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Rack 2 Workstation (R2WS) Critical Design Review 12/14/00. Agenda. Overview Design and Requirements Interfaces Manufacturing and Materials Software Plan Operational Scenarios and Constraints Safety EEE Parts Testing Thermal Analysis Stress Analysis

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Rack 2 Workstation (R2WS) Critical Design Review 12/14/00

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Rack 2 Workstation (R2WS)

Critical Design Review



  • Overview

  • Design and Requirements

  • Interfaces

  • Manufacturing and Materials

  • Software Plan

  • Operational Scenarios and Constraints

  • Safety

  • EEE Parts

  • Testing

  • Thermal Analysis

  • Stress Analysis

  • Criticality assessment, Reliability and Maintainability, Limited items.

  • Waivers

  • Deliverables and Schedule

  • Documentation

  • RIDs


  • Why a CDR?

  • What is the purpose of the CDR?

  • What are the differences between

  • WS, R2WS and WS-2?

Overview cont.

  • Why a CDR ?

    • LM was given the go ahead on Oct. 1 1999 to build Workstation-2 (WS-2). Which was to be an 8 PU drawer.

    • A TIM was held to gather information critical to the hardware’s design.

    • WS-2 development was in support of HRF Rack 2 (Flight 12A.1)

    • Design changes between WS and WS-2 required a new CDR

    • The goal was to have a CDR on March 2, 2000. And hardware delivery by August 2001.

    • All that changed when upgrades were made to the Workstation(WS) and the Rack 2 delivery schedule was moved to the left. The upgraded WS changed over 50% of the internal system boards.

    • Fabrication schedules indicate a 1 year turn around after baseline design.

    • With no work being performed on Workstation-2 a new plan had to be taken.

    • A new 4 PU Workstation was the only feasible alternative given the time duration

What is the Purpose of the CDR

  • The purpose of this CDR is three fold.

    • To formally review the design to determine if the 90% completed design meets or exceeds NASA standards and requirements established at Preliminary Design Review (PDR) and in the Functional Requirements Document (FRD).

    • To capture any additional requirements not previously identified before the final product is delivered and no more changes can be made. (The primary reasoning being there has been no PDR since 1996.)

    • To achieve consensus on the delta design approach and the tradeoffs between the Workstation, Rack 2 Workstation and the Workstation-2.

What are the differences between WS, R2WS and WS-2 High Level?

  • Physical WSR2WSWS-2

    • Drawer Size4 PU4 PU8PU

    • Removable Media5 SCSI2IDE, 3 SCSI, 1 PCMCIA

    • Connector SpacingWaiver1 inch between each connector

  • Performance

    • CPU(Pentium)Dual IIDual IIIDual II

    • Storage(IDE)68 Gig68 Gig min68 Gig

    • Storage(SCSI)90 Gig90 Gig min68 Gig

    • PCMCIA SupportType III Type I, II and III

    • Operating SystemNT 4.0???NT 4.0

    • On-orbit Board


Rack 2 Workstation Design and Requirements

  • What are the Design Objectives?

  • What’s the Plan?

  • Physical Description

  • Performance Requirements

  • System Configuration

  • Delta Changes from Workstation PDR, CDR and –302 Configuration.

  • Compatibility with the present Workstation

Rack 2 Workstation Design and Requirements

  • Design Objectives

    • Increase WS original functional capabilities.

    • Decrease or eliminate the number of waivers required by WS.

    • Create a more user friendly, flexible and reliable machine than WS.

  • Plan without an entirely new product

    • R2WS will decrease quantity of “full-time” outputs without reducing overall system effectiveness.

    • R2WS will support more peripheral types to allow greater flexibility.

    • R2WS will allow ORU replaceable IDE Hard Drives.

Rack 2 Workstation Design and Requirements

Physical Description

  • 4 PU Drawer Chassis

    • Interchangeable Drive Bay (IDB)

      • Replaces the SLIME of WS

      • 2 Removable IDE drives, 1 PCMCIA (Type I, II or III) and 3 SCSI slots.

    • Front Panel will consist of 9 full-time connectors each spaced at least 1 inch from an obstructions.

    • Will utilize the same handle design of the previous Workstation.

    • The only difference in physical dimensions and appearance will be the front panel from the Workstation.

      • However, if time permits we are attempting to replace hinged latch design with a hinged 4 turn fastener design, which will be more in line dimensionally with other rack drawers.

Replace with front panel / decal drawing.

Rack 2 Workstation Design and Requirements

Performance requirements

  • Dual PIII 700 MHz with AGP (SBC vendor is building the 850 Mhz )

    • Ultra-Wide SCSI, USB and Ethernet, 256K Cache on the CPU

  • 512 Meg RAM, 2 IDE Drives 75 Gig each (Single partitions)

    • DOS will not be supported for on-orbit operations.

  • SCSI hard drives 30 Gig

    • Hard Drives support AVI

  • Support Windows NT 4.0 or Windows NT 2000

    • NT 2000 required to support hot swapping of SCSI devices, USB and easy disk formatting

  • Support Ethernet and RS-422 to the Rack

  • Provide support for HMD device, stereo sound output and audio input

  • Provide “true” PCMCIA support, PCMCIA Hard Drives available.

    • PCMCIA drives at least 1 Gig at delivery, standard laptop is 500 Meg.

Rack 2 Workstation Design and Requirements

Performance Requirements cont

  • Keyboard with integrated pointing device

  • Provide high speed mass storage capability

  • Support serial connections and Universal Serial Bus (USB) peripherals

  • Support Voice Recognition

  • Perform Digital Streaming Video using IEEE 1394

  • Provide Ethernet and RS-422 to users

    • Will be provided through either PCMCIA along with any standard PC Card capability: RS485, A/D and RS232.

  • Provide Auxiliary Power, to support peripheral devices

  • Rack Requirements

    • WS-2 will provide the same rack interfaces as the original WS.

  • 8 A/D channels with anti-aliasing

Rack 2 Workstation Design and Requirements

System Configuration

Passive back-plane with Single Board computer

  • 10 PCI slots, 2 ISA slots and a CPU slot on the passive back-plane

    • PCI Slots

      • 2 Graphics Slots; Right and Left Eye

      • PCMCIA Controller

      • A/D Board

      • Sound Card

      • IEEE 1394 Board

      • Ethernet (Plug-in slot)

      • A/D (Plug-in slot)

      • RS-422 to the front panel (Plug-in slot)

    • ISA Slots

      • Custom Isolation Board (Ron will describe)

      • Anti-aliasing board

A B C 1 23 4 5 6 7 8 9 10





















ATA 100


















Subject to change depending on final board selection, note present 1394 WS boards are obsolete.

Rack 2 Workstation Design and Requirements

Delta Changes from Workstation PDR/ CDR and –302 Configuration Capability changes


  • Graphics Intergraph(3)GVX1(2)GVX2 (1 double)

  • CPUDual Pent. ProDual PII 450Dual P III 700 (850)

  • Sound N/ASB LiveSB Live (DVD pos.)


  • A/D 32 Single Ended3216

  • VoiceThru DSPSound CardSound Card

  • Video Grab N/A(NTSC)IEEE 1394IEEE 1394 (Digital)

    Custom Board Changes

  • Video, Analog and Digital will be replaced with a single ISA Isolation Board, effectively eliminating the need for the ICBM.

  • ICBM mechanical system for IDE drives now part of IDB. No loss in ability with introduction of single ISA Isolation Board

ISA Isolation Board a Detailed Look

  • Provides signal isolation for the IRIG-B signal

  • Provides conversion from front panel NTSC video input to RS-170A to the rack.

  • Converts Com1 to RS-422 and the patches that signal to the rack.

  • Used to provide signal isolation for 2 Digital Input, 2 Digital Outputs and 2 D/A outputs

IDB Custom Board a Detailed Look

  • Utilizes ATA-100 Controller

    • Presently only 33 MHz supported. New drives are ATA-100 compatible.

    • The IDB will be able to read any drive 33, 66, or 100Mhz.

  • New IDB will be SCSI 160 compatible

    • Requires use of Low Voltage detection SCSI Hard Drives

    • Will still be compatible with present SCSI drives.

    • Note: Presently we are hoping the next generation CPU board will have a 160 controller

    • Will support present PCMCIA Reader / Writers.


    • Will NOT support present Reader / Writers, but will support the PCMCIA hard drives.

    • Will support present PCMCIA Hard Drive (Both PC and WS)

Rack 2 Workstation Design and Requirements

  • Will it be backwards compatible?

    • In a word, Yes

    • Same Keyboard will be used by both systems.

    • The Flat Screen display will be used by both systems

    • Most cables will not remain the same.

    • Data could be easily transferred between the two systems.

    • Any experiment that ran on WS should be able to run on R2WS.

      • CPBD would use the laptop configuration as it’s R2WS configuration.

      • The R2WS will not support the HRF common Serial Breakout Cable.

    • SCSI devices could be placed in either the SLIME or the IDB SCSI.

      • Notable exception, the SLIME would operate at the lowest speed of any item on the SCSI bus. The BBND experiment would be supported.

    • Note: The R2WS will operate in both Rack 1 and Rack 2. Most cables should be de-manifested to support the new cable locations.

Electrical Breakout (See IDD for details)

  • A/D: Consists of 8 anti-aliasing A/D inputs (Designed to support EKG or ECG types), 2 D/A outputs, 2 Digital Inputs and 2 Digital Outputs.

  • VGA: VGA, Keyboard and Com2.

  • Audio/ NTSC : Provides NTSC in, a microphone input and stereo output for headphones .

  • IRIG-B: Standard IRIG-B time sync and trigger as on present WS.

  • RGB: Left and Right eye for use with the HMD. (No power)

  • KTMC: Reserved (Part of 90% design still available)

  • Ethernet: Standard Ethernet, single port.

  • USB / IEEE 1394: Provides power and connection for USB.

  • Power: 28 VDC, max 10 amps.

Electrical Breakout cont

  • Ideas for KTMC connector

  • Number of pins available are 55.

  • Possibilities Include

    • Breakout for an IDE device.

      • Could be IDE CD-ROM, or possible DVD.

      • Negatives: Would need to certify a DVD or CD device. Because of cable length restrictions unit would have to mounted to the WS. Presently ideas to mount the device to the IDB cover, are Velcro only and would inhibit the PCMICA connections when installed. Would most likely require a special board to support movies.

      • Positives: Great for ground operations, burning CD or DVDs. The DVDs would reduce the number of CDs needed on orbit because of greater storage capacity. And of course movies

    • Floppy or Parallel port

    • Any Suggestions?

Manufacturing and Materials

  • 3 Major Sections to be manufacturing

    • Drawer

      • All major mechanical drawer parts will be out-sourced.

      • Minor mechanical components may be made on site.

      • Previous WS had an MUA on alodined 7075 Al.

        • New parts will be anodized except in areas that require electrical continuity, which will be masked and then alodined.

    • Electrical Harnesses

      • All harnesses will be made by Bldg. 36 or 56 personnel.

    • Boards

      • Back-plane will be made by CPU vendor, details will be designed by LM.

      • Normal COTS boards will be modified by bldg. 36 or 56 personnel.

      • Custom PC boards will be manufactured by outside vendor

        • Boards will be populated by Bldg. 36 or 56 personnel.

    • Materials

      • Same materials will be used in R2WS as in WS.

Software Overview

  • Plan

    • To configuration control the hardware with the software.

    • Software will be tied to drawing via the Version Description Document (VDD).

    • Software load will be tracked on each hard drive.

    • Each hard drive will have a 911 part number tag and information detailing the software load resident on the drive.

    • There will be two kinds of software loads

      • GSE and Flight

    • Workstation will deliver two separate types of loads

      • Operating system

      • Test Loads (Reference the schedule)

      • Common Software will be responsible for integrated and applications loads.

    • Software certification path as followed by Workstation

    • There will be no software PDR

Software Documentation

  • Documentation

    • Version Description Document (VDD) for each flight software package.

      • Describes the software that is being certified.

      • Describes how to install the software being certified.

      • Identifies known “bugs” or problems

    • Software Test Plan

      • Describes what requirements are being satisfied by the software.

      • Describes the procedures for satisfying those requirements.

    • Software Design Document

      • Describes system architecture

      • Provides description of the Computer Software Configuration Item (CSCI)

      • Provides breakdown of the Computer Software Unit (CSU) software elements.

Software & Health and Status

  • Housekeeping software

    • Presently not supported

      • Will hope to provide thermal sensor data

  • Health and Status Data

    • Common Fan Controller used by cooling stowage drawer will be used.

      • Provides fan speed data.

Safety Hazards for the R2WS

The following Standard Hazards were identified on form 1230:

  • Structural Failure – stowed equipment

  • Sharp Edges

  • Flammable Materials

  • Materials Offgassing

  • Non-Ionizing Radiation - non-transmitters

  • Battery Failure

  • Touch Temperature

  • Electrical Power Distribution

  • Rotating Equipment

  • Mate/Demate

  • Rapid Safing

    A unique hazard report will cover rack-mounted structural failure issues.

    Only a Phase III safety review will be conducted on this item.

EEE Parts

  • System will consist of both COTS and Custom Boards.

  • COTS boards will undergo EEE parts screening at a Top Assy only.

  • Custom PC boards will be tested at the RITF via coupon testing.

  • All parts selected for custom PC boards will be reviewed and accepted by the EEE parts department prior to use.

    • In the event that GIDEP identifies a part that we are currently using as defective or prone to failure, an alternate will be selected when reasonably possible.

  • All individual parts and connectors will be reviewed and accepted by the EEE parts department prior to flight integration.

  • The integrated flight system will undergo EEE parts screening for 72 hours at ambient and at 35 degrees C for 96 hours as part of the testing program.

    • Parts review has been conducted by Pam Branch who reports >>>>>


  • Standard Acceptance Testing Regime

    • Vibration at Acceptance Level 6.06 Grms for 60 seconds.(Drawer only) per axis.

    • Thermal Testing will be 1.5 cycles from 20 to 120 F.

      • Operating Temperature for 45 to 95 F.

    • EEE parts screening testing

    • Touch Temperature Testing

    • Acoustics

  • Standard Qualification Testing Regime

    • Vibration at Qual. levels 7.92 Grms for 120 seconds. (Drawer only) per axis.

    • 7.5 cycle Thermal Testing from 15 to 125 F with same operating range.

    • Offgas

    • Sine Sweep

    • Shock (Bench Handling, drawer only)

    • EMI

    • Radiation Testing – Results indicate satisfactory

Waivers or Exceptions

  • This is a listed of expected Waivers required by R2WS

    • 4 PU Drawer weight limit. (64 lbs; R2WS will weigh about 80 lbs)

    • EMI System Only

      • The R2WS drawer will pass EMI, however as an integrated system with the HMD or Flat Screen Display it will fail.

    • ESD Sensitive

      • The R2WS will not seek to test or be labeled as ESD sensitive.

    • Payload Envelope

      • To operate the R2WS will most likely require a Bogen arm which would violate present operating envelopes.

    • Drawer Envelope

      • The R2WS Computer Drawer like the WS Computer Drawer will have the same footprint, thus violating the keep out zones behind the front panel.

        • Note: If time permits the latches will be replaced with fasteners, the hinge will remain.

Thermal Analysis

Stress Analysis

IAC, R&M and Limited Life

Deliverables and Schedule

  • Deliverables

    • 1 Qualification Unit

    • 3 Flight Units

    • 2 High Fidelity units, packaged as an 4 PU drawer (functionally equivalent)

  • Schedule Highlights

    • First high fidelity unit by January 2000

      • Will be refurbished later.

      • Made available to perform Human Factors, Label, Science and Crew evaluations for practical design enhancements before it is too late.

    • Qualification unit completes by June 2001.

    • Flight units complete by July 2001.

    • Software development units available by October 2000.

WS-2 Schedule

WS-2 Schedule

WS-2 Schedule

Schedule Risk Summary

  • Risks:

    • Verifying anti-aliasing operation will take programming commitment that we don’t currently support.

    • OS selection and finding the drivers for the selected boards.

    • Very ambitious schedule

      • Turn around time is usually longer than 9 months.

  • Mitigation

    • Fully electronically operational development unit prior to CDR.

    • After development unit is operational, remaining parts will be procured.

      • Lessons learned from WS

    • Flight units fabricated before Qual. unit has passed testing.

    • No destructive testing on flight units until Qual. Testing complete.

  • Approach

    • Design approach to make make late changes only if time permits, such as: Card hold downs, non-hinged lid and other upgrades.


  • Hardware Requirements Document (CDR)

  • Interface Definition Document(CDR for review)

  • Software Documentation(CDR, Test Plan preliminary)

  • Stress Analysis Report(CDR preliminary)

  • Thermal Analysis (CDR preliminary)

  • No FMEA, IAC only(CDR)

  • Reliability and Maintainability Report(CDR preliminary)

  • Limited Life Items List (CDR preliminary)

  • Battery Certification Report (No change from WS)

  • Fracture Control Analysis

  • Payload Safety Data Package

  • Safety Analysis Report

  • Functional Test Procedures

    • Pre-Installation Acceptance and Pre-Delivery Acceptance


  • Build it, but……...


  • A/D - Analog to Digital

  • AGP - Accelerated Graphics Port

  • AVI - Audio Video Interleave

  • CDR/W - Compact Disk Reader/Writer

  • COTS - Commercial Off The Shelf

  • CDR - Critical Design Review

  • DSP - Digital Signal Processor

  • HMD - Head Mount Display

  • HRF - Human Research Facility

  • ICD - Interface Control Drawing

  • ICBM - Integrated Circuit Board Module

  • IDB - Interchangeable Drive Bay

  • IDD - Interface Definition Document

Acronyms cont.

  • IDE - Integrated Drive Electronics

  • LM - Lockheed Martin

  • MHz - Megahertz

  • PII - Pentium II

  • PCI - Peripheral Component Interconnect

  • PDR - Preliminary Design Review

  • SBC - Single Board Computer

  • SCSI - Small Computer Systems Interface

  • SLIME - SCSI Linear Insertion Mechanical Enclosure

  • TIM - Technical Interchange Meeting

  • USB - Universal Serial Bus

  • VDD - Version Description Document

  • VGA - Video Graphics Array

  • WS - Workstation

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