1. (EFW Systems Engineer) University of California, Berkeley
Integration and Test
Michael Ludlam
(EFW Systems Engineer)
Space Sciences Lab
University of California, Berkeley
Sept 30 – Oct
RBSP EFW ICDR

2. Integration and Test Outline
Requirements, Plan
Environmental Matrix
Test Flows
Calibrations, Deployments, Interface Tests
Environmental Tests
Alignments
Contamination
Facilities
Documentation
Operating Hours
Observatory-level Tests
Sept 30 – Oct
RBSP EFW ICDR

3. Requirements Verify Instrument Requirements per IRD (RBSP_EFW_SYS_001)
Meet/Verify Quality Requirements per (Matrix)
Meet/Verify Contamination Requirements per RBSP_EFW_PA_005
Verify Environmental Requirements (ERTRD) per
Verify EMC Requirements (EMECP) per
Verify Spacecraft Interface Requirements per ICD
Verify EMFISIS Interface Requirements per ICD
Verify Performance Requirements per IRD
Approach Described in RBSP EFW Verification, Validation, Test, and Calibration Plan RBSP_EFW_TE_001
Sept 30 – Oct
RBSP EFW ICDR

4. Integration and Test Plan
Philosophy:
Requirements are verified as early as possible at a low level
Verifies subsystems, Retires risk
Requirements are verified at the highest level of assembly possible
Often involves verifying a requirement at several levels
Maintain flexibility in test sequencing to maintain schedule
Tests on ETU and two Flight Units
Subset of tests on ETU to qualify the design where practical and possible.
Full tests on Flight units
Except EMC testing is limited on second unit per
Typical Test Levels:
Subassembly (circuit board): functional
Component (AXB, SPB, IDPU): functional, mass properties, vibration, TV, deployments, magnetics
Instrument: functional, calibration, interface, EMC, TV
Sept 30 – Oct
RBSP EFW ICDR

5. Environmental Test Matrix
notes:
(*)
"AXB less whip" is the AXB Deployment mechanisim less the Cage/whip/preamp A1
Analysis to show saftey margins per A2
Units follow design rule of 1 sq in vent area/ft^3 of volume as per Waiver EFW-008 T1
Per T2
Test conducted as part of Spacecraft Structure verification. T3
Per Section for protoflight hardware. Test is done unpowered and no functional between axes as per waivers EFW-005 & EFW-003 T4
Cable assemblies on EFW Booms undergo static load test T5
EMFISIS Interface test done with simulators, plus an ETU to ETU test, and finally on the spacecraft T6
Safe-to-Mate and compliance to ICD prior to Integration T7
Per , full testing on F1, CE testing on ETU, F2 T9
Total Dose and SEE Testing at part level as needed
T10
60C for 48 hours prior to TV w/ integrated payload
T11
Contamination Verification w/ TQCM
T12
Deployments occur at start of test sequence (ETU and FM) and in thermal vac at temperature extremes; tests self-shock;
T13
Whip deployment test after AXB vibration; then Whip removed and deployed again in thermal vac, stacer deployment in "AXB less Whip" thermal vac separately
T14
SPB partial deploy during Spacecraft EMC test.AXB Whip deploy test after S/C Vib & Deployment service testing with actuator simulators as agreed per Waiver EFW-004
T15
AXB runout measured during horizontal deploy testing
T16
Instrument level thermal vac test excludes the AXB Tube M1
Mass, CG, MOI measured stowed; deployed by analysis M2
DC Magnetics measured prior to Instrument Payload integration M3
Mass only measured for the harness, no CG or MOI A
Analysis T
Test M
Measurement
Sept 30 – Oct
RBSP EFW ICDR

6. Environmental Test Matrix
notes:
(*)
"AXB less whip" is the AXB Deployment mechanisim less the Cage/whip/preamp A1
Analysis to show saftey margins per A2
Units follow design rule of 1 sq in vent area/ft^3 of volume as per Waiver EFW-008 T1
Per T2
Test conducted as part of Spacecraft Structure verification. T3
Per Section for protoflight hardware. Test is done unpowered and no functional between axes as per waivers EFW-005 & EFW-003 T4
Cable assemblies on EFW Booms undergo static load test T5
EMFISIS Interface test done with simulators, plus an ETU to ETU test, and finally on the spacecraft T6
Safe-to-Mate and compliance to ICD prior to Integration T7
Per , full testing on F1, CE testing on ETU, F2 T9
Total Dose and SEE Testing at part level as needed
T10
60C for 48 hours prior to TV w/ integrated payload
T11
Contamination Verification w/ TQCM
T12
Deployments occur at start of test sequence (ETU and FM) and in thermal vac at temperature extremes; tests self-shock;
T13
Whip deployment test after AXB vibration; then Whip removed and deployed again in thermal vac, stacer deployment in "AXB less Whip" thermal vac separately
T14
SPB partial deploy during Spacecraft EMC test.AXB Whip deploy test after S/C Vib & Deployment service testing with actuator simulators as agreed per Waiver EFW-004
T15
AXB runout measured during horizontal deploy testing
T16
Instrument level thermal vac test excludes the AXB Tube M1
Mass, CG, MOI measured stowed; deployed by analysis M2
DC Magnetics measured prior to Instrument Payload integration M3
Mass only measured for the harness, no CG or MOI A
Analysis T
Test M
Measurement
Sept 30 – Oct
RBSP EFW ICDR

7. Environmental Test Matrix
notes:
(*)
"AXB less whip" is the AXB Deployment mechanisim less the Cage/whip/preamp A1
Analysis to show saftey margins per A2
Units follow design rule of 1 sq in vent area/ft^3 of volume as per Waiver EFW-008 T1
Per T2
Test conducted as part of Spacecraft Structure verification. T3
Per Section for protoflight hardware. Test is done unpowered and no functional between axes as per waivers EFW-005 & EFW-003 T4
Cable assemblies on EFW Booms undergo static load test T5
EMFISIS Interface test done with simulators, plus an ETU to ETU test, and finally on the spacecraft T6
Safe-to-Mate and compliance to ICD prior to Integration T7
Per , full testing on F1, CE testing on ETU, F2 T9
Total Dose and SEE Testing at part level as needed
T10
60C for 48 hours prior to TV w/ integrated payload
T11
Contamination Verification w/ TQCM
T12
Deployments occur at start of test sequence (ETU and FM) and in thermal vac at temperature extremes; tests self-shock;
T13
Whip deployment test after AXB vibration; then Whip removed and deployed again in thermal vac, stacer deployment in "AXB less Whip" thermal vac separately
T14
SPB partial deploy during Spacecraft EMC test.AXB Whip deploy test after S/C Vib & Deployment service testing with actuator simulators as agreed per Waiver EFW-004
T15
AXB runout measured during horizontal deploy testing
T16
Instrument level thermal vac test excludes the AXB Tube M1
Mass, CG, MOI measured stowed; deployed by analysis M2
DC Magnetics measured prior to Instrument Payload integration M3
Mass only measured for the harness, no CG or MOI A
Analysis T
Test M
Measurement
Sept 30 – Oct
RBSP EFW ICDR

8. Planned ETU Integration and Test Flow
Sept 30 – Oct
RBSP EFW ICDR

9. Actual ETU Integration and Test Flow
CE Measurements still to be done
TVAC reduced to Thermal Test for BEB and LVPS
Due to connector change IDPU Vibration was not done – Qual needed for FM
PCB section of LVPS still to be tested
Sept 30 – Oct
RBSP EFW ICDR

10. Rationale for ETU Test Plan
IDPU Vibration
New connector requires IDPU to be qualified at FM.
RBSP IDPU very similar to THEMIS IDPU for board mounting, board size and design that response to vibration is well known.
IDPU Chassis was vibrated at ETU level, no issues.
IDPU Thermal Vacuum to BEB and LVPS Thermal
BEB not a thermal issue (no need for vacuum), although there is a desire to characterize it’s response over temperature.
LVPS has higher dissipating components than other IDPU boards and some thermal testing would be helpful, but fildelity of parts on supply and setup issues with full Thermal Vacuum would prevent timely input to the LVPS flight design. Thermal chamber test presents best chance at spotting design issues to keep LVPS on schedule.
DCB and DFB: main reason for Thermal test is for timing, but FPGA parts are not rated to temperature extremes. Margin testing on ETU DCB and early thermal tests on DFB are used to mitigate lack of test at ETU level.
Power Control Board (PCB) Circuit Verification
Will be done in September 2009.
EMC CE Test
Will be done in October 2009.
Sept 30 – Oct
RBSP EFW ICDR

11. FM Integration and Test Flow
Sept 30 – Oct
RBSP EFW ICDR

12. Validation All instrument requirements are captured in IRD.
IRD contains columns detailing how and where the requirement is met.
IRD doubles as verification cross reference matrix.
Systems Engineer is responsible for verifying test procedures meet requirements and responsible for verifying that all requirements are met by following test plan.
Sept 30 – Oct
RBSP EFW ICDR

13. Procedures Each test shall be documented by a Test Procedure
Test procedure shall identify IRD requirements to be verified by the test
Test procedure shall include pass/fail criteria
System Engineer, QA, Subsystem lead to sign off on proc before use
System Engineer, QA to sign off on completed as-run proc
QA to ensure Red-lines to be transferred into proc before next use
Each completed test to be documented by a Test Report
ETU and subassembly test reports may be a combination of the as-run proc and lab notebook
System Engineer to sign off on test reports, and determine if test adequately verifies associated requirements
Discrepancies found during tests to be documented in a Problem Failure Report (PFR)
Starting with first functional tests at flight subassembly level
Includes any problem (including software) not immediately identified as a test setup or operator problem which cannot stress the flight article
QA will track PFRs to closure with concurrence of the Failure Review Board (includes APL)
Sept 30 – Oct
RBSP EFW ICDR

14. Calibrations
Four calibration tests verify the EFW instrument performance
Performed one time for each flight unit prior to environmental tests.
Science Calibration (SciCal)
Verifies DC gain and offset and AC gain and phase for the sensors and bias channels
Verifies the DAC calibration for the bias channels
Done at the subassembly level, and involves boom pairs plus the BEB board.
Fields Timing and Phasing (FTP)
Verifies the absolute and relative timing and phasing (polarity and shift) amongst EFW, MSC, MAG.
Done at the Instrument level, with partially deployed EFW sensors and simulators for MSC and MAG.
A simplified version of this test (SFTP), not requiring partial EFW boom deployment, shall be done at the Observatory level of integration
using the flight EMFISIS instruments and a common EFW-provided stimulation GSE source
verify instrument relative timing between EFW and EMFISIS.
Omnibus DFB Spectral Data Test
Verifies end-to-end function of the DFB spectral and derived data quantities
Requires the same configuration and FTP
a similar test is run at the DFB level
Slew Rate and DC and AC CMRR Test
Verifies the instrument slew rate and common mode rejection ratio in an integrated instrument configuration (a similar test is run at the DFB level)
Requires the same configuration as FTP
Sept 30 – Oct
RBSP EFW ICDR

15. Boom Deployments
Boom deployment testing takes place at the component level (AXB, SPB). A minimum of 2 full deployments will take place on each unit prior to the start of the environmental test program.
In addition, during component level thermal vacuum tests, there will be one deployment at hot and one at cold. Special GSE and conditions are required for these deployments which are typically inconsistent with deployments at the Instrument or Observatory levels.
During functional tests at the instrument and Observatory level, actuator simulators shall be used to verify the ability of the system to run the deployment of the booms. A frangibolt (for AXB) and pin puller (for SPB) will be fired using the IDPU on each flight unit to verify that it can successfully actuate the device. Hi-fidelity motor simulators will be used to verify the IDPU can deploy the booms correctly.
SPB must be partially deployed (walk-out) for calibrations at Instrument level and for Spacecraft level EMC compatibility testing
Requires removal from the spacecraft to re-stow the booms.
Sept 30 – Oct
RBSP EFW ICDR

16. Interface Tests
Interface tests verify interfaces meet requirements from ICD and/or specifications.
EFW ETU to be tested with APL hardware test bed
Verify ICD functionality
Q4 2009
EFW ETU tested with EMFISIS ETU
Detailed in next slide
At other times (prior to Observatory I&T) interfaces simulated with GSE
Board, Component level tests performed with
Board Interface Simulation GSE
Instrument-level tests performed with:
APL-provided spacecraft emulator
Command and Telemetry GSE software
Stimulation GSE or internal test signal
EMFISIS simulator
Deployment actuator simulators
GSE functionality, design described in GSE section
Sept 30 – Oct
RBSP EFW ICDR

17. EFW & EMFISIS Interface Test – August 2009
EFW traveled to University of Iowa in mid August 2009 with completed ETU instrument for interface tests with EMFISIS instrument.
Interface Verified
voltage levels, pinouts, harnessing, circuit compatibility.
Flow of data through instruments verifed.
Interface Performance tested but not verified
Performance verification happens on FM
Details (when, where, how) need to be worked out with EMFISIS team.
Sept 30 – Oct
RBSP EFW ICDR

18. Mechanical Tests
Tests Per Environmental Spec (ERTRD) as described in the mechanical section.
Sept 30 – Oct
RBSP EFW ICDR

19. Thermal Tests Tests Per 7417-9019 Environmental Spec:
1 survival and 6 operational thermal vacuum cycles
Temperatures range detailed in thermal presentation.
Per RBSP_EFW_TE_001 Plan:
1 survival and 4 operational cycles at the component level
Boom units to be deployed once each at hot and cold operational limits
IDPU Comprehensive Performance Test & BEB Characterization.
2 operational cycles at the Instrument level (plus bakeout)
No actual deployments, but actuator simulators used
Preamps get 1 survival and 6 operational cycles at subassembly level
Deployed preamp temperatures are much wider than deployment mechanism temperatures
AXB Whip and stacer are Thermal Vac’d separately.
No Instrument or Component level Thermal Balance Test
All components thermally coupled to the spacecraft deck
Observatory-level thermal balance test
Sept 30 – Oct
RBSP EFW ICDR

20. EME Tests (1) Tests Per 7417-9018 EME Spec:
Deep Dielectric Discharge Test
Interfaces Only for IDPU (Shielded) - Passed
All points on Preamp (<350 mils equivalent shielding) - Passed
DC Magnetics (sniff test)
ETU and Flight Units, Component level
Target <5nT DC, <0.1nT AC At Magnetometer (for whole S/C)
Results of sniff test reported to Magnetics Working Group for analysis and possible mitigations
Test to be performed by EMFISIS MAG personnel
Deployment motors have permanent magnets, are shielded
Configuration tested for THEMIS
Test data provided to EMFISIS MAG
Sept 30 – Oct
RBSP EFW ICDR

21. EME Tests (2) Surface Charging / Electrostatic Cleanliness
Measure resistance between exposed surfaces (FM1 and FM2)
Requirement <105 ohms per square to chassis ground
Some surfaces may be covered with thermal blankets
blanket testing needs to be done at Observatory level
repeated late in the flow
Ground Bonding and Isolation
Chassis bonding
< 2.5 milliohms between adjacent chassis elements
< 5 milliohms box to chassis
Ground Isolation
>1Mohm primary to secondary (chassis) ground
Measured at Instrument-level EMC testing
ETU, FM1, and FM2
Turn On/Off Transients
Inrush and transient current profile limits per EME spec
Measure Inrush current and transient profile at Instrument-level EMC
ETU, FM1, FM2
CE, CS, RE, RS Tests as detailed in EMECP.
ETU and FM2 only get CE measurements
Sept 30 – Oct
RBSP EFW ICDR

22. Alignment EFW Boom unit alignment achieved by bolt-hole tolerance
Verified to meet IRD alignment requirements by EFW analysis
No observatory-level alignment measurement required
EFW AXB run-out measurement
verifies deployed AXB meets straightness (alignment) requirement
at Component level testing (before delivery to APL)
Sept 30 – Oct
RBSP EFW ICDR

23. Contamination
RBSP EFW Contamination Control Plan (RBSP_EFW_PA_005) documents how EFW will be Project contamination control requirements
The only significant EFW contamination sensitivity is the sensor surfaces
Will be enclosed in caging mechanisms through most of I&T
Special handling/cleaning procedures apply when sensors exposed
No purge requirement
Instrument I&T will be in Class 100,000 facility at UCB
Subassemblies / Components delivered to I&T will be inspected and cleaned as needed prior to integration into components
When Instrument is not in a Class 100,000 environment the unit will be bagged
Flight units will be baked out per RBSP_EFW_PA_007 Bakeout plan prior to delivery to APL
Vacuum bakeout at max survival temp for at least 48 hours with TQCM
Sept 30 – Oct
RBSP EFW ICDR

24. Thermal Vacuum Fixture.
Facilities
Component and Instrument I&T will take place at the University of California, Berkeley Space Sciences Laboratory (SSL)
Instrument integration will take place in a Class 100,000 clean room at SSL
SSL has several Thermal Vacuum chambers
Some can be equipped for boom deployment tests
TQCM available for bakeouts
Fixture developed to hold instrument suite on single plate.
SSL can perform Conducted Emissions tests to 50MHz
Adequate for ETU and FM2 EMC testing
Full EMC suite testing on FM1 will be at a subcontractor facility
Vibration testing at near-by commercial facilities (Quanta)
Thermal Vacuum Fixture.
Sept 30 – Oct
RBSP EFW ICDR

25. Cleanroom (with 5 THEMIS probes)
Facilities
Cleanroom (with 5 THEMIS probes)
‘Bertha’ TVac Chamber
SPB Deploy GSE in TVac
‘Snout’ TVac Chamber (AXB deploy)
Sept 30 – Oct
RBSP EFW ICDR

26. Operating Hours RBSP Matrix requirement is:
Instrument teams shall demonstrate a period of 300 hours of total powered test time, 100 hours of which are consecutive failure-free operation in its simulated mission orbital environment (thermal vacuum), at the conclusion of their verification program prior to delivery to the observatory.
Hours include component-level and instrument-level test time
Operating hours excludes deployment system operation
Deployment systems shall be demonstrated at least 4 times prior to delivery
twice on the bench, once hot and once cold in thermal vac
To achieve this number of hours without impacting schedule requires intervals of several days of 24-hour operation
In addition to hours accumulated during normal tests
Early testing will always be manned by an operator who can monitor operations
Later, after the system has been adequately rung out, operating hours will be accumulated in flight-like, unattended operations
GSE shall monitor and safe the instrument
GSE shall page an operator in case of limit violation
Sept 30 – Oct
RBSP EFW ICDR

27. Observatory-Level Tests
EFW and APL have discussed S/C level testing in detail at ‘End to End’ Test Meeting, June 2009.
EFW has internal stimulus to support CPT functional testing – no GSE required
GSE will be required for a System-level Phasing and EFW/EMFISIS interface test to simultaneously stimulate EFW and EMFISIS
One-time test
AXB will not be deployed at Spacecraft level
Too hard to implement off-load GSE at spacecraft level
AXB Whip will be deployed after vibration.
SPB will be partially deployed at Spacecraft EMC
To allow EFW to measure spacecraft radiated emissions
Allows a test of SPB deployment circuits
Sensors are walked out and placed in holders by EFW personnel
SPB units must be removed from the spacecraft to re-stow the boom
Sensors inspected and cleaned if required by EFW personnel prior to re-stowing
Actuator simulators will be provided to perform simulated boom deployments
simulators contain flight-like motors and actuators (or equivalent loads)
simulators attach to boom unit enable plug
Simulators will be used at spacecraft-level Thermal Vac
Sept 30 – Oct
RBSP EFW ICDR

28. Backup Thermal Profiles EMC Test Levels Sept 30 – Oct 1 2009
RBSP EFW ICDR

29. Thermal Profiles
Example
Sept 30 – Oct
RBSP EFW ICDR

30. Thermal Profiles
Sept 30 – Oct
RBSP EFW ICDR

31. EME Tests Conducted Emissions CE01, CE03, CE07
Performed at Instrument EMC test
ETU, FM1, FM2
Test power lines and Harnesses (common mode)
Differential Mode Limit
Common Mode Limit
Sept 30 – Oct
RBSP EFW ICDR

32. Integration and Test EME Tests
RE02 Low Frequency Limits
Radiated Emissions
RE01, RE02
Performed at Instrument-level EMC test on FM1 only
RE01 Limits
RE02 High Frequency Limits
Sept 30 – Oct
RBSP EFW ICDR

33. EME Tests Conducted Susceptibility Radiated Susceptibility
CS01, CS02, CS06
Performed at Instrument-level EMC test on FM1 only
1Vp-p 30Hz – 400MHz
10V spikes
Radiated Susceptibility
RS03
Sept 30 – Oct
RBSP EFW ICDR