TRIO-CINEMA 1 UCB, 2/08/2010 Integration and Test Program Dave Curtis UCB/SSL Space Sciences Laboratory University of California, Berkeley

TRIO-CINEMA 2 UCB, 2/08/2010 Overview This presentation describes early thinking on the CINEMA I&T planning CINEMA is a highly cost and time constrained mission, which may not be able to achieve all of the testing indicated Testing will be prioritized on the basis of the most value added within the existing constraints

TRIO-CINEMA 3 UCB, 2/08/2010 Documentation Test Plan –Organize how we will verify each requirement –Verify as early as possible, and also at as high a level of assembly as possible Test Procedures –Describe details of each test Test Reports –Describe results of testing Problem/Failure Reports –Document each problem and how its root cause was determined –Keep track of any non-repeatable problems Verification Report –Requirements document annotated with links to test reports Some documentation may be at the log book level of formality –Preferably an electronic log book –As complete a set of documentation as consistent with the time available

TRIO-CINEMA 4 UCB, 2/08/2010 Prototype Testing Early testing of prototype units reduces risks of surprises later Subsystem and System level tests The ability to mix Prototype and Flight units reduces schedule risk Prototype system serves as a software development test bed Prototype system serves as a test bed for development of operational sequences and diagnosis of post-launch anomalies Given funding and schedule constraints, we will probably not have a full set of prototypes, and what prototypes we have may not have full functionality or form factor –So far we have two prototype processor board (development systems), with EPS and battery on order and S-band transmitter and UHF radio to be ordered soon. –We have a prototype STEIN in test, but with STEREO prototype electronics which are not compatible with CINEMA –IC has a prototype MAGIC in work

TRIO-CINEMA 5 UCB, 2/08/2010 Subsystem Level Tests Prior to integration of the payload each subsystem shall be thoroughly tested Verify that the subsystem meets its functional requirements Verify that all subsystem problem/failures have been closed Little or no environmental testing planned at the subsystem level – deferred to System level Ensure that verification which cannot be repeated at the system level is thoroughly tested at the subsystem level Plan in advance for what Ground Support Equipment will be needed to simulate the rest of the payload during subsystem testing “Pre-ship” review to determine if subsystem is ready to integrate or needs more testing Following list of tests is notional. –Test Plan to list complete plan

TRIO-CINEMA 6 UCB, 2/08/2010 General Subsystem Tests Functional tests Calibrations Voltage Margin Tests Mass, Power measurements Early fit-check Magnetics screening Cleaning (just prior to integration)

TRIO-CINEMA 7 UCB, 2/08/2010 STEIN Testing Sensor Cal (Vacuum) –Light sensitivity, collimator –Noise threshold, FWHM –Bias optimization –Electron, Ion energy/angle response vs HV setting –Electron scattering/suppression (center channels) –Ion dead layer measurement –Electron/Ion energy/angle response with attenuator in Sensor Cal (air) –Radiation source testing (baseline for system level tests) Actuator Mechanism Testing –Voltage margin –Thermal/vacuum testing (verify how fast actuator relaxes) HV Cal –Stability over temperature –Calibrate output vs settings

TRIO-CINEMA 8 UCB, 2/08/2010 MAGIC Testing Sensor Calibrations (IC) –Noise level in different modes –Offsets vs temperature –Gain vs temperature –AC response –Sensor cross-talk –Power supply conducted susceptibility (power supply rejection ratio) Boom deployment testing (SSL) –Hot/cold (subsystem or system level test?) –Variation in final MAG orientation –Actuator Voltage margin –Harness continuity and isolation after each deploy –Magnetics

TRIO-CINEMA 9 UCB, 2/08/2010 Telecom Testing May need C&DH and Instrument Interface Board for some of these tests Antenna Characterization (polarization, impedance, VSWR, etc) Berkeley Ground Station compatibility tests –Link encoding –Data Rates –Polarization Antenna Pattern and Link Margin Testing –BGS to Telecom system at a distance –Vary antenna orientation –Transmitter and Transceiver –Telemetry and Command Transmitter/Receiver Interference test Thermal stability (or system level) Conducted Susceptibility

TRIO-CINEMA 10 UCB, 2/08/2010 Attitude Control Testing Software Simulation of Performance –Include instrument noise, etc. ACS software in C&DH –Verify performance using sensor simulators Sun Sensor characterization –Noise, sensitivity –Earthlight, Moonlight suppression –Angular response, calibration Torque Coil characterization –Measure impedance –Calibrate field generated vs PWM setting –Calibrate field vs bus voltage Solar Arrays –Characterize solar array monitors vs solar array aspect to the Sun

TRIO-CINEMA 11 UCB, 2/08/2010 Power System Testing Solar Arrays –Power generation (sunlight test?) –Magnetics (back-bias test or sunlight test) Battery –Capacity test –Note special handling requirements (state of charge) –Magnetics (vs charge/discharge rate) Power System –Verify battery charging function from solar arrays and umbilical Charge Rate Trickle charge Low state of charge load sheding –Verify current delivery capability with dummy loads Simulate resistance and capacitance of load, transient loads Measure output impedance on power busses (voltage vs load) Check overcurrent protection Solar Array driven, Battery driven, and both –Verify noise on power bus Vs. charging mode

TRIO-CINEMA 12 UCB, 2/08/2010 Avionics Testing Processor board functional testing Instrument Interface Board –FPGA simulation testing –Power converter and switching functional tests Dummy loads, noise tests –Interface testing Processor, STEIN, MAGIC, ACS sensors/torque coils, Transmitter Flight Software –Flight Software Acceptance Test (in addition to ACS testing) On development system with subsystem simulators or prototypes Verify each functional requirement Long duration tests to look for rare interactions

TRIO-CINEMA 13 UCB, 2/08/2010 System Tests (1) System-level Functionality –Verify functional requirements at system level –Phasing tests to verify ACS sensors functionality and polarity –Torque coil / Magnetometer calibration (boom deployed) Verify sufficient field generated to determine OB MAG orientation –Perform ‘baseline’ functional test suite Repeat after environments –Autonomy testing Return to safe mode –Need a Comprehensive Performance Test we can run before/after environmental tests to verify no change in functionality/performance Self Compatibility, Noise (RE, CE) –RF uplink interference –STEIN detector noise –MAG AC and DC fields Power consumption vs mode –Safe –ACS (duty cycle) –Telecom passes –Science Ground system compatibility (BGS) –Direct link test –Transceiver uplink/downlink and Transmitter downlink

TRIO-CINEMA 14 UCB, 2/08/2010 System Tests (2) P-POD compatibility Thermal Vacuum Test –Verify functionality hot and cold (repeat functional test & compare to baseline) –Cycle to verify workmanship –Thermal Balance test to verify thermal model –Deployment hot/cold (or at subsystem level?) –System level STEIN test (Calibration chamber?) Vibration –Post-vibe functional (compare to baseline), deployment Magnetics –AC (currents), DC (materials) –Sunlight test? Mission simulation test –Operate with limited contacts using scheduled passes –Test transitions between modes –Long duration tests (as time permits) Launch Pad –Battery charge maintenance –Pre-launch functional test (constrained by launch environments) –Possible late software delivery/test

TRIO-CINEMA 15 UCB, 2/08/2010 Facilities Thermal Vac –Feed-through harnessing –Vacuum-compatible stimulus –Extra thermal monitoring Vibration –Vibration fixture (P-pod simulator) –Accelerometers BGS –Compatibility tests Magnetics –Sense magnetometer –Measurements in Earth’s field –Unit Under Test manipulation –Power on/off cycling –Solar array current Solar Array Test –Sunlight? Contamination Control –Most hardware cleaned at integration (some, like STEIN, need to be clean before that) –class 100K; smocks/booties/hair nets/gloves –Clean room or bagged after that –STEIN purge? ESD protection –All handling of flight hardware containing electronics should utilize ESD protection