Retrofit Engineering

As equipment and machinery age, they may become outmoded, unserviceable, or unable to satisfy today's high-performance requirements. To modernize or replace this dated equipment, Southwest Research Institute (SwRI) provides a wide range of retrofit engineering services, including:

• Redesign of mechanical, electrical, and software systems, subsystems, or components
• Replacement of outdated technology with modern and innovative solutions
• Increase of mean-time-between-failure of high-failure items
• Development of efficient and effective in-house diagnostic and maintenance capabilities
• Improvement of system or subsystem reliability and maintainability

Drawing upon the Institute's multidisciplinary capabilities, SwRI engineers solve problems associated with:

• Requirements for drawings or technical data ownership
• Need for enhanced functionality of component or system
• Necessity to establish in-house maintenance capabilities
• Need for new or additional qualified vendors
• Requirements for product improvement

Using a systems engineering approach, SwRI conducts all aspects of retrofit engineering, including:

• Analysis and design review
• Design
• Prototype development
• Design validation
• Documentation and support

Analysis and Design Review

SwRI engineers use an optical microscope to determine detailed metallurgical information of components that are undergoing re-engineering.

During retrofit analysis and design review, SwRI engineers comprehensively review system documentation and maintenance records. Experienced staff members analyze component and assembly requirements, material and mechanical properties, and reliability, maintainability, and supportability deficiencies. They perform the following tasks:

• Analyze stress and thermal capabilities
• Provide dynamic mechanical modeling
• Analyze worst-case signal timing
• Determine accuracy and stability of electronics
• Verify virtual component operation and physical tolerances

To analyze component requirements, SwRI staff members use state-of-the-art equipment, including:

• Optical, scanning, and Auger microscopes
• X-ray, ultrasonic, and other nondestructive test equipment
• Coordinate measuring machines

Design

Dimension measurements are input to Pro/ENGINEERTM software packages to fully characterize and model designs before prototypes are manufactured.

During design, engineers resolve maintenance and support problems, enhance equipment functionality, and generate required drawings. SwRI staff members incorporate revised physical and environmental criteria into the newly designed component, addressing safety issues and eliminating environmentally sensitive materials where possible. Activities performed during this phase may include:

• Re-engineering or redesigning the component
• Preparing a form, fit, and function replacement
• Providing a printed circuit board layout
• Developing embedded software

Prototype Development

As part of a re-engineering effort for AWACS aircraft, Institute engineers redesigned a radar video card, fabricated a prototype, tested it, and delivered verified prototypes.

State-of-the-art rapid prototype development equipment enables Institute engineers to verify precision tolerances and fittings quickly and inexpensively using scale models produced from detailed three-dimensional CAD designs.

Following the design effort, Institute engineers assemble a prototype of the newly designed component to complete the following tasks:

• Validate drawings
• Prove assembly, operability, and feasibility of manufactured component
• Perform physical and electronic tests

SwRI has modern facilities to support program efforts in manufacturing and fabricating prototypes. Qualified to military, government, commercial, and international specifications and standards, including the ISO 9000 series, the facilities include:

• Printed circuit board fabrication facility
• Electrical and mechanical fabrication laboratories
• Fully equipped machine shop

Design Validation

SwRI maintains extensive laboratory facilities to test and evaluate the operability of prototype components and equipment in adverse physical conditions. Full-scale tests are performed on large components in temperature environments ranging from -65 degrees Celsius to 350 degrees Celsius.

Using the prototype component developed in earlier phases of a retrofit program, SwRI engineers conduct all aspects of design validation, including:

• Proving component operability in actual environmental conditions
• Verifying maintenance, support, and safety requirements
• Establishing timing, accuracy, and stability of electronic components

The Institute, with state-of-the-art equipment, modern facilities, and industry-accepted specifications, offers:

• Environmental assessment
  • Servo-hydraulic mechanical loading
  • Vibration, shock, thermal, and relative humidity
  • Electromagnetic interference and compatibility 
• Electronic verification
• Field evaluation and installation simulation

Documentation and Support

SwRI designed and validated this transmitter unit, one of more than 5,000 used in the U.S. Air Force's AN/FPS-85 phased array radar system. SwRI developed a data package for high-volume production of the transmitter.

To document a newly designed component or assembly, SwRI provides a detailed and validated technical data package, allowing vendors to manufacture the new design. To permit continuing in-house maintenance and support capabilities, the Institute prepares technical manuals and develops test systems for the new design. As part of its support capabilities, the Institute offers the following services:

• Documents test procedures and reports
• Establishes vendor qualifications
• Locates and qualifies vendors
• Provides input for in-house maintenance
  • Drawings and procedures
  • Theory of operation
  • Method of disposal
  • User's manual
  • Software design and software version description
  • Automated test sets and manual testers

This brochure was published in September 1997. For more information about retrofit engineering, contact Christopher E. Camargo, Aerospace Electronics and Information Technology Division, Southwest Research Institute, P.O. Drawer 28510, San Antonio, Texas 78228-0510, Phone (210) 522-2095.

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