1. Integration, Test, and Verification
HMI00372
Integration, Test, and Verification
Michael Levay
Integration and Test Lead

2. Integration and Test – Agenda
Review of Driving Requirements
Instrument Integration
GSE
Verification Approach
Functional Test
Environmental Test Flow
Test Facilities
Open Issues

3. Driving Requirements
Provide facilities, equipment, and personnel to verify system functional performance
Demonstrate instrument compliance to environmental requirements: Vibration, Acoustics, Shock, TB/TV, EMC
Perform test/qualification of selected engineering model Sub-assemblies/Subsystems
Mechanism life test (shutters and hollow motors)
Engineering Test Unit (ETU) filter oven performance test
(OP) Structure Model (SM) test
SM Oven
SM Telescope
Prototype alignment mechanism (functional)
Prototype door mechanism (functional)
Engineering model ISS
Perform testing and characterization of selected flight model Sub-assemblies/Subsystems
Telescope, ISS, filter oven with optics, focal planes
Support integrated spacecraft level testing at GSFC

4. Integration Approach Mechanical/Optical Electrical Software
Integrate major subsystems outside the OP
Telescope
Filter Oven
Focal Plane Assemblies
ISS
Subsystems and sub-assemblies first integrated to an “identical” non-flight baseplate
Bench is in clean tent
Sub-assemblies and subsystems are aligned and focused on the NF baseplate
Sub-assemblies and subsystems are transferred to OP with little additional adjustment
Assembly sequence is rehearsed during SM build-up
Stimulus telescope system allows focusing to vacuum positions in air
Electrical
Brass board system with at least one of each type of board for design verification
Brass board is then used for flight board testing and software development
During initial phase of integration, brass board electronics may be shared between flight board testing, software development, and flight system integration
Software
Software builds match schedule requirements for board/box level electronics test
Software acceptance dry run uses BB electronics and mechanisms
Two subsequent complete Software acceptances planned at the beginning and end of environmental testing
Regression testing if/when major software modifications occur during the test flow

5. Integrate & align telescope subsystem Verify optics performance
Telescope Build-up
Window/Filter
Calibrate filter
Telescope structure
Integrate & align telescope subsystem
Verify optics performance
Optics fabrication

6. Filter Oven Build-up Lyot element fabrication
Assemble/align Lyot cells
Assemble/calibrate
Lyot filter
Michelsons
fabrication
Assemble/test filter oven system
Oven & controller fabrication
Test oven & controller
Fabricate mechanisms
Test mechanisms
Integrate mechanisms and waveplates/polarizers
Fabricate polarizers/procure waveplates
Test Waveplates and Polarizers

7. Electrical and Software Build-up
BAE
Flight model integration
Develop SUROM software
SUROM software Test
Procure FM RAD6000’s
Flight electronics build and test
Procure EM RAD6000
Design/Fabricate Brassboard interconnect and Bridge
Flight software development on BB electronics
Flight software test on BB electronics
Flight software acceptance dry run on BB electronics
Test flight boards with BB electronics
Design/Fabricate BB Electronics
Test BB electronics

8. Focal Plane Assembly Build-up
Flight sensor evaluation at LM
Flight focal plane integration and test at LM
Sensor evaluation GSE procurement at LM
Development sensor program (e2v)
Flight sensor program (e2v)
Development camera program (RAL)
Development camera integration and test (RAL)
Flight camera program (RAL)
Flight camera test (RAL)
Development camera to LM for electrical and software test

9. HMI Assembly & Integration Flow
Install and align fold mirrors and beamsplitters
Install &
align telescope
BB electronics available for test support
Install focus & polarization analyzers
Install flight ISS
Install filter oven system
Install shutters and focal plane optics
Install alignment mechanism
Install focal plane assembly & camera
Install flight electronics and software
Install misc. hardware (baffles, etc.)
Install front door
HMI functional testing
HMI environmental testing
HMI calibration
Spacecraft integration and test
Launch and Commissioning
Ops and Analysis

10. GSE Mechanical Optical Electrical Lifting Fixtures
Shipping containers and handling fixtures (OP and HEB)
Rotation fixture (for access to underside, e.g., MLI installation)
Vibration fixtures (OP and HEB)
Alignment stand
Protective covers (Radiators, Instrument, CEB)
Subsystem support fixtures (telescope, oven)
TV/TB GSE (hot/cold boxes, support structure, MLI)
Optical
Stimulus telescope
Supply a reference beam for locating optical component to their final vacuum positions
Provide method for testing the ISS
Provide a method for integration optics in air to their vacuum positions (Air to Vacuum correction capability)
Tunable laser at 6173
Electrical
Spacecraft simulators (GFE)
EGSE workstations
IEEE control instrumentation

11. Verification Approach
Verification items consist of
Spacecraft driven resource limitations
Science driven performance requirements
The approach is to demonstrate compliance to requirements at the integrated instrument level
Verification will show that the instrument is capable of producing the measurements required to realize the science requirements
Instrument level verification will demonstrate integrated optical, mechanical, electrical and sensor performance using solar and synthetic targets.
Measurements of individual elements and sub-assemblies will be performed to gain confidence that the integrated instrument will perform as required
The SM and Spacecraft Interface Simulator will be used to show compliance to interfaces and resource limitations

12. Verification Approach
HMI formal verification will be per the requirements in the functional specification.
The spec includes items that can be verified at the integrated instrument level
The Test and Verification Plan will define test activities and plans beyond those that are required for verification in order to give NASA insight into sub-assembly level testing, life testing, etc.
Most testing will occur at LMATC or other LM facilities
Optical tables, heliostat feed, vacuum test facilities are already available
Project specific equipment yet to be purchased include stimulus telescope, lifting and handling fixtures, shipping containers, etc.
Some environmental testing may be sub-contracted/purchased

13. Preliminary Verification Matrix

14. Functional Testing
The tests will be run with controlled STOL procedures (STOL, Systems Test & Operations Language).
The aliveness test will require less than 30 minutes and will test the major subsystems.
The Short Form Functional Test (SFFT) will require a few hours and will test all subsystems but not all paths. It will not require the stimulus telescope.
The Long Form Functional Test (LFFT) will require ~8 hours and will test all paths and major operational modes (the SFFT is a subset of the LFFT). The LFFT will require the use of the stimulus telescope and perhaps the laser.
Comprehensive Performance Test (CPT) sets the baseline at the start of the Environmental Test Program and is performed again at the end. This test will require several days and will contain extensive optical and functional testing of the integrated instrument and will test all capabilities including those not normally used during operations.
Special Performance Tests (SPT) are tests that measure a specific aspect of the HMI performance. These are detailed tests that require the stimulus telescope, lasers, sunlight, or other special setups. They are performed only a few times in the program. Some tests require operating in vacuum

15. Preliminary Environmental Test Matrix

16. Levels of Assembly Part P
Part P
A part is an individual end item. Parts are assembled into assemblies. Examples of parts are: CCD, filter, lenses and mirrors without mounts
Assembly A
An assembly is more than one part. Examples of assemblies are: electronics boards, shutter or hollow core motors, beam splitters and optic assemblies
Subsystem S
A subsystem consists of multiple components. Examples are: an imager path, i.e. the ISS, telescope, or electronics box
Instrument I
The instrument is the combination of the OP, electronics boxes, harnesses and most or all other flight hardware.
Model M
The unit under test is a non-flight model

17. Environmental Test Flow
Comprehensive Performance Test
Special performance test dry runs
Long Form Functional Test
IT & Cal
Alignment and Acoustics Prep
EMI/EMC
Cal
SFFT
Long Form Functional Test
Alignment, Vibration Prep
Random Vibration
Acoustics
SFFT
Sine Sweep
Long Form Functional Test
Long Form Functional Test
Alignment Shock Prep
Alignment and TB/TV Prep
SFFT
Shock
SFFT
Chamber Certification
Thermal Vacuum
Alignment, TB/TV De-prep
Comprehensive Performance Test
Special performance test in air
Special performance test in vacuum
Thermal Balance
Delivery

18. Test Facilities LMSAL Sun Laboratory LMSAL Astro Lab - Vacuum Chamber
1500 sq ft room with 4 separate bays
Blackout curtains separate the areas
HMI will use about ½ the area
Heliostat for natural sunlight testing
Includes class 10, 000 clean tent
Adequate for buildup on GSE bench and flight box
LMSAL Astro Lab - Vacuum Chamber
1.5 m diameter x 5.5 m length vacuum chamber used for other projects
Heliostat feed used for optical tests during thermal vacuum test
Heliostat upgrade in progress (LM fixed asset)
Plan to use hot/cold box method rather than cold shroud
Method proven on other programs
LMSAL Optical Characterization Facilities and Equipment
Cary Spectrophotometer - transmittance and reflectivity measurements
Zygo Interferometer – wave front error and flatness measurements
Eschelle Spectrograph - wavelength standard for filter calibration
HeNe (6328 A) and tunable lasers

19. LMSAL Sun Laboratory Clean Room Flight Buildup Class 10,000 Heliostat
Non- Flight Base Plate
Clean Tent
Class 10,000
EGSE
Room 110

20. Heliostat

21. Class 10,000 Clean Tent
EGSE Consoles
Heliostat Fold Mirror

22. Thermal Vacuum Setup Class 1,000 Clean Tent Clean Tent Class 100,000
MGSE Rails
LMSAL
Room 116 OP
Heliostat
HEB
Spectrograph Lab
Room 117

23. TV/TB Chamber in B252

24. Mechanical Model Fit Check in TV Chamber

25. Spacecraft I&T
HMI will have a presence at spacecraft integration and test sites
We intend to participate in all significant test and integration activities that involve HMI
There are no items that require late installation or reinstallation
There is a purge port
We expect to be able to purge whenever we choose
We can supply the purge equipment but expect NASA to supply the purge gas
We will supply whatever lifting and handling mechanical GSE that attaches directly to HMI
(Electrical) test connector will be used for troubleshooting only
There are a few non-flight items (protective covers for radiators)
There will be stimulus telescope system that we will use for optical health checks
We intend to use this through a window in vacuum
HMI includes an LED for camera aliveness tests
We understand that we will test HMI using our automated (STOL) test procedures on our GSE during spacecraft testing.

26. Open Issues
Integration, test, and verification concepts are at PDR level, so there are no significant open issues.
There are several items that require resolution prior to CDR. These include:
Agreement with NASA on detailed contents of the specification
Implement HMI verification database (modification to existing capability)
Detailed description of the interface between Stanford and LMSAL supplied test and calibration software
Baseline design for stimulus system including air-to-vacuum adjustment capabilities
Update Integration, Test, and Verification Plan