reflections on cots in avionics/vetronics

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Reflections on COTS in Avionics/Vetronics The Use of COTS Assemblies in Harsh Environment Two-Level Maintenance Systems – May 12th, 2005

James A. Robles, Senior Technical FellowThe Boeing CompanyPhn: (206) 655-9062Email: [email protected]

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Context – The Environment Changed

We Won the Cold War Control of the Electronics Industry

Acquisition Reform New Generation of Users

0

10

20

30

40

1980 1990 2000 2010

Piece parts -mil-spec % of

total

Equipment -military % oftotal avionics

Source: AvionicsMagazine, 01/01

Source:TACTech,’95

Per

cen

t

Defense Outlays As a Share of Gross Domestic Product

2

4

6

8

10

12

50 60 70 80 90 003.0

GDP (%)

4.4 4.7

11.9%9.1%

6.3%

Year

1994 Perry Memo• Streamline procurement of reduce cycle

time and cost• Strengthen technology/industrial base• Increased access to advanced

technologies• Move away from the military

specification system

Not My Generation• Better educated and more aware of

technology• Not willing to tackle a difficult job with

obsolete hardware• Useful life reduced to correspond to

desired technology refresh cycle




What My Customers Require on Advanced Fighters, Helicopters, and Ground Vehicles

• Minimize Total Ownership Cost (TOC)• Development Cost• Unit Recurring Flyaway (URF) Cost• Operation and Support (O&S) Cost

• High functional density to minimize weight and volume• Thermal density (watts/cm)

• Perform reliably in harsh environment ↑ Reduce thermal strains to improve inherent reliability↑ Uniformity of temperature distribution across module↓ Exposure to coolant↓ Complexity

• Compatibility with two-level maintenance• Facilitate insertion of new technology and mitigation of

component obsolescence• Thermal margin




Obstacles to Wider Usage of Available COTS

Low Functional Density

Current standards do not meet the need

IEEE 1101.1 Air Cooled

IEEE 1101.2 Conduction Cooled

Not Compatible with Two-Level Maintenance Requires an ESD protected connector and covers for handling protection

Two to three times O&S cost penalty

F/A-22 example

Lack of a Standard for Environments

A Gaping hole in our “open architectures’

Exposes programs to risk with each DMS fix or upgrade cycle




Enablers for Wider Usage of Tomorrow’s COTS

Higher Functional Density

Standards under development will meet the need

VITA 46

VITA 48

Compatible with Two-Level Maintenance

VITA 46 and VITA 48 will have an ESD protected connector

VITA 48 will provide optional covers for ESD and handling

We Have a Standard for Environments

Fills the gaping hole in our “open architectures’

ANSI VITA 47 is released




The Thermal Management Challenge and Answer

• Thermal management challenge• More heat to remove• Less “potential” to drive it out

• Consequences• Unit Recurring Flyaway cost• Functional density – fuel cost

(O&S cost), lethality, survivability.• Reliability (O&S cost)• Margin for DMS fixes• Margin for technology insertion

• The answer --- VITA 48• Enhanced conduction cooling• Liquid Flow Through Cooling• Spray Cooling

Functional

Densit

y

Power per Function

Thermal Density

Allowable Component Temperature

Functional

Densit

y

Power per Function

Thermal Density


Functional

Densit

y

Power per Function

Functional

Densit

y

Power per Function

Thermal Density


Thermal Density


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Outlook for the Future

• We are addressing the obstacles to wider usage of COTS assemblies in avionics/vetronics

• The environment will continue to change in ways that encourage the use of COTS

• We are at a tipping point – much wider use of COTS assemblies in harsh environment two-level maintenance systems

reflections on cots in avionics/vetronics

Technology

twolevel maintenance

reliability os cost

need vita

connector vita

wider usage of cots

wider use of cots assemblies

flyaway urf cost operation

times os cost penalty