Ultra Electronics

Aug 2006 to May 2007
Sector:
Defence.  Fibre optics electronics packaging for an Encrypted Aero comms unit.

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Overview: Electro-Mechanical packaging of a unit for battlefield comms in an Unmanned Airborne Vehicle (UAV.)
.
Complete unit - power pack base, and comms box
Lid Off. Jam packed full of PCB's



Work comprised:

Design, including materials and finishes selections.
Drawings, parts list BoMs, and item procurement.
Using PDM / PLM s/w.
Design Reviews.
MIL-STD-810 environmental qualification.
MIL-DTL-38999 connectors.
EMC shielding of PCB components to Tempest levels.
Solving complex problems due to chronic lack of space.
Full details of this role.
1) Responsible for the mechanical design of one unit in a 2 unit communications project.
2) Detail drawing and BoM parts listing of all components within the unit.
3) Quote requests placed on suppliers and bids evaluated.
4) Government Security cleared to ‘SC’ level. (SC Cleared.)
5) Attended Design Review meetings on a regular basis to present the design evolution to the review panel.
6) Selected Materials and Finishes. Interrogation of existing supply chain to maximise use of current parts.
7) Used ‘Windchill’ to create automated parts lists from the CAD model.
8) Unit designed to pass MIL-STD-810 environmental and vibration qualification tests, with mechanical contingency designed in.
9) Chronic lack of space availability for the overall electronics envelope – PCB’s mounted ‘Face to Face’ for component overlap space savings.
10) Awareness of Hard Nuclear protection against power surge – gamma ray sensing and de-powering.
11) EMC Shielding design and appreciation of Tempest levels of EMC protection.
12) Fibre Optics connectivity with MIL DTL 38999 series connectors.
13) Used PCAD viewer to interrogate board layouts so the mechanical envelope could be established for overcoming space constraints.
14) Offered permanent employment.
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