Designed for Success: A Mechanical Illustration

Originally intended  as a controller for fracking rigs, essential design elements for the Relio R1 Industrial Computer included enhanced thermal management and extreme shock and vibration tolerance.

Thermal Management

The original specifications required the ability to withstand operating temperatures of -40° to 70°C. To put that into perspective, the highest recorded temperature on Earth is 56.7°C (Death Valley, CA on July 10, 1913). Sealevel’s engineering team was able to achieve an operating temperature range of -40° to 71°C through

• Intentional component selection and placement
• System component power estimation
• Thermal simulation
• Heatsinking high power components

Shock & Vibration

The customer-specified, rigorous requirements for shock and vibrations nearly doubled that of MIL-STD-810.

Shock

• Amplitude:  5, 10, 15, & 20g Half-Sine
• Duration:  11ms
• Reps:  10 per axis

Vibration

• Amplitude:  0.5, 2, 4, 6 gRMS
  • Random Vibration
  • w/ 50 g peaks or greater may be seen during test
  • (Increase until failure)
• Frequency:  5 to 1000Hz
• Duration:  180 minutes

Sealevel’s mechanical and electrical engineers work closely to develop a highly integrated enclosure and carrier board selection. The teams carefully selected components that meet the most demanding electrical and physical requirements, including

• Low-profile surface mount designs
• Rugged high retention connectors
• Locking fasteners with thread-locking adhesives

They then wrapped the carrier board in a 6063-T5 aluminum extruded enclosure that was precisely machined to meet the contours of the carrier board assembly. By allowing the enclosure and assembly board to work together, we were able to provide support at critical areas, creating a rigid shock and vibration resistant assembly.

MIL-STD-810

Vibration

• Amplitude:  2, 5 gRMS
  • Random Vibration
• Frequency:  5 to 500Hz
• Duration:  30 minutes per axis

Sealevel Standard

Vibration

• Amplitude:  6 gRMS
  • Random Vibration
  • w/ 50 g peaks or greater may be seen during test
• Frequency:  5 to 1000Hz
• Duration:  60 minutes per axis

“The R1 is the only system that we’ve ever tested that has passed all of our tests without any failures.” 

-Alexander C., Control Systems Engineer