2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Laura Watson, SME, LPE, Senior Electronics Engineer
Naval Undersea Warfare Center Division (NUWC), Keyport
Desk Phone: 360-396-1981
Email: [email protected]
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
1
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Problem
•
Numerous fielded Department of Defense (DoD) electronic systems become
unsupportable due to discontinued Circuit Card Assemblies (CCAs) driven by
component obsolescence.
o Original Equipment Manufacturers (OEMs) no longer provide maintenance
nor spares support for their electronic systems.
o Design changes are costly and time consuming.
 Design, test, validation, and re-qualification
 Documentation changes and other logistics costs
 System capability degradation
•
Reverse engineering is a viable, cost effective alternative to the redesign of
subassemblies or vendor replacement of systems.
•
NUWC Keyport has been evolving methods of Printed Wiring Board (PWB)
reverse engineering, but they are inherently destructive and time consuming.
o De-populated PWB wired to cable analyzer to obtain net list
o Surface grind PWB using milling machine and photograph layers
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
2
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Solution
•
Radiographic analysis of PWBs using Computed Tomography (CT) as well as Two
Dimensional (2D) X-ray techniques, where images are converted to a vector format
suitable for Computer Aided Manufacturing (CAM).
o Raster-format images from a PWB X-ray analysis are modified and combined
using complex software algorithms.
 Algorithms perform layer isolation, volume stitching, intensity and filtering,
edge detection, and feature detection.
o Modified raster images are converted to vector format, and open American
Standard Code for Information Interchange (ASCII) vector format files (Gerber
files) are generated for use in CAM.
 All accomplished using commercial software packages
Modified
Raster
Raster
Image
Modification
Vector
Conversion
to Vector
Gerber
Gerber
Generation
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
3
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Example
Modified
Raster
Layer 2
Modified
Raster
Layer 1
Test
Coupon
Gerber File
Vector
Layer 1
Gerber File
Vector
Layer 2
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
4
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Solution (continued)
•
X-ray reverse engineering of PWBs has several advantages over previous reverse
engineering methods.
•
Faster process turnaround
o Example: Reverse engineer of 8 layer PWB:
 Grinding method – 8 weeks
 X-Ray method - 2 to 4 weeks
•
Non-destructive and non-intrusive
•
More accurate reproduction
•
Complete enhanced visualization of individual PWB layers
•
X-ray accurately reveals very fine details such as thermals, hidden trace vias, and
layer thicknesses.
•
Can also be used for troubleshooting and repair of Original Equipment Manufacturer
(OEM) assets
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
5
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Benefits
•
Sustainment breakthrough
o Mitigates PWB obsolescence and vendor system planned
obsolescence
o Preserves system supportability and avoids costly redesign
of the subassembly or end item
o Enables Service Life Extension Program (SLEP) decision
•
Accurate reverse engineering to provide exact copies instead of
more costly redesign options, requiring re-certification
•
New source for obsolete PWBs
o Components stay the same (if available)
o Transparent, plug-and-play insertion into next higher
assembly
o May improve component reliability over original part
o Reduced risk of counterfeit parts (controlled re-supply)
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
6
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Challenges and Risks
•
Acceptance of replacement PWBs may still require system
requalification
o Cost/risk/schedule tradeoffs
•
May not be a complete solution to obsolete electronic assemblies
o Component level obsolescence
o Modifications to original design
•
NUWC Keyport designs and builds custom designed Assembled
Replacement Integrated Circuits (ARICs) to replace certain
obsolete Integrated Circuits (ICs).
o Mitigates component obsolescence
o Allows the use of original circuit board design
o Transparent IC replacement
•
DoD community awareness/exposure
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
7
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Innovation Status
• NUWC Keyport has been reverse engineering printed wiring
boards for 16 years. X-ray is simply a quicker, more accurate
method of analysis.
• Lifecycle continuum status – Technology Readiness Level (TRL) 9
o X-ray method has been used to analyze printed wiring boards
for Naval Sea Systems Command customers and generate
needed drill files.
o Process proven up to eight board layers
o Engineering estimates this may expand to 12 – 14 layers
• Demonstrated capability to use radiographic analysis for future
reverse engineering efforts
• Continued improvements with experience will decrease the overall
process time.
• Goal is a highly automated process
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
8
2016
Maintenance
Innovation
Challenge
X-Ray Reverse Engineering
Techniques
Vision / Final Thoughts
•
Excellent solution for maintenance of obsolete systems
o
o
o
o
o
•
Fast, accurate, non-destructive Circuit Card Assemblies (CCAs)
analysis
Facilitates generation of Technical Data Packages (TDPs)
Minimizes first article testing and board requalification
Extends repair capability through accurate reproduction of
assets
Extends life expectancy of systems nearing obsolescence
Radiographic analysis is an extremely accurate, non-destructive
solution to obsolete and unobtainable PWBs.
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
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What we do:
Fix it…
Build it…
Design it…
Manage & resolve obsolescence…
Keep it running…
Questions?
“The positive thinker sees the invisible, feels the intangible, and achieves the impossible."
Anonymous Quote
Distribution Statement A: Approved for Public Release; Distribution is unlimited. NUWC Keyport #16-064.
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