Air Combat Training System (ACTS) Transponder Redesign

The Client
The overall objective of this effort was to redesign the Air Combat Training System (ACTS) Airborne Instrumentation Subsystem (AIS) Transponder Assembly for the U.S. Air Force. This specific contract was a follow on to a previous contract where we successfully demonstrated the feasibility of using state-of-the-art technology to replace the legacy P4B range tone transceiver. Given the success of the previous contract we were tasked to fully develop the prototype transceiver and a companion front-end signal conditioner board into flight worthy assemblies meeting all of the original P4B requirements.

The Solution
Our solution for this project included the following criteria:

• Develop a single board, logistically supportable transceiver that replaced five legacy circuit boards.
• Develop a signal conditioner board using an advanced multi-layer flexible circuit materials that eliminated the obsolete Mil-Std-1553 components.
• Demonstrate improved system tracking sensitivity over the legacy design.
• Conduct system level tests with the ASM-694 Test Set to validate the signal conditioner and transceiver's performance against the established specifications.
• Conduct project design reviews, and formal qualification testing including operational flight testing.
• Create a signal conditioner and transceiver technical data package suitable for procurement .

The Results
We successfully completed both the transceiver and signal conditioner board’s "first spin" in time to demonstrate functional performance at the project's critical design review (CDR). In terms of system performance, the transceiver demonstrated better sensitivity than its legacy counterpart. Formal qualification and air worthiness testing was completed on 15 April 2006, and we successfully completed operational flight testing at Tyndall AFB during May to September 2006.

These were operational "firsts" for us. This was the first time we had ever conducted an operational flight test on our redesigned circuit card assemblies. We completed the rigorous 6 month qualification and flight test process without a single component failure.