GLAST LAT Project 3-4 May 2005 LAT Environmental Test Planning and Design Review 3-4 May 2005 2.0 Dynamics Tests John Ku kuj@slac.stanford.edu Naval Research Lab Bldg 226 Rm 113 Call-in number: 510-665-5437 Passcode: 3992 LAT Environmental Test PDR 1 GLAST LAT Project 3-4 May 2005 Tue May 3 PM Agenda • 2.0 Dynamics Tests (John Ku) – 1:00 pm 2.1 Sine Vibe • • • • – 2:30 pm • • • • – • 2:30 3:00 3:30 3:50 4:00 pm • • • • – 1:00 1:30 2:00 2:20 4:00 4:10 4:15 4:25 4:30 pm 2.1.1 2.1.2 2.1.3 2.1.4 Test Plan Test Configuration Test Logistics Open Issues 2.2 Acoustic 2.2.1 2.2.2 2.2.3 2.2.4 Test Plan Test Configuration Test Logistics Open Issues 2.3 Weight and CG 2.3.1 2.3.2 2.3.3 2.3.4 Test Plan Test Configuration Test Logistics Open Issues 2.4 Open Issues To get through these 57 Slides in 4 hours, we must average 4.2 minutes/slide LAT Environmental Test PDR 2 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Plan Overview • • Objectives of the test are well understood by all – Verify the strength of the LAT and subsystem interfaces under PFQ loads and durations – Measure primary natural frequencies (fn) of the primary modes of the LAT – Determine transmissibility (Q) of the LAT – Validate the math model used for coupled loads analysis – Verify the workmanship and processes used in the manufacture and assembly Test Plan – Third draft of test plan is out for review – first major update in over a year – Many technical details have been addressed in previous meetings – the current draft is very mature and should be released in 1-2 weeks • – First comments in from GSFC mechanical branch have been minor and already incorporated Instrumentation list is nearing completion, but not finished yet • • • Internal accelerometers defined and CAD layout complete Strain gauges (16 channels) on flexures defined (NRL can accommodate up to 40 channels, ¼ bridge) External accelerometer mathematical positions defined, but CAD layout needed LAT Environmental Test PDR 3 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Plan Overview • Test Plan (Continued) – Entrance/Exit Criteria are well understood by all; from the test plan: • • The sine vibe dynamic test is the first environmental test to be performed after arrival to NRL and the subsequent CPT. Criteria which must be met before this test can be executed are: – LAT mechanical integration is complete—all visual, dimensional, and torque testing has been complete, and all travelers verified to be complete. The LAT is in its flight configuration, except as detailed in Section 8.3. – All subsystem units/modules function—each subsystem has passed its CPT following removal from the shipping container. Any performance discrepancies have been clearly documented. – Ensure all E-GSE needed is installed and functioning. After moving and attaching the LAT to the vibration test equipment, ensure each subsystem has passed its LPT. All E-GSE cable harnesses have been removed from the LAT prior to test. – All test instrumentation is in place and functioning—instrumentation has been verified to be securely mounted in the correct locations and oriented in the correct direction, as defined in the test procedure, and electronics are working correctly, and reading out signals. Cable harnesses for this instrumentation are connected and properly restrained for the test – Pretest analysis which provides predictions for Fn and Q for significant modes at all test accelerometers Following the sine vibration test, an LPT will be performed. Prior to breaking test configuration, the following criteria must be met: – Visual inspection of the LAT indicates that there is no visible damage to the LAT – Successful completion of the LPT verifies that all components and subsystems function properly after testing – Rough analysis of test data shows that all recorded data is useable for analysis purposes – Comparison of pre-test and post-test modal signatures match to within 5%, or at the discretion of the test director, showing that modal frequencies have not changed significantly as a result of the test. LAT Environmental Test PDR 4 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Plan – Requirements • Test Requirements – Instrument Verification Plan • The tests will be performed to the levels published in the LAT environmental specification document, LAT-SS-00778 • The dynamics tests are to be performed in the mode in which the equipment will observe the environment – LAT will be launched in a “powered off” mode – The sine vibration tests will be performed with the article powered off LAT Protoflight Test Levels Axis Thrust Z X&Y Lateral Notes: Freq. (Hz) 5 - 15 15 - 25 25 - 35 35 - 50 5 - 15 15 - 25 25 - 35 35 - 50 Sweep Rate Test levels [g] [oct./min] 0.4 4 1.2 4 2.8 1.5 0.7 4 2.2 4 0.5 4 0.5 1.5 0.5 4 LAT and Subsystem Low-level Sine Test Levels Test Sweep Rate [Oct/min] Axis Freq. (Hz) levels All (X, Y, & Z) 5 - 150 0.15 g 2 1) The test levels represent LAT Net CG responses 2) Input levels may be notched so that the interface forces or response accelerations do not exceed flight loads predictions LAT Environmental Test PDR 5 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Configuration • • The LAT is transported and supported on the TIP – TIP is already installed for all handling before and after test – TIP assembly uses SC flexures from Spectrum – TIP is designed to simulate SC flexure/top deck interface, so it provides a nearly flight-like interface for the test Interface to both the slip table and expander head is by way of a simple bolt pattern that fits well with the LAT geometry X/Y-Axis Vibration Configuration LAT Environmental Test PDR Z-Axis Vibration Configuration 6 GLAST LAT Project 3-4 May 2005 MGSE Requirements Flowing from Sine Vibe Test Plans • • • • • See the table, below, for a list of all MGSE/STE that is needed for conducting the sine vibe test Test Interface Plate – TIP and mounting hardware capable of handling inertial loads of LAT during test – TIP bolt pattern and size compatible with expander head and slip table – TIP plate supported adequately to ensure stiff connection to slip table/expander head Dust Tent – Capable of providing clean, dry environment before/during/after vibe testing – Provides clearance around LAT for unrestricted motion during vibe – Capable of being on/off-loaded from GPR to vibe table Heat Pipe Restraining Plates – Supports DSHP/XLHP 3-way joints during vibe since Radiator VCHP’s are not mounted – Provides flight-like interface to simulate VCHP flange Chill Bars – Capable of handling vibration loads (obviates need to de-/re-integrate them) MGSE Assembly Test Interface Plate Ass'y Dust Tent Grid Perimeter Ring 4x4 Lift Fixture MGSE Cart Heat Pipe Restraining Plates Chill Bars and Aux. Cooling LAT Environmental Test PDR Use / Comments Mounts LAT to slip table/expander head Covers LAT in un-regulated environment Lifting fixture for hoisting LAT into position Lifting fixture for hoisting LAT into position Parking space for GPR/4x4 Fixture Supports un-attached DSHP's/XLHP's Cool LAT for pre-/post-test LPT's MGSE/STE Needed for Sine Vibe Testing 7 GLAST LAT Project 3-4 May 2005 Auxiliary Cooling and Mechanical Handling • Auxiliary cooling plans – LAT needs to be cooled during LPT’s between each vibe axis run and before and after • • Chill Bars: one under each of the two X-wings on the Grid X-LAT Aux Cooling: using fly-away cooling lines already mounted to X-LAT Plate – – • This is room-temperature cooling to remove LAT process heat To simplify cooling connections, Chill Bars and X-LAT cooling will be designed to handle vibe loads – Hoses will be disconnected using quick-disconnect fittings Handling and mechanical operating procedures – LAT lifting procedure – TIP mounting procedure – Dust tent handling and operating procedure – LAT auxiliary cooling system operating procedure LAT Environmental Test PDR 8 GLAST LAT Project 3-4 May 2005 MGSE Issues for Sine Vibe Testing • Dust Tent – This is likely needed for sine vibe, but is still TBR – If needed, how will dust tent be supported off of the slip table/expander head around the LAT, while the LAT is vibed? – How do we access the LAT for electrical and aux. cooling interconnects before/after vibe testing? – How is the Dust Tent handled with the LAT • • • LAT is transported with the Tent hanging from the GPR After integration on the slip table, the Tent will need to be re-positioned onto the vibe table base Logistics in the vibe lab – Space is tight in the vibe lab, and the LAT MGSE is large • • – We will have 4 large-footprint objects in the lab nearly simultaneously – LAT on the TIP – GPR – 4 x 4 Lift Fixture – MGSE Cart Vibe lab also has 2 vibe tables and the expander head which will need re-positioning during our test We will be running through the handling logistics with paper dolls, then with the pathfinder, so we should be able to catch the problem areas early LAT Environmental Test PDR 9 GLAST LAT Project 3-4 May 2005 MGSE Structural Analysis Status • • • LAT Environmental Test PDR TIP was analyzed for lift loads and dynamic performance (see FEA Mesh shown at left) – High margins were calculated for both cases Rough calculations for the mounting shoes were performed, with more detailed analysis to follow – Conservative hand calculations show high margins for strength and stiffness Rough calculations for the test stand have been performed, wth more detailed analysis to follow – Concentrated on regions of highest load – Design is extrememly stout, and calculations show corresponding high strength margins 10 GLAST LAT Project 3-4 May 2005 MGSE Structural Analysis – TIP – Lift case • The TIP is only attached to the mounting shoes by 16 screws, in a thinned section – When lifted, how much will the TIP sag from its own weight? 148 microns (0.6 mils) – How much stress is imparted from the prying loads? 3.02 MPa (241 MPa Yield) LAT Environmental Test PDR 11 GLAST LAT Project 3-4 May 2005 MGSE Structural Analysis – TIP – Dynamic Performance Calculated First Mode = 417 Hz Required Performance: >225 Hz (1.5*150 Hz) LAT Environmental Test PDR 12 GLAST LAT Project 3-4 May 2005 MGSE Structural Analysis – Mounting Shoes LAT Environmental Test PDR 13 GLAST LAT Project 3-4 May 2005 MGSE Structural Analysis – Test Stand Test Interface Plate LAT Radiator SC Strut simulators LAT Environmental Test PDR Test Stand Radiator 14 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Plan – Constraints – EGSE Constraints • • Cables – Disconnected during vibration – Must be long enough to reach LAT while mounted to either expander head or slip table – Cable trays or protection if laid on floor Cart with EGSE Hardware – Portable, can be rolled out of the way – Power interface to lab? LAT Environmental Test PDR 15 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Configuration • Mechanical Configuration – Radiators not attached • – Mounted to GD/Spectrum Astro-provided test flexures • • • By agreement with the GPO, no mass simulators are needed Test flexures will be proof tested at SLAC prior to GRID static test TIP to interface test flexures and slip table/expander head – LAT Z-axis is always vertical – Access to connectors needed (scaffold around expander head?) on +X side – Layout needed to check cable run lengths Electrical Configuration – SLAC purchased accelerometers are voltage type and have 10-32 connectors, with a special proprietary triax connector • • – – Adapters will be needed to interface with NRL equipment ACD accelerometer interface to be verified Strain gauges do not have connectors (open leads) EGSE needed for LPTs between axes (Rich Baun to define requirements) LAT Environmental Test PDR 16 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Configuration – Instrumentation • Test instrumentation by subsystem, total of 57 channels, calibrated and installed by SLAC I&T, final checkout by NRL Anti-Coincidence Detector 10 Accel Channels 10 Uni (9 Fly-away) 0 Tri (0 Fly-away) Trackers 7 Accel Channels 7 Uni (7 Fly-away) 0 Tri (0 Fly-away) Calorimeters 6 Accel Channels 0 Uni (0 Fly-away) 2 Tri (2 Fly-away) Electronic Boxes 9 Accel Channels 5 Uni (3 Fly-away) 2 Tri (2 Fly-away) Mechanical Systems 25 Accel Channels 1 Uni (1 Fly-away) 8 Tri (0 Fly-away) 500045 Bottom Edge Center of Panel -X Y 500353 500599 Z Y 500043 -X Y 500021 500202 Z -X LAT Environmental Test PDR Z 500142 17 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Configuration – Instrumentation Z 301285 308801 Y 309282 X Z 324985 307082 Y 315185 Z 230614 -Z X 315085 LAT Environmental Test PDR X -Y -Z X 218623 -Y 18 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Configuration – Instrumentation 400580 Z X -Z Z -Y 400001 404665 (PDU) 401182 X 401618 Z Z 401609 -Z 406023 (GASU) Z X Z 103058 X Z Z X X Y Y Y Attach Accelerometers to Clevis part of RMB 104216 Z X LAT Environmental Test PDR Y 19 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Configuration – Instrumentation • • • LAT Environmental Test PDR Four strain gauges installed per flexure for a total of 16 strain gauge channels – Assumed to be 120 Ohm, ¼ bridge, GF=2 – Strain gauges should be temperature compensated if possible The gauges and data acquisition equipment should be sized to capture a maximum strain of 2500 microstrain (titanium has a yield strain of 7500 microstrain) and have a 0.25% precision (6 microstrain error) The combination of strain gauges will allow measurement of axial strain and bending strain – Shear strain will not be directly measured, but may be ascertained from the combined strain readings of the two legs and pre-test analysis 20 GLAST LAT Project 3-4 May 2005 Sine Vibration Test Planning: Detailed Sequence • Pre-test Activities – Move dolly into position in vibration lab and disconnect LAT from dolly (SLAC-IFCT) – Lift LAT and TIP onto expander head, and torque bolts (NRL) – Cable Hook-ups and system checkouts • • • Electrical connections to shaker system and accel tap checks (NRL) Electrical connections to EGSE and perform LPT on expander head (SLAC) Z-Axis Vibration Test – Low-level Signature Sine Sweep to 150 Hz (sweep up and down) • • • • • • – Set-up sheet printouts (NRL), verification and approval (SLAC) If LPT results are okay, disconnect EGSE cables Run test Output FRF data (NRL) Review Data (SLAC) – Determine notching, if needed – Provide feedback to test conductor – Check pass/fail criteria for Modal Test requirement Give OK to proceed (SLAC), or decide alternate action is needed Half-level run to 50 Hz • • • • • Set-up sheet printouts (NRL), verification and approval (SLAC) Run test Output data hardcopies (NRL) Review Data (SLAC) – Check notching and adjust, if needed – Provide feedback to test conductor Give OK to proceed (SLAC), or decide alternate action is needed LAT Environmental Test PDR 21 GLAST LAT Project 3-4 May 2005 Sine Vibration Test Planning: Detailed Sequence (cont.) • Z-Axis Vibration Test (continued) – Full-level run to 50 Hz • • • • • – Low-level Signature Sine Sweep to 150 Hz • • • • • • • Set-up sheet printouts (NRL), verification and approval (SLAC) Run test Output data hardcopies (NRL) Review Data (SLAC) – Check peak levels – Check pass/fail criteria for Modal Test requirement Give OK to proceed (SLAC), or decide alternate action is needed Set-up sheet printouts (NRL), verification and approval (SLAC) Run test Output data overlays (NRL) Review Data (SLAC) – Re-Check pass/fail criteria for Modal Test requirement Concurrent with data review, hook-up EGSE and perform LPT If data review and LPT are good, Give OK to break configuration, or decide is alternate action is needed Post- Z-Test / Pre- X-Test Activities – Disconnect all electrical connections – Remove mounting bolts and move LAT from expander head and set on handling dolly – Remove expander head, rotate shaker to horizontal position and attach drive bar to slip table – Lift LAT and TIP onto slip table for X-axis vibration and torque bolts – Hook-up accelerometers only and perform vibration control system checkout (no EGSE hook-up here) LAT Environmental Test PDR 22 GLAST LAT Project 3-4 May 2005 Sine Vibration Test Planning: Detailed Sequence (cont.) • X-Axis Vibration Test – Low-level Signature Sine Sweep to 150 Hz • • – Half-level run to 50 Hz • • Full-level run to 50 Hz X Slip Table Low-level Signature Sine Sweep to 150 Hz • • • • Same steps as Z-axis test Give OK to proceed (SLAC), or decide alternate action is needed Shaker Y • • – Same steps as Z-axis test Give OK to proceed (SLAC), or decide alternate action is needed LAT – Same steps as Z-axis test Give OK to proceed (SLAC), or decide alternate action is needed Same steps as Z-axis test Concurrent with data review, hook-up EGSE and perform LPT If data review and LPT are good, Give OK to break configuration, or decide is alternate action is needed Post- X-Test / Pre- Y-Test Activities – Disconnect EGSE electrical connections, leaving Accel cables connected – Remove mounting bolts, lift and rotate LAT in place Shaker – Lower LAT to slip table and torque bolts – Perform vibration control system checkout (no EGSE hook-up here) Y Slip X Table LAT LAT Environmental Test PDR 23 GLAST LAT Project 3-4 May 2005 Sine Vibration Test Planning: Detailed Sequence (cont.) • Y-Axis Vibration Test – Low-level Signature Sine Sweep to 150 Hz • • – Half-level run to 50 Hz • • – Same steps as X-axis test Give OK to proceed (SLAC), or decide alternate action is needed Low-level Signature Sine Sweep to 150 Hz • • • • Same steps as X-axis test Give OK to proceed (SLAC), or decide alternate action is needed Full-level run to 50 Hz • • – Same steps as X-axis test Give OK to proceed (SLAC), or decide alternate action is needed Same steps as X-axis test Concurrent with data review, hook-up EGSE and perform LPT If data review and LPT are good, Give OK to break configuration, or decide is alternate action is needed Post- Y-Test Activities – Disconnect all electrical connections – Remove mounting bolts, lift and set LAT on handling dolly – Attach LAT to handling dolly LAT Environmental Test PDR 24 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Configurations – Deviations From Flight • The Radiators are not integrated to the LAT for this test. – Structural interactions between the Radiators and the Grid are not captured • – Coverplates to constrain the down spout heat pipes (DSHPs) and X-LAT heat pipes (XLHPs) to prevent relative motion to the Grid • • • This interface will be strength verified at the subsystem level This interface will be strength verified at the subsystem level The LAT is mounted to STE using test flexures which simulate the flight connection to the SC – The STE and test flexures will be included in the pre-test FEA analysis, so its impact on the response of the LAT will be understood. Since the Radiators and SC are not included in this test, not all flight cable harnesses and supports will be integrated for this test – These cables and their associated support brackets will not be adequately verified by this test – Workmanship for these flight connections and harnesses will be accomplished with the Observatory level sine vibration test. LAT Environmental Test PDR 25 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Document List and Status • • • • • • • • LAT-MD-00408: LAT Instrument Performance Verification Plan LAT-MD-02717: LAT Environmental Test Sequence LAT-MD-01196: LAT Dynamics Test Plan LAT-MD-01533: LAT EGSE Plan LAT-MD-00649: LAT Transportation and Handling Plan LAT-MD-00404: LAT Contamination Control Plan LAT-SS-00778: LAT Environmental Spec LAT-TD-00890: LAT Instrumentation Plan LAT Environmental Test PDR 26 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Logistics • Test Personnel – Test support personnel have been identified (to be verified) • • • • • • • • • • Test Director: John Ku (SLAC) Test Conductor: Bob Haynes (NRL) Discipline Lead: Jim Haughton (NRL) Facility Manager:Bill Raynor (NRL) MGSE Lead: Martin Nordby (SLAC) EGSE Lead: Mike Huffer (SLAC) Test Script Lead: Rich Baun (SLAC) High-bay operations: Paul Dizon (NRL) Quality Assurance: Joe Cullinan (or Doug Bartholomew) (SLAC) I&T: Ken Fouts (SLAC) – Subcommittees will be assembled from the appropriate personnel above, with expert consultation brought in if needed • Potential Vibration Experts: Paul Baird; Chris Fransen; Bill Haile LAT Environmental Test PDR 27 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Test Logistics • Many logistics have already been worked out; these remain: – Complete and release drawings/model of slip table and expander head • • • • • • – Identify what contamination and humidity control is needed in vibe facility • • • Verify slip table and expander head size, inserts and pattern Clearance to off-load frame on expander head Verify that Test Interface Plate fits completely on expander head Verify that LAT clears bracket parts on slip table Develop paper doll work-up to verify we have floor space for 2 carts, GPR, and 4x4 Lift Fixture Lay out EGSE cable routing and locate EGSE crates Is GN2 purge neccesary? Cleanliness (need blanket?) – CG Alignment / sensitivity of equipment to offsets (by analysis TBD) – Instrumentation patch panels and cable supports (ensure all connectors interfaces) – Complete detailed design and analysis of TIP and flexure mount brackets (In-process) – Verify response / control channel capability (NRL) Contingencies – Need to be prepared to perform a modal test if the LAT frequencies do not meet expectations • • • Modal test will not need additional instrumentation May require the use of portable shaker with stinger to RMB or other hardpoint Impact to schedule is not believed to be more than one day of testing (but rigorous post test data reduction will be needed) LAT Environmental Test PDR 28 GLAST LAT Project 3-4 May 2005 Sine Vibration Test – Open Issues • • • Complete structural analysis of MSGE Complete pre-test analysis, including a simulation of LAT on fixtures 10 action items are open and being tracked. – 9 have clear closure paths and are actively being worked on – 1 action not addressed yet is not a high priority, as MGSE has not been designed yet Dynamics Test Action Item List Test Director: John Ku Acoustic, Vibe, Mass Properties Total Actions: 32 ID Test Action Item Actionee V100 VIBE Add strain Gages on S/C flexures. Additional instrumentation for John Ku box level qual. Updated: Printed: Open Actions: 1 ECD Status 1/2/2005 Open* 2/15/2005 3/25/2005 2/28/2005 Open* V102 VIBE Provide CAD file of vibe table: size and bolt pattern for slip table Paul Dizon and expander head. V108 VIBE Muon survey, electrical function, dimensional inspection after each axis to determine if there is a performance change? Pat Hascall Rich Baun V112 VIBE Determine criteria by which modal survey decision is made during/after sine vibe VIBE Generate CAD layout of vibe facililty, incl room, entrance, crane, tables VIBE Work out specifics of integrating LAT on flexures and vibe adapter plate, plus transporting with it on VIBE Identify cooling needed for vibe LPT's, and whether Chill Bars can stay attached to wings VIBE Identify cleanliness req's for LAT during vibe, since lab is not a clean room John Ku 11/30/2004 12/17/2004 2/28/05 7/15/2005 Paul Dizon 3/7/2005 Martin Nordby 3/15/2005 John Ku Martin Nordby Martin Nordby 3/15/2005 V118 VIBE Work through vibing a pressurized component with NRL safety 7/15/2005 V120 VIBE Send updated floor layout of sine vibe lab as well as an overall layout showing relative layout of different labs John Ku Marc Campell Bob Haynes Bill Raynor / Paul Dizon V114 V115 V116 V117 LAT Environmental Test PDR 4/15/2005 3/25/2005 18-Feb-05 3-May-05 Status Comments/Disposition/Conclusions Added extra accel's to Instr Plan. Strain Gauge locations defined. Need to add strain gauges to Instr Plan. Old ID ET2-23 Will be redrawn at NRL and provided to SLAC. An ET 2-4 unreleased draft has been provided, but need drawing to be signed off. Open* Rich Baun is working on it. Cooling bars have been sized to ET2-37 support these performance tests. Open* 2/15: opened at Plan Mtg. Criteria will be known after pretest analysis is completed Open* 2/15: opened at Plan Mtg. First cut 2d drawing sent out. Need to send out final drawings Open* 2/15: opened at Plan Mtg. Cf V110 Open* 2/15: opened at Plan Mtg. This is intimately tied to the LPT requirements. Concept in-work. Open* 2/15: opened at Plan Mtg. Not clear we need anything yet, but the provision for tent is there. Martin is working on this requirement Open 2/15: opened at Plan Mtg. HP's are pressurized components: How much gas is in each HP and what is the pressure level? Open* 3/14: Plan Mtg at NRL 29 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Plan Overview • • Objectives of the test are well understood by all – The objective of the acoustic test is to demonstrate that the fully integrated LAT is capable of withstanding acoustic noise loads, simulating launch conditions. – A secondary objective is to verify the acoustic analysis, i.e. that the LAT components were qualified to high enough levels of Random vibration Test Plan – Third draft of test plan is out for review – first major update in over a year – Many technical details have been addressed in previous meetings – the current draft is very mature and should be released in 1-2 weeks • – First comments in from GSFC mechanical branch have been minor and already incorporated Instrumentation list is nearing completion, but not finished yet • • • Internal accelerometers defined and CAD layout complete Strain gauges (16 channels) on flexures defined (NRL can accommodate up to 40 channels, ¼ bridge) External accelerometer mathematical positions defined, but CAD layout needed LAT Environmental Test PDR 30 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Plan Overview • Test Plan (Continued) – Entrance/Exit Criteria are well understood by all; from the test plan: • • The LAT acoustic test is performed immediately following the LAT sine vibe test. Criteria which must be met before this test can be executed are: – LAT mechanical integration is complete—all visual, dimensional, and torque testing has been complete, and all travelers verified to be complete. The LAT is in its flight configuration, except as detailed in Section 10.3. – All subsystem units/modules function—each subsystem has passed its CPT following removal from the shipping container. Any performance discrepancies have been clearly documented. – Ensure all E-GSE needed is installed and functioning. After moving and attaching the LAT to the vibration test equipment, ensure each subsystem has passed its LPT. All E-GSE cable harnesses have been removed from the LAT prior to test. – All test instrumentation is in place and functioning—instrumentation has been verified to be securely mounted in the correct locations and oriented in the correct direction, as defined in the test procedure, and electronics are working correctly, and reading out signals. Cable harnesses for this instrumentation are connected and properly restrained for the test. Following the acoustic test, an LPT will be performed. The criteria for declaring a successful completion of the acoustic test are:: – Visual inspection of the LAT—indicating that there is no visible damage to the LAT – Successful completion of the LPT—verifying that all components and subsystems function properly after testing – Preliminary analysis of test data—verify that all recorded data is useable for analysis purposes – No significant mode shifts—pre- and post-test signatures match within 5% showing modal frequencies have not changed as a result of testing LAT Environmental Test PDR 31 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Plan – Requirements Test Requirements – Instrument Verification Plan • • The tests will be performed to the levels published in the LAT environmental specification document, LAT-SS-00778 The dynamics tests are to be performed in the mode in which the equipment will observe the environment – LAT will be launched in a “powered off” mode – The acoustic test will be performed with the article powered off LAT Environmental Test PDR Freq (Hz)* 31.5 40 50 63 80 100 125 160 200 250 315 400 500 630 800 1000 1250 1600 2000 2500 3150 4000 5000 6300 8000 10000 OASPL Accept Test (dB) 124.4 127.3 131.2 132.1 134.4 131.9 130.6 128.6 129.4 126.6 123.4 119.9 119.1 116.6 117.5 117.2 118.4 119 117 117.3 115.6 113 108.9 104.9 101.8 99.8 140.8 Qual Test (dB) 127.4 130.3 134.2 135.1 137.4 134.9 133.6 131.6 132.4 129.6 126.4 122.9 122.1 119.6 120.5 120.2 121.4 122 120 120.3 118.6 116 111.9 107.9 104.8 102.8 143.8 150 Acoustic Loading 145 Sound Pressure Level (dB) • 140 135 130 125 120 115 110 Accept Test (dB) 105 Qual Test (dB) 100 10 100 1000 10000 Frequency (Hz) (*) One-third octave center frequency Protoflight Levels = Qualification Levels T est Duration = 60 seconds for acceptance and protoflight tests T est Duration = 120 seconds for qualification (prototype) tests 32 GLAST LAT Project 3-4 May 2005 MGSE/STE for Acoustic Testing • • LAT (on the TIP) is mounted on the Test Stand for acoustic testing – LAT + TIP mounts to Test Stand then Radiators are integrated – LAT is rolled into the acoustic chamber, then jacked off its casters – Dust Tent remains over the LAT for the entire operation, including during testing (TBR) SC top deck simulator – A circular honeycomb-core panel is mounted in the hole of the TIP – This simulates the acoustic behavior of the SC top deck – There is free access to the underside of the TIP through the Test Stand to integrate and instrument this Test Interface Plate LAT Radiator SC Strut simulators Test Stand Radiator Acoustic Test Configuration LAT Environmental Test PDR 33 GLAST LAT Project 3-4 May 2005 MGSE Requirements Flowing from Acoustic Test Plans • • • • • See the table, below, for a list of all MGSE/STE that is needed for conducting the acoustic test Test Interface Plate – TIP accommodates a top deck acoustic simulator – Top deck acoustic simulator adequately simulates the acoustic behavior of the SC Dust Tent – Capable of providing clean, dry environment before/during/after acoustic testing – Provides clearance around LAT – Does not impact the acoustic response of the LAT or acoustic environment in the chamber during testing SC Strut Simulators – Provides flight-like interface to simulate SC struts that support the Radiators – Interface with Radiator at flight interface, and with Test Stand Chill Bars – Capable of handling acoustic loads (obviates need to de-/re-integrate them) MGSE Assembly Test Interface Plate Ass'y Test Stand SC Top Deck Acoustic Sim SC Strut Sim's Dust Tent Chill Bars and Aux. Cooling Use / Comments Mounts LAT to slip table/expander head Use with casters/jacks to move into chamber Simulates SC top deck acoustic response Simulates SC support struts for Radiators Covers LAT in un-regulated environment Cool LAT for pre-/post-test LPT's MGSE/STE Needed for Acoustic Testing LAT Environmental Test PDR 34 GLAST LAT Project 3-4 May 2005 Auxiliary Cooling and Mechanical Handling • Auxiliary cooling plans – LAT needs to be cooled during LPT’s before and after acoustic testing • • Chill Bars: one under each of the two X-wings on the Grid X-LAT Aux Cooling: using fly-away cooling lines already mounted to X-LAT Plate – – • This is room-temperature cooling to remove LAT process heat To simplify cooling connections, Chill Bars and X-LAT cooling will be designed to handle acoustic loads – We may be able to leave all hoses and fittings connected during the test (TBR), otherwise will quick-disconnect them Handling and mechanical operating procedures – LAT lifting procedure – Radiator integration procedure – Test Stand handling and operating procedure – Dust tent handling and operating procedure – LAT auxiliary cooling system operating procedure LAT Environmental Test PDR 35 GLAST LAT Project 3-4 May 2005 MGSE Issues for Acoustic Testing • • Dust Tent – This is likely needed for acoustic testing, but is still TBR – If needed, what is impact of dust tent on acoustic environment in the chamber? – Dust tent will need to be designed to not overly-attenuate sound pressure levels Transportation issues – The acoustic chamber has a ¾” door sill/threshold • • – We plan to build a ramp to roll up and over the sill This will definitely by prototyped with the pathfinder, since the LAT c.g. is moderately high Test Stand will be moved into the room with an electric forklift • We need to verify that it can position the LAT adequately LAT Environmental Test PDR 36 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Plan – Constraints – EGSE Constraints • • Cables – Disconnected during vibration – Must be long enough to reach LAT while mounted to either expander head or slip table – Cable trays or protection if laid on floor Cart with EGSE Hardware – Portable, can be rolled out of the way – Power interface to lab? LAT Environmental Test PDR 37 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Configuration • Mechanical Configuration – Radiators attached (with flight thermal joint) • – Mounted to GD/Spectrum Astro-provided test flexures • • – – – • Need to ensure thermal joint has enough time to cure (7 days RT) Test flexures will be proof tested at SLAC prior to GRID static test Mounted on LAT acoustic test stand LAT Z-axis is vertical Access to connectors needed (ladder around MGSE) on +X side Layout needed to check cable run lengths Electrical Configuration – SLAC purchased accelerometers are voltage type and have 10-32 connectors, with a special proprietary triax connector • • – – Adapters will be needed to interface with NRL equipment ACD accelerometer interface to be verified Strain gauges do not have connectors (open leads) EGSE needed for LPTs between axes (Rich Baun to define requirements) LAT Environmental Test PDR 38 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Configuration – Instrumentation • Test instrumentation by subsystem, total of 57 channels, calibrated and installed by SLAC I&T, final checkout by NRL Anti-Coincidence Detector 10 Accel Channels 10 Uni (9 Fly-away) 0 Tri (0 Fly-away) Trackers 7 Accel Channels 7 Uni (7 Fly-away) 0 Tri (0 Fly-away) Calorimeters 6 Accel Channels 0 Uni (0 Fly-away) 2 Tri (2 Fly-away) Electronic Boxes 9 Accel Channels 5 Uni (3 Fly-away) 2 Tri (2 Fly-away) Mechanical Systems 25 Accel Channels 1 Uni (1 Fly-away) 8 Tri (0 Fly-away) 902227 Y 902264 LAT Environmental Test PDR Y X 904433 Y 39 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Configuration – Instrumentation • Acoustic Chamber • M2, ACD Mid-pnl The STE will be centered in the acoustic chamber, rotated to an angle of approximately 20-30 degrees, as measured between the Radiator surface and chamber sidewall Additionally, there will be a plastic sheet placed under the STE to help identify any items that may come loose as a result of the acoustic vibration. ~36” M1, ACD Mid-pnl M5, RAD Mid-pnl M3, ACD Mid-pnl M6, RAD Mid-pnl M4, ACD Mid-pnl M7, monitor only LAT Environmental Test PDR 40 GLAST LAT Project 3-4 May 2005 Acoustic Test Planning: Detailed Sequence • Pre-test Activities – Chamber Setup and empty cell calibration • • – – Move LAT on dolly (radiators already installed) into chamber and set orientation to the appropriate angle Cable Hook-ups and system checkouts • • • This is needed to verify the test cell is clean and ready to accept the LAT for testing The empty cell calibration will verify that the specified sound pressure levels can be achieved Electrical connections to shaker system and accel tap checks (NRL) Electrical connections to EGSE and perform LPT on expander head (SLAC) – LPT on acoustic test stand Low-Level run at -6 dB for 30 seconds (establish pre-test signature, review data) – Set-up sheet printouts (NRL), verification and approval (SLAC) – If LPT results okay, disconnect EGSE cables and close chamber door – Purge chamber of air – Run Test – Output Data, accel ASD’s and strain gauge SSD’s (NRL) – Review data (SLAC) • • • – Check for “dead” channels Review mic average for level and chamber uniformity Review Grms values for obvious anomalies Give Okay to proceeed (SLAC), or decide if alternate action is needed LAT Environmental Test PDR 41 GLAST LAT Project 3-4 May 2005 Acoustic Test Planning: Detailed Sequence (cont.) • Full-Level run at -0 dB for 60 seconds (impart full SPL, check SPL, linearity, review data) – Set-up sheet printouts (NRL), verification and approval (SLAC) – Run Full level Test • • – Immediately following full level run, perform low level run • – – Do not review data between full level and post-test low level run Output Data accel ASD’s and strain gauge SSD’s (NRL) Review data (SLAC) • • • – As level steps up to -3dB, check critical channel linearity and record data Hold at full level for 60 seconds Check for “dead” channels Review mic average that PFQ level is met and chamber uniformity Review Grms values for linearity Give Okay to proceeed (SLAC), or decide if alternate action is needed LAT Environmental Test PDR 42 GLAST LAT Project 3-4 May 2005 Acoustic Test Planning: Detailed Sequence (cont.) • Low-Level run at -6 dB for 30 seconds (Signature check, review data, complete axis) – Output Data (NRL) – Review data (SLAC) • • • • Check for “dead” channels Review mic average for level and chamber uniformity Review pre- and post- test overlays for frequency shifts and amplitude changes – Give Okay to proceeed (SLAC), or decide if alternate action is needed Post- Acoustic Test Activities – Fill chamber with air (may be done automatically following final low-level run) – Connect EGSE and perform LPT – Visually inspect plastic sheet under LAT – If everything looks okay, give okay to break configuration – Disconnect all electrical connections – Move LAT out of chamber LAT Environmental Test PDR 43 GLAST LAT Project 3-4 May 2005 Acoustic Test – Configurations – Deviations From Flight • The LAT is mounted to STE, which is intended to simulate the influence of the SC volume and geometric proximity on acoustic pressures immediately adjacent to significant LAT surfaces, such as the Radiators and XLAT plate – The SC top deck and lower radiator strut mounts were identified as the critical regions for SC simulation • • • The top deck simulator will be of the same construction as the SC top deck and will be attached to the TIP MGSE The lower radiator strut mounts will have a similar interface with the radiators and the stiffnesses will be approximated, but cross-coupling and stiffness differences will not be captured in this test SC-LAT cabling is not connected for this test, so these connections, the cable harnesses, and the attachment methods are not verified as part of this test – These will be verified at the Observatory acoustic test LAT Environmental Test PDR 44 GLAST LAT Project 3-4 May 2005 Acoustic Test – Document List and Status • • • • • • • • LAT-MD-00408: LAT Instrument Performance Verification Plan LAT-MD-02717: LAT Environmental Test Sequence LAT-MD-01196: LAT Dynamics Test Plan LAT-MD-01533: LAT EGSE Plan LAT-MD-00649: LAT Transportation and Handling Plan LAT-MD-00404: LAT Contamination Control Plan LAT-SS-00778: LAT Environmental Spec LAT-TD-00890: LAT Instrumentation Plan LAT Environmental Test PDR 45 GLAST LAT Project 3-4 May 2005 Acoustic Test – Test Logistics • Test Personnel – Test support personnel have been identified (to be verified) • • • • • • • • • • Test Director: John Ku (SLAC) Test Conductor: Bob Haynes (NRL) Discipline Lead: Jim Haughton (NRL) Facility Manager:Bill Raynor (NRL) MGSE Lead: Martin Nordby (SLAC) EGSE Lead: Mike Huffer (SLAC) Test Script Lead: Rich Baun (SLAC) High-bay operations: Paul Dizon (NRL) Quality Assurance: Joe Cullinan (or Doug Bartholomew) (SLAC) I&T: Ken Fouts (SLAC) – Subcommittees will be assembled from the appropriate personnel above, with expert consultation brought in if needed • Potential Vibration Experts: Paul Baird; Chris Fransen; Bill Haile LAT Environmental Test PDR 46 GLAST LAT Project 3-4 May 2005 Acoustic Test – Open Issues • Many logistics have been closed already; the logistics that still need consideration are: – Lip at threshold (how to transport into room) • • Accommodation for moving Test Stand over ½” door sill Use pneumatic wheels or air bearings? – Cleanliness (need blanket?) – is rating worse than 100K? – Instrumentation feedthrough and cable supports – Is a dust tent needed around LAT in acoustic chamber – What type of panels are needed in/around LAT to simulate SC response Complete structural analysis of MSGE Complete pre-test analysis – Verify top plate simulator attached to TIP MGSE adequately replicates SC response 5 action items are open and being tracked. – All actions have clear closure paths and are actively being worked on • • • Dynamics Test Action Item List Test Director: John Ku Acoustic, Vibe, Mass Properties Total Actions: 14 ID Test Action Item A109 ACST How to bag the LAT during acoustic test to maintain cleanliness (especially wrt contacting Radiator FOSR) A110 ACST How to get over 1/2" door sill of acoustic chamber Actionee Martin Nordby Martin Nordby A111 ACST Deliver acoustic chamber CAD model with door, etc Paul Dizon A112 ACST Check cable length, since connection to facility cables is through a penetration and outside the chamber (check if NRL has cables available) ACST Ensure enough cure time for radiator thermal joint (7 day RT cure) John Ku Rich Bielawski A113 LAT Environmental Test PDR Marc Campell Updated: 18-Feb-05 Printed: 3-May-05 Open Actions: 0 Status Comments/Disposition/Conclusions ECD Status 4/15/2005 Open* 2/15: opened at Plan Mtg; Often, instruments are bagged in ESD bagging, which sits on a light-weight frame 4/15/2005 Open* 2/15: opened at Plan Mtg. Agreement made to use wheels and not air bearings. Details TBD 3/7/2005 Open* 2/15: opened at Plan Mtg. First cut 2d drawing sent out. 4/15/2005 Need to send out final drawings 4/15/2005 Open* 2/15: opened at Plan Mtg. Being worked. 4/15/2005 Old ID Open* 3/14: Plan Mtg at NRL. Most likely will have Radiators present for EMI, which would provide the 7 day cure before acoustic. However, this has not been finalized yet. If there are no Radiators for EMI, there would be a 7 day delay before the acoustic te 47 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Test Plan Overview • Objectives – The primary objective of this test is to measure and/or calculate the overall mass and CG of the fully integrated LAT, to verify that it meets the IRD [433-IRD-0001] requirements of: • • • – A secondary objective is to verify measured mass properties match well when compared with the math model mass matrix. • • • Mass is less than 3000 kg Z-cg is a maximum of 185mm above the LAT Interface Plane (LIP) – Because of the difficult involved in measuring Zcg, this requirement will be verified through calculations, based on measurements of all LAT constituents. – From the Xcg and Ycg measurements and comparison with calculated values, an appropriate confidence level can be established and applied to the Zcg calculations. X-cg and Y-cg are within 20mm of LAT Coordinate System (LCS) Z-axis Due to the complexity of measuring moments of inertia, only mass and CG properties will be validated. Differences will be reconciled by updating the math model to reflect measured values Since structural dynamics is intimately tied with mass and stiffness, mass property updates are important to preserve the true dynamic behavior of the LAT. Test Plan – This is a new addition to the test plan draft 3 – Many technical details have been addressed in previous meetings – the current draft is very mature and should be released in 1-2 weeks – All needed instrumentation has been identified, but MGSE design is still needed LAT Environmental Test PDR 48 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Test Plan Overview • Test Plan (Continued) – Entrance/Exit Criteria; from the test plan: • • The LAT mass properties test is performed following the LAT thermal vacuum test and the subsequent CPT and removal of the radiators. Criteria which must be met before this test can be executed are: – LAT Radiators have been removed and the LAT, Flexures and TIP have been moved into the mass properties test area—visual inspection verifies that all the LAT has been re-configured correctly. All travelers verified to be complete. The LAT is in its flight configuration, except as detailed in Section 10.3, below. – All subsystem units/modules function—each subsystem has passed its CPT following TVAC. Any performance discrepancies have been clearly documented. – All non-fly-away accelerometers and other test instrumentation, cables and harnesses are removed. Following the mass properties test, an aliveness will be performed. The criteria for declaring a successful completion of the mass properties test are: – Visual inspection of the LAT—indicating that there is no visible damage to the LAT – Successful completion of the aliveness test—verifying that all components and subsystems are still properly interconnected. – Preliminary analysis of test data—verify that all recorded data is useable for analysis purposes LAT Environmental Test PDR 49 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Test Plan – Constraints – MGSE Constraints • – Platform to distribute weight into three load cells – Must be stiff enough to carry load from TIP (four points) to load cells (three points), i.e. to evenly distribute load from the four flexures – Must be light enough to not affect load cell accuracy (use load cells with highest possible accuracy and precision; load cell precision generally goes down with increased capacity) – Must have a way to precicely locate the LAT and TIP with respect to some arbitrary reference coordinate system – Must be able to accommodate the LAT in 0 and 90 degree orientations EGSE Constraints • • Cables – Disconnected during vibration Cart with EGSE Hardware – Portable, can be rolled out of the way – Power interface to lab? LAT Environmental Test PDR 50 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Test Configuration • Mechanical Configuration – Radiators not attached • – Mounted to GD/Spectrum Astro-provided test flexures • • • MGSE to hold DSHP and XLHP attached Test flexures will be proof tested at SLAC prior to GRID static test TIP to interface test flexures and weight and CG test platform – LAT Z-axis is always vertical – All unnecessary instrumentation removed (such as removable accels) Electrical Configuration – No electrical connections to the LAT – 16 Strain gauges and 3 load cells are the only instrumentation needed – EGSE needed to verify “aliveness” after weight and CG test LAT Environmental Test PDR 51 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Test Configuration – Instrumentation • Test instrumentation by intrument type; Load cells installed by NRL; Strain gauges installed by SLAC I&T Load Cells 3 Channels 3310 lbf peak 15 lbf resolution Strain Gauges 16 Channels 350 ue peak 6 ue resolution F1 Wtot=F1+F2+F3 Xcg= (F2-F3)*a/Wtot h Ycg= F1*h/Wtot LATcg y F2 x a LAT Environmental Test PDR F3 a 52 GLAST LAT Project 3-4 May 2005 Weight and CG Test Planning: Detailed Sequence • Weight and CG Run – Instrumentation check—use dummy masses to verify that all instrumentation is operational and taking useful data – Align LAT on test platform – Measure overall mass and centers of gravity – Rotate LAT 90 degrees and align to test platform – Measure overall mass and centers of gravity – Aliveness Test—execute aliveness test after LAT has been packed in shipping container LAT Environmental Test PDR 53 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Configurations – Deviations From Flight • • • • The LAT is mounted to STE (flexures and TIP), which is not part of the flight LAT structure. Radiators not attached – Radiator mass will be added to the LAT math model MGSE to hold DSHP and XLHP attached – The added weight will be subtracted from the LAT math model – The added weight is insignificant and within the measurement precision of the load cells SC-LAT connector savers are attached during this test – The added weight will be subtracted from the LAT math model – The added weight is insignificant and within the measurement precision of the load cells LAT Environmental Test PDR 54 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Document List and Status • • • • • • • • LAT-MD-00408: LAT Instrument Performance Verification Plan LAT-MD-02717: LAT Environmental Test Sequence LAT-MD-01196: LAT Dynamics Test Plan LAT-MD-01533: LAT EGSE Plan LAT-MD-00649: LAT Transportation and Handling Plan LAT-MD-00404: LAT Contamination Control Plan LAT-SS-00778: LAT Environmental Spec LAT-TD-00890: LAT Instrumentation Plan LAT Environmental Test PDR 55 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Test Logistics • Test Personnel – Test support personnel have been identified (to be verified) • • • • • • • • • • Test Director: John Ku (SLAC) Test Conductor: Bob Haynes (NRL) Discipline Lead: Jim Haughton (NRL) Facility Manager:Bill Raynor (NRL) MGSE Lead: Martin Nordby (SLAC) EGSE Lead: Mike Huffer (SLAC) Test Script Lead: Rich Baun (SLAC) High-bay operations: Paul Dizon (NRL) Quality Assurance: Joe Cullinan (or Doug Bartholomew) (SLAC) I&T: Ken Fouts (SLAC) – Subcommittees will be assembled from the appropriate personnel above, with expert consultation brought in if needed • Potential Vibration Experts: Paul Baird; Chris Fransen; Bill Haile LAT Environmental Test PDR 56 GLAST LAT Project 3-4 May 2005 Weight and CG Test – Test Logistics • Many logistics have been worked out already; the remaining logistical issues are: – Where to perform this test – How to precisely align the LAT with respect to the load cells – Finalize load cell selection • • • Ensure load cells availability Ensure load cells meet precision requirements Provide load cell ICD to SLAC for MGSE design • Other work to be performed – Design the weight and CG Test platform to the requirements – Perform structural analysis of MGSE and test platform • A/I Closure plans – Currently NO OPEN ACTION ITEMS!!! LAT Environmental Test PDR 57