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RAF Tabtronics LLC Overview 2013

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Overview of RAF Tabtronics capabilities, markets, and technology innovations.

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RAF Tabtronics LLC Overview 2013

  1. 1. www.raftabtronics.com 888 876 6424 RAF Tabtronics LLC – OVERVIEW Creating Cost-Effective Customized Transformers & Inductors for the World’s Leading Power Technology Companies
  2. 2. WHO WE ARE 2
  3. 3. VISION: Build the global leader in the custom electromagnetic components industry by leveraging the transformative power of innovation. QUALITY: We are responsible for, and committed to, delivering reliable products that meet our customer’s delivery, quality, cost and performance objectives with hassle-free service and continuous improvement of our management systems. TRANSFORMATIVE POWER 3
  4. 4. COMPANY HISTORY Tomter Inc. Tabtronics Inc. Chloride Electro Networks (CEN) RAF Technologies Inc. RAF Magnetics Inc. Caledonia Transformer 4
  5. 5. • Robert MALKANI, Chairman & CEO • James TABBI, President& COO • Susan SCIPIONI, CFO EXECUTIVE TEAM 5
  6. 6. • Victor QUINN, Director of Engineering / CTO • Dean COX, Supply Chain Manager • Robert KINDELL, Business Development Manager • Jason MANN, Quality Assurance Manager • Glenn MOORE, Plant Production Supervisor (F1) • Frank SANTUCCI, Plant Production Manager (F2) LEADERSHIP TEAM 6 High-Volume Low Cos SMT Air Coils w/ removable PNP
  7. 7. WHAT WE DO 7
  8. 8. OUR SWEET SPOT • Ultra-high power density magnetic components for high-reliability applications in defense, aerospace, medical, mass-transit and high-grade industrial markets. Planar Transformer Module for Radar Application 8
  9. 9. • Aerospace, Defense& Homeland Security • Mass-Transit / Commercial Transportation • MedicalInstruments & Devices • Computer, Electric & Electronic Equipment • Instruments & Related Equip • Mining & Exploration • Industrial Machinery MARKETS 9
  10. 10. • Communications Systems • Ignition Systems • Controls (Flight, Process, etc.) • Sensors • Linear & Switch Mode Power Supplies • Current & Potential Transformers • Radar/Sonar • Vetronics • and many more… APPLICATIONS 10
  11. 11. • F-35 Lightning II (JSF) • F-22 Raptor • F-18 Hornet • F-16 Fighting Falcon • F-15 Eagle • F-117 Nighthawk • B-1 Lancer • E-3A Sentry (AWACS) • MRAP • JLTV • AIM-9X Missile • International Space Station • Space Shuttle • Boeing SLAM-ER Launcher • Virginia Class Nuclear Sub • AEGIS Destroyer • Comanche Helicopter • Blackhawk Helicopter • LAMPS Helicopter System • Improved Fire Control System (IFCS) • GE, Rolls-Royce, Pratt & Whitney, BMW & other Jet Engines HIGH GRADE PROGRAMS 11 High Voltage Xfmr for Jet Engine Exciter High Current Xfmr for Aircraft Power Application
  12. 12. FLORIDA Operations (F1) • COE for Commercial Aerospace Magnetics • AS9100C Certified • J-STD-001 Certified Soldering • 15,000 sq. ft. • Glenn MOORE, Plant Supervisor 12
  13. 13. ROCHESTER Operations (F2) • COE for MIL-PRF-27, HV & Hi-Rel Magnetics • ISO9001 Certified, AS9100C Compliant • J-STD-001 Certified Soldering • 30,000 sq. ft. • 5,000 sq. ft. Encapsulation Facility • Frank SANTUCCI, Plant Production Manager 13
  14. 14. NEAR SHORE Operations Frank MARTINEZ, Nearshore Operations Quality Engineer • Central America (F6) • ISO9001:2008 Certified • 30,000 sq. ft. • ~100 direct labor • ITAR MLA Licensed • CARIBBEAN (F7) • Established 2005 • 35,000 sq. ft., • ~250 direct labor 14
  15. 15. WHO WE SERVE 15
  16. 16. CUSTOMER LOYALTY MARKET / PRODUCT Lockheed Martin 35+ Years Radar, Sonar, Defense Systems GE Aviation | Unison Industries 30+ Years Jet Engine Exciters/Igniters HARRIS | RF Communications 25+ Years Secure Communications ALSTOM | Transport Signaling 25+ Years Rail Transportation Control & Signaling Moog Inc. 20+ Years Aerospace & Defense Fluid Control TEKNIC Inc. 15+ Years Machine Automation Systems GE Aviation | Power Systems 12 Years Aircraft Power & Control Champion Aerospace 10 Years Jet Engine Exciters/Igniters BAE Systems EIS 10 Years Defense & Commercial Power Systems Communications & Power Ind 5 Years Microwave & RF Power Amplifiers TOP LOYAL CUSTOMERS 16
  17. 17. CUSTOMER ENGAGED MARKET / PRODUCT Wave Technologies IPT 2013 Wireless Charging Technology Marotta Controls 2012 Power Supply, Conversion and Conditioning Crane | Aerospace & Electronics 2012 Power Solutions: TWT, TRUs, ATRUs, LVPS Invensys Rail 2011 Rail Automation & Control Systems Rockwell Collins 2011 Aircraft Power & Avionics Parker Aerospace 2010 Aircraft Electronic Controls Astronics LSI / DME 2010 Aircraft internal, External & Runway Lighting ITT Exelis | Electronic Systems 2010 Defense Electronics / Avionics / Power Systems DRS Technologies 2010 Defense Targeting, Control & Electronics IBM / Jabil Singapore 2010 File Server Power Supplies EXCITING NEW CUSTOMERS 17
  18. 18. HOW WE DO IT 18
  19. 19. • Dedicated Project Engineer • Cross-functional Design Review Team • Flexible, menu based NPD process • Advanced design tools & methods - 3D Mechanical CAD (Pro-E) - specializedMagnetics design & optimization tools - thermal modeling - simulation • Sophisticated Process Documentation • Robust Process Controls • AS9102 First Article Inspection Reports ADVANCED DEVELOPMENT PROCESS 3D CAD Model of Transformer in development using Pro-E software. 19
  20. 20. • Power supply topologies - Flyback; Resonant; Buck; Boost; Forward; Bridge • Winding geometries - planar, annular, hybrid, SESI - Litz, foil, specialty wire & windings - conventional • Magnetic core geometries - all standard shapes & sizes - custom shapes & sizes • Magnetic core materials - standard ferrites, powdered iron, MPP, silicon steel, nickel, cobalt alloys, amorphous metals & nanocrystalline TECHNICAL EXPERTISE HXMT Planar Transformer for High-Efficiency Solar Array Inverter 20 Large Electromagnet (Square Wire on Copper Coil Form)
  21. 21. • HXMT optimizes coil constructions • Yields optimal configuration to achieve desired functions • Optimization reduces lost energy within coil • Transformers operate cooler & more efficiently • Gives size, weight and cost reduction • Is based on loss and energy solutions of the diffusion equation for generalized boundary conditions • Finds hidden value in magnetic components U.S. Patents: 7506280, 7885787, 7888931 Optimum Thickness Predicted by Hyper-XMT 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0 0.00 2.00 4.00 6.00 8.00 Wire Thickness Watt HYPER-X MAGNETIC TECHNOLOGY TM 21
  22. 22. 22 HIGH GRADE OPTIMIZATION Conventional Versus HXMT Total Loss For 12 Turn Winding, 5 δ Thick Limit V aryin g T o tal L ayers (resu lts n o rm aliz ed to o p tim iz ed co n ven tio n al 1 layer) 0.00 0.20 0.40 0.60 0.80 1.00 1.20 1.40 1 2 3 4 Total Layers Loss conventional HXMT Sum of 10 Harmonics -2 0 2 0 2 4 6 8 Phase Amplitude 22% Loss Reduction 22
  23. 23. HIGH GRADE ENCAPSULATION Power Inductor Redesign To Achieve 75 uH @ 300 Adc 165.6 165.7 165.2 163.8 161.5 158.2 153.2 132.0 85.2 59.4 45.9 166.3 165.9 163.4 159.7 152.9 127.9 59.1 39.6 31.5 29.8 166.3 0 15 30 45 60 75 90 105 120 135 150 165 180 0 50 100 150 200 250 300 350 400 450 Bias Current (Adc) IncrementalInductance(uH) +118% inductance increase within package constraints 23
  24. 24. • J-STD-001 certified trainers / solderers – Lockheed Martin Special Process Supplier • IPC-610 certified inspectors – GE Aviation DSQR • Hi-grade finishing capabilities – High-vacuum / Pressure Encapsulation – Impregnation - Special Coatings – Precision sizing - MIL-Spec Painting • Hi-grade testing – partial discharge (Corona) – high-voltage – thermal shock SPECIAL PROCESSES High Voltage (10kV) Transformer for TWT Power Amplifier 24
  25. 25. • Military standards - MIL-PRF-27 - MIL-STD-981 - MIL-T-21038 - MIL-STD-1533 - MIL-STD-454 - MIL-STD-83446 • Safety standards - UL, CSA, TUV, VDE, BSI, CE • Quality & Environmental Standards - AS/ISO, IEC, RoHS • Technical Data Protection - International Traffic in Arms Regulations - US/Canada JCP registered - intellectual property protection STANDARDS & CONTROLS UL Listed Commercial Grade Power Supplies for Motion Control Applications 25
  26. 26. • Ongoing collaboration in leading edge Power Electronics • IEEE/APEC Power Technology Roadmap contributor • Advanced Harmonic Analysis • Coil loss / Core Loss Studies • Wide band current sensing • Ultra high operating temperatures • 230 °C, 260 °C, 300 °C + • High-voltage Planar Magnetics • Ultra-light high-power Planar Magnetics • Integrated Magnetics (proprietary) • Strategic Product Design Partnerships LATEST INNOVATIONS / CURRENT R&D SMT 8kW 500kHz PSFB Radar Application 26
  27. 27. THE RESULTS 27
  28. 28. 510-6050: 40 uH INDUCTOR • Aerospace / Defense • 40 uH Inductor • High Current • Foil Windings • Integrated Heat Sink •Nano-crystalline Tape-Wound Cores • Proprietary Hi-Temp Insulation System • MIL-PRF-27 Grade 5 28
  29. 29. 510-6041: 3-PHASE INDUCTOR ASSY • Commercial Aerospace • 3-Phase Inductor Assy • Machined Heatsink •Nano-crystalline Tape- Wound Cores • Designed for minimal size and weight 29
  30. 30. 510-6043: SOLAR INVERTER INDUCTOR • Solar Inverter Inductor • Design Goal: Maximum Efficiency in given Volume • Bifilar Helical Winding 30
  31. 31. C59401: HIGH CURRENT INDUCTOR • Naval Defense • Multi-filar twisted windings • High Shock & Vibration Environment (MIL-S-901) • Anodized Al Heatsinking Mounts 31
  32. 32. 568-5220: PLANAR AEROSPACE XFMR • Aerospace Power Supply • Planar Windings • J-STD-001 Class 3 32
  33. 33. 568-6087:Vehicular Power XFMR • Defense Vetronics • Extremely low leakage inductance • 5KW, 100 kHz Bridge XFMR •Planar Geometry 33
  34. 34. 568-5210: TRAVELING WAVE TUBE XFMR • Aerospace Defense • High-Voltage TWT Application • Planar Geometry • 100 kHz 34
  35. 35. 568-6109: ENERGY TRANSFER XFMR • Commercial Bus • Contactless Charging Application • 150 KW 20 kHz 190A •<1000 W Dissipation • Custom Cores, Coil- Forms, Terminations, Mounts 35
  36. 36. 580-6003: 3-PHASE IND/XFMR MODULE • Defense Missile Launcher Application • Ultra-High Efficiency • Ultra-Low Weight • Complex Heatsinking 36
  37. 37. 599-6012: XFMR/IND ASSEMBLY • Defense Missile Launcher Application • Ultra-High Efficiency • Ultra-Low Weight • Complex Heatsinking •Nano-Crystalline Core • Proprietary Insulation System 37
  38. 38. AND MORE… Railway Sensing Application Three-Phase Line Filter Three-Phase High Power Density Aerospace SMT 8kW 500kHz PSFB Radar Application High Density Hybrid Planar Transformer Aerospace Power Supply High Voltage Medical X-Ray Transformer High Density SMT Hybrid-Planar Transformer 38
  39. 39. • AS9100C & ISO9001:2008 Quality Systems • Focused, value oriented company • World-class customers in diverse markets • Depth of electromagnetic design engineering capability to solve complex customer problems • Hyper-X Magnetics Technology patents for optimization of magnetic components • Unique capabilities, expertise, and experience • Strong technical & management teams • Strong Business Record • ITAR & US/Canada JCP registered • LCC Manufacturing • MIL-PRF-27 experts • Commitment to the Customer, first and foremost! Why RAF TABTRONICS LLC? 39
  40. 40. The information in this presentation is proprietary and confidential, and is intended solely for the audience to whom it is delivered. Any disclosure of the information contained in this presentation and in presentation handouts is a violation of non-disclosure & confidentiality agreements currently in force. © 2010 RAF TABTRONICS LLC 40

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