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John Mazurowski

Electro-Optics Manufacturing Technology Center

Navy Manufacturing Technology Project S2306

National Shipbuilding Research Program All Panel Meeting March 2015

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Technology Discussion

This project has developed a cable test system that incorporates all cable

media types- power, communications, digital, coaxial, and fiber optic.

Integrated Link Test System (ILTS) Paradigm

• Manual link-to-link tests take time / multiple personnel.

• Test results are handwritten and contain many transcription / hookup errors.

• ILTS coordinates testing and stores test results automatically.

• MRP database contains cable data, acceptance criteria, test results, and

certification record.

• Networked communication between database / system / remote test units.

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Project Team

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Project Team

COMPANY TELEPHONE

ONR ManTech Richard Henson

Penn State EOC David Ditto, John Mazurowski, Lucas

Cashdollar, Melissa McCandless

HII Newport News Dave Gruszkowski, Vannia Willis, Lisa

Maddrey, NP Rao, Jason Jaques, Billy

Marshall, Steve Harbick, Gordon Burr,

Bob Smole, Mark Dunford

DIT-MCO International John Kusek, Gregg Carder, Charlie

Jennings, Mike Reed, TJ Surgeon, Kurt

Morrison

General Dynamics

Land Systems

Steve Spurlin, Eric Clore, Greg Bagwell

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Project Description

Participants and Roles

• Penn State Electro-Optics Center- Project Management and Systems

Engineering

• Huntington Ingalls Newport News- End User

• PMS 450- Program Representative

• NSWCDD- Technical Warrant Holder

• DIT-MCO International- System Supplier

• General Dynamics Land Systems- System Designer

Technical Deliverables

• Monthly Spend Plan, Project Schedule, Monthly Reports, EVM Report

• Technology Transition Plan, Risk Assessment

• Final Report, Demonstration

Period of Performance

• June 2010 – June 2015

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ILTS System Features

Primary Customer:

PMS 450 Virginia Class Submarine

Requirements: • Must fit through 30 inch opening.

• Processor / Electrical: 16 in x 15 in x 5 in.

• RF: (Agilent 9918A): 12 in x 7 in x 3 in.

• Fiber Optic: 18 in x 13 in x 7 in.

• Weight < 25 pounds.

• Processor: 18 pounds.

• RF Unit: 6.6 pounds.

• Fiber Optic: 10 pounds.

• MRP database stores requirements and test data.

• Communications complies with Information Systems policies.

• Compliance with military test equipment specification (Mil-PRF-28800 Class 2).

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ILTS System Features

Benefits:

• In shipbuilding, deck access time is valuable and highly choreographed. ILTS

measurement setup is done offline in order to minimize deck access.

• ILTS modular design supports electrical, RF, and fiber optic cable measurements in

accordance with recognized standards.

• ILTS is portable; hot-swappable batteries last >1 shift each.

• The ILTS supports a baseline MRP / EDA system, and can be adapted to others.

• ILTS system suppliers form the ILTS supply chain to provide downstream support.

BASELINE OPTIONAL

Electrical continuity 100 pin x 3 DC voltage to 600 volts

Electrical isolation 100 pin x 3 AC voltage to 500 volts

RF insertion loss to 26 GHz Resistance to 50 megohm

RF return loss / VSWR to 26 GHz Capacitance to 100 microfarad

Fiber Optic insertion loss SM / MM Time Domain Reflectometry (Electrical)

Fiber Optic return loss SM 200 MHz Oscilloscope

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ILTS System Integration

External Network

(ILTS Portable Test System)

HII Domain

(ILTS Central Database Manager)

HII DB Server

HII Domain

Computer

HII Web

Service

FIREWALL

ILTS Portable Test System

ILTS

Analyzer

Network

Node

ILTS Tablet

RF Module Optical Module

DISTRIBUTION STATEMENT A. Refer to cover page.

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ILTS Supply Chain

ADAPTERS

BASELINE SYSTEM

CUSTOMER

REQUIREMENTS

NEW FUNCTIONS

DATA STRUCTURES

ILTS SYSTEM SUPPLIER

DIT-MCO BASIC

FEATURES

GDLS

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Metrics

• Estimated cost avoidance 7200 hours X $65/hour = $468,000 per hull.

• The project goal is a reduction in labor connected with cable measurement

and fault diagnosis.

PARAMETER

BASELINE

GOAL

CURRENT

Cost Metric:

VCS Cable Measurements

36,000

Hours

28,800

Hours

36,000

Hours

Performance Metric:

Requirements Defined 0%

376

(100%)

534

(>100%)

Performance Metric:

Verification Complete 0%

534/534

(100%)

520/534

(97%)

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Progress

Administrative Progress: Award received from ONR June 2010

Subcontract awarded October 2011

Technology Transition Plan submitted May 2012

Task 2.1 – 2.4 complete June 2012

Task 2.5 Test System Supplier identified and PO placed January 2013

Weekly teleconferences begun May 2013

Review meeting and requirements review (PDR) June 2013

Task 2.5 – 2.12 complete July 2014

System requirements verification (CDR) July 2014

Technology Transition Plan update submitted July 2014

System demonstration August 2014

Final Review December 2014

Risk and Mitigation: Risk assessment completed each review in accordance with Navy ManTech guidance.

Technical Progress: Requirements and Specification June 2012

Requirements reviewed June 2013

Design activities begun July 2013

Preliminary design review August 2013

Critical design review July 2014

System demonstration August 2014

Software task list finalized November 2014

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Project Schedule

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Transition

TRANSITION STRATEGY: Documented in ManTech Technology

Transition Plan (TTP), submitted May 2012 and updated July 2014.

IMPLEMENTING ORGANIZATION: Ingalls Shipbuilding Newport News.

SUPPLY CHAIN: Future product of DIT-MCO International and General

Dynamics Land Systems.

FUNDING SOURCES: Ingalls Shipbuilding Newport News transition

funding ($50K) and capital acquisition ($50K). In-Kind: RF network

analyzer.

DEMONSTRATION: System verification held July 15-17 at GDLS.

System demonstration August 2014 aboard future SSN 785 USS John

Warner.

DISTRIBUTION STATEMENT A. Refer to cover page.

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Related Projects

• PROJECTS:

• NAVAIR N00421-03-D-0044 Fiber Optic Network Development

• NSWC Crane N00164-09-C-GR34 Task V Copper Replacement

• COLLABORATIVE INTERACTIONS:

• Army Stryker Vehicle- General Dynamics Land Systems

• National Shipbuilding Research Program “Flexible Interface for

Automated Circuit Tester”

• INDUSTRY:

• HII-NNS ACCS System

• DIT-MCO International internal product development for air platforms

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Future Actions

Close software task list.

Integration of ILTS into HII-NNS shipyard.

Future: Adapt for use at other shipyards / platforms.

Future: Merge functionality with ship cabling EDA tool.

Future: Enhance fiber optic measurement function.

DISTRIBUTION STATEMENT A. Refer to cover page.

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Jointness

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Acknowledgements

This material was supported by the Office of Naval

Research under contract N00014-05-D-0275 / 0002.

Any opinions, findings, conclusions, or recommendations

expressed in this presentation are those of the authors

and do not necessarily reflect the views of the Office of

Naval Research.

DISTRIBUTION STATEMENT A. Refer to cover page.