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Ruggedization Guidelines

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Our products are designed for use in harsh environment applications, where they may be subjected to extreme temperatures, thermal cycling stress, and high shock and vibration conditions. To accommodate a wide spectrum of platforms with differing environmental requirements, we offer products with a choice of ruggedization levels.

Form Factor Options

Our products are offered in two different form factors, aircooled and conduction-cooled.

Air-cooled (also referred to as convection-cooled) products are for use in applications where cooling air is blown over the surface of the card. VME, CompactPCI (3U and 6U) and PMC products are all available in air-cooled configurations. Aircooled cards comply with the mechanical specifications of the ANSI/VITA-1, ANSI/VITA-30 or ANSI/VITA-20 published standards. Air-cooled cards may employ stiffening ribs and specialized heat sinks for operation in rugged environments. Our air-cooled products are designated SVME, SCP and SPMC.

Conduction-cooled cards are designed for use in high shock and vibration environments. The cards are constructed with an aluminum frame, which serves the dual purpose of providing mechanical stiffening, and the conduction of heat from the electronic components to the edge of the card where it is transferred to the chassis. Conduction-cooled cards do not rely on any direct cooling air. Advanced cooling techniques include the use of top-side copper shunts, the Thermax™ frame design, additional PMC cooling surfaces and dedicated cooling layers in the PWB. Conduction-cooled cards comply with the mechanical specifications controlled by the IEEE 1101.2 VME specification or ANSI/VITA-30-199x (cPCI). Our conduction-cooled products are designated DMV, DCP and DPMC.

Click here to view/download a pdf of our ruggedization guidelines (registration required).

Click here to view/download an article that appeared in MIL/COTS Digest titled 'Understanding the Elements of Ruggedization'.

The levels are described in the table below. This table defines, for each ruggedization level, the environmental conditions that our products are specified to withstand. It should be noted that these levels of ruggedization are provided as a guideline; individual products might have a slight variation in each range.  Also note that not all products support all levels. Please refer to each product’s datasheet for availability.

Air-Cooled

LEVEL 0

LEVEL 50

LEVEL 100

LEVEL 200

Operating Temperature
(Note 4)

0°C to 50°C

-20°C to 65°C

-40°C to 71°C

-40°C to 85°C

Non-Oper. Temperature (Storage)

-40°C to 85°C

-40°C to 85°C

-55°C to 125°C

-55°C to 125°C

Operating Humidity

0 to 95%
non-condensing

0 to 100%
non-condensing

0 to 100%
non-condensing

0 to 100%
non-condensing 

Non-Oper. 
Humidity
(Storage)

0 to 95%
non-condensing

0 to 100%
condensing 

0 to 100%
condensing

0 to 100%
condensing 

Vibration Sine
(Note 1)

2 g peak
15-2k Hz

2 g peak
15-2k Hz

10 g peak
15-2k Hz

10 g peak  
15-2k Hz

Vibration
Random

(Note 2)

0.01 g2/Hz
15-2k Hz

0.02 g2/Hz
15-2k Hz

0.04 g2/Hz
15-2k Hz

0.04 g2/Hz
15-2k Hz

Shock
(Note 3)

20 g Peak

20 g peak

30 g peak

30 g peak

Conformal Coat     
(Note 5)

No

Consult Factory

Yes

Yes

Conduction-Cooled

LEVEL 100

LEVEL 200

LEVEL 300
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(Note 6)

Operating Temperature
(Note 7)

-40°C to 71°C

-40°C to 85°C

-40°C to 85°C

Non-Oper. Temperature (Storage)

-55°C to 125°C

-55°C to 125°C

-55°C to 125°C

Operating Humidity

0 to 100%
non-condensing

0 to 100%
non-condensing

0 to 100%
condensing 

Non-Oper. 
Humidity
(Storage)

0 to 100%
condensing

0 to 100%
condensing

0 to 100%
condensing 

Vibration Sine
(Note 1)

10 g peak
15-2k Hz

10 g peak
15-2k Hz

10 g peak  
15-2k Hz

Vibration
Random

(Note 2)

0.1 g2/Hz
15-2k Hz

0.1 g2/Hz
15-2k Hz

0.1 g2/Hz
15-2k Hz

Shock
(Note 3)

40 g peak

40 g peak

40 g peak

Conformal Coat     
(Note 5)

Yes

Yes

Yes

2 Level Maintenance Ready

No

No

Yes

Notes:

  1. Sine vibration based on a sine sweep duration of 10 minutes per axis in each of three mutually perpendicular axes. May be displacement limited from 15 to 44 Hz, depending on specific test equipment. 
  2. Random vibration 60 minutes per axis, in each of three mutually perpendicular axes. 
  3. Three hits in each axis, both directions, 1/2 sine and saw tooth.  Total 36 hits. 
  4. Standard air-flow is 8 cfm at sea level.  Some higher-powered products may require additional airflow. Consult the factory for details. 
  5. Conformal coating type is manufacturing site specific.  Consult the factory for details.
  6. This is a non-standard product. Consult factory for availability.
  7. Temperature is measured at the card edge.

Rugged Products for Military Applications

With more than 25 years of technology leadership behind it, CWCEC delivers cutting-edge embedded computing solutions to a wide range of demanding military and defense applications. As a key partner to major defense contractors, we are fully committed to serve strategic DoD initiatives with innovative electronics technologies that deliver a decisive advantage in today's network-centric battlefield and that refresh aging platforms with advanced technical capabilities. Our ingenuity can be seen in a number of critical defense programs - from UAVs that can conduct reconnaissance anywhere in the world to a fleet of all-weather, long-range helicopters designed for special missions behind enemy lines.

Rugged Military exampleTechnology Benefits

In the battlefield, our expertise gives our forces dominance through state-of-the-art architectures and cost-effective technology refresh programs that keep numerous military systems on the leading edge. These include:

  • Advanced COTS-based Technology Refresh
    Using a single board to address multiple processing functions, our COTS-based retrofit strategy reduces cost, size and power while increasing performance and capability for aging electronics in existing programs. In the last 24 months, our high-performance, cost-effective solutions have resulted in many design wins based on this strategy.
  • Ruggedized and Conduction-cooled Solutions
    Mission-critical systems can operate in harsh conditions of temperature extremes, high humidity, shock, and random vibrations using our proven ruggedization methodology.
  • Open Systems Design
    Boards based on our open-systems design methodology combine best-in-class technologies to achieve the quantum leap in performance and bandwidth required to move and process the massively parallel real time data streams of DSP applications such as radar, sonar, digital imaging. The open-systems approach ensures an easy migration path for technology upgrades and avoids the development pitfalls and high costs associated with proprietary solutions.
  • Modular Architecture
    Various network topologies can be built cost effectively using emerging switch-fabric technologies. These high availability, high bandwidth crossbar topologies can be scaled by simply adding nodes for in-chassis, chassis-to-chassis, and rack-to-rack systems.

Making the Right Choice

On the program level, CWCEC delivers what each DoD program manager seeks in a technology choice: (1) exact conformance to specifications, (2) superior performance and quality, (3) low entry costs, (4) quick time to market, and (5) a robust investment return. This investment return begins with our Engineer-to-Engineer customer service support and wraparound software packages that give the development team a head start in program development, and concludes with a breadth of lifecycle services designed to sustain the program through several technological generations.

Record of Wins

Based on our broad military program experience, CWCEC has insights about many strategic defense initiatives that only a breadth of expertise and a wealth of experience can provide. The proof is in the programs we have won. Our record of success includes many of the US military's most successful platforms, ranging from surveillance (Predator UAV) to intelligent targeting (TOW-ITAS missile) to strategic retrofit to electronic upgrades. Along the way, we have won recognition and awards from partners such as Raytheon, Boeing, General Dynamics, Lockheed Martin, and Northrup Grumman. Other program managers have followed suit, giving us a vote of confidence that equaled more than 50 design wins in the last eighteen months alone.

Partnership for the Long Term

CWCEC engineers never settle for the status quo. Time and again, our established partners rely on our ability to consistently deliver first-to-market designs with the best price-to-performance ratio in the industry. Our tack has paid off for the defense sector in terms of costs that are well below that of competing products and innovations that have raised the bar for customer support and design capabilities. MCOTS Program Support. Our dedication to our customer's success lasts throughout the program itself. After working closely with the development team, we take programs one step further by protecting the operational integrity of long-lived systems through our MCOTS program support services for full lifecycle sustainability.