radar based air surveillance system (rass)
TRANSCRIPT
This case study showcases Mistral’s expertise
in the architecture and design of a complex radar
sub-system meeting requirements of
JSS 55555 and MIL-STD-416E
The Customer
The Requirement
A leading Defense Lab selected Mistral to design, build and integrate a system
capable of functioning as a Radar Controller, Radar Data Processor, Radar Signal
Processor and Radar Data Recorder.
The customer’s requirement was to design and integrate a solution that
matched their overall functional and performance criteria; while adhering to the
longevity, product lifecycle management and integration norms. The solution
had to meet the following requirements:
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Equipment mechanical dimension constraints: 1500mm x 550mm x 474mm
(Width x Depth x Height)
Radar Controller:
6U VME64x COTS product based on a PowerPC processor
User programmable FPGAs with FPGA core capable of
communicating using sFPDP protocol on optic fiber interface
LVTTL to RS422 level convertors
GPS to provide location and time information
Ethernet switch to communicate with external sub-systems
Power Supply Unit to cater to the system requirement
Radar Data Processor:
6U VME 64x COTS product based on three Intel processors
Flash based storage module and multiple gigabit ports
Ethernet switch to communicate with external sub-systems
and intra board communication
Power Supply Unit to cater to the system requirement
Radar Signal Processor:
6U VPX COTS product based on PowerPC
Support for sFPDP based communication
High-speed communication channels between boards
Power Supply Unit to cater to the system requirement
Case Study
Radar based Air Surveillance System (RASS)
Introduction
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The Radar based Air Surveillance System (RASS) is a radar sub-system
providing resources for Radar Signal Processing, Radar Data Processing,
Radar Controller Functions and Radar Data Recording.
The RASS consists of the following line-replaceable units (LRUs)
Signal Processor Unit (SPU)
Data Processor and Controller Unit (DPCU)
Radar Data Recorder Unit (RDRU)
Power Distribution and Control Unit (PDCU)
This case study highlights Mistral’s expertise in the architecture and
design of radar sub-system to meet the requirements of input/output
signals, communication links, processing capability and data transfer
capability.
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Radar Data Processor:
Radar Data Processor based on three 6U VME 64xCOTS based Intel
Core2-Duo Processor boards, each having two PMC sites
Two PMC sites populated with flash based storage card and two
additional gigabit ports using the second PMC slot
Power Supply Unit consisting of DC to DC converter modules and a filter
module to cater to the system needs of +3.3v, +5v, +12v and -12v.
SP LRU consists of:
Liquid cooled chassis for conduction cooled VPX boards
Customized VPX backplane
Customized Power Supply Unit consisting of DC to DC converter modules
and a filter module to cater to the system needs of +3.3v, +5v, +12v and -12v
Customized Front Connectors Panel to connect signals from VPX boards
Radar Signal Processor based on five 6U VPX COTS based Quad Dual Core
PowerPC processor boards, each having an XMC site
VPX Fire Blade Ethernet switch to communicate with external sub-systems
and intra board communication
XMC site populated with sFPDP card.
Radar Data Recorder consists of:
Recording capacity of 3.6TB
Concurrent recording of four channels of sFPDP data
Removable storage.
Design Services and System Integration:
Mistral was involved in the design and development of the entire system
from the initial phase of system architecting, to component selection, system
engineering and validation. The solution offered included:
System Design
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/ internal cable harness.
Hardware Design
Design and development of:
VME based I/O translation card
VME based GPS and clock module
Seven slot VPX backplane
VME Sandwich board
Front panel I/O connector PCBs
Complete cable harness design
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Radar Data Recorder:
Programmable unit based on PowerPC 6U VPX COTS
Recording capacity of 3.6TB
Concurrent recording of four channels of sFPDP data
Capable of operating in harsh environmental conditions with a
removable storage unit.
Solution Provided
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 and Wind River Systems, enabled Mistral to
provide a complete solution to meet the customer’s specific requirements.
Mistral developed a system comprising of the following components:
The RASS enclosure was made of light; non-ferrous material to withstand and
sustain the extreme environmental conditions that it will be exposed to.
The RASS enclosure consists of the following:
Signal Processor (SP) LRU
Data Processor (DP) LRU
Wide Band Recorder (WBR) LRU
Power Distribution & Control Unit LRU
Connectors in the right side panel of RASS enclosure
Liquid cooling mechanism for the LRUs inside the RASS enclosure
Isolated platform for the LRUs to negate the vibrations and shocks
from the RASS enclosure
Power status indicators of the LRUs.
RDP and RC LRU consists of:
Liquid cooled chassis for conduction cooled VME64x boards
Seven slot VME64X backplane
Customized Power Supply Unit consisting of DC to DC converter modules
and a filter module to cater to the system’s need of +3.3v, +5v, +12v and -12v
Customized Sandwich card for intra slot connectivity of I/O lines and front
panel I/O connections
Customized Front Connectors Panel to connect signals from VME64x boards
6U VME64xCOTS based Ethernet switch to communicate with external
sub-systems and intra board communication
VME Translation I/O card for LVTTL to RS422 level conversion
Radar Controller:
Based on one 6U VME64x COTS based Quad PowerPC processor boards,
each having two PMC sites
Two PMC sites populated with user programmable FPGA cards with
sFPDP IP core
VME GPS Receiver card to provide location, time information and IPPS
signal
Mistral Solutions Inc.,
solutions
4633 Old Ironsides Drive,Suite 410, Santa Clara, CA 95054 USAPhone: +1-408-705-2240Fax: +1-408-987-9665E-mail: usa@mistral .com
Branch Offices:
INDIA
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USA
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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: [email protected]
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Integration
Integration of all boards within the system; and establishing functional
capabilities of base card, inter- and intra-system communication, HA
validation, GigE network establishment, Inter Processor Communication
with inter- and intra-system dependencies
Integration and testing of COTS and custom designed hardware
Integration of drivers, BSP, DSP libraries and system monitoring
programs provided by our solution partners
Verification and Validation
Design and validation of ATR for a high-power application, with
thermal management
Rugged systems adherence to ground based application - All boards
supplied cater to the requirements of JSS 55555 and MIL-STD -416E.
The design of the cooling system for a complex system like the RASS
was a challenge. This was addressed by using liquid cooled cold plates
as an ideal high-performance heat transfer solution
Designing and fabrication of seven slot VPX backplane with full mesh
fabric connection between five slots while maintaining high level of
signal integrity
Conformance to environmental conditions including thermal
management, structural rigidity, EMI/EMC conformance.
Incorporation of liquid cooling in the side walls of the LRUs to provide an
effective cooling system. This is one of the first designs wherein liquid
cooled cold plates were used for cooling the LRUs
Various key elements of the system were built indigenously at Mistral.
This includes, the seven slot VPX backplane, VME based translation I/O
card, Sandwich backplane for I/O termination, Front Panel I/O boards, Cable
Harness creation and routing plan for the same
The Challenges
Key Achievements
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Customization of GPS module for VME form factor. Mistrals design team
adapted a non-standard COTS module to conform to the VME form factor by
designing a board that will host the GPS module without any modification to
the original GPS module
Complete integration of the LRUs that used two industry standard bus
architectures VPX and VME. The system realized with two different
operating platforms (Linux and VxWorks)
Establishing optical links for sFPDP and Fiber channel and Gigabit ethernet
network for external and internal network
Designed an intelligent power distribution box that will regulate optimum
power supply to the units and regulates temperature sensors to prevent over
heating
The system designed to withstand solar radiations, vibration and shocks
that the unit might receive during transportation and operation of the Radar,
operation of the system in extreme weather conditions like rain, snow, high
humidity and high temperature environments like desert
Provided the end user with complete software development tools on Linux
and VxWorks operating systems, also provided optimized signal processing
libraries for SP LRUs
System designed meets requirements of JSS 55555 and MIL-STD-416E
Specifications
Designed a highly computing intense system for multi beam processing.
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
the coming years
Shortened customer’s end-to-end product development cycle and ensured
on-time deployment schedule
A fully integrated deployable solution, thoroughly verified and certified for
deployment, and compliant with functional and environmental standards
was made available.
Customer Benefits