Customer Solutions

Creating a High-Throughput Security Tape Reclamation System

Author(s):

Brandon Dineff, Data Science Automation; Richard M. Brueggman, Data Science Automation; Gregory C. Cala, Data Science Automation

Industry:

Aerospace/Avionics

Product:

GPIB & Instrument Control, LabVIEW

The Challenge:

Increasing the efficiency of the cassette tape testing process of the U.S. Government, which uses large numbers of 19 mm SD1 cassette tapes to archive sensitive information for national security purposes.

The Solution:

Upgrading the existing DMS system, which processed 24 tapes, and expanding its capabilities significantly, we at Data Science Automation integrated multiple bit analyzers, Sony DIR-1000 recording systems, and the new Sony DMS-8800 tape transport system using NI LabVIEW, serial, and GPIB control.

Simplifying the Simulation of Tape Use
The process currently implemented when testing the validity of each tape is designed to simulate actual use of tapes. This testing process consists of a time-consuming testing process that rewinds each tape, which allows the stress on the tape to settle. Once each tape has been tested, the primary testing process begins in testing order.

When a tape is tested, that tape is written to and read from. The testing process uses a recorder and a device called a bitalyzer, which creates an arbitrary binary pattern for each track of the tape tested. This arbitrary binary pattern transmits to the DIR 1000 recorder device, which then writes this pattern to each track. Once a track is written, the recorder simultaneously reads each track and compares it with the pattern written, while writing the new track. We perform this comparison for eight different heads of the tape, and produces output voltage levels and error information per track, identified by track set IDs (TSIDS). Potentially, a track can have thousands of errors, but a fail determination is assigned if more than two TSID errors occur per tape.

Both bitalyzer and recorder devices communicate over the same GPIB bus. The DMS8800 system uses a serial connection to monitor the DIR1000 recorders. This serial connection is the backbone of the DMS8800 system.

Test Manager Controls a Variety of Functions
The test manager is the top-level application that controls the sequencing of tapes, manages all tapes in the library, and gives us the ability to specify when to print the results. Using the PRINTOUT control on the front panel of the test manager, we can specify to print on fail, display, always print, or do not print or display.

The test manager displays all tapes currently in the library and handles any new tapes inserted or exported. The tape bin array contains the bin number, the tape serial number, and the status of the selected tape. There are 13 possibilities for tape status: UnPreTested, PreTesting, PreTested, UnTested, Testing, Test Passed, Test Failed, ReTesting, ReTest Passed, ReTest Failed, 2nd ReTest Passed, and 2nd Retest Failed. Once each of the tapes in the library processes, the system continuously polls the library and looks for any imported or exported.

We used a companion software package provided by Sony with the DMS8800 system to move the tapes in and out of the library. This application runs simultaneously with the test manager. The test manager also creates test result files and can recall files for display or print.

We developed a process loop controller to handle each of these statuses and process them accordingly in each processing loop. These loops run independently, processing tapes, and do not interfere with each other. We added a third processing loop accommodate a third recorder in the future.

A Cost-Effective and Efficient Solution
With National Instrument products such as NI GPIB, NI SERIAL, and NI LabVIEW 6.1, we found a cost-efficient and effective solution to testing tapes for reuse. Our system can handle 94 tapes, and we may purchase expansion bays to accommodate more throughput. This library can contain up to three recorders and three bitalyzers. The resulting system tests up to 87 tapes simultaneously, resulting in a cost savings of more than $3MM/year. This solution helps our customer improve productivity and increases the return on investment threefold.

For more information, contact:
Brandon Dineff
Data Science Automation
400 Southpointe Blvd., Ste 210
Canonsburg PA 15317
Tel: 724-745-8400
Fax: 724-745-8461
E-Mail: bjd@dsautomation.com

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