Design Methodologies

The AP Labs Rugged Enclosure Design group's main goal is to create products that cost effectively meet customer expectations in performance and schedule.

The following sections outline the major steps in our product development process.

3D-Solid Modeling - After review of the customer’s product specifications we will create a product concept with overall dimensions in our SolidWorks CAD system. This may include components and sub-systems located in the integrated Product Data Management (PDM) system. In some situations, we may create a product animation to assist the customer’s comprehension of the design concept. As the design matures, our PDM system enables our cabling, manufacturing and assembly teams to analyze the design from all angles in an internal digital 3D-product review. This is typically followed by a Critical Design Review (CDR) with the customer.

Structural Analysis - Designs that significantly differ from existing products often require additional analysis, to ensure the enclosure meets the designated MIL or commercial specification. We use a combination of integrated analysis tools to simulate real world environments on the digital prototype. If necessary, we will perform Finite Element Analysis (FEA) to assess the structure’s natural harmonics and review stress levels in heavily loaded areas of the design. We use COSMOS/Works, which enables us to add loads and constraints directly to the 3D solid CAD model, in SolidWorks. This enables us to perform analysis on some parts in le

ss than 30 minutes.

Thermal and Airflow Analysis - Under certain circumstances the need to explore the thermal and airflow characteristics of an enclosure prior to the first prototype is necessary. We use a tool called CFDesign, which is integrated into our CAD software, enabling us to study the airflow velocity, pressure and heat transfer inside an enclosure while still in the design phase.

CNC Manufacturing from 3D model - After completion of the fabrication drawings following the CDR, each sheet metal part is unfolded in the CAD software.

The bend parameters applied by the software to each sheet metal bend can be individually controlled, to optimize the accuracy of the finished part. The CNC punch press codes are generated directly from the unfolded CAD model of the sheet metal part.

Prototype - With a major new enclosure design, AP Labs will produce a final tack welded prototype for final evaluation and approval by the customer and the engineering team, before the startup of volume production. This also enables our cabling group to finalize cable lengths and routing, before receiving production sheet metal.

Design Testing - To assure our products meet the designated stringent MIL standards, we perform a variety of testing. Our analysis tools allow us to predict system performance, but our empirical testing closes the loop and affirms our design. The airflow test fixture allows us to evaluate individual card cage PCB slots for air velocity quickly and efficiently. The six hot wire probes, located on the test board, feed data through a controller directly into MS Excel, allowing us to create graphs and display comparisons.When a contract requires we also validate our chassis’ environmental performance at independent test facilities in San Diego. This testing can include shock, vibration, thermal, humidity, electromagnetic as well as other required tests. For some 901D test requirements we perform "barge tests" in conjunction with end-customer organizations such as the US Navy.