PWS.docx

U.S. AIR FORCE

Performance Work Statement for NPN Silicon Power Transistor

Prepared By:

Ankit Sur / John Bryant

407 SCMS / GUEA

Date:

6/8/2010

DISTRIBUTION STATEMENT B: Distribution authorized to U.S. Government Agencies only. Other requests for this document shall be referred to 407 SCMS/GUEA.

PERFORMANCE WORK STATEMENT

FOR

NPN SILICON POWER TRANSISTOR

NSN: 5961-01-304-5718

P/N: 515538-2

1.0 Description of Services

The objective of this effort is for the contractor to re-engineer and design a more reliable replacement to the NPN Power Transistor. This power transistor is a critical component of the Driver Power Amplifier (DPA). The DPA is used on the AN/GRT-21/22 Very High Frequency (VHF)/Ultra High frequency (UHF) transmitters. The contractor shall fabricate eight prototypes, accomplish form-fit-function test, and provide a level 3, competitive procurement engineering data package free of proprietary/limited rights.

1.1 Scope

This specification details the requirements for the NPN Power Transistors intended for use as RF amplifiers operating from 100 to 400 MHz.

1.2 Applicable Documents

The information contained below documents the form and function of this part. For testing standards refer to MIL-STD-750 “Test Methods for Semiconductor Devices” and “Alternate test procedures for VHF/UHF Driver Power Amplifier.”

1.3 Requirements

1.3.1 Mechanical requirements

Configuration and dimensions: Shall be per Figure I below.

Lead Finish: Shall be gold, 60 micro inches minimum.

Flange Finish: Shall be gold, 60 micro inches minimum.

1.3.2 Electrical Requirements

Absolute maximum ratings: Shall be per Table I and apply to case temperature of 25⁰C.

Table I: Absolute maximum ratings (each side) @ TC = 25°C Electrical Specifications: Shall be per Table II below.

Table II: Electrical Specification (see note below) Note:

1. When used in test fixture.

2. As drive level is increased to 1.5W, the observed output power shall increase continuously, such that ΔPout/ΔPin > 0, and thermal runaway and/or self-destruction shall not occur.

As power is increased to 2W, there shall be no fallback in power output.

3. Parts shall be 100% tested to withstand 30:1 load mismatch at all phase angles when driven at the input level required to produce Pout into a 50Ω load. Maximum rate of change of load phase is 120⁰/sec and total phase change shall be greater than 360⁰. Parts shall be capable of withstanding an indefinite 30:1 mismatch at any phase angle at 80⁰C heat sink temp & above input level unless otherwise specified.

4. The parts when tested on the curve tracer for BVCES, the trace shall be continuous with no reversal or discontinuity.

Safe Operating Conditions: Shall meet the requirements in Figure II below.

Figure II: Safe Operating Conditions

1.3.3 Environmental Requirements:

Units shall be capable of withstanding the following conditions when applied in accordance with applicable test conditions of MIL-STD-750.

Temperature Cycle: Method 1052, -65°C to 150°C, 6 cycles Thermal Shock: Method 1056, 100°C to 0°C Moisture resistance: Method 1021, 95% RH, 10 cycles, 10°C to 65°C Shock: Method 2016, 1500 G’s, 0.5 millisecond Vibration: Method 2056, 20 G’s 100 to 2000 CPS Constant acceleration: Method 2006, 20,000 G’s Storage life: Method 1031, 150°C for 1000 hours Soldering heat: Method 2031, 260°C, 10 sec Fungus: All materials used shall be fungus-insert and non-nutrient or shall be suitably enclosed and protected

1.4 Testing

The contractor shall design appropriate test fixtures to be used to measure the characteristics of all eight prototype units produced to ensure all the requirements specified in section 1.3 are met. For testing the transistor in the next higher assembly, please refer to the “Alternate test procedures for VHF/UHF Driver Power Amplifier.”

1.5 Application Data

The devices specified herein are intended for use in a solid-state RF power amplifier operating at 100 to 400 MHz in military communications equipment, providing reliable service in continuous unattended use, with end-item equipment providing average times-between-failure of greater than 10,000 hours. The transistor devices are expected to be as failure-free as current technology can produce. Any condition in the transistors which is incompatible with these intended use requirements shall be clearly identified by the supplier at the time of design review.

1.6 Qualification

Parts shall be capable of meeting destructive physical analysis and qualification testing such as 1000 hours operating life test, high temperature reverse bias, high temperature storage, temperature cycling, and other applicable requirements defined above.

(CDRL - A002 – Test/Inspection Report)

1.7 System Safety

The contractor shall notify government personnel regarding any safety issues that arise during the production of the prototypes. All safety concerns shall be addressed by the contractor and the solution shall be made available to the government.

2.0 Government Furnished Property and Service

2.1 Government Furnished Property (GFP)

To enable the contractor to perform the activities of this effort, the Government will provide a AN/GRT-21, NSN 5996-01-229-6007RY, within 30 days after contract award. The Government Furnished Property (GFP) shall be used for analysis and development purpose at the contractor’s facility for the duration of the contract. It can be used to conduct integration testing by installing the power transistor in the Driver Power Amplifier (DPA) assembly and following the Alternate test procedures for VHF/UHF Driver Power Amplifier. The Item shall be returned within 30 days after government acceptance of the prototypes. Receipt and return of the GFP will be coordinated through the Government Program Manager’s office.

3.0 General Information

3.1 Proposed Schedule

The period of performance on this contract will be limited to 6 months with the schedule stated below.

3.2 Schedule Chart

3.3 Service Summary

4.0 Analysis Study and Design

4.1 Phase I

The contractor shall analyze the existing NPN power transistor and provide a report detailing their proposed design recommendation for the replacement power transistor. The objective of this report is to technically document how the contractor proposes to meet the current specifications of the power transistor; the form-fit-function. As such, this report must identify items with long term availability which shall be used in the new design.

The report will also explain the methodology the contractor shall assure that the power transistor design will meet, or exceed, the current performance functionality.

(CDRL - A006 - Design Review Information Package)

4.2 Phase II

Once the government approves the design recommendation from Phase I, the contractor shall begin Phase II to implement a final design of the Power Transistor. The activities of this phase shall include fabrication of the eight prototypes, unit testing, integration testing, and the development of a complete engineering data package for the power transistor. The developed prototypes need to conform to the specification supplied to the contractor; and the engineering data package furnished by the contractor shall reflect the end item being delivered to the government at the end of the project.

4.3 Engineering Data

The contractor shall develop/produce/maintain a Technical Data Package (TDP) that accurately depicts the final product. The TDP shall provide the necessary design, engineering, manufacturing, testing and quality assurance requirements information necessary to enable the procurement or manufacture of an interchangeable item that duplicates the physical and performance characteristics of the original product, without additional design engineering effort or recourse to the original design activity. Product data shall reflect the approved, tested, and accepted configuration of the defined delivered item. All engineering product definition data created as a result of this contract shall be considered a part of the TDP. This data includes, but is not limited to: CAD data, models and model based definition data sets, and Gerber data.

(CDRL - B001 - Product Drawings / Models and associated lists)

4.4 Engineering Data Updates and Revisions

The contractor shall (and shall cause subcontractors and vendors to) update and maintain engineering data for the item(s) designed/ developed/modified/produced by this contract for the life of this contract and shall incorporate all changes in accordance with the following:

a. All engineering changes shall be incorporated into the applicable engineering data within 90 days after engineering release/Air Force concurrence or at intervals of five changes, whichever occurs first, except a change involving safety, which shall be incorporated immediately.

b. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of data for review.

c. All engineering changes shall be incorporated into the applicable engineering data prior to delivery of final media (this includes all Engineering Orders EO’s generated as a result of the preliminary data review.)

4.5 Relationship of Contractor with Subcontractors/Vendors

The contractor shall levy on sub-contractors and sub-vendors the same requirements for Technical Data Packages (TDPs) as are levied on them by this contract. This requirement shall apply at all tiers of sub-contractor/vendor levels associated with the program.

5.0 Test and Evaluation

5.1 Acceptance Test Plan

The contractor shall develop an Acceptance Test Plan (ATP) for government approval that demonstrates that the Power Transistor meets the specifications stated above. This test plan will be composed of a functional test and an integration test using the end item (AN/GRT-21/22).

The contractor shall perform the following test and evaluation subtasks using the government approved ATP:

a. The contractor shall verify that the power transistor meet all form-fit-function requirements by testing all eight prototypes.

b. All eight prototypes must pass the testing with no problems.

c. The contractor shall provide results of the testing to the government in the Test/Inspection Report (Section 5.3).

d. If any prototype fails testing, the contractor will have 30 days to fix the problem and re-schedule testing.

(CDRL - A001 - Test Procedure)

5.2 Ground Test

The Ground test will be conducted at Tobyhanna Army Depot, PA and will mainly consist of testing the power transistor in the next higher assembly (Driver Power Amplifier) using “Alternate test procedures for VHF/UHF Driver Power Amplifier.” The test will be conducted on at least five of the eight prototypes produced. The contractor shall be present during testing to support the effort and provide guidance as needed to government personnel conducting the test.

5.3 Test/Inspection Report

The contractor shall deliver a test/inspection report for the redesigned Power Transistor in accordance with DI-NDTI-80809B on the overall test results (functional, integration and ground test).

(CDRL - A002 - Test/Inspection Report)

6.0 Review

6.1 Engineering Data Conference

The contractor shall support and co-chair a Guidance Conference for engineering data within 60 days after contract award. The Conference shall be convened at a site and on a date agreed upon by the Government contracting officer and the contractor. The contractor shall prepare an agenda and record the minutes of the Guidance Conference.

The contractor shall address, discuss, and provide status on the following:

a. Understanding of all CDRL requirements, applicable DIDs, specifications and standards.

b. TDP review requirements and schedules.

c. TDP delivery requirements and schedules.

d. Contractor's drafting practices/procedures/TDP drawing formats.

e. The contractor's quality assurance procedures relating to TDP documents, including quality control of subcontractor and vendor data.

f. The role of subcontractors and vendors who may deliver TDP documents under this contract.

g. The contractor's configuration management system, including methods for releasing documents, approving documents, and incorporating changes into documents.

h. Digital Technical Data Package (TDP) deliverables.

Note: Guidance Conference may be held in conjunction with other meetings or conferences.

(CDRL A005 - Contractor's Management Report)

6.2 In-Process Review (IPR) of the TDP

The contractor shall host, support, and co-chair an IPR of the engineering drawings and associated lists and other documentation to be included in the TDP. The IPR shall be conducted only after the contractor's quality assurance personnel have completely reviewed the data and determined that data are of sufficient quality that Government time will be effectively utilized during the review. IPR may be scheduled when data has reached the 50% percent completion point and shall be held, when possible, in conjunction with other reviews (i.e., PDR, CDR). The contractor shall notify 584 CBSS /GBHBC a minimum of 30 days prior to the anticipated date of completion point. The IPR shall focus on the contractor's progress in the preparation of the TDP. The contractor shall support and provide the necessary resources, i.e., meeting agenda, conference room, applicable data, minutes, and appropriate personnel available to answer any questions to perform the IPR effectively. The contractor shall correct all discrepancies identified in the IPR. All subcontractor/vendor data shall be made available for review. If the quantity of subcontractor/vendor data is of sufficient magnitude, the Government may schedule a separate IPR at the subcontractor's/vendor's facility.

6.3 Conference Minutes

The contractor shall prepare an agenda and record the minutes of all conferences/meetings conducted in support of this contract. The minutes shall document all significant discussions, conclusions reached, and unresolved issues, and all action items. The contract should be able to support a Video Teleconference if the government is unable to be present at contractor’s facilities.

(CDRL - A003 - Conference Agenda; A004 - Conference Minutes)

6.4 Physical Configuration Audit (PCA)

After the prototypes have successfully passed the ground test (Section 5.2), a Physical Configuration Audit (PCA) shall be held to focus on the reviewing the data package and the prototypes. The purpose of this audit is to ensure the TDP reflects the prototypes being procured accurately. The contractor shall support and provide the necessary resources, i.e., meeting agenda, conference room, applicable data, minutes, and appropriate personnel available to answer any questions to perform at the time of the PCA.

(CDRL – A007 – Design Review Information Package)

7.0 Recordkeeping and Payment

Wide Are Workflow (WAWF) shall be utilized for recordkeeping, CDRL submissions and payment purposes.

8.0 References

A. MIL-STD-750 “Test Method Standard for Semiconductor Devices” 20 November 2006 B. Alternate test procedures for VHF/UHF Driver Power Amplifier Page | 6 image3.emf

Microsoft_Office_Excel_Worksheet2.xlsx Sheet1

Characteristic Symbol Conditions Limit

Note Min Max Units

Collector-Emitter Voltage BVCEO IC = 10 mAdc, IB = 0 mAdc 4

Collector-Emitter Voltage BVCES IC = 5 mAdc 4

Base-Emitter Voltage BVEBO IE = 5 mAdc

DC Current Gain HFE VCE = 5 Vdc, IC = 100 mAdc 20 100 -

Power Gain GP VCC = 18 Vdc, F = 100 - 400 MHz Pout = 2.0 W 1 12 dB

Total Quiescent Current ICQ Same as Power Gain 1100 mA

Collector Efficiency n 1

Power Overdrive Po VCC = 18 Vdc, F = 100 - 400 MHz Pin = 1.5 2 2 W

Load Mismatch Ψ VCC = 18 Vdc, F = 100 - 400 MHz Pout = 2.0 W VSWR = 30:1 1,3 No Degradation in output power image4.png image5.emf

Microsoft_Office_Excel_Worksheet3.xlsx Sheet1

Item Timeline

Period of Performance of Contract 24 weeks

Critical Design Review (CDR) 8 weeks

Ground Test 20 weeks

Physical Configuration Audit 22 weeks image6.emf

Microsoft_Office_Excel_Worksheet4.xlsx Sheet1

Performance Objective PWS Para Performance Threshold

Engineering Data Conference / Critical Design Review (CDR) 4.1 / 6.1 The contractor shall host a conference within 8 weeks of contract award.

Phase I report 4.1 The contractor shall submit a report detailing approach of design as part of CDR with no more than 1 minor technical error. The error must be corrected and the CDR passed within 5 working days of the failed review.

Ground Test 5.2 The prototype must pass a ground test in the next higher assembly at government facility within 20 weeks.

Test / Inspection Report 5.3 The contractor shall submit a report detailing the results of unit test and ground test with no more than 1 minor technical error. The error must be corrected and the reports be passed within 5 working days of the failed review.

Physical Configuration Audit (PCA) 6.4 The contractor shall host a PCA within 22 weeks of contract award for review of the data package, the package shall have no more than 1 minor techinical error. The error must be corrected and the PCA passed within 5 working days of the failed review.

image1.png image2.emf

Microsoft_Office_Excel_Worksheet1.xlsx Sheet1

RATING 515538-2

VCBO 60 Vdc

VCEO 32 Vdc

VCES 60 Vdc

VEBO 3.5 Vdc

IC 2 Adc

IB 0.5 Adc

PT @ TC = 80°C 16 Watts

Derate > TC = 80°C 133 mw/°C

Tj 200°C

Θjc 7.5°C/W

TSTG - 65°C to 150°C