SAMPLE CANISTER CAPTURE MECHANISM FOR MSR: CONCEPT DESIGN …

ASTRA 2015, Noordwijk, The Netherlands, 11 May 2015

SAMPLE CANISTER CAPTURE MECHANISM FOR MSR: CONCEPT DESIGN AND TESTING RESULTS INCLUDING 0-G ENVIRONMENT

Authors: Riccardo Carta, Daniele Filippetto, Politecnico di Milano

Co-authors: Prof. Michèle Lavagna, Politecnico di Milano

Mr. Filippo Mailland, CGS S.p.A.

Dr Peter Falkner, ESA

Mr Jonan Larranaga, Aurora Technology B.V. for ESA

ASTRA 2015, ESTEC, The Netherlands, 11 May 2015

Presentation Outline 2

1. Introduction to SCCM study 2. SCCM breadboard Manufacturing, Assembly, Integration and Test (MAIT)

I. Manufacturing Assembly and Integration II. Test Plan and test facility III. Test results

a. Functional Tests b. Thermal Vacuum Tests (TVT) c. Vibration Test (VT)

3. SCCM Parabolic Flight experiment I. Introduction II. Experiment Design III. Test Plan IV. Results

4. Conclusions


Mars Sample Return (MSR) architecture 3


Study Overview 4

Objectives: • The Sample Canister Capture Mechanism (SCCM) is a feasibility Study to

develop a technology concepts for a future Mars Sample Return (MSR) mission

• The SCCM will be in charge of capturing and securing an Orbiting Sample (OS) which accommodates the Martian soil samples

Main goals of the Study: Build the Elegant Breadboard Model (EBM) Functional/ Environmental tests for TRL-4 Parabolic flight campaign for TRL-6


Study Critical Requirements

5

• 6 kg spherical OS: 230 mm diameter,

• Incoming relative velocity: 5 - 15 cm/s

• Angular misalignment: ±5°

• Radial offset: 10 cm

• Whole capture procedure within 90s

• Retention within 7 s

• Maximum stowed envelope 800 x 800 x 500 mm

• First natural frequency higher than 100 Hz

• Single point failure tolerance


Elegant Breadboard Model Design

EBM assembly

Funnel

Arm

Baseplate Support Tower

Motor End Rotation Sensors Shims

CAM Hinge

6


High Level Test Plan

Test Plan Functional Tests

Environmental Tests Thermal Vacuum

Tests

Mechanical Tests (Vibration)

7


Ground Test Objectives

Type of Test

Test Article Test Objective Test facility

Functional Tests EBM

Arm actuation functionalities

Polimi (Including 0g GSE &

OS Mockup)

Hold Down Release Mechanism functionality

OS detection

Actuation chain performances

Motorization Factors assessment

Motor Maximum Torque Estimation

Thermal-Vacuum Tests

EBM (excl. OS Mockup)

EBM functionality at expected operative thermal conditions

Serms srl

EBM survival at the expected non operative thermal conditions

Vibration test

EBM (excl. OS Mockup)

EBM withstanding of expected vibration levels Serms srl

8


Functional Test: Test Facility

GSE @ PoliMi-DAST

Criticalities: • OS swinging

motion • Funnel-OS

position accuracy

Requirement drivers: • Cost • Reusability • Functionality

Motorization factor EBM configuration

9


Functional test 10

Test Article Test Objective Test Results

EBM

Deployment Successful Duration: 17,70 – 17,84 s

Maximum torque Successful Measured values: 10,85 – 10,94 Nm

Motorization factors Successful Measured values: 60,28 – 60,68

Closure and reset Successful Duration: 17,61 – 18,15 s

Retention

Successful Duration: 6,60 – 7,60 s Sensor failure simulation of test case 25/26 results in test failure

Functional tests results


Environmental Test: Thermal-vacuum, cycles details

Temperature Values Minimum Non-Operational/Survival Temperature 248 K

Minimum Operational Temperature 252 K

Maximum Operational Temperature 322 K

Maximum Non-Operational/Survival Temperature 335 K

11


Environmental Test: Thermal-vacuum, test facility

Thermal-vacuum chamber

Thermocouples location

12


Funnel and Motor case temperature profile

Thermal-vacuum tests

-50.00-40.00-30.00-20.00-10.00

0.0010.0020.0030.0040.0050.0060.0070.0080.00

0 2000 4000 6000 8000 10000

Tem

pera

ture

(°C

)

Time (min)

FunnelMotor

13


Environmental Test: Vibration, Test Plan Details

# Run Test type Initial Conditions Characteristics

1 Resonance search test

SCCM EBM in stowed configuration, not operative

Band 10 – 2000 Hz Level: 0.2 g (Peak)

2 Sine vibration test X and Y axes


Frequency 5 – 21 Hz ±5.7 mm Frequency 21 – 60 Hz 10 g (*) Frequency 60 – 100 Hz 6 g

2 Sine vibration test Z-axis


Frequency 5 – 21 Hz ±11 mm Frequency 21 – 60 Hz 20 g Frequency 60 – 100 Hz 6 g

3 Random vibration test X and Y axes

SCCM EBM in stowed configuration, not operative 9,03 gRMS

3 Random vibration test Z-axis

SCCM EBM in stowed configuration, not operative 14,00 gRMS

(*) Limit imposed by test facility equipment

14


Environmental Test: Vibration, test facility

Slip table

Shaker + head expander

Sensor Location MP15 Baseplate (Tower) MP17 Baseplate (Funnel) MP20 Arm tip MP21 Funnel top MP23 Arm shaft MP31 Lug top MP42 HDRM/arm MP65 Motor flange

15


Vibration tests

Mode ID FEM analysis

[Hz] Before vibration test [Hz] (Reduction %)

After vibration test [Hz] (Reduction %)

1 123.75 107 (13.5%) 107 (13.5%)

2 134.24 117 (12.8%) 117 (12.8%)

3 141.56 125 (11.7%) 125 (11.7%)

4 150.17 138 (8.1%) 136 (9.4%)

5 151.22 145 (4.1%) 144 (4.8%)

6 223.21 200 (10.4%) 201 (10.0%)

Resonance search results

• 1 natural frequency higher than 100 Hz as required • FEM increases stiffness Reduction percentage <15%

16


Parabolic Flight

ECSS standards for TRL-6 Testing full scale in relevant environment • Microgravity operations • Relative dynamics funnel-OS • OS capture operations • Impact forces

17

• Aircraft manoeuvre allowing simulate weightlessness

• About 20 s microgravity each parabola

• Elliptic path relative to the centre of the Earth


Experiment Design

Experiment components: • Elegant Breadboard Model • Orbiting Sample (OS) • OS Launcher • Trap • Safety brake • Frame Structure • Protective Layer • Acquisition and Control System

18


Parabolic Flight Experiment Design: OS launcher

Fully manual OS launcher: • Initial OS velocity, from 0.1 to 0.2 m/s; • Easy 5 degree predefined attitude misalignment (included into attitude correction); • Easy 10 cm predefined radial misalignment (included into initial offset correction; • OS retention under an acceleration of 2g in all directions; • Simple reset; • Quick launch.

19


Parabolic Flight Test Objectives

Type of Test Test Article Test Objective Test facility

Parabolic Flight EBM

Demonstrate of arm actuation functionalities in microgravity environment

Novespace

Demonstrate motor capability of withstanding OS impacts in capture configuration Demonstrate of OS detection in microgravity environment Demonstrate of retention operation in microgravity environment Demonstrate transfer capability in microgravity environment Demonstrate funnel capability of withstanding OS impacts

Raise TRL to 6

20


Parabolic Flight Test Plan

First Day •The first set: verify the arm functioning (opening, closure and holding); •The second set: verify retention maintaining with the OS inside funnel; •The third set: verify the transfer operation; •The fourth and fifth sets: verify OS launcher operations and OS trajectory; •The sixth set: verify OS launch, sensor triggering and arm closure.

Second and Third days • Complete test execution.

Set OS initial angle [deg]

OS initial offset [cm]

1 0 0 2 0 0 3 0 10 4 5 0 5 5 10 6 5 10

21


Parabolic Flight Test Results

Test Day Test Case

OS Initial Condition Success [%]

Success with triggered

sensors [%]

Success with OS inside funnel for more than 4s [%]

Speed [cm/s]

Offset [cm]

Angle [deg]

1

INIT - - - 100 100 100 CAPT - - - 100 100 100 TRA - - - 100 100 100 LNC 15 0 0 100 100 100 RET 15 0 0 100* 100 100

2 C-15

15 0 0 83 (5/6) 100 (5/5) 100 (5/5) 15 10 0 50 (2/4) 100 (2/2) 100 (2/2) 15 0 5 100 (4/4) 100 (4/4) 100 (4/4) 15 10 5 75 (3/4) 100 (3/3) 100 (3/3)

TOT - - - 78 (14/18) 100 (14/14) 100 (14/14)

3 C-20

20 0 0 80 (8/10) 80 (8/10) 100 (8/8) 20 10 0 50 (2/4) 50 (2/4) 100 (2/2) 20 0 5 60 (3/5) 75 (3/4) 100 (4/4) 20 10 5 78 (7/9) 100 (7/7) 100 (7/7)

TOT - - - 71 (20/28) 83 (20/24) 100 (20/20)

• Transfer completed within one parabola • No pinching during transfer • Launch affected by microgravity perturbations • Successful execution of complete test within one parabola (~22 s) • Failed test due to perturbations • Occasional Arm/OS impacts before retention

Retention successful even when the OS was manually delivered inside the funnel to react to perturbations

22



DAY 2 Perturbations effects analysis

23

• Aircraft acceleration between OS launch and first impact with funnel • Release time measured through the video analysis • OS velocity: - acceleration measurements integrations - speed provided from launcher • OS trajectory: - velocity integration.

• Successful test • Failed test OS-funnel impact area




24

• OS-funnel edge impact at entering conditions • Upward perturbation acceleration at launch (green vertical line)



OS impacts • Calculated from OS acceleration measurements

Force [N] Duration [ms]

Day 2 Day 3 Day 2 Day 3 Mean 257.0 327.0 15.6 16.1 Maximum 497.6 734.0 24 26.0 Minimum 154.0 139.3 10 6.0

Force [N]

Day 2 Day 3 Mean 216.5 218.9 Maximum 430.7 368.1 Minimum 71.8 106.2

OS-Funnel • Forces higher than expected (design

phase) 240N @15 cm/s Higher impact velocity Higher forces in Day 3 tests (higher

OS speed) • Impact duration as expected (design

phase) 12-20 ms • No visible damage to protective layer

Need for less stiff material or no protective layer at all

OS-Arm • Short Impact duration (~20 ms) • Unknown impact distance from

actuation chain Not directly comparable with

maximum motor torque • No motor synchronization loss

recorded during impacts

25



Microgravity phase example OS-Funnel impacts OS-Arm impact

26



Microgravity Perturbations

Smooth parabola Low perturbations (first half) Successful test

Disturbed parabola High perturbations: • 0,05g peak Z acceleration; • 0,02g mean Y acceleration during

launch (first 5 seconds) Failed test

27


Conclusion

• On-ground test campaign successfully completed Breadboard design effective both at system and component level in laboratory

environment EBM able of withstanding mechanical and thermal loads induced during all

mission phases Breadboard performances not affected from environmental loads

• TRL-4 achieved

• Parabolic flight test campaign successfully completed EBM full functionality in relevant 0-g environment Test cases doubled with respect to test plan Strong perturbations effect on OS during free floating phase resulting in some

failed tests • OS trajectory not rectilinear • OS speed higher than requirements

Testing condition more demanding with respect to design phase estimation Design concept robust and reliable

• Arm and funnel geometry • Arm closure speed • Detection sensors position

Possible improvement: implementation of automatic release mechanism triggered by acceleration sensor

• TRL-6 achieved

28


Complete test example 29


Thank you for the attention Questions?


Backup



Test ID Result Remarks

1 – INIT

1 N/A Not available for tests 2 OK Only deployment 3 OK Only closure 4 OK Only deployment 5 OK Only closure 6 OK Only deployment

2 – CAPT

1 OK 2 OK 3 OK 4 OK 5 OK

3 - TRA

1 OK First half of transfer 2 OK Transfer completion 3 OK 4 OK 5 OK


4 – LNC

1 ENTER 2 ENTER 3 ENTER 4 ENTER 5 ENTER

5 – LNC

1 ENTER 10cm offset 2 ENTER 10cm offset 3 ENTER 4 ENTER 5 ENTER

6 - RET

1 SUCCESS No arm/OS impacts 2 SUCCESS Arm/OS impacts 3 FAIL 10cm offset 4 FAIL 10cm offset

5 SUCCESS 10cm offset Arm/OS impact

DAY 1

No pinching during transfer OS Launch affected by microgravity perturbations

32




1 – 1 N/A Not available for tests INIT 2 OK RET 3 SUCCESS Arm/OS impacts TRA 4 OK RET 5 SUCCESS Arm/OS impacts TRA 6 OK

2 – C-15

1 SUCCESS Arm/OS impacts 2 OK Transfer 3 FAIL 4 SUCCESS Arm/OS impacts 5 SUCCESS

3 – C-15

1 FAIL

2 SUCCESS Switch to retention Arm/OS impacts

3 OK Transfer 4 SUCCESS Arm/OS Pinching 5 FAIL


4 – C-15

1 SUCCESS 2 SUCCESS 3 SUCCESS 4 FAIL 5 SUCCESS

5 – C-15

1 MISSED 2 SUCCESS Switch to retention 3 OK Transfer

4 SUCCESS Switch to retention Arm/OS impacts

5 SUCCESS Arm/OS impacts

DAY 2 attempting execution of complete test within one parabola

• Successful execution of complete test within one parabola

• Failed test due to perturbations

33




1 – 1 N/A Not available for tests INIT 2 SUCCESS C-20 3 FAIL C-20 4 SUCCESS C-20 5 SUCCESS C-20 6 SUCCESS Arm/OS impacts

2 – C-20

1 SUCCESS 2 SUCCESS 3 SUCCESS 4 SUCCESS Arm/OS impacts 5 FAIL

3 – C-20

1 SUCCESS 0 offset Arm/OS impacts

2 SUCCESS Arm/OS impacts 3 FAIL 4 SUCCESS Arm/OS impacts 5 FAIL


4 – C-20

1 SUCCESS 2 FAIL 3 FAIL 4 SUCCESS 5 SUCCESS Arm/OS impacts

5 – C-20

1 SUCCESS 2 FAIL 3 SUCCESS 4 FAIL 5 SUCCESS Arm/OS impacts

6 – C-20

1 SUCCESS

2 SUCCESS 3 SUCCESS Arm/OS impacts 4 SUCCESS Arm/OS impacts

5 N/A N/A

DAY 3 OS speed @ 20cm/s (not 10cm/s) because of perturbations

• Failed test due to perturbations

34



Retention test

35


Complete test example

Successful test

36


Complete test example

Failed test

37




38

• Aircraft acceleration between OS launch and first impact with funnel • Release time measured through the video analysis • OS velocity: - acceleration measurements integrations - speed provided from launcher • OS trajectory: - velocity integration.

• Successful test • Failed test OS-funnel impact area




39

• OS entered funnel close to nominal conditions • Perturbation forced OS to escape funnel before arm reached retention configuration



Video fps

Piston stroke [cm]

Measured speed [cm/s]

Mode [cm/s]

Expected speed [cm/s]

Test Day 1 30 3.4 17 17 15

Test Day 2 30 3.4 16 17 15

Test Day 3 60 4.4 21 22 20

OS speed • Number of frames between start and stop of OS support plate • Speeds lower than mode value due to launcher components friction

40


Vibration tests

Sine test Y-axis

First resonance frequency amplification of arm tip response

EBM rigid behaviour below 100HZ

41


Vibration tests

Location X [g] Y [g] Z [g]

test FEM test FEM test FEM

Arm tip 85.87 68.75 104.79 165.88 131.48 134.32

Funnel top 58.11 59.27 116.04 97.33 81.33 46.23

Arm shaft 81.84 110.43 63.42 63.31 130.62 153.59

Lug top 64.89 107.29 115.20 75.32 57.54 70.77

HDRM/arm 72.87 106.26 64.44 81.89 95.58 100.24

Motor flange 45.66 99.20 76.62 69.63 48.03 72.98

Random tests - 3σ rms response

42

SAMPLE CANISTER CAPTURE MECHANISM FOR MSR: CONCEPT DESIGN …

Documents

Transcript of SAMPLE CANISTER CAPTURE MECHANISM FOR MSR: CONCEPT DESIGN …