Brian S. Backer

Recent improvements and developments in uncooled systems at BAE SYSTEMS North America

BAE SYSTEMS has designed and developed MicroIR microbolometer focal plane arrays (FPAs) in three formats (160x120, 320x240, and 640x480) and with two different pixel sizes (46micrometers and 28micrometers ). In addition to successfully demonstrating these FPA technologies, BAE SYSTEMS has produced and delivered thousands of 320x240 (46micrometers pixel) imaging modules and camera cores for military, thermography, firefighting, security and numerous other applications throughout the world. Recently, BAE SYSTEMS has started production deliveries of 160x120 (46micrometers ) systems, demonstrated 320x240 and 640x480 second-generation (28micrometers ) imaging, and demonstrated second-generation thermoelectric cooler-less operation. This paper discusses these recent accomplishments and, when possible, provides quantitative NETD and performance data for our newly developed FPAs and systems. Video will be shown to demonstrate sensor performance capabilities.

Recent developments in uncooled IR technology

Sanders IR Imaging Systems (IRIS), a Lockheed Martin Company, has made recent improvements in high performance uncooled IR focal plane arrays and systems. This paper provides performance results for three of these new FPAs and systems. First we discuss a new 320 X 240, 46 micrometer pitch FPA, which when put into a system with a transmission of 74%, will provide a system NETD of < 26 mK (F/0.8, 60 Hz). This FPA has a power of < 250 mW (which includes on-chip 14 bit analog to digital conversion), and virtually no crosstalk from saturation. Second, we discuss the first ever 640 X 480 element uncooled IR camera. This camera, which is based on a 28 micrometer pitch microbolometer staring FPA, produces a system sensitivity of < 150 mK, (F/1, 30 Hz) and has a Minimum Resolvable Temperature Difference of < 0.4 degrees Celsius at the Nyquist frequency. Finally, we have developed a new lightweight thermal weapons sight (TWS). Our TWS, which weighs < 3 lbs. (with battery) and operates over the -37 degrees Celsius to +49 degrees Celsius temperature range, has demonstrated a boresight retention of < 0.2 mrad after 1000s of rounds were fired.

Commercialization of uncooled infrared technology

BAE Systems is the leading producer of uncooled microbolometer based thermal imaging engines in the world. Initial investments to develop and produce uncooled infrared (IR) technology were primarily driven by military applications, but it was the commercial market with the potential for large product volumes which provided BAE Systems with the business model required for investment in uncooled IR technology. This paper reviews the heritage of BAE Systems technology and current products and is an example of the success of a Dual-Use technology area which DARPA invested in during the 1990s.

Developments in uncooled IR technology at BAE SYSTEMS

Uncooled microbolometer thermal imaging sensor technology has begun to successfully address military, government and commercial applications in the real world. BAE SYSTEMS, located in Lexington MA, has been involved in the design and development of uncooled IR technology since the early 1980s. Our current MicroIRTM products are based on vanadium oxide (VOx) microbolometers. Thousands of uncooled microbolometer thermal imaging sensors are now being produced and sold annually. A the same time, applied research and development on the technology continues to improve the basic products and make them suitable for new applications. In this paper we report on the status and improvements achieved in the MicroIRTM product line, based on 320 X 240 element and 160 X 120 element FPAs with 46 μm pixel pitch. Other near term MicroIRTM products include 320 X 240 and 640 X 480 FPAs with 28 micrometers pixel pitch and measured sensitivities below 50 mK. In the systems area we discuss development and testing of a Light Thermal Weapon Sight (LTWS) for the U.S. Army, being developed by BAE SYSTEMS in partnership with Thales, based upon our uncooled MicroIRTM focal plane arrays (FPA) and systems. The LTWS prototypes were based upon our Standard Imaging Module SIM200, which employs our LAM2C, 320 X 240 element, microbolometer FPA. Finally we discuss the 480 X 640 element FPA and its application to the Heavy Thermal Weapon Sight application.

Advances in uncooled technology at BAE SYSTEMS

BAE SYSTEMS has made tremendous progress in uncooled technology and systems in the last year. In this paper we present performance results and imagery from our latest 640x480 and 320x240 small pixel focal plane arrays. Both were produced using submicron lithography and have achieved our lowest NETDs to date. Testing of the 320x240 devices has shown TNETDs of 30mK at F/1. Video imagery from our 640 x 480 uncooled camera installed in a POINTER Unattended Aerial Vehicle is also shown. In addition, we introduce our newest commercial imaging camera core, the SCC500 and show its vastly improved characteristics. Lastly, plans for future advancements are outlined.

Lockheed Martin's 640x480 uncooled microbolometer camera

Lockheed Martin is developing the first ever 640 X 480 uncooled microbolometer camera. This camera, designated the LTC650, has a new 28 micrometers pitch 640 X 480 microbolometer focal plane array and electronics which operate at a 30 Hz frame rate. The electronics are based on previous successful 320 X 240 camera electronics which use low power, high performance DSP and FPGA technology. A DSP based software solution provides flexibility to answer the challenge of change and varied customer needs while meeting the low cost, low power, and low real estate requirements of portable, hand held applications. Test data for the first camera are presented.

Infrared on-orbit RCC inspection system (IORIS)

Designed to fulfill a critical inspection need for the Space Shuttle Program, the Infrared On-orbit RCC Inspection System (IORIS) can detect crack and surface defects in the Reinforced Carbon-Carbon (RCC) sections of the Space Shuttle’s Thermal Protection System (TPS). IORIS performs this detection by taking advantage of the natural thermal gradients induced in the RCC by solar flux and thermal emission from the Earth. IORIS is a compact, low-mass, low-power solution (1.2cm3, 1.5kg, 5.0W) for TPS inspection that exceeds existing requirements for feature detection. Taking advantage of ground-based IR thermography techniques, IORIS provides the Space Shuttle program with a solution that can be accommodated by the existing inspection system. IORIS augments the visible and laser inspection systems and finds cracks that are not easily measurable by the other sensors, and thus fills a critical gap in the Space Shuttle’s inspection needs. Based on crack IR signature predictions and on-orbit gradient expectations, IORIS can achieve crack detection over approximately 96% of the wing-leading edge RCC (using multiple inspections in an orbit period). This paper discusses the on-orbit RCC inspection measurement concept and requirements, and then presents a detailed description of the IORIS design.

Test methods and technology for uncooled imaging systems

BAE SYSTEMS produces hundreds of low cost, high performance, uncooled IR imagers each month for use in commercial and military applications. The production process of each imager includes several steps that begin at the wafer level and end at an in-camera test. Each step is critical to end yield improvement by detecting failure at various stages in the production flow. Both automated test equipment and an integrated database system are essential at each phase to efficiently build and automatically configure cameras for each customer. This paper discusses the process and tools used to reliably test and ship uncooled thermal imagers in addition to specific methods and calculation techniques for characterizing key performance parameters such as Responsivity, Noise Equivalent Temperature Difference, and Operability.

An advanced infrared thermal imaging module for military and commercial applications

The low-cost day and night imaging capability of uncooled infrared imagers significantly enhances the situational awareness capability of an unattended ground sensor. BAE Systems has leveraged its Standard Camera Core 500 product to develop an advanced imager, the MIM500TM, for use in unattended ground sensors and other military applications. Key improvements implemented in the MIM500TM include reduced operating power, pixel synchronization to an external clock, variable frame rate, a ruggedized mechanical design, a new reduced power standby mode, and electronic zoom,. This paper presents an overview of the MIM500TM design, it describes MIM500TM features that enhance the capability of unattended ground sensors, it discusses imaging performance data, and it provides an overview of current MIM500TM applications.

Uncooled Microbolometer Sensors for Unattended Applications

BAE SYSTEMS has been developing and producing uncooled microbolometer sensors since 1995. Recently, uncooled sensors have been used on Pointer Unattended Aerial Vehicles and considered for several unattended sensor applications including DARPA Micro-Internetted Unattended Ground Sensors (MIUGS), Army Modular Acoustic Imaging Sensors (MAIS), and Redeployable Unattended Ground Sensors (R-UGS). This paper describes recent breakthrough uncooled sensor performance at BAE SYSTEMS and how this improved performance has been applied to a new Standard Camera Core (SCC) that is ideal for these unattended applications. Video imagery from a BAE SYSTEMS 640x480 imaging camera flown in a Pointer UAV is provided. Recent performance results are also provided.