Engineering Design Services

Design, Development and Prototyping of  Variable Tuned Filters from 2MHz to 2000MHz:

Design of electronically variable tuned filters covering the SINCGARS, EPLRS, VHF, UHF, and new WNW military communications bands. The filter bank, using varactors and/or switched capacitors and residing on a single monolithic PC board, have tuning bandwidths of up to 800MHz  and use a variety of lumped element as well as microstrip topologies (interdigital and combline) to achieve low insertion loss as well as high, close-in rejection. The filters have been specifically designed to eliminate the need for on-bench/factory  component tweaking, as the expected volume of these monolithic PCB filter boards is expected to be greater than 40,000 units. All filters were designed, simulated, built and tested using best-in-class EDA, CAD and test equipment. The client is a large  Defense Contractor actively participating in the Cluster 1 Program for the redesign of all secure DoD field radios.

Wireless Load Cell Design:
Our client came to us to both design a unique load cell based on a patented measurement topology as well as convert the subsequent load cell into one that could remotely send the load data via a wireless link. Using our in-house design capabilities we designed and analyzed the mechanical structure of the load cell and optimized it for the measurement topology. We also designed, built and tested the prototype telemetry capability based upon the use of SAW devices. We advised, designed, and built a low power capability into the load cell so that battery consumption was reduced and lifetime was extended. This was an additional component that our client did not initially ask for but whole-heartedly embraced in our overall design.
The primary drivers for the design were performance and cost effectiveness, both of which were achieved

High Efficiency RF Amplifier:
Our client tasked us with the development of a high efficiency (DC to RF) Class E amplifier to work up to 10 GHz. We not only designed, built and tested the device but developed a stand alone software synthesis tool to allow our client to create their own designs of other Class E amplifiers.

Implantable, Wireless, Batteryless, Intracardiac pressure monitoring system:
Our client asked us to develop a prototype of an implantable pressure sensor to be inserted via catheterization into the heart. The core technology had already been patented by our client, but they lacked the engineering disciplines of RF/wireless, Mechanical packaging, Biocompatability Materials, and Antenna design to create the necessary prototype for practical implementation. We developed the prototype which included the sensor, telemetry, and antenna, all within a package size that is readily insertable into a catheter sleeve.

6 GHz low noise, PLL DRO:
We were asked to design a 6 GHz dielectric resonator oscillator that had ultra low noise. We chose a Phase Locked Loop topology using a Phase/Frequency Detector that achieved a phase noise of –120dB at 10KHz off the carrier.

Advanced Narrowband Filter:
We were asked to design a 0.5% Band Pass Filter for use in satellite communications. We were required to use resonators that all had the same resonant frequency. The multi-pole dielectric resonator based filter we designed offered both performance and size/weight advantages over conventional filters, and was Space Qualified for on-orbit implementation.

Engineering Management Services

Cost reduction and re-manufacturing of DoD Antenna:
Our client was faced with high manufacturing costs for an Antenna that intermittently did not meet performance goals. Analysis of the antenna was impossible as all design material was lost to poor legacy documentation. With our forensic engineering capabilities we were able to determine the root cause of both the high cost of production as well as the intermittent performance issues. We undertook a redesign of the antenna and a re-evaluation of the manufacturing processes in place, and were able to achieve consistent performance that exceeded the requirements as well as a substantial reduction in production costs. We reduced the cost of the antenna from $400 to $20, and with the manufacturing, test, and quality assurance programs we put in place were able to save the small size company over $800,000 per year in production costs. This went directly to the profit line, as the antenna is ultimately resold at a fixed contract cost.

Robotic platform development:
Our client conceived of a concept incorporating the use of a robotic platform as the core for application development. We were tasked with creating the engineering effort, provide direction and project management, as well as team building for a sustained engineering department.  Using the limited resources and budget of the start-up company, we have been able to leverage our engineering and management experience in order to achieve the desired engineering management development.

Subsequent to this, a follow on effort was undertaken in which we were given the lead for developing the first generation robotic platform. We designed, built and tested all the necessary microcontrollers, motor control boards, interface boards and navigational aids required for the successful demonstration of the first article platform. We also designed and programmed all the required navigational and motor controlling algorithms used in the continuously correcting motion control of the platform.

We produced a short video (MPEG1 format, 10Mb, 1 min.) of the robotic platform in action. The video shows the self orienting capabilities as well as the real time navigational correction so that the platform follows a straight path.

Download video here [requires login and password]