PROPOSAL FOR DR-1 DIGITAL DISPLAY UNIT

• Document Type: CREST
• Collection: General CIA Records
• Document Number (FOIA) /ESDN (CREST): CIA-RDP78-03330A004100010004-7
• Release Decision: RIPPUB
• Original Classification: S
• Document Page Count: 18
• Document Creation Date: December 22, 2016
• Document Release Date: February 8, 2012
• Sequence Number: 4
• Publication Date: April 2, 1962
• Content Type: LETTER

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NOT RELEASABLE TO FOREIGN NATIONALS
In Reply Refer To:
2 April 1962
~~ 25X1
BY ~~1~~+ ~ v
IG COMP _ t'P! _ TYPE ~__
ORIG CLASS ~_ P~ ~5 ~_ gpY CLASS ~,
JUSt _~~ Ni:XT REY ~~~ AUTHs HR i0-T
ATTENTION:
SUBJECT:
Proposal for DR-1 Digital Display Unit
REFERENCE: Government RFP, dated 2 March 1962
In response to referent RFP, and in accordance with discussions between
the Technical Representatives of the Government and the Contractor 25X1
is pleased to submit a formal proposal fora 25X1
Fixed Price Redeterminable Contract covering the furnishing of one hundred
(100) DR-1 Units, accessories and manuals as set forth in the attached
Technical Discussion. This proposal consists of the following:
Exhibit "A" -Statement of Work
Exhibit "B" -Technical Discussion
Exhibit "C" -Price ,Summary
Exhibit "D" -Delivery Schedule
Exhibit "E" -Government Furnished Property
Exhibit "F" -Special Terms and Conditions
The prices quoted herein, which are f.o.b.
are exclusive of royalty payments, warranty, federal,
state or local excise, sales and use taxes, may be considered firm until 30
April 1962. Said prices, together with the other Exhibits of this proposal may
be considered the basis for the negotiation of a Fixed Price Redeterminable
Contract containin the same General Provisions presently incorporated in
Contract No
"This doeament contains informs+ien affecting }he
Netiona! Defend c+ +no Vni+od ~+.+e< wi+hin the
mer.~ing ,.! i}.n r;.,.-,ire 1._,,.,c, THi, ti3. U. 5. C.,
Sections 7~? .~~d 1i4, ++1n +rrn~,rn;s,ion or revela?
Lion of wh~c~ in z=y r~er^.or to an unauthorized
person is prohibited by law".
NOT RELEASABLE TO FOREIGN NATIONALS
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rnn~Fin~nrrini
25X1
25X1
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CQNFIDENTIAL 25X1
Page Two
Requests for additional information concernin this corres ondence m
REF/smc
Enclosures: (6)
Exhibits "A", "B", "C", "D", "E" and "F"
C~IVFIDENTIAL
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Y Y V ~i Y ?1
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DESCRIPTION
5 each DR-1 Digital Display Unit Sets consisting
of one (1) each of the following: Digital
Display Unit DR-1; Cable, Radio Receiver
to DR-1; Test Cable, DT-I to DR-1; Power
Supply Cable, External 3 Volts to DR-1 and
Indicating Lamp Removal Tool (if necessary),
and three (3) each spare indicating lamps all to
be in accordance with Exhibit "B" of this proposal.
2 10 each Preliminary Instruction Manual in accordance with
Exhibits "B" and "F" of proposal.
1 95 each DR-1 Digital Display Unit Sets consisting of
one (1) each of the following: Digital Display
Unit DR-1; Cable, Radio Receiver to DR-1;
Test Cable, DT-1 to DR-1; Power Supply Cable,
External 3 Volts to DR-1 and Indicating Lamp
Removal Tool (if necessary), and three (3) each
spare indicating lamps all to be in accordance with
Exhibit "B" of this proposal.
2 150 each Operator's Instruction Manual in accordance with
Exhibits "B" and "F" of this proposal.
3 50 each Theory, Maintenance and Parts List Manual in
accordance with Exhibits "B" and "F" of this
proposal.
4 Lot One (1 ): set of reproducible and two (2) sets of
reproduced drawings in accordance with Exhibit
"B" of this proposal.
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STATEMENT OF WORK (CONT'D)
PHASE II (CONY' D)
ITEM 42UANTITY DESCRIPTION
5 Lot Fabrication of special tooling required for
Phase II production. Tooling is to be con-
structed to high commercial quality.
1. Upon completion of Government evaluation of Phase I, and Government
concurrence that Phase I units meet the requirements of the specification,
Contractor will construct ninety-five (95) units to the accepted design.
$~uality Control to be in accordance with good commercial practice.
3. Preservation, packaging and packing shall be in accordance with standard
commercial practice for domestic shipment and short term storage.
4. Final inspection and acceptance of the above items is to be accomplished at
Contractor's facility by a Representative of the Government.
5. Acceptance of Phase II units will be to factory test specifications which do
not include reliability or environmental testing. If further assurance as to
reliability and environmental requirements on the Phase II units is desired,
Contractor will be pleased to propose a program of additional testing.
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DIGITAL DISPLAY UNIT, DR-1
This proposal is in response to a production requirement of 100
DR-1, Digital Display Units with instruction manuals and accessories.
This production is to be accomplished in two phases. Phase I consists of
the fabrication of five units built to production drawings. Upon acceptance
of these units by the customer, fabrication of the remaining 95 units will
follow; this is Phase II of the program.
2.0 BRIEF UNIT DESCRIPTION
The DR-1 Unit is a miniature tone receiver and display device.
The display panel consists of numbered lamps illuminated in accordance
with information derived from coded audio tones. The tones are supplied
by an associated radio receiver, which is not part of the display unit:
3. 0 APPLICABLE SPECIFICATIONS
For the purpose of .this proposal and in the interest of economy,
it is assumed that specification MIL-E-4158 shall be acceptable as a guide
in the design and performance of the equipment. Where conflict exists be-
tween MIL-E-4158 and Specification No. 62-A-1140-A, the latter shall
have precedence.
3.1 Fungus Treatment
All material used in the DR-1 shall be non-nutrient to fungus . If
it is determined that suitable non-nutrient materials are .not available, a
waiver may be obtained; however, any nutrient material used shall be
treated by a suitable fungus-resistant compound after machining or form-
ing and prior to installation.
3.2.1 Operation
The equipment shall be designed for continuous operation for a
period of one year, alternating six hours on and two hours off with no more
than normal maintenance and replacement of batteries and parts. After
a warmup period of five seconds, the DR-1 shall meet the performance re-
quirements of this specification.
3.2.2 Temperature
Thy DR-1 s call operate normally under temperature conditions
of from -20 C to +40 C, after soaking for four hours . It shall be capable
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EXHIBIT "B"
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of sustained storage under temperature conditions of -60?C to +60oC with-
out impairing operation under appliccble conditions. The foregoing require-
ment does not apply to the battery supply of the DR-1.
3.2.3 Relative Humidity
The DR-1 shall operate normally in 95 percent relative humidity.
3.2.4 Elevation
The DR-1 shall operate normally at elevations up to 15, 000 feet
above sea level.
The DR-1 shall operate without impairment after being subjected
to vibrations from 5 to 500 cps and having a double amplitude of 0. O1 inch
with a maximum acceleration of 2 g, whichever is the limiting value.
The DR-1 shall operate without impairment after dropping through
an angle of 30? to a solid 2-inch fir table top using any edge of the case as
an axis .
3.3 Electrical Requirements
3.3.1 Input Characteristics
The input impedance of the DR-1 shall be 2000 ohms . The unit
shall operate properly with a 0.3-volt rms signal at a 3-db signal to-.noise
ratio. The required signal-to-noise ratio is interpreted as meaning the ratio
of desired rms-input signal panel to the rms-noise power appearing in a
nominal 3-kc bandwidth at the input to the DR-1. At this input signal-to-noise
ratio, the indication of the DR-1 shall contain not more than one error per
thousand characters displayed. The unit shall operate over an input level
range of 0. 3-volt rms to 10.0-volts rms .
3.3.2 Signal Characteristics
Each digit transmitted is represented by a composite signal con-
sisting of four sequential tones each of which is 40 ms in duration and which
are separated by 40 ms. The transmitting speeds of the DR-1 ar 5, 7-1~2,
10, or 12 wpm. These different speeds are obtained by varying the spacing
between groups of binary tones. The different spacings are: 2120, 1320, 920,
and 729 ms, respectively. Two tones are used with frequencies of 1000 and
and 1100 cps. The DT-1 tone generator maintains the accuracy of these tones
to withing t3.0 cycles. The digits to be transmitted are represented by the
following binary code. In the following table, "0" represents a 4-ms 1000-
cps tone, and "1" represents a 40-ms 1100-cps tone.
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Number
Binary Code
1
0000
2
0001
3
0011
4
1001
5
1000
6
1101
7
0010.
g
1100
9
1111
0
0111
3.3.3 Power Supply
The DR-1 shall operate properly on supply voltages which range
from 2.0 to 3.2 volts with the maximum current drain not exceeding Z00
ma.
3.4 Mechanical Requirements
3.4.1 Size
The size of the DR-1 shall be 3 X 2 X 7~8 inches or less . Any
improvements in packaging or circuitry shall not cause an increase in size.
Battery Holders
The battery supply for the DR-1 shall consist of two external size
"D" batteries. They may be held in place by two-hinged doors which fold
out from the bottom of the DR-1 as in the prototype unit.. However, the
contractor, in order to facilitate production, may propose another type of
battery holder using the same. concept. The battery holder shall be capable
of accommodating zinc oxide, mercury, or rechargeable nickel-cadmium
size "D" cells.
The control and display panel in the existing prototype shall be
used in the production models. The only operator control on the DR-1, is an
on_off-test switch. The test position allows the operator to determine whether
his battery is usable fey observing a test lamp which flashes when the momen-
tary-hold test switch is depressed.
4.1 Electrical
The circuits to be used are essentially those employed in the Govern-
ment-furnished prototype; however, the transistor Raytheon CK4A is to be
substituted for the CK4.
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In order to make the DR-1
more suitable for large quantity pro-
duction and at the same time increase
the reliability of the unit, the circuits
will be packaged as welded modules.
An example of this module is shown
in Figure 1. Usually the completed
welded module is encapsulated in an
epoxy resin, but for the application
under consideration, this step is not
recommended since space is at a
premium. Instead, a dip coat of a
suitable compound will be employed
to produce a rigid enough package to
withstand the vibration and shock re-
quirements . The number of modules
making up the DR-1 will be reduced
by approximately three in order to
simplify the interconnection problem.
An etched circuit board is proposed
as the means to interconnect the
modules . Plated-through holes would
be used where necessary and possibly
hook-up wire would supplement the
etched wiring in especially tight
places. The use of large numbers
of jumper wires as is evidently employed in the prototype will be avoided
both from the standpoint of reproducibility as well as maintenance. A de-
tailed description of welded module techniques as practiced at
~l~Telded Module Techniques
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The lead material of each component to be used in the welded
modules is specified, as well as the electrical characteristics, in order
to assure proper welds when assembling the modules. Knowing the exact
dimensions and material used in each component, it is possible to determine
a weld schedule in advance which is posted for the assembly workers' refer-
ence. stored-energy welders are used to weld the modules. As 25X1
used on a assembly line, the welding machines consist of a power supply
and two welding heads. Two heads are used so that different welding tips
may be used without delaying the operator for different watt-second ratings.
After a module has been welded, visual and microscopic inspections are
performed before the module goes into dipcoating to determine that all welds
have been properly made.
To ensure that the welding machines are operating properly,
several weld samples each day are taken from each machine and tested
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for weld strength. The weld strength test measures the number of pounds
of force required to break the weld. Each module is electrically tested
before and after dip-coating.
Advantages of Welding Over Soldering
Listed below are some of the advantages of welding over soldering.
1) Reproducibility of the process with semiskilled labor; using
sequentially programmed and controlled welders greatly attenuates operator-
induced variances.
2) High Strength of weld.
3) Presents a single molecular diffused interface (homogeneous
fusion of base materials) as opposed to the two questionable interfaces ob-
tained with soldering.
4) Fluxes and cleaners are not used, eliminating the entrapment
of caustic agents with possible future corrosion.
5) Energy released during the welding process is concentrated
in a very small area for as short as 10 ms, which virtually eliminates the
possibility of heat damage to. sensitive semiconductors.
6) Weight and size reductions frequently accomplished are 50
percent in volume and 30 percent in weight, compared with conventional
packaging approaches.
7) Reliability, thermal shock, and bending tests have shown that
welded electrical connections are more reliable than soldered connections .
Shock tests conducted at MIT on 47, 000 weld samples produced no failures.
A bending test performed by Raytheon Company, Waltham, Mass . , showed
that an average of 1152 motions were required to fracture a welded joint,
while an average of 70 motions fractured soldered joints.
Tests in Progress
The present life test program consists of evaluating and testing
30 welded modules of various digital circuits similar to those used in the
DR-1. These circuits have an average of 20 to 25 components per welded
module. This circuitry comprises a portion of the complete electronics
of a typical unit of an over-all system.
The actual tests are comprised of an active input to the welded
rr~odules while monitoring the loaded output. The temperature is held to a
constant +100?C. The rise time, delay time, and voltage outputs are
measured.
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EXEIBIT ?B?
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Every 1000 hours the modules under test are subjected to four
temperature- cycles. gne temperature cycle consists of lowering the
temperature from 100 C to -55?C and remaining there for 30 minutes.
At the end of the four temperature cycles, the modules are at +100?C
and remain there for another 1000 hours. These temperature cycles test
the effects. of low temperature, expansion, contraction, and high tempera-
ture on the module.
The theoretical MTBF of a typical module under test at 100?C
ambient was calculated, using as a reference document RADC-TR-58-111,
RADC Reliability Handbook.
The calculations show that the theoretical MTBF for the modules
under test is approximately 196, 500 hours at 100?C. The actual tests
have run for 3407 hours on the 30 modules for a total elapsed module test
time of 102, 210 hours. No failures or degradation have been experienced
to date, so the actual measured MTBF is indeterminate. However, at
this point in time, there is an 85-percent confidence that the MTBF of
each module under test exceeds 34, 000 hours.
The performance of Phase I units under applicable circumstances,
will be equivalent to or better than that of the prototype to be supplied as
Government Furnished Equipment. In the interests of improving reliability
and with the approval of the contracting agency the contractor may employ
design or packaging techniques which differ from those used in the proto-
type, except that:
1) Electrical compatibility with the associated receiver and tone
generating equipment (DT-1) will be maintained.
25X1
2) Display and control functions of production units will be identical
to those on the prototype.
3) The method of attaching batteries to the DR-1 will .be essentially
the same as that used in the prototype.
5. 1 Preliminary Instruction Manual
The preliminary instruction manual will contain sufficient informa-
tion for personnel to install and operate the equipment produced under the
first phase of this program. It will be prepared in accordance with good
commercial practice.
5.2 Operator's Instruction Manual
The operator's instruction manual will contain sufficient informa-
tion for personnel to install and operate the equipment produced under the
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EXHIBIT ,'B"
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second phase of the program. It will be prepared in accordance with good
commercial practice.
5.3 Theory, Maintenance and Parts List Manual
The theory, maintenance and parts list manual will be prepared
in accordance with good commercial practice. It will contain sufficient
data for personnel to understand and maintain the equipment developed
under the second phase of this program.
5.4 Production Drawings.
Production drawings submitted under the contract will be of good
commercial quality.
6.0 GOVERNMENT FURNISHED EQUIPMENT AND INFORMATION
The following Government Furnished Equipment and information
is required to accomplish the proposed task.
1) DR-1 Digital Display unit prototype is to be used in comparing
performance.
2) A complete and accurate schematic diagram and parts list
for the DR-1 prototype.
3) An adapter DT-1 to be used for test purposes.
4) A complete and accurate Theory, Maintenance and Parts
List Manual for the DR- 1 prototype.
This proposal is predicated on the electrical characteristics of the
customer's prototype. units meeting the requirements of paragraph 5 of
Spec No. 62-A-1140-A, dated 23 February 1962.
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The below listed prices are contingent upon receiving contractual coverage by
30 April 1962 and completion of Government evaluation of Phase I within six (6)
weeks after completion of said Phase I.
25X1
PHASE I
ITEM
QUANTITY
DESCRIPTION
TOTAL TARGET
PRICE
1
2
5 each
10 each
DR-1 Digital Display Sets
Preliminary Manuals
$ 44, 952.00
845. 00
Total Target Price - Phase I
$ 45, 797. 00
Ceiling ~ 20?'/0
9, 159.00
Total Ceiling Price - Phase I
$ 54, 956.00
PHASE II
ITEM
QUANTITY
DESCRIPTION
TOTAL TARGET
PRICE
1
95 each
DR-1 Digital Display Sets
$ 119, 394. 00
2
150 each
Instruction Manual
I, 456.00
3
50 each
Theory, Maintenance & Parts List
Manual
5, 935.00
4
Lot
Drawings
244.00
5
Lot
Production Tooling
28, 942.00
Total Target P
rice -Phase II
$ 155, 971.00
Ceiling ~ 20%
31, 194. 00
Total Ceiling P
rice -Phase II
$ 187, 165. 00
NOTE: The prices quoted above are predicated on the electrical characteristics
of the customer's prototype units meeting the requirements of paragraph
5, of Specification No. 62A-1140-A, dated 2 /23 /62. In the event that it
is subsequently determined that the prototype does not meet these re-
quirements, the prices quoted above will be subject to negotiation.
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PHASE II
MANUFACTURING COST BREAKDOWN
PRODUCTION DRAWINGS
ITEM 4
Material
.MANUFACTURING COS T
(Reproduction Costs Only)
$ 200
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The below listed delivery schedule is contingent upon receiving contractual
coverage by 30 April 1962, and upon receiving Government approval of the
Phase I effort by 15 December 1962.
Items 1 and 2 - To be delivered complete by 31 October 1962.
Item 1 - To be delivered as follows:
Two (2) Sets in April 1963.
Fifteen (15) Sets in May 1963
Twenty (20) Sets in June 1963
Twenty (20) Sets in July 1963
Twenty (20) Sets in August 1963
Eighteen (18) Sets in September 1963
Items 2 and 3 - To be delivered complete by 15 May 1963 .
Item 4 - To be delivered complete by September 1963.
Item 5 - To be delivered complete by October 1963.
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C4N1'IDENTIAL
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In the performance of this program the Contractor will require the following
GFF by the dates indicated below:
QUANTITY DESCRIPTION DATE REQUIRED
1 each Prototype DR-1 Unit 30 April 1962
1 each Complete and accurate 30 April 1962
schematic diagram and parts
list for the DR-1 Prototype
1 each DT-1 Adapter
30 April 1962
2 each Operation, Theory, Maintenance 14 September 1962
and Parts List Manual for the DR-1
Prototype
In the event that the above Items cannot be furnished by the dates indicated,
the price and delivery schedules quoted herein will be subject to negotiation.
~n
~?~~~~
~!TIAL
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COrJFIDENTiAL
Pagelofl
SPECIAL TERMS AND CONDITIONS
1. Item 5 (Production Tooling), which is not to be delivered until the
completion of Phase II, may be invoiced by the Contractor after
Government acceptance of the first units to be delivered under
Phase II,
2. The following conditions are applicable to all Handbook Items (Item
2, of Phase I and Items 2 and 3 of Phase II).
a. Manuals will not be prepared in accordance with any military
specifications, but will be prepared in accordance with good
commercial practice.
b. Contractor will retain all illustrations and other materials
used to produce the manuals.
c. Contractor does not contemplate submission of the manuscripts
to the Government for review prior to production. In the event
that Government review becomes a requirement, the prices and
delivery schedule quoted herein will be subject to negotiation.
~~ ENTIAL
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