Thebackplanehas12VPXslotsand2VMEslots. DesignServicesandSystemIntegration: Mistral was involved in the design and development of the entire system from the initial phase of system architecting, to component selection, system engineeringandvalidation.Thesolutionofferedincluded: SystemDesign System Study with report generation to ensure all the operational environmental conditions and performance requirements were met. This included the complete 3D computer modeling of the system, system power consumption calculations, system cooling calculations, system structural analysis, system thermal analysis and external/ internalcableharness HardwareDesign Designanddevelopmentof: RuggedAircooledRack HybridBackplanehaving12VPXslotsand2VMEslots RedundantPowersupplies Completecableharnessdesign Integration Integration of all boards within the system; and establishing functional capabilities of base card, inter and intra-system communication, GigE network establishment, Inter Processor Communication with inter- and intra-systemdependencies : : : : : : : : : : : ! : ! # # # # : ! ! ! : ! ! : : : : : : : : : : IntegrationandtestingofCOTSandcustomdesignedhardware Integrationofdrivers,BSPandDSPlibraries VerificationandValidation Design and validation of the rack for a high-power application, with thermalmanagement. Rugged systems adherence to ground based application - All boards suppliedcatertotherequirementsofJSS55555and . Design and fabrication of 14-slot hybrid backplane comprising of VPX and VMEbusarchitecture VPX backplane had to incorporate half mesh fabric connection while maintaininghighlevelofsignalintegrity Conformance to environmental conditions including thermal management, structural rigidity, EMI/EMC conformance. Complete integration of the COTS that used two industry standard bus architectures VPX and VME. The system was realized with two different operating platforms (Linux and VxWorks) Power ON sequencing, temperature monitoring and control inside the SDP Rack Establishing optical links for sFPDP, Fiber Channel and Gigabit Ethernet for externalandinternalnetwork The integrated SDP rack was qualified i.e. EMI / EMC tests and environmental tests carried out as an integrated system instead of qualifying the individual sub-systems. System designed adhered to the requirementsofJSS55555and Specifications. A multi-vendor selection of best-of-breed sub-systems was made available as an integrated system through a single system integrator; who not only provided the solution but would also provide support and maintenance for thecomingyears Shortened customer’s end-to-end product development cycle and ensured on-timedeploymentschedule A fully integrated deployable solution, compliant with functional and environmentalstandardswasmadeavailable. MIL-STD461E MIL-STD461E The Challenges Key Achievements Customer Benefits www.mistralsolutions.com