Transcript Section 6.0 - Verification Test Plans

GLAST LAT Project
Gamma-ray Large
Area Space
Telescope
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
GLAST Large Area Telescope:
Mechanical Systems Peer Review
March 27, 2003
Section 6.0 – Subsystem
Verification Test Plans
Leonard Lee
SLAC
Systems Engineer
[email protected]
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Topics
Agenda
• Overview
• Verification Test Levels
• Mechanical Subsystem Verification Matrix
• Verification Items
• Verification Test Flow
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Overview
The intent of the Mechanical Subsystem verification plan is to
ensure that the component, assembly and subsystem
hardware:
- Verify workmanship and performance of hardware
per Level III and IV subsystem specification
- Provides traceability back to requirements in the
Level III and IV subsystem specifications
- Satisfies LAT Performance Specification (LAT-SS-00010)
- Compatible with other LAT subsystem’s interfaces
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Verification Test Levels
• Mechanical Systems hardware verified with tests performed at
one or more of the following test levels:
– Qualification
– Proto-Flight
– Flight
• Hardware test levels driven by
– Design Maturity of Hardware
– Hardware Flight History
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Test Levels/Durations Table
Test
Qual
Protoflight
Acceptance
Structural Loads1
T est Level
1.25 x Limit Load
1.25 x Limit Load
1.0 x Limit Load
1.4 x Limit Load
1.4 x Limit Load
Test
Acceptance
Actual Device
Simulated
2 actuations
1.4 x Limit Level
2 x Each Axis
2 actuations
1.4 x Limit Level
1 x Each Axis
1 actuation
Limit Level
1 x Each Axis
Max/Min Predict
±10° C
Max/Min Predict
±10° C
Max/Min Predict
±10° C
Max/Min Predict
±10° C
<1X10 -5 T orr
<1X10 -5 T orr
T hermal Vacuum
T emperature4
Acoustics
Level2
Limit Level + 3 dB Limit Level + 3 dB Limit Level
Duration
2 minutes
1 minutes
Normal Operation
1 minutes
Survival
Random Vibration
Level2
Vacuum
Limit Level + 3 dB Limit Level + 3 dB Limit Level
Duration
2 minutes/axis
1 minutes/axis
1 minutes/axis
3
Level
1.25 x Limit Level 1.25 x Limit Level Limit Level
Duration
2 oct/min
Pressure Profile
Level
As Specified For
Mission
4 oct/min
4 oct/min
# of Cycles
Rate
Normal Operation
# of Cycles
Same
Acceleration (Centrifuge)
1.25 x Limit Level 1.25 x Limit Level Limit Level
1 minute
30 Seconds
30 Seconds
Max/Min Predict
<1X10 -5 T orr
4
4
<20°C/Hour
<20°C/Hour
<20°C/Hour
Max/Min Predict
±15° C Predict
Max/Min
±15° C
Max/Min Predict
±15° C Predict
Max/Min
±15° C
Max/Min Predict
±5° C
Max/Min
Predict
±5° C
T emperature4
Survival
Same
8
Max/Min Predict
T hermal Cycling
Rate
Level
Duration
Protoflight
Mechanical Shock
Analysis
1.4 x Limit Load
(show positive margins for all
ultimate failure modes)
Sine Vibration
Qual
Radiation
EMC & Magnetics
12
<20°C/Hour
As Specified For
Mission
As Specified For
Mission
6
6
<20°C/Hour
<20°C/Hour
Same
Same
Same
Same
Shaded areas do not apply.
1- If qualified by analysis only, positive margins must be shown for load factors of 2.0 on yield and 2.6 on ultimate. Composite materials cannot be qualified by analysis
alone.
Note: Test and Analysis levels for composite strictures, including metal matrix, requires acceptance level testing to 1.25 x Limit Level.
2- As a minimum, the test level shall be equal to or greater than the workmanship level.
3- The sweep direction should be evaluated and chosen to minimize the risk of damage to the hardware. If the sine sweep is used to satisfy the loads or other requirements,
rather than to simulate an oscillatory mission environment, a faster sweep rate may be considered, e.g., 6-8 oct/min to reduce the potential for over stress.
4- Normal operating temperature for the LAT is –10° C to 25° C. Survival temperature is –20° C to 40° C.
5-The number of thermal cycles for spares is 8.
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Mechanical Subsystem Verification Matrix
1
1
P
P
TQ
P
P
4
TQ
TA
TA
P
TQ
TQ
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
I
I
TA
TA
Non-Condensible Gas(NCG)
Comments
Validates HP bonding process
EM testing of CAL-Grid joint
Validates Grid fab processes
Qual's HP thermal joint design
Proofs tapped holes
TA TA HP's qual'd by similarity
TA TA HP's qual'd by similarity
TQ
T
Heat Transport
Thermal Cycle
1
Thermal Balance
2
1
Thermal Vacuum
Thermal Control System
Controller Unit
Radiator Pair w/ TCS
Functional
C PF Q
S PF Q
ESD (Grounding)
1
EMI/EMC
12
2
Interface Verif
Radiator Assemblies
Radiator VC Heat Pipes
Radiator Ass'y (individual)
M
I
I
Alignment
C PF A
A PF Q
T
T
T
Fit / Dim Chk
1
6
1
2
1
Electrical Environmental
Mass, C.G.
X-LAT Thermal Plate/Mid-Plate
X-LAT Heat Pipe EM
X-LAT Heat Pipes
X-LAT Thermal Plate Qual Unit
X-LAT Thermal Plate
Mid-Plate
Pressure
Q
A
Q
A
Q
Mech shock
E
F
PF
F
PF
Acoustic
A
C
A
A
A
Random Vibe
1
3
1
3
1
5
12
1
1
Sine Sweep
Grid Assembly
Grid Top Flange Heat Pipe Bond.
CAL-Grid Joint Shear Test
Grid Mock-up -1 x 4
Heat Pipe Thermal Interface Test
Grid Structure
Top Flange Heat Pipe
Down Spout Heat Pipe
Grid Box Base Assembly
Grid Box Assembly
Static Load
Q
Q
Q
Q
Q
A
A
Q
Q
Proof Test
E
E
E
E
PF
F
F
PF
PF
Component
Flight Spares
Qualification Level
A
A
C
A
C
C
C
A
A
Quantity
Unit Type
Mechanical
Assembly Level
Hardware
TQ
Thermal cycle w/ STE heaters
TQ
TQ TQ
I
TA
TQ
TA
TA TA HP's qual'd by similarity
Qual's X-LAT thermally, struc
TA TA Gas test to be used in lieu of NCG
I
TQ
TQ TQ
TQ
TQ TQ
TQ TQ TQ
Part of SIU qual
LEGEND
Assembly Level
S – Subsystem
A- Assembly
C – Component
Unit Type
PF – Proto Flight
F – Flight
S – Spare
Document: LAT-PR-0XXXX
Q – Qual
E – Engineering Model
V – Verification Model
Verification Method
T – Test
TQ – Test, Qualification Level
A –Analysis
TA – Test, Acceptance Level
M – Measurement
P – Proof
I – Inspection
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Verification Items
• Mechanical Systems hardware to be verified consists of the
following assemblies and components:
– Heat Pipes*
– 4x4 Grid Structure
– X-LAT Thermal Plate/Mid-Plate*
– Grid Box Assembly
– Radiator Assemblies*
– Thermal Control System(TCS)*
* Addressed in Section 4 of this review
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
4 x 4 Grid Structure Verification
• Mass properties and c.g. verified
• Dimension Check verified
• Proof Test of inserts
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Grid Box Assembly Verification
Grid Box Assembly
Dimension Check
Grid Box Assembly
Mass Properties/C.G.
Grid Box Assembly
Alignment Check
Grid Box Assembly
Functional Test
Grid Box Assembly
Static Load Test
Grid Box Assembly
Functional Test
Grid Box Assembly
Thermal Cycle
Grid Box Assembly
Functional Test
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Mechanical Verification Tests
• Dimensional Check
• Mass Properties and C.G. verified
• Alignment verification per LAT Survey & Alignment Plan (LATMD-01586)
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Functional Test
• Grid Box Assembly to undergo functional verification
– Resistance check of heaters
– Isolation check of harnesses
– Continuity check of harnesses
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Static Load Test
•
•
Test Objectives
– Primary Objective: Verify static strength and stability of the Grid
Box Assembly under worst case Delta II-H vehicle loads of 1.25
times limit loads
• Achieve maximum stresses in grid box assembly
• Load subsystem interfaces to qualification design loads
– Secondary Objective: Verify the design analysis process by
comparing measured strains and deflections to predictions from
the finite element analysis model
Test Success Criteria
– Successful test completion is when all load cases have been
performed and it is verified that no yielding, buckling, de-bonding,
or fractures have been observed.
• A visual inspection is to be performed after each load case to
check the critical joints and bonded interfaces
• A review of all pertinent data during test including deflections
and strains to verify linearity
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Grid Box SLT Configuration
•
•
The SLT configuration consists of all primary structure grid box
components as described below
The SLT article will be grounded at the SC Mount Brackets with
correct degrees of freedom
Calorimeter
Plates -16X Flight-like
Grid - Flight
Radiator Mount
Brackets - 4X Flight
EMI Skirts - Flight
Down spout
HPs - 12X - Flight
Spacecraft Mount
Brackets - 4X - Flight
XLAT Plate - Flight
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
SLT Instrumentation (preliminary)
•
•
Strain Gauge Requirements
– Sensitivity range is between 0 and 3000 microstrains
– Strain gauge type LE (lead wires already attached)
– Approximately 100 locations will be specified in the test procedure
Displacement Gauge Requirements
– Approximately 25 locations will be specified in the test procedure
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
SLT Load Cases
•
•
Specific load cases and load application methods are in work
Load cases will test
– Max X + max Z loads applied to Grid
– Max Y + max Z loads applied to Grid
– Radiator Mount Bracket loads
– ACD insert loads
– TRK flexure insert loads
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Thermal Cycle Test
Thermal Cycle Grid Box Assembly to “Qualification” level
• 4 cycles to protoqual temperatures
• Thermal vacuum test meets MAR but thermal cycle may be
adequate(TBR)
– Verify Flight heater, thermistors and thermostats
• can be performed in ambient pressure
– Verify Downspout & Top Flange Heat Pipe bond integrity
(mechanical & thermal).
• Heat transport of heat pipes are verified at ambient
pressure at component level
• X-LAT plates thermal vacuum cycled at component level
• Thermal performance of X-LAT and Heat Pipes are verified
in Thermal Balance test
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Thermal Cycle Test Configuration
• Thermal chamber sized to accommodate Grid Box assembly
• Grid Box Assembly with test heaters (STE) and thermocouples
(STE)
Document: LAT-PR-0XXXX
Section 6.0 Subsystem Verif. Test Plan
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GLAST LAT Project
DOE/NASA Mechanical Systems Peer Review, March 27, 2003
Mechanical Systems
Verification Test Flow
Grid Structure
-Proof Load
-Mass Properties & C.G.
-Dimension Check
Radiator Mount
Bracket
X-LAT Plates
Grid Box
Base Assembly
Disassemble
Grid Box
Base Assembly
Grid Box
Base Assembly
-Static Load
-Thermal Cycle
-Mass Properties &
C.G.
-Dimension Check
-Alignment
-Functional
-Static Load Test
-Mass Properties & C.G.
-Dimension Check
-Thermal Vacuum Test
Grid Assembly
LAT Integration
X-LAT Plates
Mid-Plate
X-LAT Plates
-Static Load Test
-Mass Properties & C.G.
-Dimension Check
Radiator
-Sine Sweep
-Acoustic
-Mass Properties & C.G.
-Dimension Check
-Interface Verification
-EMI/EMC
-Functional
Document: LAT-PR-0XXXX
Assemble Radiator
pair test configuration
Radiators
LAT Level
Verification Tests
-Thermal Balance
-Mass Properties & C.G.
-Dimension Check
Section 6.0 Subsystem Verif. Test Plan
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