military aerospace presentation

3600 Rider Trail South A Top 50 Company phone:314.785.0900

St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044

Innoventor®

Top 50 Award Recipient

Your Engineering Problem SolverGold Rating at Boeing

DiversityBusiness.com Winner

SBA Award WinnerInc 5000 Winner

“Outstanding Small Business” at Lockheed Martin

http://www.innoventor.net/



Table of Contents

• Overview

• Flight Systems

• Factory Equipment

• Test Equipment

• Support Equipment

• On-Board Weapons Systems

• AGV’s




• 2010 “Legislative Showcase” award for contributions to the economic

development of the state of Missouri through the creation of businesses and jobs

• 2009 “Outstanding Small Business Performance” Company by Lockheed Martin

Corporation

• 2007 and 2008 St. Louis Business Journal “Top 50 Fastest Growing Privately-

Held Company”

• 2007 and 2008 Inc Magazine Top 5000 award

• 2007 Missouri Small Business Person of the Year

• 2006, 2007 and 2008 Small Business of the year from Dell sponsored

Diversity.com

• Letter of Commendation from Lockheed Martin for work on F-35 Aircraft

Electronic Mate & Assembly Stand

• 2006 Region VII Subcontractor of the Year for the U.S. Small Business

Administration

• 4 time Top 50 Award Winner for St. Louis Region

Awards and Recognitions




• Inception

• Program Management

• System Engineering

• Preliminary Design

• Detailed Design

• Detail Analysis

• Fabrication

• Testing

Full Turn-Key Capabilities




The Engineer Corps

• 90+ engineers with, over

1,800 combined years of

experience

• Engineering talent in a

wide range of disciplines

• Engineers average 20 years’

experience at Innoventor and

previous industry positions




• PC/PLC Programmers

• Mechanical Engineers

• Manufacturing Engineers

• Hydraulic/ Pneumatic Engineers

• Electrical/ Electronics Engineers

• Bio-medical Engineers

Engineering by Technical Discipline• Systems Engineers

• Structural Engineers

• RF Design Engineers

• Optical Design Engineers

• Nuclear Design Engineers

• Chemical Engineers




Joint Strike

Fighter

Overview of

Military/Aerospace Experience

787F-18C-17 Tunner

Bell Helicopter




Military/Aerospace

• Test Equipment

• Factory Support Equipment

• Engineering Service

• Flight Experiments and Flight

Hardware

• Mil-I-45208

• ISO 9001 Compliant




Flight Systems




E-4B Master Regulating Clock• Form, Fit, Function replacement for legacy Cesium timing standard

• Modified COTS solution, hardened for MIL operating

environment(vibration, shock, EMI)

Deliverables include:

• 4 Prototypes

• Complete Technical Data Package for production

• Intermediate and Depot Maintenance Technical

Orders

• Validation and Acceptance Test Plans




The Boeing CompanyMulti-mission Maritime Aircraft

• Software and Hardware Design for a Flight Data Processor for a

Multi-mission Maritime Aircraft.

• Software was designed for high speed data acquisition and processing

while in flight.

• Hardware was designed, tested and qualified for flight.

• Qualification process included: EMC Testing, Vibration and temperature

testing, and Shock testing.




•Stress Analysis Support for detail structure:

-Finite Element Analysis(FEA)

-Clamshell door analysis

-Wing Retrofit/Corrosion repair

• Develop high level process flow models

• Provide support for various material

processing audits; for Boeing

and Lockheed Martin.

• Develop 3-D Computer Aided

Design Models

Sabreliner

Clamshell Doors FEA

Process Flow Model




The Boeing CompanyKC-767 GTTA Tanker

• Boeing awarded Innoventor the task of determining the integrity of this highly publicized, high performance tanker

• The Team performed stress hand-calculations to analyze wide ranging structures including the galley, crew bunk, cargo handling systems and side wall liners

• Success awarded the Team additional work scope to meet an aggressive delivery schedule




SpiritStress Design of

Forward Fuselage

BoeingFuselage Integrity

Structural Test

787 Partner ProjectsVought

Pneumatic Testing

VoughtGraphic Composite

Laydown Inspection




Bell HelicopterIndustry Support Engineering Services

Innoventor, Inc has provided ongoing design

expertise to Bell Helicopter (a Textron Company).

A team of over 25 engineers supported and

assisted Bell on upgrades for the Huey, the V-22

and the Cobra models in the following areas:

• Structural Design

• Unigraphics modeling

• Catia modeling




• Complete team with lead engineer

for schedule issue

• 6-month on-site team provided:

– Critical UniGraphics CAD system drawings

– Required to produce this full-scale mock up

used to train Navy and foreign military in the

proper maintenance methods for a variety of aircrafts

• Design that utilizes scrapped aircrafts parts,

low cost replications of aircraft structure &

commercial off-the-shelf items

The Boeing CompanyF/A-18 Maintenance Trainer Program




Factory Equipment

Lockheed Martin F-35 JSF

Final Assembly Dolly FixtureBoeing - JDAM

Lockheed Martin F-35 JSF

EMAS Platform




GKN AerospaceCH-53K Work Stands

• Innoventor was asked by GKN Aerospace to to design and build new work stands for the CH-53K

helicopter.

• Innoventor provided three work stands to GKN:

-The Forward work stand has roll-up stairs that attach to a scissor lift platform that rises and

lowers to reach work content, including safety sensors.

-The AFT work stand is a large stand made up of two halves and a set of stairs. This stand

accommodates efficient tool component insertion and removal during the Aft section’s build

cycle without the need to disassemble the work stands.

-The Join work stands bring the AFT and the Forward sections together. These stands have two

levels, can raise and lower 24”, and have a moving “diving board” that can extend over their

tool and move down the length of the work stand so workers can build in hard-to-reach places.

Forward Work StandAFT Work Stand

Join Work Stand




F-35 JSF – Moving Assembly LineFour Stage Jack

Autonomous Ground Vehicle

Hydraulic motor

for Jack locking

Wire Encoder




Lockheed Martin F-35 JSF Electronic & Mate Assembly System




• The 830-2 stands (Final Checkout Stands) are a fully engineered product

using 3-D modeling for a precision fit around the F-35 aircraft.

• Currently there are 4 systems with 6 more for assembly, 4 more for Italy

& 13 more for flight line

F-35 JSF 830-2 Checkout Stands




The Boeing Company - JDAM

Foam Pack Parallel Gripper

Tail Kit Lift and Translate

• Implemented production support equipment

for JDAM assembly line

• New end effectors added ability to produce

MK-82 tail kits along with all ready produced

MK-83 and MK-84 tail kits

• Assisted in increasing production from

1,300 to 3,000 units per month

Tools Include:

• TAS Lift

• Tail Kit Lift and Rotate

• Foam Pack Parallel Gripper

• Tail Kit Lift & Translate




HoneywellFederal Manufacturing and Technologies

EB Welder Programming and Hardware Updates • The Customer asked Innoventor to create a new

control system for their high precision electron

beam welder

• The new system needed to meet very tight

timing requirements and maintain/improve the

system safety features

• The Team used National Instruments hardware

and LabVIEW software to create the new control

system

• Innoventor also updated the user interface to

provide process improvements and reduce

operator input errors

“The project… exceeded our expectations with

respect to performance and ease of

use…(Innoventor) came up with innovative

solutions to numerous challenges

throughout…”

Letter of Commendation from Honeywell’s Principle

Weld Engineer




Nitrogen Generators

• Systems for aerospace, food &

beverage, pharmaceutical &

petrochemical industries

• Nitrogen purity to 99.95%




F-35 JSF Wing/Installation Fuselage450-420

• An assembly platform that supports:

-Final Structural Completion,

-Subsystem installation, and

-Final Installation of wing skins• OSHA Safety compliance

• Multi-configuration capable




F-35 JSF Wing Assembly461-462

•Wing Substructure Build up

•OSHA Safety Compliance

•Multi-configuration in one tool

461(LH) and 462(RH)




F-35 JSF Wing Dolly460-450

• Transports “wing sections” from one assembly station to another.




F-35 JSFPaint Cell Dolly

The Dolly supports a 40,000 pound aircraft.




F-35 JSFPaint Cell Dolly




F-35 JSF Forward Fuselage CG Leveling Bar




F-35 JSF – BF-01 STOVL

Innoventor Work Stands




F-35 JSF Paint Cell Stands




The Boeing CompanyFlexible AirFrame Support System

• A five scissor hydraulic lift system with trolleys

designed to accommodate 8 different types of

helicopters

• System allows for ease of raising each

helicopter 24 inches off of the deck allowing a

flash jet system to remove paint off the aircraft

belly

• Trolleys located 18 inches under the concrete

deck allow for moving the scissor lift dolly in

position and rolling the helicopter in place

• A simple relay logic system is used to lift the

helicoptersFlexible Airframe Support System (FASS)




The Boeing Company F/A-18 Hornet Automated Drilling System

(ADS)• Systems upgrade of an Automated Drilling

System for F/A-18 Hornet assembly

• Tight resources, schedule & quality

standards

• Assisted with all phases

• Developed system schematics & panel

assembly drawings

• Minimized customer down time &

maintained production schedule




Test Equipment

Boeing C-17 Hydraulic Test Stand

787 Portable Fuselage Pressure

Test SystemThales ATM Interface

Test Adaptor

F-35 PAO Unit




The Boeing Company 787 Fuselage Pressure Test System

• Validates the structural integrity and leak rate of a large airplane

fuselage during production under various pressure scenarios

• Operates independently of plant compressed air, requiring only

electrical energy to operate

• Integrates sufficient back-up energy sources to ensure a

controlled depressurization response in the event of a total plant

power outage

• Incorporates sophisticated filtration and air monitoring gear to

ensure that the fuselage is pressurized with breathable air

when personnel are aboard the aircraft

• Completely self-contained on two towable carts

• Innoventor Engineers performed Thermodynamic analysis to

size equipment to meet the customer’s pressure, temperature

and cycle-time requirements




CAT Dynamometer CartTrack Tester & Mobility Tester

• Data generated develops and validates virtual analytic

models

– Provides insight on how products interact with

different soils

• Tests tractive and mobility devices on a variety of soil

types in a laboratory

• Investigates complex interaction between machine

and soil

• Exposes innovative solutions, improving tractive and

mobility performance

• Evaluates track, rubber tires or steel drums for traction,

mobility & compaction performance




The Boeing Company – Long Beach, CAC-17 USAF Transport Portable Fuselage

Pressure Test System

• Portable design allows cart movement to

the C-17 test location

• A specially designed 27 foot Manometer

overflows at a pre-determined pressure

point to prevent over pressurization to the

C-17 being tested

• Cutting edge technology resulted in a

highly portable system that incorporates

a touch screen, electronic controls and

feedback circuitry to provide critical

feedback data

• Boeing gave high marks on quality; budget and delivery were met




The Boeing CompanyF/A-18 EO-CASS Tooling

• Assisted in update & release of AT-FLIR OTPS drawing package

• Produced over 300 plus Pro-E drawings

• Successfully supported Boeing’s schedule & quality

• Assisted in developing detailed designs compatible with Boeing Drawing Release

Standards

• Completed on-time with high quality & within budget

• F/A-18 CASS OS Alignment tool performed analysis & testing to determine cause of

alignment of instabilities

• Designed modifications to tool and mount to obtain

& exceed stability requirements

• Presented analysis & design to Navy customer during CDR

-Initiated by Navy for design improvement

• Design & analysis for tools & fixtures for AT-FLIR OTPS

for Laser Simulator

• Six optical alignment tools & two test tools for ARC




Elgin Air Force Base F-35 Polyalphaolefin (PAO) Unit

• Innoventor designed a PAO system that is used to support fround testing of

the F-35 JSF electronic control equipment

• The system has a built-in heat exchanger to cool PAO fluid returned from

equipment

• Supplies liquid cooling to F-35 (JSF) Electronics for bench testing

• PAO is a synthetic

hydrocarbon that has

excellent heat transfer

capabilities




F-35 JSF PAO Chillers

66 gpm 90 gpm

• Features

• Constant Pressure &

Temperature @ Unit

Under Test

• Tight Temperature

Controls

• Flow Rate Controls




SEI Liquid Cooling Unit

Step 1: Design, fabrication & test of

“Proof-of-Concept” unit to

demonstrate viability of cooling concepts

Step 2: Provide design, development,

fabrication & test of prototype system

incorporating electronic controls for fluid

system

Step 3: Provisioning of design, fabrication

& test of production units

Innoventor's extensive background in fluid cooling systems won them the

contract to design and develop the cooling systems for avionics test

consoles - as part of the overall project to dynamically test aircraft

avionics

Production units to meet or exceed all

specified performance criteria Innoventor’s

extensive experience Proof-of-Concept &

Prototype units




Ametek Thermal Vacuum Test Station

• Checks accuracy & calibrates

pressure transducers

• Experiences condition of space

– Vacuum extremes of heat in

sun’s view & cold out of

sun’s view

• Answers hard vacuum

challenges

• Includes needed safety features




The Boeing Company X45 Mobile Motor Actuators Drivers (MMAD)

• Allows for direct connection to &

operation of

all actuators at any time during

development, assembly and test

• It allows for maximum flexibility

of operations

• Simple operation by hand held

pendant control

• Multiple safety provisions

eliminate errors




The Boeing Company C-17 Hydraulic Test Stand

• Innoventor awarded contract

February 2003 with delivery

schedule in late June 2003

• Design and Build Hydraulic

Test Stand used to fill, proof

pressure and operate C-17

aircraft hydraulic functions

• Touch screen operator

interface controlling a system

with dual circuits each

capable of up to 35 GPM and

6,000 PSIG




Compressed Air Chiller• Provides chilled air 20ºC to

-100ºC

• Mix with warmer air to

reach specific test

temperature for aircraft

system testing

• Conditioned air is chilled by

a piping system using liquid

nitrogen as the chilling

medium

• Dual heat exchanger trains

complete with 3-way

switching valves allow a

defrost cycle




Lockheed Martin F-35 JSFRetractable Access Ramp (RAR)

RAR platform slides to Simulator

Ramp being lowered into the pit

and installed in Simulator Room

• Easier ramp mating to JSF Simulator

-Clear view of platform

-Current ramps on the market have limited view, draw-bridge configuration

• Designed retractable access ramp that slides out from under base

• Designed & built for a high risk environment

• Accommodates 2,000 pound load

• Safe for seismic conditions

• Design & performance well accepted by Lockheed Martin

• Currently in use on the JSF Program




The Boeing Company Delta IV Air Vehicle Ground Support & Factory Test Equipment

• Development of performance & manufacturing

specifications

• Engineering team included systems test, integration,

& design engineers

• Addresses all aspect of flight vehicle interface

-facility power

-test instrumentation

• Seamless integration of designed hardware

into manufacturing facility

-automated controls

-data collection system




The Boeing Company Delta IV RocketHelium Leak Test System (LTS)

• Designed a one-of-a-kind patented automated

Helium Leak Test System that reduces a 16 to

20 hour test cycle to less than 4 hours

• Designed to perform low and high pressure

leaks on 110 different locations on the Delta IV

rocket propulsion system located at Boeing’s

production facility in Decatur, Alabama

• Using a dual vacuum system design and Varian

mass spectrometer, it measures individual helium

leaks in 15-20 seconds

• PLC driven with analog and digital I/O

• The LTS was delivered 6 weeks ahead of schedule

and on budget




The Boeing Company Active Avionics Cooler

• Designed to cool electronics

mounted on cold plates for

space station ground testing

• Electrical systems are hazard

proof in accordance with Class I,

Division II requirements




The Boeing Company Space Station GSE Subcooler

• Tested, built & assisted in design of Space Station GSE Cryogenic Subcooler

• Used to test Space Station radiators

• Major money savings over traditional approaches to cooling systems




The Boeing CompanyModule/Rack Simulator

• Simulates flight elements

during ground testing of

space station

• Drawings incorporated

commercial design

approaches

• Performed final assembly




The Boeing CompanyPassive Avionics Cooler

• Convectively cools flight electronics

during ground tests

• For use on the Space Station Program

• Designed with off-the-shelf equipment for

maximum cost benefit

• Delivery of the system met a limited

budget & created reduced production

costs

• System was produced, tested and

integrated under an aggressive

delivery schedule




Thales ATM Interface Test Adaptors

• Provides interface between custom designed

circuit card assembly & computer control

automated test equipment for FAA

• Multi-axis adjustability of CCA/ITA interface

connector




• Verifies wiring to the fuel boost pumps

located in the C-17 Wings

• Modified to interface with the aircraft and

other GSE

The Boeing CompanyC-17 Phase Tester

• Provides phase sequence

and voltage wiring to the

aircraft wiring




The Boeing CompanyDelta IV Nozzle Extension

Deployment System

• Simulates upper stage Flight Nozzle Extension Deployment System for Delta IV Rocket

• Tests effect of the motor load on electrical system without depleting useful life of flight component




Support Equipment

Boeing Munitions

Handling Unit

DRS Technologies

Flatrack Refueling Capability




Boeing Munitions Handling Unit

• Innoventor was contracted by the Boeing Company to overhaul an out-of-service

munitions handling unit (MHU), which lifts and orients munitions on various

aircrafts.

• Innoventor evaluated the unit and developed solutions to get the unit back in

working order. Services included: he repair of hydraulic system components,

running gear components, and exterior re-paint. Future maintenance costs were

reduced by adding foam to the tires, eliminating the possibility for flat tires.• Innoventor developed the requirements to

replace the existing diesel engine with a

propane-fueled engine, enabling the unit to

run inside an aircraft hangar.

• Following the retrofit of the engine and full

refurbishment of the unit, comprehensive

safety and functional tests were conducted

prior to final delivery to Boeing.




DRS-M1200 Targeting Under Armor(TUA)• The M1200 Targeting Under Armor project provides greatly improved personnel

protection for the Combat Observation Lasing Teams (COLT) and the Fire

Support Teams (FIST).

• Operations are carried out remotely from within the vehicle

• The M1200 TAU system also has the special ability to locate, identify, and track

targets while moving at great distances.

• Innoventor’s role in this project was the following:

- Determine final locations for the LRUs

(Line Replaceable Units)

- Design supports (brackets) for all LRUs

- Fabricate / install LRU and support

bracket)mockups / prototypes

- Finalize cable designs and develop

cable routing

-Develop a stowage plan for all required equipment




• Innoventor designed a compressed module containing the system components, which could be assembled

outside the FRC and then dropped in as a single unit allowing for efficient packaging with all-around access

for assembly

• Maintenance and service of the module can be performed without having to remove it from the frame

DRS TechnologiesFlatrack Refueling Capability

• DRS Technologies sought Innoventor’s expertise to help design a portable, rugged “gas station” providing

a stand-alone storage tank and pumping system for fueling aircraft and ground vehicles for the Army and

Marines

• Innoventor creatively routed the piping, valves and controls to one side

of the unit, which enables the system to be controlled by a single

operator, even though Marine procedures allow for two operators

• The entire system can be hoisted onto Marine and Army transport

vehicles, shipped via standard rail protocol on any train throughout

the world, and even stacked eight high on transport ships

• DRS employees were located at Innoventor’s facilities, enabling the

customer and Innoventor to work as an integrated project team




Chemical Biological Protected Shelter

(CBPS)




DRS TechnologiesVehicle Mounted Combat Cooling System

• Innoventor was asked to prototype a DRS concept for a

rugged, insulated field cooler system that chills water to

support operations in hot and arid remote areas

• The requirement was to chill 100 liter bottles of water by 40

Degrees F in a 24- hour period

• The system had to be designed to plug

into the power outlet of a HumVee

• The rugged, impact tolerant design

dispenses water bottles in a first-in, first-

out basis.




Predator Shelter• Redesigned existing control shelter for

manufacturability w/o impacting quality testing

• Developed improved raw material process and

flow

• Designed tooling to match production

projections




SEI Engineering Projects

• Innoventor has provided design expertise to Systems &

Electronics, Inc., an Engineered Support Systems

Company

• In a five year span with this customer, Innoventor has

placed teams of engineers in multiple manufacturing

facilities

• Innoventor has assisted SEI in the following areas:

-Concept Development -Structural Design

-Hydraulic Design -Electrical Packaging

-Pro Engineering Modeling -Cost Reduction

-Program Management

• SEI considers Innoventor to be a trusted source for

engineering teams when their work load requires it

Tunner

M1000




DRS Mobile Environmental SystemsKingpin Converter Dolly

• GVWT of 8,500lbs

• Vertical kingpin load of 1,500lbs

• Adjustable Pintle Height

• Single wheels

• “NATO” lights with blackout lights

• Military specification transportability and lift

able

• The ability to run at highway speeds of

65mph and limited off road use at reduced

speeds




Lockheed Martin F-35 JSF Crew Station

• Provides access to crewstation & other work areas in its vicinity

• Stands are light & maneuverable

• Supports a 40 psf load




On Board Weapon Systems




Innoventor personnel:

• Did the proposal and design

effort for a 4-shot launcher as

opposed to the older two-shot

model

• Installed the launcher mock-up

on the vehicle for US Army

demonstration

SEI TOW Missile Launcher for Bradley Infantry Fighting Vehicle




Ground Support Equipment - Mechanical• Weapon Systems and

Weapon Support

Equipment

• US Navy EMERLEC

30mm Cannon Turret

• US Navy ASROC Missile

Launcher

• US Navy ASROC

Weapon Handling

System (AWHS)




Ground Based Weapon Systems, Weapon Support Equipment and GSE include:

• M901 Improved TOW Vehicle (ITV)

• FISTV Vehicle Laser Target Identification System for ITV

• M860 Patriot Missile Launcher





• Served as the lead

mechanical engineer

• Upgraded the standards

and drawing packages

for the B-52H for

production of 2 units 30

years after the initial

order

SEI ASG-21 Gun Laying Mount (GLM)





• Served as the lead hydraulic engineer

• Performed stress analysis for compliance with shipboard and launch load environments

• Supported installation and integration of Armored Box Launcher on multiple US Navy ship platforms

Unidynamics Armored Box Launcher for Cruise Missile




AGV’S




Automated Guided Vehicle

for Major Wireless Manufacturer

Innoventor was awarded a short turn-around contract to:

• Design and Build two AGV’s for testing the latest wireless technology

• Features include: - Self guided abilities using laser technology- Electrical, mechanical, programming and

industrial design by Innoventor- Break through design makes it half the

weight of robots on the market for use on standard floor loads and standard doorways




CLOVerS




• Central PC Programmed in Microsoft Visual Basic

• Graphical display AGV position, doors x-rays etc

• Mouse based click to dispatch

• Controls using Allen Bradley programmable controller

• Radio with custom designed serial protocol

AGV for DARPA

AGV for DARPA Demonstrator

to X-Ray Fully Loaded Tractor

Trailers

Developed by an Innoventor

Engineer




A Solutions Engineering HouseInnoventor, Inc.

3600 Rider Trail South

St. Louis MO 63045 (USA)

P 314.785.0900

F 314.785.0044

www.innoventor.net
