to your rugged computer needs
Our Solution Specialists and Engineers work closely with each customer to design, build, test and support a computer system that meets and exceeds their specific requirements. With a library of over 2,000 designs, SolidWorks 3D CAD software, rapid prototyping, and in-house testing, our team quickly delivers complete solutions. Our experience in the use of AutoCAD, SolidWorks, thermal modeling/analysis software, and rapid prototyping using fused deposition 3D printers can assists with:
- System Design
- System Integration
- Electrical Engineering
- Mechanical Engineering
- Project Management
- Configuration Management
- End Of Life Management
It’s very rare that even one of our thousands of already-designed systems will meet a customer’s exact needs – and frequently what our customers perceive as ideal solutions present new challenges once they begin evaluating prototype equipment.
We deploy state-of-the-art equipment for prototyping, including 3D printing technology that allows us to go directly from engineering design to prototype. We can test prototypes against all manner of thermal, shock, and moisture tests so customers can focus on the suitability of the design for their particular projects.
Once signed-off, customers know that the resultant production units will incorporate any nuances identified during evaluation and that these systems will function as required in the much larger solutions of which they are generally a part.
Mercury’s System Integration services can integrate a variety of COTS devices and components into a computing solution that extends from a small form factor computer to a 72U rack. We can:
- Design and layout an entire system.
- Integrate a variety of your products, or those from third parties, including breakout panels, switches, routers, power units, displays, keyboards, cabling, shelves. etc.
- Assemble, wire, test and custom package your equipment for shipment.
- Install, configure and test third party software.
- Configuration Management of hardware and software, including serial number and revision tracking.
- Manage configuration of hardware and software, including serial number and revision tracking.
Mercury can provide conformal coating material for printed circuit boards. Conformal coating will protect PCBs from dust, moisture, salt fog and fungus. Conformal coating can reduce thermal and mechanical stress on individual electronic components.
Our services include product selection, masking, fixturing, curing and inspection. A variety of coating materials are available. The materials we use have a maximum operating temperature up to 257°F/125°C. All materials used by Mercury are non-ozone depleting.
Our conformal coating processes are MIL-I-46058C compliant and UL94 V-0 rated.
Mercury offers Environmental Qualification Confidence Testing, analysis and reports for the equipment we build for our customers. Our in-house testing environment can perform shock, vibration, airborne noise, structure borne noise, air flow, temperature and humidity assessments to verify that our products will meet stated environmental test requirements, including Military Standards: MIL-STD 810F/G, 901D, 167-1, 740-2, 461F, 1474D.
Thermal and Humidity
Mercury ensures that our thermal tested computers operate at extreme temperature ranges without reducing performance, reliability, or the life of the product. Our calibrated temperature chamber has a range from -73°C to +190°C. Our test instrumentation supports up to 80 discrete thermal couple channels. In addition, Mercury’s thermal chamber can add humidity up to 100% to test the operation and corrosion resistance.
Mercury’s custom designed Airflow Test Bench can control and measure airflow and air pressure. The ability to measure and validate airflow performance and efficiency enables air cooled computer hardware to be tuned for the correct amount of airflow for each system. This lets the designer select the correct number of fans and fan speed to provide the right level of cooling while minimizing noise and material cost.
The Acoustic Chamber measures structure borne and airborne sound. Measuring sound levels provides accurate data for verifying units comply with government and industry standards. Reducing structure borne noise can reduce vibration and enhance the life of the product. Also reducing noise levels, both structure borne and airborne, reduces noise pollution and can improve the environment for personnel working around the equipment.
Mercury’s shock table provides ½ and full sine wave shock impulses up to 50Gs. We can design custom text fixtures to test your designs on all six axis. Our design engineers tune every system.
Testing for shock can provide confidence that your design will not break during a shock event. For mission critical applications shock testing can validate that your equipment continues to operate during an earthquake, drop or explosion.
Vibration testing can help ensure that your design will operate normally and not experience premature failure when exposed to continuous vibration. Our vibration shaker table can create sinusoidal or random vibration events at single or swept frequencies. Testing is available to ensure compliance with MIL-STD 801G and MIL-STD 167.
Configuration and EOL Management
Mercury offers configuration management consulting and support. Our robust Configuration Management process is inherent in all procedures and business systems utilized to design, build and support our customers’ solutions. This methodology allows us to maintain tight revision control throughout the product life cycle. From firmware on a PCI card to the serial number of a specific COTS component, Mercury has the ability to differentiate, identify and track those discrete elements that matter most.
We maintain specifications on every unique solution we design: Source Control Documents (SCDs), drawings, and the Bill of Materials (BOM) are all controlled and managed using a state-of-the-art EPDM System. This tightly-integrated system allows us to manage the sourcing and production of every product we build, and maintain a history of every serial number we have produced.
Mercury provides on-going support in keeping our customers up-to-date with the latest technology available. We specialize in helping customers extend the lifecycles of Mercury products and identifying componentry and designs that will help extend products’ usefulness far beyond their typical obsolescence dates.