TRANSPORTATIONGetting to the core of ruggedtransportation systemsBy Jeff Munch, ADLINKMobility <strong>and</strong> environmentalextremes are criticalin transportation applications;by selecting the right core <strong>and</strong>rugged framework, focusingon <strong>and</strong> prioritizing anyadded customizationbecomes much simpler.Figure 1. The cPCI-6880 blade is availablewith an extended operating temperaturerange of -20°C to +70°C <strong>and</strong> supports aconducted cooling option. Transportation means movement. Movementmeans variability. Variability means design challenges.When building a small form factor embeddedcomputer for transportation applications,there are inherent design challenges regardlessof application-specific requirements.In fact, it can be argued that small form factordesign trends are paradoxical. As form factorsize decreases, functionality requirements increase.And at the same time that processingpower requirements heighten, lower powerconsumption <strong>and</strong> thermal output is expected.Now add to that the requirement for ruggednessto accommodate for the shock, vibration, humidity,<strong>and</strong> temperature extremes <strong>and</strong> varianceinherent in mobile <strong>and</strong> outdoor applications;developers are often left wondering where theycan safely compromise while still meetingoverall application design specifications. Knowingthe application needs <strong>and</strong> what alreadyexists on the market fitting those requirementsmakes transportation design less daunting.Adlink has made a blade available with an extendedoperating temperature range of -20°Cto +70°C. To withst<strong>and</strong> high-vibration environments,the blade can be configured withjust 4 GB of solder-down memory, <strong>and</strong> it containsan on-card 4 GB USB based NAND flash.The blade also supports a conduction-cooledoption. With up to 8 GB of system memory,the cPCI-6880 has a GM45 memory controllerthat supports two channels of memory. Theblade routes one channel to 4 GB of solderdownmemory <strong>and</strong> the second channel to anSO-DIMM connector that can support an additional4 GB of memory. The ability to h<strong>and</strong>le8 GB of memory as well as its VT-d1 supportmatches up well with virtualization environments.Dual BIOS PROMs provide redundancyin the event of a BIOS corruption or a need toroll back the BIOS to a previous known goodrevision. Other peripherals include four PCIExpress based 10/100/1000BASE-T Ethernetports, one DVI-I port, one analog CRT port,three USB 2.0 ports, a serial port, an onboardhard drive, 4 GB of NAND flash, <strong>and</strong> a PMCsite. Additional peripherals are available onthe rear transition module. The blade can doits job residing in either a CompactPCI systemslot or a peripheral slot <strong>and</strong> supports 5.0 V<strong>and</strong> 3.3 V backplane V (I/O). A PCI-Expressto-PCI-bridgemakes it possible for a 66 MHz64-bit PCI interface to be used for the PMC<strong>and</strong> bridged for use on the CompactPCI bus.It is fully compliant with PICMG specifications2.0 R3.0, 2.1 R2.0, 2.9 R1.0, <strong>and</strong> 2.16 R1.0.PC/104 <strong>and</strong> Embedded Board eXp<strong>and</strong>able(EBX) are good format options for designsthat can h<strong>and</strong>le slightly larger single boardcomputer (SBC) form factors. Intended fordata acquisition in rugged environments, thePC/104 embedded computing format has nobackplane, instead allowing modules to stacktogether like building blocks more ruggedthan typical bus connections in PCs. And withjust 46 square inches of surface area (8“ x5.75“), EBX balances size <strong>and</strong> functionalitywith a bolt-down SBC format supportingrugged embedded designs with higher-performancecentral processing units (<strong>CPU</strong>s), suchas those using multicore technology for networking,digital signal processing (DSP), <strong>and</strong>graphics-heavy applications, <strong>and</strong> generous onboardinput/output (I/O) functions to supporteverything from large data exchange to video.However, the most extendable <strong>and</strong> customizableapplication design method accommodatesa broad range of custom <strong>and</strong> off-the-shelfneeds by using modularity. Computer-on-Modules (COMs) are complete embeddedcomputers built on a single circuit board foruse in small or specialized applications requiringlow power consumption or small physicalsize. Though they are compact (ETX/XTX at114 x 95mm <strong>and</strong> COM Express at 125 x95mm) <strong>and</strong> highly integrated, COMs can accommodatecomplex <strong>CPU</strong>s. With the COMapproach, all generic PC functions are readilyavailable in an off-the-shelf core module. Acustom-designed carrier board complementsthe COM with additional functionality that isrequired for specific applications. The carrierboard provides all the interface connectors forMay 2013 12
TRANSPORTATIONperipherals, such as storage, Ethernet, keyboard/mouse,<strong>and</strong> display. This modularityallows the designer to upgrade the COM onthe carrier board without changing any otherboard design features, <strong>and</strong> also allows morecustomization of peripherals as dictated by aspecific application.COMs allow system developers to focus ontheir core competencies <strong>and</strong> the unique functionsof their systems. The COM Express formfactor offers flexibility in the development <strong>and</strong>advancement of ultra-rugged embedded applicationsfor a plethora of industries, includingtransportation. By using the modular processingblock, the designer creates a price <strong>and</strong>value advantage; he/she is not locked into asingle vendor for board creation <strong>and</strong> can customizebased on pricing <strong>and</strong> performance requirements.Because it is easily swapped froma carrier board <strong>and</strong> comes in one of thesmallest form factors, COM Express is idealfor long-life embedded applications with acritical development cycle, as well as moreprogressive applications that require frequentprocessor upgrades without affecting otherapplication design elements. Transportationsolutions are most often housed outdoors orin moving vehicles, where exposure to a varietyof climates dictates the need to operate inextended temperatures <strong>and</strong> to power up inany extreme. The easiest initial step is to selecta rugged board or system that is designed forharsh environments from the ground up. Tosupport the extremes of shock, vibration, humidity,<strong>and</strong> temperature, care is given to componentselection, circuit design, printed circuitboard (PCB) layout <strong>and</strong> materials, thermal solutions,enclosure design, <strong>and</strong> manufacturingprocess. Robust test methods, including highlyaccelerated life testing (HALT), ensure optimalproduct design phases in order to meet thestringent requirements of a product, such as-40°C to +85°C operating temperature range,MIL-STD, shock <strong>and</strong> vibration, <strong>and</strong> long-termreliability.Onboard train systems also deal with highconcentrations of sulphur <strong>and</strong> humidity whengoing through tunnels. Designers can look forboards with conformal coating to reduce degradationfrom such exposure. Conformal coatingis used in small form factor manufacturingrather than potting, which is a similar processthat uses a heavier material <strong>and</strong> is harder toinspect, test, <strong>and</strong> repair. Though consideredthe highest level of environmental protection,potting encapsulates the entire PCB, whichadds weight <strong>and</strong> exp<strong>and</strong>s dimensions of aunit. Even an extra mm can be critical insmall form factor design, which is why conformalcoating with a single-part material thatconforms to the board is a better option. A varietyof conformal coating materials (such asacrylic, polyurethane, epoxy, <strong>and</strong> silicone) <strong>and</strong>application methods (such as brushing, spraying,<strong>and</strong> dipping) are currently used to protectagainst moisture, dust, chemicals, <strong>and</strong> temperatureextremes that can potentially damageelectronics. The correct coating or applicationmethod varies depending on established st<strong>and</strong>ardoperating conditions for an application.With transportation applications, differentcoatings may be selected based on a primaryneed for moisture resistance versus abrasionresistance versus temperature stability.Transportation applications typically need asmuch functionality as possible in the smallestform factor, meaning the controller may beburdened with extreme loads of information<strong>and</strong> intricate tasks. Rugged computing solutionsalso dem<strong>and</strong> more memory space than everbefore for both data storage <strong>and</strong> applicationperformance. Options for storage include rotatinghard disk drives (HDDs) for economyor solid-state drives (SSDs), which are truly