Military Aerospace Presentation

SBA Award Winner DiversityBusiness.com Top 50 Award Recipient
Inc 5000 Winner Winner

Innoventor®

Your Engineering Problem Solver
“Outstanding Small Business” at Lockheed Martin Gold Rating at Boeing
3600 Rider Trail South A Top 50 Company phone:314.785.0900
St. Louis MO 63045 (USA) www.innoventor.net fax:314.785.0044

Table of Contents
• Overview
• Flight Systems
• Factory Equipment
• Test Equipment
• Support Equipment
• On-Board Weapons Systems
• AGV’s


Awards and Recognitions
• 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

Full Turn-Key
Capabilities
• Inception
• Program Management
• System Engineering
• Preliminary Design
• Detailed Design
• Detail Analysis
• Fabrication
• Testing


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


Engineering by Technical Discipline
• Systems Engineers • PC/PLC Programmers
• Structural Engineers • Mechanical Engineers
• RF Design Engineers • Manufacturing Engineers
• Optical Design Engineers • Hydraulic/ Pneumatic Engineers
• Nuclear Design Engineers • Electrical/ Electronics Engineers
• Chemical Engineers • Bio-medical Engineers


Overview of
Military/Aerospace Experience

F-18 Joint Strike Bell Helicopter
787 C-17 Tunner
Fighter


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 Company
Multi-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.


Sabreliner
•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

Process Flow Model
Clamshell Doors FEA


The Boeing Company
KC-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

787 Partner Projects
Vought
Pneumatic Testing
Spirit
Stress Design of
Forward Fuselage

Boeing
Fuselage Integrity Vought
Structural Test Graphic Composite
Laydown Inspection


Bell Helicopter
Industry 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


The Boeing Company
F/A-18 Maintenance Trainer Program
• 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

Factory Equipment

Lockheed Martin F-35 JSF Lockheed Martin F-35 JSF
EMAS Platform Boeing - JDAM Final Assembly Dolly Fixture


GKN Aerospace
CH-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.

AFT Work Stand
Forward Work Stand Join Work Stand


F-35 JSF – Moving Assembly Line
Hydraulic motor Four Stage Jack
for Jack locking

Wire Encoder

Autonomous Ground Vehicle


Lockheed Martin
F-35 JSF Electronic & Mate Assembly System


F-35 JSF 830-2 Checkout Stands

• 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

The Boeing Company - JDAM
• 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 and Translate
• Tail Kit Lift & Translate
Foam Pack Parallel Gripper

Honeywell
Federal 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 “The project… exceeded our expectations with
respect to performance and ease of
• Innoventor also updated the user interface to use…(Innoventor) came up with innovative
provide process improvements and reduce solutions to numerous challenges
throughout…”
operator input errors 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 Fuselage
450-420
• 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 Assembly
461-462
461(LH) and 462(RH)
•Wing Substructure Build up
•OSHA Safety Compliance
•Multi-configuration in one tool


F-35 JSF Wing Dolly
460-450

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

F-35 JSF
Paint Cell Dolly

The Dolly supports a 40,000 pound aircraft.


F-35 JSF
Paint 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 Company
Flexible 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
Flexible Airframe Support System (FASS)
helicopters

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

787 Portable Fuselage Pressure
F-35 PAO Unit Test System
Boeing C-17 Hydraulic Test Stand Thales ATM Interface
Test Adaptor


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 Cart
Track Tester & Mobility Tester
• Tests tractive and mobility devices on a variety of soil
types in a laboratory
• Data generated develops and validates virtual analytic
models
– Provides insight on how products interact with
different soils
• 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, CA
C-17 USAF Transport Portable Fuselage
Pressure Test System
• A specially designed 27 foot Manometer
overflows at a pre-determined pressure
point to prevent over pressurization to the
C-17 being tested
• Portable design allows cart movement to
the C-17 test location
• 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 Company
F/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

• Features
• Constant Pressure &
Temperature @ Unit
Under Test
• Tight Temperature
Controls
• Flow Rate Controls

66 gpm 90 gpm

SEI Liquid Cooling Unit
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 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
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 JSF
Retractable Access Ramp (RAR)
• 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

RAR platform slides to Simulator
Ramp being lowered into the pit
and installed in Simulator Room

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 -automated controls
-test instrumentation -data collection system

• Seamless integration of designed hardware
into manufacturing facility


The Boeing Company Delta IV Rocket
Helium 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 Company
Module/Rack Simulator
• Simulates flight elements
during ground testing of
space station
• Drawings incorporated
commercial design
approaches
• Performed final assembly


The Boeing Company
Passive 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


The Boeing Company
C-17 Phase Tester
• Verifies wiring to the fuel boost pumps
located in the C-17 Wings
• Modified to interface with the aircraft and
other GSE
• Provides phase sequence
and voltage wiring to the
aircraft wiring


The Boeing Company
Delta 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

DRS Technologies
Boeing Munitions
Flatrack Refueling Capability
Handling Unit


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

DRS Technologies
Flatrack 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 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

• 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 Technologies
Vehicle 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: Tunner
-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

M1000


DRS Mobile Environmental Systems
Kingpin 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


SEI TOW Missile Launcher for
Bradley Infantry Fighting Vehicle
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


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


SEI ASG-21 Gun Laying Mount
(GLM)
• 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


Unidynamics
Armored Box Launcher for Cruise Missile
• 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

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


AGV for DARPA

AGV for DARPA Demonstrator
to X-Ray Fully Loaded Tractor
Trailers
Developed by an Innoventor
Engineer

• 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

Innoventor, Inc.
A Solutions Engineering House

3600 Rider Trail South
St. Louis MO 63045 (USA)
P 314.785.0900
F 314.785.0044
www.innoventor.net


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