ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Integration and Test...

ITAR Restricted Data

Integration and TestIntegration and Test

Marc Kaylor

301-902-4392

[email protected]


I&T Focus on Major System Components to be VerifiedI&T Focus on Major System Components to be Verified

Launch Vehicle

Spacecraft/Probes

Ground SystemNetwork

Ground TrackingStation

Ground ControlCenter

(ITOS Databases)Instruments


I&T ApproachOverview

I&T ApproachOverview

Bottoms Up, Modular Approach- Component Level and Subsystem ETU Verification prior to Integration- System Integration Aliveness Test to verify functionality

System Level Tests- Aliveness Test

- Verifies each probe operates including basic functionality and mechanical motion where applicable

- Functional Test- Verify every interface, command, telemetry point, and function- Uses EGSE as stimulus to test systems more in depth than Aliveness

- Comprehensive Performance Test- Measures performance on each subsystem- Demonstrates measurements of performance at a system level

- Mission / Orbits Simulation Test- Verifies system from simulation test modes at steady state orbits

- Environmental Tests- Verifies subsystem and system at design environment loads with margin


Components are flight qualified prior to bus/probe installation

– Instruments undergo thorough environmental testing individually and as a assembly at UCB

– Bus components are qualified at vendor level and retested as part of the Bus integration and test process

• Battery AEA Technology• Antenna PSL• Transponder L3 Com• S/A Cells & Laydown COI (CICs SpectroLab)• Gyro’s Systron Donner (Swales does

Module testing)• Sun Sensor Adcole• Tanks & RCS ARDE & Aerojet • BAU Swales & General Dynamics• Primary Structure with Clampband Swales

Single instruments to spacecraft electrical interface through IDPU

Plan to verify BAU and IDPU (EDU) interfaces as early as possible for compatibility

EDU bus avionics and IDPU support early h/w and s/w development on the FlatSat system

I&T ApproachComponent Qualification Program

I&T ApproachComponent Qualification Program


Test Personnel and RolesTest Personnel and Roles


I&T OrganizationI&T Organization

SubsystemEngrs / Leads

QAE/PAE I&T GroupElectricalSystems

Safety Contamination

I&T Engineers I&T TechniciansSpacecraft Test

Conductors

UCB InstrumentTeam

I&T Manager

UCB/SwalesSystem

Engineering

Mechanical Flight Software


Core TeamTest Personnel and Roles

Core TeamTest Personnel and Roles

I&T Manager- Responsible for Integration and Test Activities- Directs Test Activities- Coordinates Integration and Test Team- Prepares Facility and Test Stimuli

Systems Engineers- Plans System Tests and creates input parameters to tests- Writes system level test plans / procedures such as Comprehensive Performance Test, Aliveness Test, and

Orbits Simulation Test- Assist in the direction of test activities- Leads Verification Program and assures test objectives and requirements are verified and documented

Subsystem Leads / Engineers- Address technical issues regarding operation and design of subsystem- Works with Systems Engineering in verifying subsystem requirements through test

Quality Assurance Engineer- Cognizant of the execution of the test- Verifies quality of integration hardware, test data and equipment- Witness integration and sign-off of critical procedure steps

Spacecraft Test Conductors- In charge of operations to perform test procedure- Perform troubleshooting during test as required- Identify, report, and initiate corrective action for the flight hardware, database, or GSE- Disposition test anomalies- Conduct test briefings to the team


Core TeamResponsible Equipment Engineer (REE) /

Subsystem Engineer

Core TeamResponsible Equipment Engineer (REE) /

Subsystem Engineer

Responsible Equipment Engineer (REE) / Subsystem Engineer

– The REE is the Subsystem Engineer who was responsible for the delivery of the test hardware to the l&T Team.

– The REE is responsible for performing testing to verify delivered hardware is fully operational prior to approving the start of the l&T process.

– The REE is required to attend the Test Readiness Review (TRR), Daily Test Coordination meetings and the Post Test Review (PTR).

– The REE has signature authority on the procedures and Work Order Authorizations (WOAs) applicable to the REE's hardware.

– Prior to signing the REE is to ensure that the testing activities are safe for the hardware, that the REE fully understands the testing activities as planned, and the expected results are accurate.

– The REE's signature is required on any black or red lines made to the procedure. • The signature is required before the black or red lines are to be performed.

– The REE is required to be present and observing all Flight testing. The REE is an active participant in the test operations but only in an oversight and support role. The REE is responsible for ensuring the hardware is never at risk, understanding and approving any deviations and to aid in the investigation of any anomalies or out of tolerance readings


Core TeamSafety / Contamination

Core TeamSafety / Contamination

Safety Engineer

– The Safety Engineer is required to attend the Test Readiness Review (TRR), Daily Test Coordination meetings and the Post Test Review (PTR)

– This ensures that the Safety Engineer is cognizant of all testing operations

Contamination Engineer

– The Contamination Engineer is required to attend the Test Readiness Review (TRR), Daily Test Coordination meetings and the Post Test Review (PTR)

– This ensures that the Contamination Engineer is cognizant of all testing operations and potential impacts to the cleanliness of the spacecraft/instrument


Facilities PlanFacilities Plan


Swales 5015Swales 5015

Primary Probe Integration facility and the epicenter of our flight system development

5015 1st floor layout attachment shows separate work areas and multiple workstations to support our parallel probe I&T flow, includes class 100/10K cleanrooms, Flatsat, and harness labs

– Class 100K required in cleanrooms, Class 10K rules in effect when instrument interiors are exposed

– When the spacecraft is outside of the class 100,000 cleanroom it must be double bagged. 65-75 F, 30-60% RH

– No unique power requirements identified, standard 120VAC, 20A service should be adequate for each lab and zone. In addition zone 2 should be wired for 60A two phase service should we require a dedicated centralized UPS for sensitive GSE and grounding control

– Connectivity to the intranet and Internet required in each lab and zone. Zones 2, 2 and Lab C must also be connected to the THEMIS test net

– Existing portable crane required


5015 Layout5015 Layout

OFFICEANTEROOM

ROLLUP DOOR

SLI

DIN

G D

OO

R

GOWNINGROOM

HVAC/FILTER ROOM

FACILITY ROOMLAB B

MECHANICALASSEMBLY

&BONDING

ROOM

LAB AHARNESS

&ELECTRICALASSEMBLY

ROOM

LAB CTESTBED

&FLIGHT S/WCHECKOUT

Staff Machine Shop

LO

BB

Y

ZONE 1

BR

BR

IWS #2

WB

IWS #1

WB

ZONE 2 ZONE 3

WB

EG

SE

1E

GS

E 2

WB

WB

WB

EG

SE

CH

EC

KO

UT

AR

EASHIPPING & REC

AREA

WB WB

WB

WB

MECH ASSYAREA (Hi-Bay)

P P

PP

P

WB

WB

WB

TYP PROBE & DOLLY

WB

WB

EGSEDEVELOPMENT

EGSE 3

WB

INSTRUMENTSTAGING AREA

WB

COMPONENTSTAGING AREA

WB WB

OVERFLOW IWS


Swales 5015Mezzanine

Swales 5015Mezzanine

Second floor mezzanine area (not shown) planned for I&T staff office area and conference rooms. Includes areas for I&T team, Hammers SW Team, and Instrument Support Team

– Mezzanine must be wired to support phones Intranet, Internet and THEMIS test net connectivity

– Power requirements limited to standard 120VAC, 20A service

– Printer and photocopy machine available in lobby

Planned usage is as follows

– First floor highbay, labs and office has already begun

– First floor cleanroom 3Q04

– Second floor mezzanine 2Q04


Network Security and AccessNetwork Security and Access

UCB

ITOS Front-End WSw/ Apache Server

LabVIEW/VirtualSat PC

THEMISFlightHW

ITOS Sub-SystemWorkstations

Personal PCsOffice PC

Windows PCfor I&T Support

Visitor PCs

SWALESNAS1

File Server

Internet

Swales I&Tat GSFC

Hammers

Firewall(Swales managed,in addition to ODIN)

Zone 1A. THEMIS Secure:Zone 1 network ports see only otherworkstations in the secure zone locally andremote locations (GSFC, UCB, andHammers) configured with secure fixed IPaddresses. The Apache server will beaccessibly by fixed IP Address directedthrough the Swales firewall.

Zone 1B. Swales I&T @ GSFC

Swales Firewall Access:Remote access through the Swales Firewall to theTHEMIS Secure Zone is through encrypted site-to-siteVPN tunnels only. All devices located at GSFC,Hammers and UCB which will participate in the site-to-site VPN are expected to be dedicated, isolated from allother networks at those remote sites.

File Server: Config, DB, Proc, and Data Filesare stored on the NAS1 server and accessibleto WS with Swales VPN access. The server isbacked up daily. A terabyte of space is beingplanned for ops support.

Network Failures:In case of a NAS1 or Network failures real-timetesting will continue. Access to some archived testdata will be temporarily un-available along with testprocedure and other CM files.

HammersFirewall

UCBFirewall

ITOS Front-End WSw/ Apache Server

LabVIEW/VirtualSat PC

THEMISFlightHW

ITOS Sub-SystemWorkstations

Windows PCfor I&T Support

Ethernet

Ethernet

Ethernet

SwalesFirewall

EthernetEthernet

Zone 2. Swales Network and Servers:Zone 2 ports have the same access as generalSwales (Email, web, etc). Approved laptops canbe added and removed as needed.

Zone 3. Hammers and UCB Net


Probe Carrier Integration FacilityProbe Carrier Integration Facility

High Bay in Swales Building 11310

– The probe carrier will be fully integrated in this facility.

– There are no requirements to maintain the this hardware assembly in a cleanroom at a Class 100K

– 40’ x 40’ area needed for PC and shipping container

– Same facility that we plan to use to manufacture the probe primary structure components (decks, side and quarter panels)

– Has loading dock, clean areas, access control, bonded storage, machine shop, tooling, lots of staff etc

– No facility modifications identified at this time, expect to use as is

– First use is expected in the 3Q04


Swales 5016 HighbaySwales 5016 Highbay

ETU Clampband Requirements (Inside 5016)

– 25’ X 25’ area under beam crane – Overhead crane required –

existing ½ ton beam is acceptable – need hoist

– 65-75 F, 30-60 % RH (TBR)– Standard 120VAC, 20 A service (6

outlets)– Phone and network access in

clampband corner– Capability to partition work areas– 2 work tables one with provisions

for ESD ground– Secure cabinet and/or cage

storage– Planned first use is 1 March 2004

for ETU clampband testing


Facilities / Security ControlFacilities / Security Control

FACILITY ACCESS REQUIREMENTS

– Personnel supporting the THEMIS activity will require authorization by the I&T Manager and/or the THEMIS Program Manager for access to the facilities where the activities occur.

– Access to the Swales 5015 Building will be controlled by the use of a key card. QA will maintain a current access log of personnel working on or in the general area of the spacecraft.

– Swales has current arrangements for off duty police patrols from 6PM-6AM weekdays and 24/7 on weekend


Cleanroom Support / Contamination

Cleanroom Support / Contamination

Mission level Contamination Control Plan from UCB Baselined– SST, and ESA instrument drive mission contamination requirements– ESA and SST Instruments arrive covered and remain that way except

for TV testing and launch– GN2 purge required, 24 hour interruptions OK– Surface cleanliness levels of 500A specified

The general set of contamination critical surfaces identified in the Themis spacecraft and the instruments include– ESA Microchanel Plates OSRs– ESA Gold-Black Surfaces– SST Detectors– Thermal control surfaces– Solar panels– Sun sensor


Contamination PlanContamination Plan

The requirement is to maintain the cleanroom at a Class 100K – Historically, the facility has performed as a Class 10K

– GN2 purge lines and Flow Control for the ESA and SST

– Cleanroom Supplies / Cleanroom Monitoring Equipment

• Cleanroom garments Cleanroom gloves• Cleanroom wipes Cleaning solvents• Paper and report covers Portable vacuum equipment• Witness plates, stainless steel Room air particle counter • Tape-lift supplies Cleanroom bagging material• High purity gaseous nitrogen (GN2) bottles (UCB provided)• GN2 purge cart/lines/controls (UCB provided)

– Probe shall be bagged when ever it is necessary to relocate the probe outside of the cleanroom for any reason


Cleanroom Personnel Requirements

Cleanroom Personnel Requirements

Garment Requirements

In Control Area

Prior to instrument integration or instrument bagged (Class 100,000)

Smock

Face Hood

Beard Cover or Eye Hood if facial hair

Gloves

Shoe Cover

After instrument integration and instrument exposed (Class 10,000)

Bunny Suit

Face Hood + Beard Cover or Eye Hood

Gloves

Booties


GSFC ENVIRONMENTAL TEST FACILITIES

GSFC ENVIRONMENTAL TEST FACILITIES

A Class 100K, or better, area is required for staging and integrating the instrumentation suite to the spacecraft bus and after moving THEMIS to GSFC

– Staging implies an area that can be used to open a bay and do rework, remove/install solar array, perform functional testing, and a place to move to between environmental tests. The cleanroom supplies listed earlier will also apply. This facility must accommodate a lifting crane to lift the spacecraft from the transport dolly to/from the work stand in preparation for environmental verification at GSFC

1000 sq. ft of floor space is anticipated for handling of all probes in Building 7

Office space with phone/copier/fax to support 10-12 people will also be needed

Each probe shall remain in the GSFC cleanroom until all five probes have completed their environmental tests

The cleanroom is required from June of ’05 till launch

The I&T test operations area of approximately 600 sq. ft. will contain the computer workstations, RF rack, Probe test rack, data interface equipment, and data/voice links to the other environmental facilities

Preliminary Meeting held at GSFC in May to discuss requirements and request for facility support


I&T FlowI&T Flow


I&T FlowProbe

I&T FlowProbe

Assemble PrimaryStructure

Sine Burst Test &Modal Signature,Strength Qualified

Structure

Disassemble-S/A’s to Vendor,Bottom Deck to

Vendor

Cell Laydown &Wiring, Test &

Qual

Baseplate Mockupto RCS Vendor RCS Component

Assembly

Bottom Deckto RCS Final

Assembly & Test

Back at SAI forHarness &

Thermal Install

Bottom Deck

Panels

RCS

Component MassMockups

Tanks to RCSVendor

QualifiedSeparation System

Install FlightBAU

Install workhorsebattery

Qualified S/A Top,Bottom, & Side

Panels

Install Sun Sensor& Gyro’s

InstallTransponder

Perform BaselineCPT

Perform1st CPT

EMI Self Com TestSCM & FGM

Boom 1st MotionTest

Mag SurveyS/A Illumination

Test

Store Panels tillneeded

Probe A Ready forEnvironmental

Testing

Install TopDeck &Corner

Panels andAxial Boom

Instrument SuiteArrives at Swales

Unpack & InspectInstrument Suite

Perform Functionalon Instrument

Suite

Hold IntegrationReadiness Review

with InstrumentTeam

Integrate IDPU &Instrument cables

with BAU

Integrate ESAInstrument

Integrate EFIInstruments

Radial / AxialIntegrate SSTs Integrate SCM

Integrate FGMSide Panel

Closeout & InstallSide Panel Arrays

Install S-BandAntenna

Install Top &Bottom S/A’s

Thermal CloseoutsVerify Range andMotion of SCM &

FGM Booms

Instrument Activities


Test FlowGSFC Environmentals

Test FlowGSFC Environmentals

Mass properties &Spin Balance

Modal Signature,Protoflight/

Acceptance Sineand Random Vib

2/1 Separation Test

Thermal Vaccum& Thermal Balance

PostEnvironmentalCPT, Qualified

Probe Ready forPCA Integration

Assemble ProbeCarrier

Probe MassMockups

Install Harness &Thermal Coatings

ELV Fit Check (IfRequired)

Modal Survey,Qual Sine Burst

(Fixed Base)

Qualified Probesand PC Begin

Integration

Integrate 5 Probeswith PC to form

PCA

Perform 1st PCALevel CPT

Acceptance SineVib & Protoflight

Acoustic Test(PAF & Band)

RF Performanc &Self Compat test

CPT, Mission Sim,Launch Sim

DeintegrateProbes & PC,

Pack Separately

Probes A-E I&T

Ship to KSC forLaunch

EMI/EMCProbe #1 only

Magnetics SurveyProbe #1 only

Mass PropertiesSpin Balance of

PCA

Instrumentation

Rescreen Probefor DC Mag

characteristicsMag Facility /

Handheld


Launch Site Processing FlowLaunch Site Processing Flow

Receive Probes atAstrotech Facility

Unpack andInspect Probes

Install TLX/Umbilical Console

Perform ProbeShort Form

Functional Tests

Charge FlightBatteries

Receive ProbeCarrier at

Astrotech FacilityInspect

Perform ProbeCarrier Assembly(PCA) Functional

Test

Perform MassProperties / Spin

Balance Test

Move ProbeCarrier Assemblyto Encapsulation

Hall

Lift EncapsulatedAssembly onto

Transporter

Transport toLaunch Pad

Mobile ServiceTower (MST)White Room

Mate to VehicleRF TestPayload

Checkout

Verify AcceptableWhite RoomConditions

DisassembleGround Handling

Can

Conduct ProbeLong Form

Functional Tests

Pressure test /Leak test of RCS

Install Probes ontoProbe Carrier

Inspect

Fairing InstallationFinal Aliveness

TestLaunch Readiness

Review

Launch

Mission Rehearsal

Dry Weighing ofProbes

Mount PCA to 3rd

Stage

Set-upContamination

Tent over PayloadAssembly

Unpack andInspect EGSE/

MGSE

Check-outEGSE

Set up EGSE

Move Probe to theHPF

Setup FuelingEquipment

Fueling of Probes

Pressurization ofProbes

Wet weighting ofProbes


INTEGRATION PROCESSINTEGRATION PROCESS


Work AuthorizationWork Authorization

Manufacturing activities will begin when a Work Order Authorization (WOA) is received and accepted

Production operations shall be conducted in accordance with approved and released documentation (e.g. work instructions, drawings, specifications, standard operating procedures, bill of materials, etc.)

Applicable drawings (properly checked approved and issued through Configuration Management), specifications, and/or procedures must be available for all work requests

Any changes to the applicable documents reflected in work orders must be documented on an approved engineering change order, as a minimum


WOA ContWOA Cont

Equipment

– All special equipment (e.g. tooling, jigs, inspection fixtures, etc.) required by the production process shall be clearly specified in the work instructions. Any unique handling/use instructions shall also be identified


WOA EntryWOA Entry


WOA ReviewWOA Review


ReportingReporting


Problem RecordsProblem Records


Test FlowTest Flow


Typical Electrical I&T FlowTypical Electrical I&T Flow

HardwareDelivered

Review &Inspection

HardwareFormally

Delievered toI&T

EICIT IVT

ATLong Form

Test CPT

Has the HDWbeen modified

ordissasembled?

Has the HDWbeen

removed butnot

modified?

Safe to Mate

YES

YES

Electrical Interface Continuity and Isolation Test (EICIT)

Interface Verification Test (IVT)

Aliveness Test (AT)

Safe To Mate (STM) (only as required)

Limited Performance Test (LPT)

Comprehensive Performance Tests (CPT)


I&T Test Documentation Summary I&T Test Documentation Summary

Test Procedure– Document which details the prerequisites, test configuration,

requirements and steps to demonstrate a set of requirements

WOA– A document which details in incremental steps an operation to be

completed or references a Test Procedure

Test Summary Report– A memo which documents the completion of a test, detailing any

anomalies

Final Test Report– A formal document which details the results of the test, details the

analysis of the data collected during the test, details the status of the procedure, details the rationale for requirements being satisfied, and publishes for the record the complete as run test procedure and data


Test ProceduresTest Procedures

The I&T test procedures will be prepared in accordance with the approved I&T Test Plan

The test procedures are developed by the I&T Engineering Group and submitted to the project for review and approval. Once approved all procedures will be under CM control. The basic I&T test procedures that will be developed for each test article are as follows

– Electrical Interface Continuity and Isolation Test (EICIT)

– Interface Verification Test (IVT)

– Aliveness Test (AT)

– Safe To Mate (STM) (only as required)

– Limited Performance Test (LPT)

– Comprehensive Performance Tests (CPT)


Functional TestsFunctional Tests

Aliveness Test (AT)– The AT is a short test in which the test article(s) is powered on for

health and status checks. Telemetry is then verified to be within acceptable ranges

Limited Performance Tests (LPT) – A demonstration that the primary hardware and software meet their

performance requirements within allowable tolerances. The test shall demonstrate operation of primary circuitry and satisfactory performance in the primary operational mode

Comprehensive Performance Tests (CPT) – A detailed demonstration that the hardware and software meet their

performance requirements within allowable tolerances. The test shall demonstrate operation of all redundant circuitry and satisfactory performance in all operational modes


Verification TestConfiguration Control

Verification TestConfiguration Control

Configuration control shall be maintained for each test conducted

At a minimum the following data shall be captured

– Revision level of all EGSE software and databases

– Revision level of all FSW

– Revision level / serial no. of EGSE hardware

– Revision level of Flight Hardware System/Subsystem components


Verification PlansVerification Plan and Envr. Test Spec

Verification PlansVerification Plan and Envr. Test Spec

THEMIS Verification Plan and Environmental Test Specification Document Number SAI-SPEC-1164

Objectives of the Verification Program

– Provide assurance that specified mission objectives are met– Provide assurance that hardware will meet specific functional / performance,

interface and safety requirements– Provide confidence that the probes will survive the environments imposed during the

launch and mission sequence– Determine operating and performance characteristics from simulated mission

environments

Verification Planning of the Instruments – Documented in the THEMIS Instrument Payload Verification Plan and Environmental

Test Specification Document No. THM-SYS-005 Written by UCB


Verification PlansSummary of Required Tests

Verification PlansSummary of Required Tests

THEMIS Verification Plan and Environmental Test Specification Document Number SAI-SPEC-1164

Tests are conducted at the Component Level, Subsystem Level, Integrated Probe System Level, and Integrated Probe Carrier Level

Summary of Tests and Analysis for the applicable Components / Systems include

– Comprehensive Performance Test (CPT)– Functional / Performance Test– Electromagnetic Compatibility Test– Mission Simulation Test– Thermal Balance Test– Thermal Vacuum Test– Alignment Demonstration– Sine Sweep Vibration Test– Separation Shock Test– Magnetic Properties Demonstration – Mass Properties Measurement– Acoustic Test– Radiation Susceptibility Analysis– Pressure Profile Verification Analysis


ENVIRONMENTAL TEST USING GSFC

ENVIRONMENTAL TEST USING GSFC

The GSFC facilities have been selected as the baseline approach to be used for environmental testing. The environmental test facilities will consist of

Magnetics EMC/ EMI Mass Properties, Weight, Center-of-Gravity (C.G.), Moment-of-

Inertia (MOI) Vibration Thermal Vacuum / Thermal Balance (TV/TB) RF Compatibility Acoustics

GSFC Facilities within 7 miles & Swales staff has worked with GSFC team for many years


Magnetics TestingMagnetics Testing

Component testing previously identified and evaluated by UCLA

Probe level self compatibility with onboard FGM and SCM augmented by external magnetometer GSE in a quiet lab here at Swales baseline

Test program designed to verify magnetics requirements specification and guidelines document issued by UCB

– Draft document under UCB review

High fidelity testing at GSFC Magnetics test facility base lined for first probe with the possibility of running two probe for signature comparison

– Visit to the mag test site facility was very informative and generated the possibility of additional test configurations and EGSE needed

– The implementation and impacts of adding compensations magnets to be discussed with Swales mechanical


ELECTROMAGNETIC TESTINGELECTROMAGNETIC TESTING

The THEMIS Satellite will be tested for EMC/EMI compatibility in the EMC facility at GSFC Building 7

A self compatibility functional test matrix will be used to exercise each electronic box or function in a noise generation mode while all others are setup in their quiet modes

The objective is to determine if any box or component is sensitive to external RF or electromagnetic emissions, either conducted or radiated

Another objective is to plot an electromagnetic signature of the satellite in its various operating modes

These RF sources will be run based on requirements given in the MIL-STD-461C/462C and will be modified to test any elevated RF emissions (above the levels in the MIL-STD) to simulate transmitters at the launch site


Spin Balancing of ProbesSpin Balancing of Probes

Miller table at GSFC will be used to test and iterate to final static and dynamic balance point

UCB has been tasked to make magnetometer booms self balancing when deployed

Swales evaluating the possibility to obtain spin balance of booms both in stowed and deployed configurations prior boom integration onto probe

Masses/washers made of tungsten will be used

Mass properties for the probe (fueled) and stacked PCA shall be performed at AstroTech


VibrationVibration

Vibration and shock testing shall be perform at GSFC test facilities

Probes shall be secured to the table via a payload attachment flange

EGSE and racks to be located Upstairs

The tests shall be conducted with the probe “ON”

Probe #1 to be tested to protoflight durations

Shock testing to be conducted via separation firing of the clamp band

Post “Pop and Catch” of the booms was a review question raised during preliminary conformation meetings


Separation System Acceptance Testing

Separation System Acceptance Testing

Single firing functional test (Probe 1 twice)

– Performed at Separation System Assembly level

Single firing functional test (performed after delivery to Probes)

– Performed after each flight Probe vibration


Thermal Vacuum TestingThermal Vacuum Testing

Probe #1 to be tested alone

Evaluate the ability to test two Probes in the same chamber– Thermal balance / stability with having two probes– Number of environments to be supported– Cold plate / TCUs needed to support environment– Thermal test fixture design

Hot biased thermal design depends on solar heat absorbed on top deck VDG. The hot case thermal balance needs to be conducted using a solar simulator to create the hot top deck boundary condition. Using a heater controlled elevated deck temperature does not validate this design condition

Multiple thermal balance cases need to be run to develop correlated thermal model – at least 6 cases for Probe #1

Thermal balance case for Probes #2-5 to be reduced with in correlated results of Probe #1

Thermocouple instrumentation to be removed after TV test… – This implies that solar arrays will need to be removed prior to test and after test for removal

Hot / Cold case performance with CTV to be evaluated so as not to impact test durations


RF COMPATIBILITYRF COMPATIBILITY

The RF Compatibility Test Van (CTV) will be used at GSFC to test the RF compatibility of THEMIS RF subsystems with the Ground Network (GN) and the Space Network (SN)/Tracking and Data Relay Satellite System (TDRSS)

The CTV test will consist of testing the S-Band transponder at different data rates and different data coding modes for telemetry downlink, at 1 kbps for command uplink, and for ranging compatibility. Additional S-Band transponder testing will be done at multiple data rates with the TDRSS

UCB mission Ops has the lead to coordinate this testing

Its expected to support this test during probe thermal vacuum testing


ScheduleSchedule


Manpower Planthru Phase #1


Note: There is approximately and additional 11 subsystem staff that are not included in the I&T Team head count. In addition UCB Instrument Team & MOC staff support I&T

An additional EGSE Rack has been added based on re-evaluation program goals & schedule

ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Integration and Test...

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Transcript of ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Integration and Test...