1

ISRO Spacecraft Integration Test Establishment (ISITE)

ISRO Satellite CentreBangalore, INDIA

January 2016

2

1. Clean room Facility2. Physical Parameters Measurement Facility3. Spacecraft Checkout Laboratory4. RF Shielded Anechoic Chamber for System Level

EMI/EMC Measurement5. Compact Antenna Test Facility (CATF) 6. Mechanical Ground Support Equipment (MGSE)7. Spacecraft Alignment Activity• ISRO Satellite Centre, Bangalore is equipped with a world-

class Clean room Test Facility at ISITE, wherein the Spacecraft Assembly Integration and Testing (AIT) activities are carried out to realize satellites of different capacity and for different mission requirements.

January 2016

3

• The salient features of the Clean room Facility at ISITE are:1. The clean room facility is of 100,000 class, as per FED

standard 209E.2. Temperature, RH and particle counts are maintained as FED

STD 209E.3. The air flow inside Clean room is laminar.4. Clean room environmental parameters are monitored by

particle counter, O2 monitor and data logger.5. There are two entrances to the clean room with dress

change facility and two emergency exits are provided in clean room.

6. Clean room dimensions are approx. 53m long and 33m wide.

January 2016

January 2016 4

January 2016 5

January 2016 6

7. The Clean room flooring is of ESD epoxy as per international standard.

8. The clean room is provided with 1 number of 15t /5t capacity EOT (Electric Overhead Travelling) crane.

9. For loading/unloading of items to clean room from outside, two numbers of air lock rooms are available.

10. EOT cranes with 20 t / 5t capacity are installed in air lock rooms for loading/unloading of spacecraft and other allied equipment.

11. Dedicated grounding (9 numbers) for raw power and ESD lines available inside clean room.

12. Laminar flow table (1000 class) is available inside clean room for storing sensitive items.

January 2016 7

13. ESD garments of sufficient quantity are available for working inside clean room.

14. ESD work tables along with ESD chairs of sufficient quantity are available inside clean room for working persons.

15. Ultra-pure low pressure GN2 supply is available inside clean room.

16. Compressed air supply inside clean room as well as in air lock rooms is available.

17. Vertical Dynamic Balancing Machine (VDBM), CG, MI, POI measurement machines are available inside clean room.

January 2016

8

Spacecraft on VDBM for CG Measurement

Spacecraft on Physical Parameters Machine(Mass, C.G, M.I, P.I

measurements all in one machine)

January 2016 11

18. Sufficient number of crane weighing scales, starting from 1000 kg. up to 10000 kg. are available inside clean room for weighing the spacecraft.

19. Sufficient number man lifts are available inside clean room.20. Sufficient number work platforms are available inside clean

room.21. UPS power supply for spacecraft testing and computers

available.22. Raw power supply (230V, 50Hz) for spacecraft testing and

computers available.23. Sufficient number of power points, 5 Amp,15 Amp and

cutler hammer available inside clean room and in air lock rooms.

January 2016 12

24. Special Purpose Fixture (SPF), 4-bar fixtures, Low level work platforms of capacity to spacecraft lift off mass, 6000kg. can be provided subject to verification of interface, mass and CG.

25. Internal movement transportation system of capacity to spacecraft lift off mass, 6000kg. can be provided subject to verification of interface, mass and CG.

26. '0' G facility available inside clean room for deployment of solar panels.

27. Clean room is well connected to EMI/EMC Anechoic Chamber, Vibration Test Facility, Compact Antenna Test Facility (CATF) and Thermo vacuum Test facility.

28. Safety blast shields for propulsion activity are available.

January 2016 13

January 2016 14

29. RF Shielded fixtures for Low power level Radiation or EMI / EMC tests (if required to be carried out inside clean room) are available.

30. Necessary material movement and material handling equipment are available.

31. UV garment storage system available for de-germification of clean room garments.

32. Separate storage area attached with clean room available for storing flight hardware.

33. CCTV cameras installed at nodal places inside clean room for surveillance purpose.

34. Safety fire and smoke detection systems are installed inside clean room.

35. Spacecraft Check out Lab. is attached with clean room for testing of spacecraft.

36. Separate cooling system can be provided for cooling of battery, Payload panels, RF load panels etc.

Typically one Checkout lab at ISITE is about 10m X 12m. The lab is with air-conditioning. False flooring is provided. View glazing is available between checkout and

clean room. All RF cables / waveguides and DC cables that are required to be routed

between racks and to clean room, can be routed below the false floor. Two ducts ( 600mm X 250mm) are provided in the wall for cable routing

between Checkout and Clean room. Uninterrupted Power Supply (UPS) AC power distribution board is available

on the wall with a capacity to support up to 25KVA of power and Non-UPS upto about 5KVA.

Cutler-hammer extension boards are also provided to power the racks withCutler-hammer connectors.

Working table available can house about 7-8 monitors. One Pass-box ( 500mm X 500mm) is provided to pass small items to clean

room. Storage cupboards to store documents and small items.

Storage Area

CHECKOUT RACKS

PASS BOXDUCT-1 DUCT-2

SCC & PCOS PCs

VERTICAL AIR DUCT

12M

10M

1. Launcher and Co-passenger Compatibility Test –Radiated emission measurements and Radiated Susceptibility test

To demonstrate the functional performance of the Integrated Satellite in the Launch Vehicle and Co-Passenger Electromagnetic Environment.

To demonstrate the functional performance of the RF Components (like Antennas) that have not been tested in assembly level qualification testing.

To demonstrate the total functional performance for self compatibility of Integrated Satellite.

2. RF Radiation and Antenna Polarization Verification Tests

3. Auto-compatibility Test

Parameter Details

Frequency Range 30 MHz to 40GHz

Chamber dimensions (LxWxH)

19.5 x 14.6 x16 m3

Shielding Effectiveness • Magnetic Field: > 35 dB @ 20 MHz; • Electric Field: > 80 dB at 200 kHz up to 1 GHz • Plane Wave: > 100 dB from 1 GHz and above up to 40 GHz

Quiet Zone 5m x 5m x 5m at height of 1.5m from floorReflectivity Levels in QZ: : -10 dB at 80 MHz, -20 dB at 200 MHz and -40 dB at 1 GHz and above up to 40GHz.

RF Absorbers Power Handling of Normal Absorbers : 0.2 W/cm2Power Handling of High Power Absorbers : 2 W/cm2

Four power line EMI filter (3 phase + 1 neutral) ,

230 / 440 VAC, 50 Hz frequency with 64 A current capacity

Antenna Mast system • Fully automatic , controllable locally and through fiber optic linkfrom control room ,

• Range of scanning (Height): 0.9 to 6 m with ± 1 mm resolutionand ± 2 mm accuracy

• Supports antennas up to 10 Kg.

EMC TESTS ON GSAT – 16 COMMUNICATION SPACECRAFT

EMC TESTS ON MARS ORBITER MISSION (MOM) SPACECRAFT

Dimension: 30mx20mx16m Quite Zone:

Centre 5.5 m above floor 5.5(W)x5.0(H)x8.0(D)

DUT Positioner System:• 5 Axis Heavy duty Positioner• Can Handle up to 5000Kgf &

7500kgf-m Bending Moment Feeds : Freq. 1 – 40 GHz

Polarization Verification, Radiation Pattern

EIRP,SFD,G/T and Other P/L Parameters

PIM Auto Compatibility

Freq: 1-40 GHz Agilent Microwave receiver Synthesized Signal generator Multi channel controller Mixers, PIN Switches Data Acquisition, Data

Processing, Data Presentation Software

Spacecraft undergoing Test

in CATF

• MGSEs are used to handle and support the spacecraft and its sub systems during various phases of AIT.

• MGSEs enable access to various locations on the spacecraft and its subsystems ensuring safe operations.

• MGSEs are also required to move and transport the spacecraft to different places for carrying out various activities like conducting vibration test, acoustic test, thermo vacuum test, physical parameters measurement etc.,

• Several MGSEs have been designed, fabricated, tested and qualified to use during various phases of AIT of spacecraft.

• MGSEs are custom designed to suit particular class of spacecraft.

January 2016 24

The following MGSEs are custom built for use during AIT operations:• Spacecraft Transportation Container• Spacecraft Transportation and Storage System• Panel Transportation System• Special Purpose Fixture• S/c Integration 4-bar fixture• Equipment Panel Integration Fixture• Panel Handling System• Spacecraft Handling system• Physical Parameters Measurement System• Clamp band, Mounting Adaptors etc.

January 2016 25

• Spacecraft and its subsystems / flight components require stringent orientation and position requirement to meet its in-orbit functional objectives.

• The subsystems/system undergo a number of alignment operations to meet the specified accuracy.

• Alignment Measurement and Development section (AMDS) is responsible for conducting alignment measurements and corrections for all kind of Communication, Remote sensing and scientific spacecraft.

• The alignment activity on spacecraft is carried out at various levels viz. subsystem level e.g. wheels, reflectors, LAM etc. and at spacecraft level starting with master reference establishment.

• Further the spacecraft level alignment is also carried out in four phases: Pre-thermo vacuum test , Post-thermo vacuum test , Post Dynamic test and Pre-launch phases of spacecraft building.

• The AMDS team is also involved in developing new technology/ methods to meet critical/stringent measurement requirements of payload and spacecraft projects.

January 2016 26

• AMDS is equipped with state of the art high accuracy class alignment instruments and software, which are being used for Spacecraft alignment activity.

January 2016 27

Sl.No. Facility Description Make

1 Optics Based Theodolite Instruments Lieca 5100A

2 Close Range Photogrammetry (CRP) Gedetic Systems Inc., USA

3 Shape Analysis Software Polyworks

4 3D Coordinate Measurement and Analysis software VSTARS

5

Auxiliary Test Support Facilities such as Alignment fixtures, Surface Tables, Targets, Scale Bars, Coded targets and accessories used for various alignment instruments.

Lieca, Brunson, Hubbs

6 Target Projection SystemGedetic Systems Inc., USA

7 Multiple Camera SystemProcurement Under Progress

Thank You