Extreme design: Controller board optical switch, 36 layers, 2.5 Terabits/sec, 1.6 mi trace length

Endicott, NY — Endicott Interconnect Technologies Inc. introduced a controller board that functions as the intelligence of a powerful, advanced optical packet switch. The controller board for a 64×64 port, high-performance optical switch designed by IBM Zurich Research Lab, claimed to be one of the most complex designs ever developed, is a core component in the OSMOSIS (Optical Shared MemOry Supercomputer Interconnect System) research for computer systems.

01/28/2008


Endicott, NYEndicott Interconnect Technologies Inc. (EI) introduced

a controller board that functions as the intelligence of a powerful, advanced optical packet switch

. The controller board for a 64×64 port, high-performance optical switch designed by

IBM Zurich Research Lab

, claimed to be one of the most complex designs ever developed, is a core component in the OSMOSIS (Optical Shared MemOry Supercomputer Interconnect System) research project on next-generation optical switch technology in high-performance computing systems.

Sponsored by the U.S. Department of Energy , in cooperation with Corning Inc ., IBM scientists developed a method of using optical switch elements to transfer packet data throughout the system using light. The switch can transmit 2.5 Terabits of data, equivalent to 20 high definition movies, per second. IBM researchers implemented the complex architecture for a 64-port optical switch technology demonstrator to achieve line rates of 40 Gb/s. The board was fabricated as two sub-composites with deep blind vias that, when joined, went half way through the full thickness. Depth control for the pin connections was provided by developing a process that filled the vias to preserve the holes during lamination and mechanically drilled the holes afterward.

“The board construction consisted of 36 layers, 36,053 blind vias, 29,246 connections, a total trace length of 1.6 miles, and required multiple passes through the plating and drilling processes, highlighting the criticality of registration,” said James Fuller, EI’s vice president of Semiconductor Packaging and Printed Circuit Board Fabrication. “The biggest hurdle was accommodating 40 back-to-back, two-sided, compliant pin connections.”

According to James McNamara, EI president and CEO, “This opportunity has been among the most challenging board applications EI has undertaken since its inception. The engineering expertise and manufacturing execution required to satisfactorily build this board is rare in the industry. Collaboration between our engineering, manufacturing and R&D teams was invaluable in solving an exceedingly complex fabrication puzzle and consequently delivering a leading-edge, high-performance solution.”

The board design won a 19th Annual PCB Technology Leadership Award, a competition that attracted printed circuit board designers from around the world, in the Telecommunications Switches, Network Servers, Base Stations, and Computer Mainframes category.

- Control Engineering News Desk
( Register here and scroll down to select your choice of eNewsletters free .)





No comments
The Engineers' Choice Awards highlight some of the best new control, instrumentation and automation products as chosen by...
Each year, a panel of Control Engineering editors and industry expert judges select the System Integrator of the Year Award winners.
Control Engineering Leaders Under 40 identifies and gives recognition to young engineers who...
Learn more about methods used to ensure that the integration between the safety system and the process control...
Adding industrial toughness and reliability to Ethernet eGuide
Technological advances like multiple-in-multiple-out (MIMO) transmitting and receiving
Virtualization advice: 4 ways splitting servers can help manufacturing; Efficient motion controls; Fill the brain drain; Learn from the HART Plant of the Year
Two sides to process safety: Combining human and technical factors in your program; Preparing HMI graphics for migrations; Mechatronics and safety; Engineers' Choice Awards
Detecting security breaches: Forensic invenstigations depend on knowing your networks inside and out; Wireless workers; Opening robotic control; Product exclusive: Robust encoders
The Ask Control Engineering blog covers all aspects of automation, including motors, drives, sensors, motion control, machine control, and embedded systems.
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
News and comments from Control Engineering process industries editor, Peter Welander.
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
This is a blog from the trenches – written by engineers who are implementing and upgrading control systems every day across every industry.
Anthony Baker is a fictitious aggregation of experts from Callisto Integration, providing manufacturing consulting and systems integration.
Integrator Guide

Integrator Guide

Search the online Automation Integrator Guide
 

Create New Listing

Visit the System Integrators page to view past winners of Control Engineering's System Integrator of the Year Award and learn how to enter the competition. You will also find more information on system integrators and Control System Integrators Association.

Case Study Database

Case Study Database

Get more exposure for your case study by uploading it to the Control Engineering case study database, where end-users can identify relevant solutions and explore what the experts are doing to effectively implement a variety of technology and productivity related projects.

These case studies provide examples of how knowledgeable solution providers have used technology, processes and people to create effective and successful implementations in real-world situations. Case studies can be completed by filling out a simple online form where you can outline the project title, abstract, and full story in 1500 words or less; upload photos, videos and a logo.

Click here to visit the Case Study Database and upload your case study.