1. Pre-Environmental Review PER SearchCoil Magnetometer FM4
D.ALISON(LPP)
MMS SCM FM4 PER, 17 SEP 2012

2. Requirements/Design Updates Verification Results Test Planning
Outline
Introduction
SCM Overview
Subjects of the review
Programmatics
Requirements/Design Updates
Verification Results
Test Planning
Assurance Activities
MMS SCM FM4 PER, 17 SEP 2012

3. SCM interfaces to the CEB for power and data
Block Diagram
SCM interfaces to the CEB for power and data
MMS SCM FM4 PER, 17 SEP 2012

4. S/C Location 3 2 4 5 1 8 6 7 +X -X -Y +Y SPACECRAFT DECK COMPONENTS
DSS
Mag boom
(stowed) RF
xnpdr
Battery 3 2 4
C&DH 5 1
Navigator
USO 8
SCM
Pre-Amp
DPU 6 7
Star
Sensors
PSEES
Mag boom
(stowed)
FEEPS
S-Band Antenna
MMS SCM FM4 PER, 17 SEP 2012

5. S/C Location INSTRUMENT DECK COMPONENTS (BOOMS DEPLOYED)
AFG
SCM
SDP
CEB
EDI
SDP
AEB
ADP
INSTRUMENT DECK
COMPONENTS
(BOOMS DEPLOYED)
SDP
EDI
SDP
DFG
MMS SCM FM4 PER, 17 SEP 2012

6. Subjects of the review SCM FM4 setting-up: Harness FM4 S/N FM4
Preamp FM4 S/N FM5
Sensor FM4 S/N FM3
FM2 SENSOR
FM2 PREAMP
Mettre photo sensor FM4#FM3
FM4 PREAMP
FM4 SENSOR
MMS SCM FM4 PER, 17 SEP 2012

7. Organizational and staffing plans RFA status
1. Programmatics
Organizational and staffing plans
RFA status
Status of drawings/engineering change orders and manufacturing planning documents
Schedule
Risk management status => no open risk
MMS SCM FM4 PER, 17 SEP 2012

8. 1.a) Organizational and staffing plans
LPP TEAM
Co-I
O. Le Contel, A. Roux
Technical Manager
P. Leroy
Lead Engineer
C. Coillot
AIV/AIT Engineer
D. Alison
QA Engineer + AIT/AIV support
A. Galic, L. Meslier (Nexeya) => 0.3 FTE
Software Engineer
L. Mirioni
LPP/CNRS
Ecole Polytechnique
Route de Saclay
91128 Palaiseau, FRANCE
MMS SCM FM4 PER, 17 SEP 2012

9. All RFA AIs are in PIMS answered and concurred.
1.b ) RFA status
All RFA AIs are in PIMS answered and concurred.
MMS SCM FM4 PER, 17 SEP 2012

10. 1.c) Status of drawings/engineering change orders and manufacturing planning documents
Manufacturing planning documents => sensor, harness and preamp in house.
Current configuration is flight configuration (one SCM instrument = 1 assembly Sensor + Harness + Preamp)
Mettre photo FM4 sensor
FM2 SENSOR
FM4 SENSOR
MMS SCM FM4 PER, 17 SEP 2012

11. 1.d) Schedule: manufacturing
Harness FM4 S/N FM4 manufactured
Preamp FM4 S/N FM5 manufactured
Sensor FM 4 S/N FM3 manufactured
Lacing tape
2216 staking
MMS SCM FM4 PER, 17 SEP 2012

12. 1.d) Schedule: qualification
No Reserve for FM4
FM4 FIT (FIELDS Interference and Timing) test at UNH => 11 DEC 2012
Preamp + Sensor on schedule
Harness to be decided asap
Voir si on passe 2 harnais dans QCM en même temps
MMS SCM FM4 PER, 17 SEP 2012

13. 2. Requirements/Design Update
Requirements and hardware/software design changes since CDR
Status of ICDs
Resource status
MMS SCM FM4 PER, 17 SEP 2012

14. 2.a) Requirements and hardware/software design changes since CDR
FM4 build as FM1 except for the torque values and glue (see below)
Requirement changes => No
Software design changes => N/A
The cables of the coils have been staked, using lacing tape and 2216 glue => NC closed, changes applied on FM1 and all subsequent FMs
FM4 S/N FM3 vibration => NCR ref MMS-SCM-NC-TRI-139_Iss1_rev1_FM4_SENSOR_cracks_after_vibration
Thermal Cycling between 22°C and 60°C performed with the tubes not fastened
Change of the torque value to hold sensors 0.35Nm instead of 1.2Nm
Thermal Cycling between 22°C and 60°C performed
Glue 2216 between the structure and the sensors
This set-up was qualified successfully in vibration at proto-flight levels on QM
Vibration at proto-flight levels 07 June 2012 successful (2 Post vibration thermal cycles at LPP ok
X-Ray inspection validation
Mettre photo FM4 avec colle 2216 visible
MMS SCM FM4 PER, 17 SEP 2012

15. 2.b) Status of ICDs SENSOR: PREAMP
FIELDS SCM to Spacecraft Mechanical/Thermal ICD ( ) => rev D from DEC 2011 (due to an update needed on the CAD model of the Sensor)
Mag Boom MICD => rev A on May, 2011
Orientation of the sensor on the mag boom changed since CDR, MICD of the mag boom not yet up to date
Change of Screwlock on pigtail SCM P213 and on harness SCMJ213 conformed with Mechanical/Thermal ICD ( )
PREAMP
FIELDS SCM to Spacecraft Mechanical/Thermal ICD ( ) => rev D from DEC 2010
The FIELDS ICD, UNH-MMS-FIELDSICD-01 is the Electrical interface document for SCM
MMS SCM FM4 PER, 17 SEP 2012

16. Baseline performance/functional test results
3. Verification Results
Baseline performance/functional test results
Verification results of component and subcomponents
Analyses status
Mechanical
Thermal
Radiation => All parts are in PIMS and approved
Flight software/firmware status (if applicable) => N/A
Limited life items status => N/A
MMS SCM FM4 PER, 17 SEP 2012

17. 3.a) Baseline performance/functional test results
Electrical and Functional tests performed on the sensor after cabling of the pigtail
Functional test inside a mu-metal box with Helmholtz coils
Electrical tests will be used as baseline
Incoming inspection of the preamplifiers:
Power consumption (Feedback connector plugged, all inputs short-circuited)
Output offsets (each channel)
Transfer function (Preamp alone, each channel) => gain, cutoff frequencies
Input noise (Preamp alone, each channel)
Transfer function in field (Preamp + FM Sensor + FM Harness, each channel) => gain, cutoff frequencies
Calibration transfer function (Preamp + FM Sensor + FM Harness, each channel) => gain, cutoff frequencies
Trending parameters:
Power consumption
Total hours of operation log filled during testing
The sensitivity of the SCM depends mainly on:
The noise of the preamplifier
The gain of the assembly
The impedance of the primary coils
MMS SCM FM4 PER, 17 SEP 2012

18. 3.a) Logbook filled during FM4 S/N FM3 sensor Electrical and Functional tests
Initial
DAL
Date
15/06/2012
25/06/2012
Coil
F11 FM 4
Harness
FMS
SCM GSE A3
Preamp QM B1
SCM GSE A
Procedure
MMS-SCM-PR-TRI-119
Tested Configuration: FM4 SENSOR, Fx Coil primary winding measurement
Jun_15_09h36_Coil_FM4X#FM3_IMPEDANCE
Mesure d'impédance 1Hz - 50kHz / Vrms 1V
ORIENTATION X Ok
f [Hz]
Impédance mesurée [dB]
Ohm / H / F
COIL
Résistance (Ohm) -- 1 Hz 1
-12,86
2276
Transfer Function
oui
Jun_25_10h51_Coil_MMS_X_FM4_SN_FM3_TF
Inductance (H) Hz
201
6,81
17,35
10,2 Hz
91,0
Capacité (F) kHz
20479
-5,01
1384 f0
1 044,93
ORIENTATION Y F6
Jun_25_11h07_Coil_MMS_Y_FM4_SN_FM3_TF
91,2
ORIENTATION Z
F13
Jun_25_11h19_Coil_MMS_Z_FM4_SN_FM3_TF
90,8
Jun_15_10h04_Coil_FM4Y#FM3_IMPEDANCE
FM4#FM3
-13,29
2165
6,73
17,19
-5,77
1510
989,90
Jun_15_10h15_Coil_FM4Z#FM3_IMPEDANCE
-13,32
2157
6,72
17,17
-5,31
1432
1 017,05
Main trending parameter
=> Inductance of the primary windings
MMS SCM FM4 PER, 17 SEP 2012

19. 3.a) FM1 primary winding inductance monitoring during thermal vacuum
X is different from Y and Z due to its position in the chamber, close to the aluminum interface.
The baseline measurement for the thermal vacuum are performed just before closing the door.
No sharp drop during the cycles that could be a clue to detect a default in the ferrite core.
MMS SCM FM4 PER, 17 SEP 2012

20. 3.a) FM1 primary winding resistance monitoring during thermal vacuum
MMS SCM FM4 PER, 17 SEP 2012

21. 3.a) Logbook filled during FM4 S/N FM5 preamp Electrical and Functional tests
Date
21/06/2012 X
Personnel
DAL
503 Hz
87,26 dB
4,1 Hz
5,70
4,3
Device under Test
FM5 PREAMP
Cutoff frequency (-3dB)
4229 Hz
4251,00
SCM GSE A 3
Jun_21_15h03_flex_PA_FM5_X_BALAYAGE,txt
Saturation no
210,39
SCM GSE HARNESS 15pts 1
617
mHz
4,2
Jun_22_13h59_flex_PA_FM5_X_Field_MumetalBox_FTCAL
SCM GSE HARNESS 26pts
Noise Floor
3,8
nV/sqr(Hz)
-1,25
4,4
SCM SENSOR
FM3
Jun_21_16h38_flex_PA_FM5_X_GAIN+PHASE,txt
4794,13
SCM HARNESS
FMS
Jun_21_16h38_flex_PA_FM5_X_IN_NOISE,txt
223,43
mu-metal box
CASSINI MUMETAL BOX-GSE1
Jun_22_11h59_flex_PA_FM5_X_SignalCal_FTCAL
Procedure
MMS-SCM-PR-PRE _PREAMP_functionnal_testing
Rev
1,0 Y
I_PLUS_8V_GSE
2,74 mA
3,1
5,79
I_MINUS_8V_GSE
1,97
4320
I_PLUS_8V_GSE_PREAMP
10,92
Jun_21_15h07_flex_PA_FM5_Y_BALAYAGE,txt
I_MINUS_8V_GSE_PREAMP
10,14
Jun_22_14h53_flex_PA_FM5_Y_Field_MumetalBox_FTCAL
I_PLUS_8V_PREAMP
8,18
-0,73
I_MINUS_8V_PREAMP
8,17
Jun_22_09h16_flex_PA_FM5_Y_GAIN+PHASE,txt
4652,16
offset X 41 mV
3,2
Jun_22_09h16_flex_PA_FM5_Y_IN_NOISE,txt
230,25
offset Y 40
Jun_22_12h41_flex_PA_FM5_Y_SignalCal_FTCAL
offset Z Z
87,23
5,58
4140
4125,12
Jun_21_15h11_flex_PA_FM5_Z_BALAYAGE,txt
204,16
636
Jun_22_15h32_flex_PA_FM5_Z_Field_MumetalBox_FTCAL
-0,24
Jun_22_10h22_flex_PA_FM5_Z_GAIN+PHASE,txt
Jun_22_10h22_flex_PA_FM5_Z_IN_NOISE,txt
237,27
Jun_22_13h19_flex_PA_FM5_Z_SignalCal_FTCAL
Trending parameters:
Power consumption
Cutoff frequencies
Gain
MMS SCM FM4 PER, 17 SEP 2012

22. 3.a) Tracking of the trending parameters during FM1 preamp qualification
Vibrations (measurements after each axis in sinus and random)
Thermal Vacuum (measurements during plateaus)
MMS SCM FM4 PER, 17 SEP 2012

23. 3.a) FM1 Preamp before and after qualifications
MMS SCM FM4 PER, 17 SEP 2012

24. 3.a) Functional test, Preamp alone FM4
MMS SCM FM4 PER, 17 SEP 2012

25. 3.a) Functional test, Preamp alone FM4
MMS SCM FM4 PER, 17 SEP 2012

26. 3.a) Functional test, Preamp alone FM4
MMS SCM FM4 PER, 17 SEP 2012

27. 3.a) Functional test, FM4 S/N FM5 Preamp + Sensor FM4 S/N FM3 + Harness FMS
MMS SCM FM4 PER, 17 SEP 2012

28. 3.a) Functional test, FM4 S/N FM5 Preamp + Sensor FM4 S/N FM3 + Harness FMS
MMS SCM FM4 PER, 17 SEP 2012

29. 3.b) Verification results of components and subcomponents
SCM IRD last release Issue 1 Rev 5, JULY 2011
Instrument Suite Verification Plan used as a reference (rev 1.0, April 2011)
Verification matrix sent by Dave Rau (SCM IRD Verification Output-30Mar11.xlsx)
FM1 met the requirements after qualification and calibration => same results expected for FM4 following preliminary tests performed during incoming inspection (Gain, sensitivity, power consumption, frequency bandwidth)
Verification data to be checked with Dave Rau after this presentation
MMS SCM FM4 PER, 17 SEP 2012

30. 3.c) Analyses status (Sensor)
Sensor Analyses
Random, Sinus, Shock, Thermal => 10C379_RT_MLCR_0053_11_ed02_mechanical_analysis_triaxe_update.pdf
SY00728_RP_1445_12_MMS_Mechanical_Analysis.pdf =analysis updated (see below)
Quasi static => Mechanical_Analysis_SCM-Sensor_UNH-Addendum_ a.doc (John NOLIN, UNH)
FM1 qualification successful, at proto flight levels, one NC solved and closed => proposed solution: staking of the cables of the coils
S/N FM3 vibration at acceptance level 2-3 FEB 2012 => 2 cores cracked
NCR : MMS-SCM-NC-TRI-139_Iss1_rev1_FM4_SENSOR_cracks_after_vibration.doc
Change of the torque value to hold sensor 1.2Nm=>0.35Nm, 2216 glue added to hold sensors
This solution was applied on the QM and tested successfully in vibration 1 axis proto-flight level
New mechanical analysis done by Nexeya with thermoelastic coefficient corrected for Mapsil and new torque value: SY00728_RP_1445_12_MMS_Mechanical_Analysis.pdf
Shock qualification performed on the flight like EM4 SCM Sensor (sensors sent back to LPP, thermal cycle validation + X-Ray Inspection)
S’assurer du proto flight level sur les test sur QM
MMS SCM FM4 PER, 17 SEP 2012

31. 3.c) Analyses status (Sensor)
RUI#
Requirement
Compliance
Method
RSCM_0310
Limit Loads Y A
RSCM_0319
Fundamental Launch Frequencies
A/T
RSCM_0331
SCM Sensor Sine Vibration
RSCM_0341
SCM Sensor Random Vibration
RSCM_0641
SCM Sensor Shock
RSCM_0368
SCM Sensor Thermal
Thermo elastic Analysis updated: SY00728_RP_1445_12_MMS_Mechanical_Analysis.pdf
Temperature ranges as specified in the MICD
MMS SCM FM4 PER, 17 SEP 2012

32. 3.c) Analyses status (Preamp)
Mechanical and thermal analysis by BTS Industrie
Preamp Analyses
Random, Sinus, Shock, Thermal => 10C034_RT_LEBT_0210_10 _ed01_mechanical_analysis_MMS_box.pdf
Quasi static => Mechanical_Analysis_SCM-Preamp_UNH-Addendum_ a.doc (John NOLIN, UNH)
Full QM qualification campaign in 2011 successful, FM1 also successful (acceptance levels):
vibration at qualification levels (sinus, random)
1 thermal cycle between proto flight survival temperatures, with hot power and hot power off tests
8 thermal cycles between operational temperatures with 4 hours plateaus
RUI#
Requirement
Compliance
Method
RSCM_0310
Limit Loads Y A
RSCM_0319
Fundamental Launch Frequencies
A/T
RSCM_0331
SCM Sensor Sine Vibration
RSCM_0341
SCM Sensor Random Vibration
RSCM_0641
SCM Sensor Shock
RSCM_0368
SCM Sensor Thermal
Temperature ranges as specified in the MICD
MMS SCM FM4 PER, 17 SEP 2012

33. 4. Test Planning Environmental test sequence and levels
Status of test procedures
Science calibration plan
Test as you fly exceptions
Support equipment readiness
Facility readiness/backup plans
Operating time status => N/A
Critical parameters for trending
Contamination control
Instrument/component safety
MMS SCM FM4 PER, 17 SEP 2012

34. 4.a) Flow diagram (Sensor+Harness)
2 cycles 22°C – 60°C
Before fastening After fastening
Current step
MMS SCM FM4 PER, 17 SEP 2012

35. 4.a) Temperature profile (Sensor + Harness in the chamber)
Pumping
Verifier cycles avec Dave
Impedance of the primary winding of each coil measured each 30 min all along the test
Profile in procedure : MMS-SCM-PR-TRI-113-LPP-2.5_Cyclage thermique SENSOR
Need a verification by Dave Rau for the number of cycles
MMS SCM FM4 PER, 17 SEP 2012

36. 4.a) Sensor vibration levels (SCM IRD 1016017, rev 5)
FM1 tested at Proto Flight levels
FM2 tested at Acceptance levels
FM3 tested at Proto Flight levels
FM4 tested at Proto Flight levels
MMS SCM FM4 PER, 17 SEP 2012

37. 4.a) Spacecraft / Sensor coordinates
+Zscm
+Xscm .
+Yscm
MMS SCM FM4 PER, 17 SEP 2012

38. 4.a) Flow diagram (Preamp)
Current step
MMS SCM FM4 PER, 17 SEP 2012

39. 4.a) Temperature profile (Preamp alone in TV chamber)
Cycling
Pumping
Transfer function and power consumption measured during plateaus
Preamp always ON after the first cycle
Profile in procedure : MMS-SCM-PR-TRI-113-LPP-2.5_Cyclage thermique SENSOR
Need a verification by Dave Rau for the number of cycles
MMS SCM FM4 PER, 17 SEP 2012

40. 4.a) Preamp Vibration levels => Acceptance (SCM IRD 1016017 REV 5)
MMS SCM FM4 PER, 17 SEP 2012

41. 4.b) Bakeout/Outgassing certification
Verifier avec le waiver pour preamp et sensor
No TQCM monitoring for SCM Sensor and Preamp : -Waiver Ref : MMS(Waiver CA)SCM Sensor Bakeout
Possibility to make the TQCM for SCM FM3 & FM4 Harness during the same test:
- With the 2 harness, can the outgassing rate reach 20ng/sec/kg?
MMS SCM FM4 PER, 17 SEP 2012

42. 4.b) Status of test procedures
Each procedure includes a list of documents to be added to the Acceptance Data Package (log books, travelers, plots…)
Items tested
Description
Reference
Version
Sensor coils
Pre and post potting electrical and physical measurements
Thermal cycling at ambient pressure between 22°C and 60 °C with inductance monitoring
MMS-SCM-PR-TRI-117
1.0
Sensor
Functional testing of the sensor after pigtail cabling
MMS-SCM-PR-TRI-119
Vibration (random, sinus)
MMS-SCM-PR-TRI-127
1.1
Preamp
Incoming inspection
Trending parameters measurements
MMS-SCM-PR-PRE-128
MMS-SCM-PR-PRE-130
1.2
Harness
Thermal vacuum with QCM measurements
Monitoring during thermal vacuum (periodical resistance and impedance measurements of the primary windings)
MMS-SCM-PR-TRI-113
2.5
Pre Calibration at LPP
Calibration at Chambon la Forêt
MMS-SCM-PR-GEN-120
MMS SCM FM4 PER, 17 SEP 2012

43. 4.b) Travelers Item Description Reference Sensor
Will start with pigtail cabling and will follow each sensor until after the thermal vacuum
MMS-SCM-RP-TRI-121
Harness
Will start with the cabling of the first connector on the harness
MMS-SCM-RP-TRI-122
Preamp
Will start with the delivery of the PREAMP at LPP
MMS-SCM-RP-131
Will start when each item will be ready for the calibration
MMS-SCM-RP-TRI-123
MMS SCM FM4 PER, 17 SEP 2012

44. 4. Test Planning 4.c) Science calibration plan
Each assembly Sensor/Harness/Preamp will be identified and calibrated
Calibration at Chambon la Forêt (quiet facility)
Calibration outputs:
Transfer function (gain + phase)
Sensitivity
Axes orientation
4.d) Test as you fly exceptions => No
4.e) Support equipment readiness
GSE ready (two split boxes + mu-metal boxes + QM Preamp)
Equipments at LPP (main equipment is a Spectrum Analyzer)
Software ready
4.f) Facility readiness/backup plans
Old calibration facilities was used for FM1 and FM2.
FM2 was tested in new and old Calibration to ensure continuity with FM1 measurements.
FM4 will be only tested in the new Calibration facilities.
4.g) Operating time status => logbook filled each time the preamp is switched ON
4.h) Critical parameters for trending
Sensor => Impedance measurement of the primary winding of the coils
Preamp => High cutoff frequency, Gain in the flat band, Power consumption
4.i) Contamination control
Cleanliness will be checked
4.j) Instrument/component safety
Special case used during transportation
Shock detector on the case
Switch off limits on the power supplies
Switch off limits on the thermal chambers (+5°C above MAX and -5°C below min temperatures)
Switch off limits on the shaker (alarm = 3dB above the profile / switch off = 6dB above the profile)
MMS SCM FM4 PER, 17 SEP 2012

45. 5. Assurance Activities (Lionel MESLIER)
Reliability analyses status
QA planning for subsequent activities completion status
Non-conformance status
EEE Parts and Material status
Waiver status
Safety => N/A
End-Item Data Package (EIDP) plan
On met Alexandre ?
MMS SCM FM4 PER, 17 SEP 2012

46. 5. Assurance Activities Objective Implicit interests
To set up a Product Assurance system to guarantee required quality level
Implicit interests
Reproducibility & Productivity (5 models)
To control process & fabrication methods
To control parameters for product specified (procedures, specifications, …)
To check each information by recording, updating, & availability
Results reliability
To control analysis process
To meet requirements product by any tests or analysis
MMS SCM FM4 PER, 17 SEP 2012

47. 5. Assurance Activities Executed tasks Project support System quality
PA documentation (PA Plan, CIDL, DML, DPL, Procedures, …)
Databases setting up (NCR, modifications, controls, …)
Configuration management (logbook, configuration files, …)
Product quality
Sub-contracting followed (claims, specifications, …)
Product validation & qualification (Metrology)
Cleanroom work environment management
Traceability for delivery elements
Project support
Project manager care (MAIV plan)
Conception & support vs. AIT
Logistic event (EIDP, expedition, packaging…)
UNH reporting and meeting
Internal team training at LPP (ESD precautions, handling…)
MMS SCM FM4 PER, 17 SEP 2012

48. 5.b) QA planning for subsequent activities completion status
PA documentation
For SCM Instrument increased presence during manufacturing
=> increase PA documentation
AIT-QA Activities
More traceability (incoming records, historical records, NCR, waivers…)
Test activities (test witnessing, test readiness reviews, test procedures and reports…)
Cleanliness philosophy (cleaning procedure, laminar flow or hermetic boxes, UV lamp…) => cleanliness certificate
Mate and demate log (savers are used)
=>PA responsible: Lionel MESLIER 30% FTE
MMS SCM FM4 PER, 17 SEP 2012

49. 5. Assurance Activities 5.a) Reliability analyses status
SCM is fully qualified on environmental testing
FM1, FM2, FM3 Preamp => OK
FM1, FM2 Sensors => OK
FM3 (same design as FM4 with glue and reduced torque) => OK
5.c) Non-conformance status
MMS-SCM-NC-TRI-623-LPP-1-0_FM2 alignment measurement out of specification
5.d) EEE Parts and Materials list status
PIMS approval => OK
All material certificates are added in the EIDP
5.e) Waiver status
No waiver today
On met le waiver du bakeout?
MMS SCM FM4 PER, 17 SEP 2012

50. 5.g) End Item Data Package (EIDP) plans
0. H/W EIDP Fore Section
CoC
CIDL/ABCL
RFW & NCRs
Test reports / Verification matrix
Logbooks
GSEs
Subunits EIDP
Handling, Packing, Unpacking
I/F Docs
Doc necessary for further work
Open / Spares/ Loose Items / Red tags / Hazardous
PA Doc (DML, DCL…)
Photos
Other datas & remarks
MMS SCM FM4 PER, 17 SEP 2012

51. BACKUP SLIDES
MMS SCM FM4 PER, 17 SEP 2012