duotech's f-16 briefing during the 2015 f-16 tcg wwr

Supporting the Past. Engineering the Future.

Brett RogersVice President

• Mission• Facilities• Repair Capabilities• Engineering Capabilities• Customers• Corporate Goals• Conclusion

Outline

DUOTECH is a Requirements Driven Company designed

to solve the Repair and Remanufacturing problems for

military, civilian agencies, aerospace and commercial

users of electronic and electro-mechanical equipment.

DUOTECH provides high quality services to assist our

customers in keeping major programs operating on

schedule and within budgeted costs

Mission

• Repair – Long-term, Affordable Support

• Retrofit – Form/Fit/Function Solutions

• Upgrade – System Life Extension

Core Competencies

• State-of-the-art single site facility

• Multiple clean environments

• Extensive inventory of OEM and government-

approved test equipment

Facilities

• AS9100C Certified Processes

• EASA and FAA Part 145 Repair Station

• 33 years of US government contracting history

• ASQ and IPC-qualified personnel

Facility and Personnel Qualifications

History

• Prime contractor for US DoD since 1990• Qualified for over 12,000 unique NSNs• Support more than 25 militaries worldwide• Focused on aftermarket support for aging systems

• US Department of Defense

• Special Operations – All Branches

• Department of Homeland Security

• Federal Aviation Administration

Customers: US Government

• AAR

• Raytheon

• BAE

• Northrop Grumman

• Ametek

• DRS Technical Services

• Lockheed Martin

Customers: Prime Contractors

• Computer CCA• Motherboards• Multi-Layer• Controllers• Memory Modules• High Density

• Mixed Signal• Logic Boards• Fiber Optics• Microprocessors• Conformal Coated• Surface Mount

Circuit Board Repair

• UHF, VHF, HF • Microwave• Controllers• Power Amplifiers• Filters• Base Stations• Repeaters

• Antennas• Beacons• Modems • Multiplexers• RADAR• Fiber Optics• Voice Encryption

Communications and RF

Range Threat and Radar

• Identification Friend or Foe (IFF)o APX-76, APX-100, APX-101, APX-103, APX-109, APX-113

• Electronic Warfare/Countermeasureso ALQ-131, ALQ-165, ALQ-178, ALQ-184, ALR-46, ALR-49, ALR-56, ALR-64, ALR-69, ALE-47, ALE-50

• Detection and Fire Control Radarso APS-134, APS-137, APS-145, APQ-120, APQ-122, APQ-153, APQ-159, APG-59, APG-63, APG-65, APG-66 and APG-68, APG-70

Mechanical DMS Resolution

• Manufacture Out-of-Production Components

• Rapid Prototypingo Laser

o 3D Printing

o Machining

• Mechanical Fabricationo Multi-Axis VMC

o Multi-Axis Lathe

o Laser Cut and Mark

o Finishing

• Switching and Linear Power Supplies• Synchronous Motors and Generators• Induction Motors and Generators• Airborne Generators• DC Motors• Linear and Rotary Actuators• Power Conditioning• Airborne and Ground Based Systems

Electronic and Electro-mechanical

Why Duotech?

• Lack of OEM repair support for FMS customers• Unique combination of repair and engineering capabilities• No other sources offering responsive, full-spectrum support• LRU replacement is not cost-effective or fiscally possibleoDMS resolutionoModified and improved testing techniques for aging systemsoRemanufacturing and retrofits when practical

• Test and Recertification

• Test Fixture Solutions• Component Level Repair• Overhaul and Refurbishment

• Remanufacturing at the SRU and board level

• Operating Stock Management

Capabilities: APG-66 and APG-68

Tweet Us Your Radar Questions Using #DeltaRadar

• 1995: Duotech begins servicing APG-66/68 SRUs for NGC

• 2005: Duotech begins servicing APG-66/68 LRUs

• 2010: Duotech begins USAF LRU repair source qualification effort

• Current Qualifications:o APG-66 LPRF

o APG-66 Transmitter

o APG-68 Frequency Multiplier

• Qualifications Pending:o APG-66 Antenna

o Several APG-68 SRUs

Duotech’s APG-66/68 History


• Electronic SRUs• Gimbal• Antenna• Waveguides• Pattern testing• Full-power tests• Position and motional response

• Alignment

Antenna: Repair


Antenna: Factory New

• Waveguides• Slotted arrays• Uniphasers• Azimuth and elevation motor bands


• Electronic SRUso Powero Control o Monitoring

• Waveguide and feed lines

• TWT Repair

• Full-power testing

• Stock TWTs to decrease lead times

Transmitter: Repair


Transmitter: Factory New

• Digital SRUs• High voltage components• TWTs• Insulation components for pressure vessel assemblies


• SRU isolation testing

• Wiring and backplane integrity testing

• Waveguide and other RF plumbing

• Tuning of RF SRUs

• Characterization and simulation of the complete unit

LPRF & MLPRF: Repair


LPRF & MLPRF: Factory New

• Low Noise Assembly• Receiver• Waveguides and RF plumbing

• Voltage-controlled oscillator

• Repair and performance testing

• SRU testing and repairo Individual SRUso Component isolation from LRU level testing

• Includes capabilities for the Fire Control Computer on legacy APG-66 versions

• Complete backplane testing

Signal Processor: Repair

Obsolescence Considerations

• Customer Requirements – Top Priority• Component traceability - approved substitution (design authority, USAF, or OEM)

• Suitability of solution for specific problemoSystem sustainment requirement or expectations

oCost-benefit analysis comparisonoEffects on total supply chain for each solution

Obsolescence Mitigation Processes

• LRU LeveloO- and I-level testing sustainment and improvement

oSpares inventory investment

oTechnology insertions

oForm-fit-function Retrofits (F3)

Obsolescence Mitigation Processes (cont.)

• SRU LeveloComponent-level testing reliability and sustainmentoObsolete component traceability and replacement with suitable substitutes

o Form-fit-function retrofits (F3)

Identify Obsolete Part

Identify Suitable

Replacement Part

Customer Approval of Replacement

Install and Verify

Replacement

Delta Radar: Next Level Sustainment

• DSI-designed and manufactured fire control radar

• Response to OEM dropping support for APG-66

• Affordable, long-term solution to OEM systems


Delta Radar: Overview

• Retains basic system-level configuration of current systems

• Consolidates LPRF and Processor into one LRU

• Retains all core radar modes• Does not require physical or electrical modifications for F-16 platform

• Applications for fire control, weather, and detection applications with minimal modification


Delta Radar: Antenna

• Updated control electronics to mitigate current component obsolescence

• Duotech-manufactured slotted arrays and waveguides

• Overall MTBF greater than current systems


Delta Radar: Transmitter

Existing transmitter is single point failure tube based technology

Low Mean Time Between Critical Failure

Expensive to remove, repair and replace

Operational readiness is decreased


Delta Radar: Transmitter

Solid State Transmitter provides graceful degradation. No single point failure so radar can continue to operate.

High reliability (MTBCF up to 10X). Mean Time Between Critical Failure increases by magnitudes over tube based transmitter.

Lower sustainment cost due to less frequent failures and modular design. Up to 90% Reduction in Operation & Sustainment costs

High reliability, high efficiency transmitter leads to greater operational readiness. Lower phase noise and higher CIFLower Out of Band Emission to reduce interference from adjacent radar and other transmitters.


and

Delta Radar: LPRF and Processor

• Consolidate functions into one LRU

• Replace all RF SRUs with state-of-the-art technology (excluding LNA)

• Replace all digital SRUs with DSI-designed modules

• Calculated MTBF > 10,000 hours


Testing – Past vs. Present

PAST• Stationary equipment• Erratic operation• False positives/negatives

• Low MTBF• Obsolete technology• Extremely expensive• OEM-only support

PRESENT• Mobile, versatile stations• Multiple system applications

• Very high MTBF• Expandable capabilities• OEM Independence!


Duotech Test Solution

• THE alternative to outdated, inadequate OEM systems

• Leverage current technology to maximize capabilities

• Expandable capabilities and low cost of ownership

Duotech Test Solution Applications

• Radar (APG-66, APQ-159, etc.)

• IFF (APX-100, APX-109, APX-113, etc)

• EW, RWR, and ECM (ALR-46, ALR-69, ALQ-131, ALQ-184)

• Flight control and air data computers

• Avionics – Indicators, processors, displays, controls

Test Solution Advantages

• Acquisition Cost: < 20% cost of OEM systems

• Compliance with system OEM test specifications

• Interactive touch screen user interface

• Easy expansion of test programs

• Organizational and Intermediate level test options

• OEM Independence!

• Shorter Turn-Around Time and Lower Cost• System-level repair and engineering support• Responsive to Small Quantity Repair and Engineering Requirements

• No Conflict with New Manufacturing Requirements• Specialize in Repair and Re-Design of Older Equipment• Reverse Engineer Obsolete Technology and Unavailable Parts or Develop Technical Data

• Repair Costs Well Within Repair % Guidelines• Less Likely to “Scrap” Repairable Equipment

Why Duotech?

Corporate Goals

• 100% Quality Performance• Provide manageable solutions to obsolescence issues• Provide long-term support for critical systems• Develop customer-focused relationships that maximize end user satisfaction

• Support the warfighter!

Supporting the PastEngineering the Future

Brett RogersVice President

[email protected]

Come visit us at Booths 150, 151, and 152!
