PROJECT OVERVIEW
This project involved the development of a carrier board for an embedded computer that forms part of a system used in military, aerospace, and space applications. The client, an undisclosed company based in Western Europe, is a supplier of electronic devices for both military and civilian strategic infrastructure. As such, all electronics had to be designed to withstand harsh conditions, including extreme temperatures, vibrations, and a wide range of technical challenges.
The goal was to design a carrier board that would fully support the capabilities of a high-performance computer module while fitting mechanically into the customer’s existing chassis. Our solution was engineered to meet all the specific demands of this complex application and ensure outstanding performance, stability, and long-term reliability.
CHALLENGES AND REQUIREMENTS
- Computing power: The carrier board had to fully support the extreme processing power of the selected embedded module — in terms of power supply and heat dissipation.
- Connectivity: Provide a broad range of Ethernet ports, including Gigabit and 10GBase-KR, to ensure high-speed network communication.
- Cooling and stability: Deliver effective thermal management to maintain stable performance even under heavy load.
- Footprint minimization: Design a compact board that integrates seamlessly into the existing chassis.
- Compatibility: Ensure easy integration with high-performance servers and maximum flexibility in module selection.
OUR SOLUTION
The carrier board was designed to meet the demanding requirements of high-performance server applications and offer advanced connectivity.
Key features of the final product include:
- Support for COMe Type 7 module – Designed for use with high-performance computing modules, enabling top efficiency.
- 10ms Power Drop-out Buffer – Provides immediate backup power for up to 10 milliseconds in case of power loss, maintaining system stability and minimizing data loss risks.
- 1x GbE from COMe module – Gigabit Ethernet for basic network communication.
- 4x GbE (PCIe-based) – Four additional gigabit Ethernet ports for extended connectivity, essential for multi-interface server environments.
- 2x 10GBase-KR ports – High-speed Ethernet for real-time data transfer, ideal for demanding applications such as data streaming and big data analysis.
- 2x USB 3.0 ports – For modern peripheral connectivity with high data throughput.
- 1x RS232 port – For serial communication, useful in diagnostics and legacy system compatibility.
Additional highlights:
- Maximum stack height < 40 mm – Compact format allows easy integration into server racks and enclosures, saving space without sacrificing performance.
- Optimized dimensions for existing chassis compatibility – Final dimensions were carefully engineered and approved for seamless integration into the client’s existing systems.
- Cooling cutout for COMe SODIMM memory – The thermal design ensures stable operating temperatures, essential for long-term high-performance computing.
RESULTS
The final product successfully passed rigorous testing to verify its durability and reliability under extreme conditions.
Testing included:
- Shock and vibration tests in compliance with DEF STAN 00-35 and MIL-STD-810 standards, ensuring system stability under intense physical stress.
- Temperature range testing from -40 °C to +85 °C, demonstrating operational stability across extreme environments.
The product passed all tests and fully met the customer’s expectations in terms of performance, connectivity, and durability. The result is a cost-effective, stable solution for long-term deployment in demanding server applications.
SUMMARY
This carrier board development project delivered a high-performance and flexible solution for embedded server applications. The final product is fully compatible with modern embedded modules and offers a broad range of Ethernet interfaces for high-speed data transfer. With an optimized design, focus on performance and reliability, and compliance with all regulatory requirements, the solution is both cost-effective and robust. It passed all environmental and performance tests and was successfully deployed by the customer.
