applied mechanical engineering - integratedconsultants.com · module - stanag operator control unit...

David K. Aberizk, PE 548 I Avenue, San Diego, CA 92118 T. 619-884-8191

[email protected] www.integratedconsultants.com 1

ICI produces Concepts from Client Requirements.

ICI delivers Functional Prototype Hardware from Concepts.

ICI has delivered prototype hardware solutions for 30 Years to Industry and Government.

Delivering Critical Innovative

Technology Prototype Solutions

Timely…Cost Effective…Practical…Functional



End-to-End Professional

Engineering Services



What Problem Does ICI

Address for DoD Customers?

The Department of Defense (DoD) has an Unmanned & Autonomous Systems (U&AS) deficit regarding Research Development Test & Evaluation (RDT&E) and rapid prototyping expertise to ensure rapid delivery to the warfighter in the field of a next generation of U&AS products and platforms providing improved performance and/or lower cost than the current U&AS generation.



What Needs Result From

This Problem Set?

A successful DoD effort in Unmanned & Autonomous Systems needs over-arching technical support to both government and contractor teams tasked with delivering products and platforms, in order to accelerate delivery of viable solutions.

Specifically, skilled technical, prototyping and trouble-shooting support is needed to speed the development, testing and delivery of Unmanned & Autonomous Systems components which have high warfighter priority as fielded systems.



What Solutions Can ICI

Provide to the DoD Customer?

ICI designs, engineers, tests and develops prototype technology for subsystems and components of Unmanned & Autonomous Systems product development projects.

ICI works with government organizations and industry teams to evaluate and troubleshoot designs, create models, evaluate processes and rapid prototype hardware and components, to speed the development process and rapidly transition new technology to the warfighter in the field.



Leverages ICI design and integration experience of engineered high technology devices for military and regulated commercial industry.

Supplements fabrication design experience with computer-aided design and analysis productivity tools, then integrates artisans that can support computer-aided manufacturing.

Establishes the ICI Laboratory as part of the foundation for conceptual development of Innovation Environment for Unmanned Systems.

Offers a Development Tool Kit of capabilities to enhance Client capability.

Builds on a 30-year history of customer satisfaction, and offers 8A Program designation in addition to commercial and State professional certificates.

How Does ICI Add Value to

Products for Customers?



Company History – Evolved from federally regulated

industry sectors: Nuclear Power, Cryogenics,

Pressure Vessels, Waste Water Treatment.



Core Capabilities – Develop producible concepts

from requirements, and deliver functional prototype

hardware from these concepts.



Core Software Partnerships - Offers Rapid Integration

Robot 1 with Camera Robot 2 with GPS Facial Recognition Software

Simulator

Other Range Resources /

SystemsSoftware AgentHIM

Software Agent

Conversion Interface Module - JAUS

Conversion Interface Module - STANAG

Operator Control Unit

New Control Unit

HIM

Software Agent

HIM

Collaboration of Multiple Independent Software

and Hardware Systems



Mechanical design validation skills

Unique Skills – Leverage computer-aided design and

manufacturing productivity tool set to enhance

conceptualization, mechanical design validation and

prototype fabrication.

Conceptualization: Electronic logic diagram – printed circuit substrate

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Lean Collaborations – Through the utilization of an

established vendor base of uniquely skilled artisans,

the selection of component task processors is

optimized, resulting in a ‘best value’ solution for both

Commercial and DoD requirements.



Reverse Engineering

Finite Element

Analysis

3D Printer – Additive

Rapid Prototyping

3D Milling – Subtractive

Rapid Prototyping Component Testing

Strong Shop-Floor Assets – Equipment to transition

designs into and out of the virtual medium, for

testing and evaluating products.



Product development is embedded in process

Our business model is to fully embrace a customer’s

end-to-end needs in the course of best value product

development.



Problem Client wanted a ruggedized version of a commercial product concept, with added features.

NeedExtensive and integrated product development staff of computer design engineers, (electrical and mechanical, and firmware), drafters, programmers and producibility engineers, capable of utilizing CAD/CAM software and rapid prototyping tools.

Solutions and Deliverables• Virtual concepts and simulations were created and alternate solutions proposed that would ultimatelyenhance the final product design, its manufacturability, durability, and cost. Both virtual (FEA) and physical (R&D) analysis aided the process to a first article prototype device.• Physical prototypes were made utilizing ICI’s state-of-the-art labs and our solution partner network.• Final deliverables included first articles, plus a Product Data Management organized database of CAD files, blueprints, firmware, literature, renderings, animations et al., plus multiple patents.• Rapid engagement allowed on-time, on-budget deliveries of at-risk tasks.

ICI Success Stories

Electronic Lock for Shipping ContainerCommercial project



ProblemExisting GPS device was too large to be easily carried by a person, not waterproof, and its processor would often run too hot resulting in a system shutdown. The GPS features were incomplete and time/financial constraints put the project in an ‘at risk’ category.

NeedRedesign of the entire device, from its mechanical packaging to its internal electronics. However, redesign had to accommodate “keep out” designation of certain areas of the circuit board.

Solutions and Deliverables• The main circuit board was redesigned to add dual GPS receivers and reduce size. • Thermal issues were solved by the addition of a custom heat sink. • An RF-protected USB port was added to allow data logging of all raw and solution data.• First articles were made. Rapid engagement allowed on-time, on-budget deliveries of at-risk tasks. The final product was delivered on time and budget, and offered features two generations ahead of schedule.

ICI Success Stories

GPS DeviceMilitary project



ProblemThe M2C2 project experienced technical deficiencies causing critical cost and schedule issues, placing the project ‘at risk’. The project had to package electronic components into ruggedized, environmentally sealed containers and mount them in various vehicles with the requirement that they be easily removable and configurable (modular). But the mechanical and electrical designs became misaligned, and electrical engineers busy specifying components and designing interconnects weren’t provided necessary mechanical data on, e.g., component mounting locations, bracket designs, interference detection, constraint envelopes etc. New problems emerged such as thermal, strength and durability which prompted costly (and avoidable) re-designs. Mechanical blueprints and bill of materials were scant. With the project’s increased disorganization, purchasing long lead items became increasingly difficult, personnel conflicts arose which led to terminations, and employee moral faltered.

NeedThe customer needed department leadership as well as additional electro/mechanical designers and workstations to work ‘on site’. A process of storing, organizing and sharing data needed to be developed in order to reduce bottlenecks, errors, eliminate redundancy and speed the flow of information.

Solutions and Deliverables• Conceptual CAD models were created to provide the engineers a starting point in which to begin solving urgent critical issues.• A Product Data Management software package was utilized to store the CAD data and an MRP system was developed to unify all departments.• Assembly models were finalized and drawings delivered; additional solutions were provided via animations and renderings. • Processes were documented and training offered.• Rapid engagement allowed on-time, on-budget deliveries of at-risk tasks.

ICI Success Stories

Battlefield Communications - Mobile Modular Command and Control (M2C2)Military project



ProblemA developer invented a new type of software based communications tool that would allow different electronically controlled devices, such as manufacturing robots, autonomous vehicles, cell phones, CNC machine etc. to quickly and easily communicate with each other, regardless of their operating systems or manufacturers. The software had the potential to be revolutionary for military and commercial applications, however there was a problem. The software needed hardware to run on, and although it could potentially run on a PC, it would be too costly and inefficient to be a practical solution for use in equipment where issues such as weight and power use are critical (e.g. portable devices, UAVs, robots etc) .What the customer really needed was some sort of specialized ‘stand alone’ interfacing hardware or infrastructure in order to couple their virtual software with the electronics of prospective equipment. Since the product had the potential to be used in extreme and complex environments, the need for testing was crucial to its success. In order to accomplish this, a real world simulation would be required to replicate the necessary conditions. The option to use this simulation for demonstration purposes to prospective clients would be an added benefit.

NeedThe customer needed extensive resources involving staff (engineers drafters, programmers etc), equipment (PC’s, software, rapid prototype, CAM etc) and offsite support facilities. An additional support network of consultants, contractors, etc. was available on call to provide ‘as needed’temporary support. A communications link utilizing webcams and conferencing hardware would be used to hold virtual meetings and observe demonstrations with the customer’s Canada based facilities.

Solutions and Deliverables• Several Hardware Interface Modules and demo robots were built.• A large tent with a wooden stage were constructed for testing.

ICI Success Stories

Hardware Integration Module (HIM) and RobotsMilitary project



SPAWAR Systems Center-Pacific N66001-09-D-0029Development, Technical, Engineering, and Prototyping Services for Unmanned Systems. Indefinite Delivery Indefinite Quantity (IDIQ). Active to 3/25/2014 POC - SPAWARSYSCEN-PACIFIC 71030 Hudson ([email protected])

SeaPort Enhanced Multiple Award N00178-05-D-4380. Multiple Award Active to April 1, 2013

Integrated Consultants, Inc.

DoD Contract Vehicles

Prime Contracts

Sub Contracts Prime Epsilon Systems Solution/SSC-Pacific N66001-08-D-0074

Technical Support for Tactical Data Link. Active to 9/30/2013Subcontract: SI08009000

Prime ARINC Engineering/ SSC-Pacific N66001-08-R-0042 CODE 552 RF Communications

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applied mechanical engineering - integratedconsultants.com · module - stanag operator control unit...

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