Qualification Portfolio

Electrical, Mechanical, & Optical System Design, Construction, & Integration

Surface Analysis System   

The semi-conductor industry needed to convert and upgrade their surface inspection technology for Reticle Photomask substrate inspection down to 0.1 micron particle size resolution detection.  URS took on this challenge using a thorough and detailed strategy employing state-of-the-art technologies to solve this problem.  We conducted detailed reviews of the existing system as a baseline, developed/redesigned/optimized the technology to solve the technical challenges, and finally integrated the resulting design with client systems.  In meeting the technological challenge, the new design incorporated

  • Dual Helium-Neon (HeNe) laser optics detection heads
  • Three-axis motion system
  • Signal conditioning subsystems
  • Embedded controller and software

  • User interface

Fluorine Sensor

The semi-conductor industry needed to convert and upgrade their surface inspection technology for Reticle Photomask substrate inspection down to 0.1 micron particle size resolution detection.  URS took on this thorough and detailed strategy employing state-of-the-art technologies to solve this problem.  We conducted detailed reviews of the existing system as a baseline, developed/redesigned/optimized the technology to solve the technical challenges, and finally integrated the resulting design with client systems.  In meeting the technological challenge, the new design incorporated

Flexible Circuit Web Line

A flexible circuit manufacturer required our services to design and oversee the construction of the electrical and process control systems on their new  leading edge web development tool.  In order to exceed time constraints and reduce costs, existing web handling equipment was modified and incorporated into the new tool.  By working closely with the tool manufacturer and the end user, we were able to insure that code compliance was met on a timely schedule while maintaining exacting performance.  Our system design utilized:

  • PID controlled Web system;
  • Non-particulating homopolar magnetic braking system;
  • Variable speed pump and motor control;
  • PID controlled temperature chemical process tanks;
  • Devicenet networked motor controller and sensor system;
  • Allen-Bradley PLC with Wonderware HMI

C-17 Control Surface Test System 

Prior to initial flight, the Air Force uses this test system to assure the reliability of the drive and control circuits on the C-17 cargo aircraft's Flaps, Ailerons, Rudder, and Spoilers.  "Dummy" black boxes insert into the locations of the primary flight controllers. This breakout allows for circuitry in the 19" rack-mount cabinet to assume control over the drive systems in the aircraft.   Technicians are then able to walk about the aircraft while manipulating the desired surfaces.

  • Flaps

  • Ailerons

  • Rudder

  • Spoilers

Homopolar Traction Motor Controller

  • Phase shifted power MOS-FET chopper design

  • 5,000 Amps

  • Liquid cooled

  • Capable of Supplying to a direct short

 

Flywheel Cooling Cart

  • Dynamic Flow control Valves

  • Instrumented Flow Meters

  • Fan cooled COTS Heat Exchanger

  • COTS Centrifugal Pump

MD-80 Environmental Tester

  • COTS Motor Controller

  • High Volume Squirrel Cage Blower

  • Provides positive pressure for ventilation system capacity and leak testing

 

Electronics Circuit Design & Development

We develop diverse electronic subsystems that are customized to satisfy client needs.  We do this through active interaction with the client to remove any confusion or assumptions about the requirements, plus
  • create the circuit designs and run them through simulations before they are built
  • perform critical review of packaging
  • design toward customer requirements of price and performance

  • perform extensive validation tests

Consumer White Goods Products
Refrigeration Controller

  • Low operating current, < 1Watt

  • Very low component cost

  • High Quality & Reliability 

  • Six-Sigma Compliant

  • Embedded Microcontroller

  • High Efficiency Switching Power Supplies

  • UL & CE Certifications

Multi-Layer Precision Analog Signal Conditioning Cards

Submicron Particle Detection System - SAS2000 - Analog Signal Conditioning Card

  • Programmable gain and offset for A/D channels

  • Ground restoration circuit

  • Peak detection with sample-and-hold circuitry

  • precision pixel frame timing circuitry

 
Firing and Fault control analog card for a 9 mega joule electronic gun

  • Eight channel high-speed analog card

  • Custom VME backplane decode interface gate array logic

  • Ultra high quality DAC

  • Extreme temperature stability

  • Low noise, and minimal drift

Rapid Prototype Wire-Wrap Circuit Cards
Firing and Fault control error detection card for a 9 mega joule electronic gun

  • Fastest design to test

  • Low volume applications

  • Low cross-talk

  • Custom Field Programmable Gate Array Logic (FPGA)

  • Gold plated sockets and terminals

Data Acquisition (DAQ) & Test Systems  

Advanced Locomotive Flywheel

Sensors

  • Temperature 

  • Flow

  • Vacuum

  • Proximity 

  • Speed

Homopolar Traction Motor Dynamometer Testing

Homopolar Traction Motor  Chattanooga Mass Transit Authority Commissioned research toward achieving the following goals for an electric bus:  Very low cost electric power train system; Low voltage (<50V); High Torque; and capable of delivering 75 HP. 

  • Four pass homopolar motor

  • 75 Horse Power

  • Low Voltage < 50Vdc

  • High Current >5000A peak