Avalon Electronics

 

 

Avalon and Disk Recording

 

The following case study is offered as a brief  insight into Avalon's unique philosophy and approach to the problems of developing dependable recording systems for critical applications.  We hope that the facts speak for themselves.

Topics


Why Disk Recording?

Magnetic tape recorders have served the world's intelligence gathering agencies well for more than 50 years. Yet, paradoxically, throughout this period users would always have preferred not to entrust their precious data to 'a piece of rusty plastic' had their been any other way.  For almost as long, the death of the tape recorder has always been just around the corner - except that tape recording technology always seemed to be able to stay just that one jump ahead. The users' quest for ever greater bandwidth, capacity and/or resolution could somehow always be met by some technical advance in another market sector - generally in the broadcast video world -  and data recorder manufacturers have traditionally been very skilled at adapting the latest video recorder to the needs of the data collection world.  By the late 1990s, however, this strategy was clearly running out of steam.  The performance curve of state-of-the-art data recorders (most recently based on 19mm tape cassettes) had flattened out at about 500 Mbits/s while the price curve continued to accelerate upwards. Meanwhile, the user community needed data rates in the Gbit/s range, but at significantly lower unit costs - and very much lower on-costs.

Around 1997, Avalon was tasked by several of its major customers to 'think outside the box' and to propose possible alternative solutions to this problem.  A thorough review of all the available technologies confirmed that it was extremely unlikely that the next generation of production 'high-end' data recorders would be tape-based.  To the surprise of many observers, Avalon engineers concluded that the most promising technology was the humble computer hard disk drive (HDD) - a medium which had hitherto been thought of as too slow and of too a low capacity to be of any use in anything but the most menial of real-time data collection roles.  But in 1997, HDD capacities had reached 9 GB with the forecast of a doubling of capacity every 12-18 months for the foreseeable future. Beer mat calculations suggested that as few as eight HDDs operating in parallel could easily support data rates in excess 500 Mbits/s, while continuous recording times at least equal to a 19mm ID-1 cassette would soon be possible.  The other main contender in the media stakes - solid-state memory - was quickly discarded, due mainly to Avalon's belief that the high cost of a RAM-based solution could really only be justified for the most hostile of military environments, an area in which Avalon was not at that time engaged.  Consequently, Avalon (itself already a major player in the S-VHS wideband tape recorder market) quickly became convinced that disk-based recorders offered the most promise in terms of market potential and long term growth.


Challenges

Even if the raw calculations did look promising enough, the engineering challenges of adapting a specialized computer peripheral to the very different world of sustained, 100% reliable data capture in a range of less than benign field and platform environments were anything but straightforward - and in some cases, not immediately obvious.  The 'obvious' approach at that time was to base the new design on an off-the-shelf technology which already existed in the computer world - the RAID (redundant array of inexpensive disk).  RAIDs had some important attractions - at least on paper.  They came in all shapes and sizes and were already fully integrated into a computer environment.  All that would be needed therefore would be some form of signal conditioning to convert the user's data (analog, digital and/or telecommunications) into computer files and a new product would be born.  Indeed, the only electronic engineering that would be needed would be some suitable signal conditioning modules, since the rest of the 'recording system' could be assembled on a pick-n-mix basis from the computer store catalog.

But Avalon engineers quickly realized that this simplistic approach was fundamentally flawed in several critical areas.  Firstly, some simple experiments showed that it was impossible to write to the disk drives at anything approaching their maximum rate with an Operating System in the way.  The small block size of a standard FAT system, for example, taken together with the time the OS spent preparing to write the block, writing the block and then checking that the block had been written correctly all mitigated significantly against achieving the kind of sustained writing speeds that Avalon was looking for.  Likewise, in the real world of SIGINT data capture where one often has no chance to try again if a critical event of interest is not captured when offered, Avalon concluded that it was just not possible to achieve 100% acquisition reliability with a controller running a standard computer operating system with a mind of its own.  It was essential, therefore, that the recorder electronics should have compete control over what happened and when.

In the context of its 'field' and 'platform' customer base, Avalon also saw physical problems in the RAID-based approach.  Not only were the COTS workstations and storage devices physically too large for installation on many platforms, there would be environmental issues too in terms of packaging the equipment to operate reliably in, say, a turbo-prop aircraft.  But more important still, market research showed that the overwhelming majority of potential users would insist on a conveniently removable media package for two reasons.  Firstly, it was considered essential that it should be possible to be able to lock the storage medium away in a secure safe when not in use. Secondly, the sheer volume of data that it would be possible to store on a small bank of disk drives meant that the only viable means of transporting mission data between, say, a surveillance aircraft and its support facility was by hand-carrying the actual disk drives themselves. In many operational scenarios there is literally insufficient time to 'milk' eight hours of raw, unedited mission data to another medium or computer either while the aircraft is readied for its next mission or before the platform has to be powered down.  Most users contacted by Avalon declared that the need to carry and manage a box full of loose HDDs would not be acceptable operationally.  What was needed therefore was some form of 'hot-swappable' disk pack which could not only be hand-carried readily from place to place but could also extend the mission duration if more than one crate were carried.

So, the results of these deliberations were that the ideal disk-based data recorder should have the following characteristics:

  • no Operating System

  • no RAID storage

  • data handling under the control of the recorder from start to finish

  • removable disk pack

  • smallest possible packaging

  • rugged construction

Such a product, Avalon felt (back in 1997) would go a long way to satisfying not only the 'platform' user but also the static 'laboratory' user.  Avalon's solution therefore was to use what has been dubbed a JBOD approach (Just a Bunch of Disks).  The proprietary system used by Avalon is an advanced form of JBOD known as PRIDE (or Precision Recording Instrumentation Disk Environment).  PRIDE is described in greater detail below.


Other Considerations

In fairness to the Computer/RAID approach it has to be said however that Avalon's preferred solution had - at least initially - one perceived drawback, at least for certain applications.  This involved the absence of the very FAT file structure that the company had determined so early on would be a limiting factor to the maximum sustained data rate (and hence bandwidth) which could be realized.  Although a majority of users in the SIGINT world (analog, digital acoustic and telecoms) require to process their recorded data in its native format, there are others who wish to network and process digital files directly.

Until recently, platform disk recorders like Avalon's AE7000 and AE8200 families have required a separate extraction process to transfer selected passages of the (unformatted) recorded data to tape (usually AIT) or to a computer (via SCSI).  Even this, however, is a two-edged sword.  If the important bits of data are small, then it is easy enough to transcribe these from the disk recorder to tape.  The large file sizes of an instrumentation RAID are not so convenient in this case.  Today, Avalon's PRIDE concept has been enhanced to allow selected passages of recorded data to read directly from disk or tape by a host workstation as virtual files, therefore overcoming this problem completely.

It would be totally wrong of course to say that the RAID approach cannot deliver a perfectly satisfactory data recording solution. By de-tuning the maximum throughput to a level that allows fully for the vagaries of the Operating System and the small block size, designers of such systems are able to deliver a FAT-based system which is able to network directly to a host computer environment.  Assuming that network connectivity is a higher priority in a particular application than, say, maximum bandwidth, physical size, physical data portability and environmental issues then a RAID system may hitherto have been a perfectly acceptable solution.


Products

Avalon's first production disk recorder was the AE7000, introduced in 1999.  Although ahead of its time in so many ways, it remained until 2005 the only stand-alone compact platform recorder capable of recording analog signals to 75 MHz for sustained periods.  A wide range of interchangeable single and multi-channel analog, digital and telecommunications interfaces are available.  AE7000s have been in operational service with many of the world's leading data collection agencies since 1999.

Avalon AE7000 Disk Recorder

In 2002 Avalon, responding to market requests for a smaller disk recorder which could be used as a direct replacement for legacy 6 and 8 MHz S-VHS tape recorders, introduced its second generation AE8200 family of products.  Where the AE7000 uses eight 36 GB HDDs, AE8200 achieves a similar capacity with only two 146 GB HDDS,

In 2004 the bandwidth of this compact recorder was extended to 50 MHz with the introduction of the Series 2 variants.

Again, at the request of our customers, built-in DSP-based IF/baseband conversion was introduced across the range.

AValon AE8200 Disk Recorder

In 2005, Avalon extended the capabilities of the disk recording concept yet again with the introduction of the world's first 100 MHz wideband analog data recorder.  AE8800 SSDR is able to record baseband (video) signals at up to 100 MHz, or IF of up to 160 MHz (80 MHz BW).

Avalon AE8800 SSDR


Design Philosophy

TIME WAITS FOR NO MAN ......

AND REAL WORLD SIGNALS DO NOT WAIT FOR COMPUTERS.

In the world of Instrumentation Recorders the "Value" of the signals to be collected may be impossible to calculate. Avalon’s recorders have between them millions of hours of successful error free recordings.

The 'target' may represent an unrepeatable event with a single opportunity of capture. The recorder may be recording these events on an aircraft costing hundreds of thousands of dollars to fly whilst putting the crew in harms way, or maybe be installed in a black tube away for months at a time with a deployment costing millions of dollars. More than once Avalon’s recorders have continued to record the data when other equipment had failed all around it, bringing home priceless information.

On one occasion, around 15 years ago, the Sonar Suite on a Submarine failed at the start of the mission. The operators continued to record and change the VHS tapes in the Avalon Recorder in the hope of recovering data from the mission. On return to base, three months later, they were delighted to find that the failure had not involved the recorder and that the entire missions data could be retrieved. This particular recorder is still in front line service today, and it is planned to continue its deployment for a further 10 years.

How many times have you requested your computer to do something only to be presented with the "Hour Glass" or the "Blue Screen of Death"? Over time we have all learned to live with the unreliability of computers, saving our files on a regular basis, and most importantly, have a duplicate copy of our data stored on a separate machine. To provide additional security Avalon’s recorders have three additional data protection features.

The fundamental principles of Computer based technology is that of a collection of devices which take in a specific amount of data, processes it and returns the answer. The task is usually processed at a time and a speed convenient to the Operating System, and allows for other non-mainstream activities to interrupt the process as they see fit.

The fundamental principles of an Instrumentation Recording system is to faithfully record and reproduce the signal attached to its input socket, NO MATTER WHAT ELSE IS HAPPENING AROUND IT.

These two principles are clearly diametrically opposed.

If the input data rate is slow enough so that the process can take place sequentially or that the process can be spread out over a large number of parallel paths then a Computer based architecture may provide a solution.

However, the owner is then at the mercy of commercial parts and software which tend to be obsolete within 12 months. It also means that the data is dependant on more components than is really necessary and this increases the probability of failure.

AVALON’S MISSION, SINCE ITS INCEPTION NEARLY 25 YEARS AGO, IS TO TAKE STORAGE TECHNOLOGIES, DESIGNED FOR OTHER PURPOSES, AND TO INTEGRATE THEM INTO AN ENVIRONMENT WHERE THEY PROVIDE A RELIABLE AND DURABLE RECORDING SYSTEM, WHERE, WHEN THE RECORD BUTTON IS PRESSED THERE IS A 99.99% PROBABILITY OF CAPTURING THE SIGNAL.


Designing for Reliability and Longevity

The first task is to identify suitable primary storage devices from dependable suppliers with a good history of reliable products and who are willing to cooperate in investigating why their product fails to operate as they might have expected, based on their data sheet claims. These storage devices are then stripped of all unnecessary functions and driven by Avalon purpose designed, dedicated hardware which will enable the device to operate continuously at maximum efficiency. The task is not to take "Off the Shelf" components and link them with software since these devices were designed for an entirely different operating environment.

ALL HARD DRIVES ARE EQUAL, BUT SOME ARE MORE EQUAL THAN OTHERS

As part of our engineering investigations we found a great deal of variation in the performance of Hard Disk Drives from one manufacturer to another and from model to model from the same manufacturer. In an operating environment where time to the nearest millisecond is not of significance all drives perform a reasonable task. However with real world signals, time is of the essence. After years of investigation we have approved only two manufacturers, and as an indication of the close cooperation which has developed, each of these ask Avalon to be one of the first users to evaluate new products as they recognise that our operating environment is THE most demanding of all applications in the world.

Part of this qualification process is to monitor the drive's performance whist subject to vibration, large displacement shocks, and temperature variations - the type of thing that happens to recording systems when deployed in the real world. Whilst most disks will recover from these events, given time, as we said before time waits for no man, so the drive must perform perfectly whilst subject to these variations.

ONLY HARD DRIVES WHICH PASS OUR STRINGENT EVALUATION PROCEDURES WILL BE INCORPORATED INTO AVALON’S PRODUCTS.

Avalon is the only company able to offer with confidence and experience an unconditional 3 year Product Warranty and a 5 year Hard Drive Warranty.

Detailed descriptions of the tests and evaluations are available to qualified customers on conclusion of a Non-Disclosure Agreement.

Disk based Instrumentation Recording typically involves the use of computer Hard Drives operating in parallel to accomplish data recording rate hitherto undreamed of. Unfortunately some of the terminology associated with the low cost end of the computer market has been used to try to describe the deployed technology.

RAID IS AN IMPLIED ADMISSION OF THE PROBABILITY OF FAILURE

The acronym RAID stands for Redundant Array of Inexpensive Disks. It implies that the most important feature is their cost, and that they are configured in anticipation of failure.

JBOD IMPLIES THAT ANY DISK WILL DO

The acronym JBOD stands for Just a Bunch Of Disks. It implies that there is no significance in the quality or origin of the disks used to provide the recording engine.

PRIDE IS THE ACRONYM OF THE ENLIGHTENED

Precision Recording Instrumentation Disk Environment

(PRIDE is a trademark of Avalon Electronics)

The disks are the vital heart of any disk recording system. Whilst most hard drives perform to a satisfactory level under an operating system environment, there true performance is only evaluated when tested with continuous real world signals.

Avalon’s engineers have a long history of working with magnetic recording, including working on Computer Compatible Tape Recorders in 1968, the first Hard Disk drives imported into the UK in 1972, and Exchangeable Hard Disks in the 1990s.

Avalon has three criteria for selecting hard drives, Quality, Reliability, and Repeatability. Cost is of no importance. The quality of manufacture is just the start. The quality of the handling by the distributor and shipping organization prior to their inclusion to our products is vital. Avalon has imposed strict handling and packing requirements on the manufacturer's distributors to ensure that the product is received in perfect condition.

If Hard drives are damaged in transit, and are operated in a Windows Environment, the user will be completely unaware of any minor damage that the unit has sustained.

Damage can be inflicted on a Hard Drive very easily if it is not handled correctly. By standing a drive on its edge and allowing it to topple over on to its back exceeds the maximum shock specifications recommended by the manufacturers. When recording real world signals using a damaged disk the performance is likely to be intermittent. One day it will work another is may fail.

Avalon’s Electronics monitor the performance of the Hard Drives and reports if there is any likelihood of damage, allowing the disks to be replaced prior to a critical failure whist recording or replaying vital data