Laboratory Test Report Report No.: Date Issued: This report may not be reproduced except in full. It contains no corrections or erasures. 08CA65949-01 22 January 2009 SUBJECT: Iridium 9505/A Mount REQUESTED BY: Flightcell International Ltd 98 Vickerman Street PO Box 1481 Nelson New Zealand INSTRUCTIONS: Vibration testing based on Method 514.5 – Vibration of Mil-Std-810F “Department of Defence Test Method Standard for Environmental Engineering Considerations and Laboratory Tests”. Shock testing to customer’s specification. CONTENTS: General Date of test Description Results A: Mil-Std 810F – Method 514.5 Vibration Results B: Shock Testing Appendix A: Representative Vibration Test Results Appendix B: Representative Shock Test Results SUMMARY: Test results in this report confirm that the Iridium 9505/A Mount was tested according to Method 514.5 – Vibration of Mil-Std-810F and according to the customer’s shock test specification. The ball-joint slipped under shock loading but no damage was observed on the mount or the 9505 telephone. APPROVED BY: TESTED BY: R.A. Hills Technical Manager Christopher Bennetts Senior Project Engineer 10 VANADIUM PLACE, PO BOX 9194, ADDINGTON 8243, CHRISTCHURCH, NEW ZEALAND TEL: +64 3 940 4400 FAX: +64 3 940 4411 EMAIL: enquiries@nz.ul.com INTERNET: www.nz.ul.com Page 1 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 GENERAL a) As detailed in this report, one specimen of the Iridium 9505/A Mount was received for testing. b) The results detailed in this report relate only to the specimen submitted by the customer. c) The Iridium 9505/A Mount was tested based on Method 514.5 – Vibration of Mil-Std810F and according to a customer-specified shock test. d) All testing was carried out under the following environmental conditions, unless otherwise noted: Ambient temperature Relative humidity Atmospheric pressure 15°C to 25°C 30 % to 60 % 86 kPa to 106 kPa e) Note: N/R = Not Relevant to design assessed, N/T = Not Tested at manufacturer’s request, EUT = Equipment Under Test, DNC = Did Not Comply. f) The reported expanded uncertainties (U ) listed below are based on standard uncertainties multiplied by a coverage factor k = 2, and define an interval ±U providing a level of confidence of approximately 95%. i. acceleration 0.05 m/s2 – 500 m/s2 ±5% DATE OF TEST Testing was completed on 17 December 2008. This report may not be reproduced except in full. It contains no corrections or erasures. Page 2 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 DESCRIPTION The Iridium 9505/A Mount was a lightweight anodized aluminium cradle for a satellite telephone. It was designed to hold a 9505 or 9505A phone in a vehicle environment at an angle determined by the adjustable base. The two ball-joints on the base were tightened via a single handle. For the purpose of this test a telephone was placed in the cradle and the circular base was clamped rigidly to the shock-test surface. Approximate dimensions [mm]: Cradle: L 220 x W 70 x H 70 Ball-joint base: H 90 x Diameter 60 Iridium 9505/A Mount: Overall View Showing Adjustable Base This report may not be reproduced except in full. It contains no corrections or erasures. Page 3 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 Iridium 9505/A Mount: Overall View Showing Placement of 9505 Satellite Telephone This report may not be reproduced except in full. It contains no corrections or erasures. Page 4 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 RESULTS A: Method 514.5 – Vibration from Mil-Std-810F “Department of Defence Test Method Standard for Environmental Engineering Considerations and Laboratory Tests”. CLAUSE 1 SCOPE Applied CLAUSE 2 TAILORING GUIDANCE Noted CLAUSE 3 INFORMATION REQUIRED Noted Clause 3.1 Pre-test Noted (1) Test fixture requirements: The base of the Iridium 9505/A Mount was clamped to the vibration generator using bolts and washers. (2) Test fixture modal survey was not performed for this test. (3) Test item / fixture modal survey was not performed for this test. (4) Vibration exciter control strategy: Single point control. (5) Test tolerances: ±3 dB over the frequency range. Out of tolerance bandwidths <5 % of total test control bandwidth. (6) Combined Environments were not required for this test. (7) Test schedule and duration of exposure: Procedure I – General Vibration. Category 14. Duration = 1 hour per axis (8) Axes of exposure: The samples were exposed to vibration in each of the three axes defined in the following photograph. Measurement instrumentation configuration: Current feedback of piezoelectric acceleration signals via LDS controller and associated software. (9) Test shutdown procedures: Test shuts down if control signal acceleration departs from the desired profile by ± 6 dB. (10) Test interruption recovery procedure: Test stopped in the event of a test item failure. (11) Test completion procedure: Test is complete when all elements of the test item have successfully passed a complete test. This report may not be reproduced except in full. It contains no corrections or erasures. Page 5 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 Z-AXIS X-AXIS Y-AXIS Iridium 9505/A Mount Set Up For X-Axis Vibration And Showing Other Axis Definitions For The Purposes Of This Testing Clause 3.2 During Test Noted An Iridium 9505 satellite phone was installed in the Mount to determine whether the vibration would cause loosening. Clause 3.3 Post-test Noted Visual checks of the Mount and phone were conducted following testing. CLAUSE 4 TEST PROCESS Applied Clause 4.1 Test Facility Applied Clause 4.1.1 Procedure I – General Vibration Applied Vibration testing was conducted using Underwriters Laboratories’ electrodynamic shaker. Clause 4.1.2 Procedure II – Loose Cargo Transportation This report may not be reproduced except in full. It contains no corrections or erasures. N/R Page 6 of 19 Report No.: Date Issued: Clause 4.1.3 Procedure III – Large Assembly Transportation 08CA65949-01 22 January 2009 N/R Clause 4.1.4 Procedure IV – Assembled Aircraft Store Captive Carriage and Free Flight N/R Clause 4.2 Controls Applied Clause 4.2.1 Control Strategy Applied Clause 4.2.1.1 Acceleration input control strategy Applied Clause 4.2.1.2 Force control strategy N/R Clause 4.2.1.3 Acceleration limit strategy N/R Clause 4.2.1.4 Acceleration response control strategy N/R Clause 4.2.1.5 Open loop waveform control strategy N/R This report may not be reproduced except in full. It contains no corrections or erasures. Page 7 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 Clause 4.2.2 Tolerances Applied The following tolerances were applied: Clause 4.2.2.1 Acceleration Spectral Density: Applied a. Vibration environment: Acceleration spectral density was within ±3 dB over the specified frequency range b. Vibration measurement: The system provided acceleration spectral density measurements within ±0.5 dB of the vibration level of the transducer mounting surface over the required frequency range. The control system utilised 4096 frequency lines, with 250 degrees of freedom. Clause 4.2.2.2 Peak Sinusoidal Acceleration Noted Clause 4.2.2.3 Frequency Measurement Applied The vibration measurement system provided frequency measurements within ±1.25 % at the transducer mounting surface over the required frequency range. Clause 4.2.2.4 Cross axis accelerations Noted Clause 4.3 Test Interruption N/R Clause 4.4 Test Setup Applied Mounting method as per Clause 3.1. Gravitational orientation with respect to gravity was maintained as shown in the photograph on page 6. Clause 4.5 Test Execution Clause 4.5.1 Preparation for test Applied Applied A visual examination was carried out before the commencement of the test and no existing damage was observed. This report may not be reproduced except in full. It contains no corrections or erasures. Page 8 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 Clause 4.5.2 Procedure I – General vibration Applied Category 14: “Rotary wing aircraft – Helicopter” was chosen as helicopter transportation was thought to be the worst in-service condition for this item. No specific helicopter model was provided, so an average value was chosen using the blade frequencies in Table 514.5C-IV of Mil-Std 810F. Four blades and a frequency of 4.35 Hz were selected. “General” location within the vehicle. Four blade-passing harmonics were superimposed upon a random vibration spectrum between 10 Hz and 500 Hz as shown below: Random Vibration Frequency [Hz] Acceleration [g2/Hz] 10 0.001 100 0.01 300 0.01 500 0.001 Sinusoidal Tone Frequency [Hz] Amplitude [gn] 1 4.35 0.11 2 17.4 1.74 3 34.8 2.5 4 52.2 1.5 Further test details and a representative graphical output are included in Appendix A. Clause 4.5.3 Procedure II – Loose cargo transportation N/R Clause 4.5.4 Procedure III – Large assembly transportation N/R Clause 4.5.5 Procedure IV – Assembled Aircraft Store Captive Carriage and Free Flight N/R This report may not be reproduced except in full. It contains no corrections or erasures. Page 9 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 CLAUSE 5 ANALYSIS OF RESULTS Complied The sample was subjected to visual checks following testing. No physical damage was observed. The satellite phone was held satisfactorily in the Iridium 9505/A Mount and the base joint angles were maintained. CLAUSE 6 REFERENCE/RELATED DOCUMENTS Noted This report may not be reproduced except in full. It contains no corrections or erasures. Page 10 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 RESULTS B: Shock Testing This testing was performed to the customer specification, which was not known to relate directly to any published standard. The Iridium 9505/A Mount was subjected to the following test parameters: SHOCK PULSE PARAMETERS Peak acceleration [g] 20 Effective pulse length [ms] 25 Pulse shape half sine Tolerances on pulse shape according to ISO Shocks pulses in each axis 3 positive, 3 negative Total number of shocks 18 Refer to Appendix B for further test details and representative software outputs. An Iridium 9505 phone was installed in the Mount to determine whether the shocks would result in loosening. Gravitational orientation of the EUT was maintained as per the operational setup (see photograph on page 6). The base of the Iridium 9505/A Mount was clamped to the vibration generator using bolts and washers. TEST PROCESS Instrumentation Shock test control was by means of a single piezoelectric accelerometer (PCB type 353B03). Visual and Functional Checks Visual checks were carried out on the Iridium 9505/A Mount before and after testing. The ball-joint fastener was screwed in as tight as was practical with one hand. This report may not be reproduced except in full. It contains no corrections or erasures. Page 11 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 RESULTS During the repeated shocks the angle of the ball joints changed (<30°). In some cases this slippage resulted in the cradle contacting the mounting surface during subsequent shocks. The sample and satellite phone were subjected to a visual check following testing and no detrimental effects were observed. This report may not be reproduced except in full. It contains no corrections or erasures. Page 12 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 APPENDIX A: Representative Vibration Test Results Project File Name: Profile Name: Test Type: Run Folder: General Helicopter Mil-Std Cat14.prj Iridium Mount vertical axis Sine on Random .\RunDefault Oct 31,2008 14-39-09 (gn)²/Hz 67.5274 profile(f) high-abort(f) 10.0000 low-abort(f) high-alarm(f) 1.0000 low-alarm(f) control(f) 0.1000 0.0100 0.0010 0.0001 2.56 10.00 100.00 552.96 Frequency (Hz) Level: 100 % Control RMS: 2.975885 gn Lines: 1600 Frame Time: 3.200000 Seconds Remaining Time: 00:00:00 DOF: 250 Full Level Elapsed Time: 01:00:00 Demand RMS: 2.996112 gn dF: 0.312500 Hz Data saved at 02:51:34 PM, Friday, October 31, 2008 Report created at 02:51:36 P.M., Friday, October 31, 2008 Shaker Parameters Shaker Name: Positive Displacement Limit Peak: Negative Displacement Limit Peak: Maximum Velocity Peak: Maximum Acceleration Peak: Minimum Drive Frequency: Maximum Drive Frequency: Maximum Drive Peak: Orientation: Assume Noisy Measurement?: This report may not be reproduced except in full. It contains no corrections or erasures. LDS - V830-335 1.00 in 1.00 in 78.70 in/s 180.00 gn 5.00 Hz 3000.00 Hz 10.00 Volts Vertical Yes Page 13 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 Channel Parameters Input Channel Parameter Input 3 Type Control Max. Volts 1.00 mv/(gn) 10.05 Weighting 1.00 Coupling AC Output Channel Parameter Output 1 Type Output Max. Volts 10.00 Control Parameters Test Parameters Number of Spectral Lines: Max. Test Frequency: Measurement Strategy: Line Abort Ratio: Line Abort Number: Averaging Number: Drive Limit: Sigma Clip: Data Points/Frame: Frame Time: Sampling Rate: DOF: dT: dF: 1600 500.00 Hz Single Channel 0.30 480 125 10.00 Volts Disable 4096 3.200000 Seconds 1280 Hz 250 0.000781 Seconds 0.312500 Hz Pre-test parameters Method of Acquiring the Loop Frequency Response Function: Initial Peak Drive: Ramp-Up Rate: Response Level Goal: Maximum Peak Drive: Measure During Pre-Test 0.005000 Volts Fast 10.00 % 1.000000 Volts Profile Parameters Profile name: profile 1 Iridium Mount vertical axis Broadband Acceleration RMS: Broadband Velocity RMS: Broadband Displacement RMS: 1.790427 gn 1.068702 in/s 0.006902 in Narrowband Acceleration RMS: Narrowband Velocity RMS: Narrowband Displacement RMS: 2.402051 gn 5.602560 in/s 0.058428 in Overall Acceleration RMS: 2.995910 gn This report may not be reproduced except in full. It contains no corrections or erasures. Page 14 of 19 Report No.: Date Issued: Overall Velocity RMS: Overall Displacement RMS: 5.703578 in/s 0.058834 in Overall Expected Acceleration (Peak): Overall Expected Velocity (Peak): Overall Expected Displacement (Peak): 8.987731 gn 17.110733 in/s 0.353007 in Shaker Acceleration (Peak): Shaker Velocity (Peak): Shaker Displacement (Peak-Peak): 180.0000 gn 78.7000 in/s 2.0000 in RMS Limits come from: High Abort: High Alarm: Profile: Low Alarm: Low Abort: Calculated based on table 3.572382 gn (99.53 %) 2.529044 gn (41.25 %) 1.790427 gn 1.267527 gn (-29.21 %) 0.897341 gn (-49.88 %) 08CA65949-01 22 January 2009 Profile Table: Frequency Hz 10.0 100.0 300.0 500.0 Left Slope dB/Oct 3.01043 Const. Acce. -13.5692 Acceleration (gn) Peak 0.001 0.01 0.01 0.001 Velocity (in/s) Peak 0.00614479 0.00614479 0.00204826 0.000122896 Displacement (in) Peak 0.000195595 1.95595e-005 2.17328e-006 7.82379e-008 Right Slope dB/Oct 3.01043 Const. Acce. -13.5692 Sine Tone Profile Parameters Sweep in harmonic mode: No Amplitude Peak: Amplitude High Alarm: Amplitude High Abort: Ramping Up/Down rate: Sweep Low Frequency: Sweep Start Frequency: Sweep High Frequency: Sweep Mode: Sweep Rate: Initial Sweep Direction: Enable burst this tone on and off rapidly: Tone Number 1 0.11 gn 3 dB 6 dB 12 dB/sec 4.35 Hz 4.35 Hz 4.35 Hz Linear 0 Hz/Sec Up No Amplitude Peak: Amplitude High Alarm: Amplitude High Abort: Ramping Up/Down rate: Sweep Low Frequency: Sweep Start Frequency: Sweep High Frequency: Sweep Mode: Sweep Rate: Initial Sweep Direction: Enable burst this tone on and off rapidly: Tone Number 2 1.74 gn 3 dB 6 dB 12 dB/sec 17.4 Hz 17.4 Hz 17.4 Hz Linear 0 Hz/Sec Up No This report may not be reproduced except in full. It contains no corrections or erasures. Page 15 of 19 Report No.: Date Issued: Amplitude Peak: Amplitude High Alarm: Amplitude High Abort: Ramping Up/Down rate: Sweep Low Frequency: Sweep Start Frequency: Sweep High Frequency: Sweep Mode: Sweep Rate: Initial Sweep Direction: Enable burst this tone on and off rapidly: Tone Number 3 2.5 gn 3 dB 6 dB 12 dB/sec 34.8 Hz 34.8 Hz 34.8 Hz Linear 0 Hz/Sec Up No Amplitude Peak: Amplitude High Alarm: Amplitude High Abort: Ramping Up/Down rate: Sweep Low Frequency: Sweep Start Frequency: Sweep High Frequency: Sweep Mode: Sweep Rate: Initial Sweep Direction: Enable burst this tone on and off rapidly: Tone Number 4 1.5 gn 3 dB 6 dB 12 dB/sec 52.2 Hz 52.2 Hz 52.2 Hz Linear 0 Hz/Sec Up No 08CA65949-01 22 January 2009 Schedule Parameters schedule 1 schedule name: Schedule1 0:0:10 at Level 50.0 % SoR On 1,2,3,4, Off 5,6,7,8,9,10,11,12, Broadband On 0:0:10 at Level 50.0 % 1:00:0 at Level 100.0 % Save All Panes Auto-Save Signals Pre-Test Result Drive input 3 Noise 0.000000 volts 0.018348 volts At Level 10 % 0.013413 volts 0.012127 volts This report may not be reproduced except in full. It contains no corrections or erasures. Estimated at Full Level 0.134128 volts 0.121272 volts Page 16 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 APPENDIX B: Representative Shock Test Results Project File Name: Profile Name: Test Type: Run Folder: iDesign 20g max.prj Iridium Mount y-axis 20gn 25mSec Classical Shock .\RunDefault Dec 17,2008 13-57-04 gn 27.5000 24.0000 profile(t) 21.0000 high-abort(t) 18.0000 low-abort(t) 15.0000 control(t) 12.0000 9.0000 6.0000 3.0000 0 -3.0000 -6.0000 -9.0000 -12.0000 -15.0000 -18.0000 -21.0000 -24.0000 -27.0000 -30.0000 -0.03 -0.02 -0.01 0 0.01 0.02 0.03 0.04 0.05 0.05 Time (Seconds) Level: 100 % Frame Time: 0.170667 Seconds Full Level Elapsed Pulses: 6 Demand RMS: 7.253651 gn Amplitude: 20.000000 gn Block Size: 512 Control Peak: 20.461372 gn dT: 0.000333 Seconds Remaining Pulses: 0 Elapsed Pulses: 14 Control RMS: 7.429550 gn Demand Peak: 20.000000 gn Pulse Type: Half Sine Data saved at 01:59:10 PM, Wednesday, December 17, 2008 Report created at 01:59:26 P.M., Wednesday, December 17, 2008 Shaker Parameters Shaker Name: Positive Displacement Limit Peak: Negative Displacement Limit Peak: Maximum Velocity Peak: Maximum Acceleration Peak: Minimum Drive Frequency: Maximum Drive Frequency: Maximum Drive Peak: Orientation: Assume Noisy Measurement?: This report may not be reproduced except in full. It contains no corrections or erasures. LDS - V830-335 0.08 ft 0.08 ft 1998.98 mm/s 75.00 gn 5.00 Hz 3000.00 Hz 10.00 Volts Vertical No Page 17 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 Channel Parameters Input Channel Parameter Input 3 Type Control Max. Volts 1.00 mv/(gn) 10.53 Weighting 1.00 Coupling AC Output Channel Parameter Output 1 Type Output Max. Volts 10.00 Control Parameters Test Parameters Block Size: Averaging Number: Drive Limit: Pulse Interval: Point Abort Ratio: Low-Pass Filter Type: Data Points/Frame: Frame Time: Sampling Rate: dT: Maximum Analysis Frequency: SRS Analysis: Auto 4 10.00 Volts 3.000 seconds 0.10 Do not apply filter 512 0.170667 Seconds 3000 Hz 0.000333333 Seconds 1318.36 Hz Disable Pre-test parameters Method of Acquiring the Loop Frequency Response Function: Initial Peak Drive: Ramp-Up Rate: Response Level Goal: Maximum Peak Drive: Measure during close-loop pre-test 0.001000 Volts Fast 10.00 % 1.000000 Volts Profile Parameters Profile name: Pulse Type: Amplitude: Pulse Width: Main Pulse Tails: Compensation Template: Pre-Pulse Height: Post Pulse Height: Abort Setting: This report may not be reproduced except in full. It contains no corrections or erasures. profile 1 Iridium Mount y-axis 20gn 25mSec half sine 20.00 gn 25.00 ms ISO Standard Pre-Post half sine 80.00 % 80.00 % ISO Standard Page 18 of 19 Report No.: Date Issued: 08CA65949-01 22 January 2009 Schedule Parameters schedule 1 schedule name: Schedule1 1 Pulses at Level 50.00 % 3 Pulses at Level 100.00 % Inverse Pulse 3 Pulses at Level 100.00 % Save All Panes Auto-Save Signals Pre-Test Result Drive input 3 Noise 0.000000 volts 0.000276 volts At Level 10 % 0.108850 volts 0.019852 volts Estimated at Full Level 1.088501 volts 0.198517 volts Run log Dactron Dual DSP Shaker Control System Classical Shock Test Run Log ENTRY TIME /ELAPSED 00:00:00/ 0 00:00:02/ 1 00:00:04/ 2 00:00:07/ 3 00:00:11/ 4 00:00:14/ 5 00:00:16/ 6 00:00:20/ 7 00:00:22/ 7 00:00:22/ 8 00:00:26/ 9 00:00:28/ 10 00:00:31/ 11 00:00:35/ 12 00:00:37/ 13 00:00:40/ 14 00:00:45/ 14 00:00:45 00:00:45/ 14 00:00:45/ 14 00:00:45/ 14 LEVEL 0.00 % Open 0.53 % 2.12 % 8.46 % 10.00 % 10.00 % 10.00 % 10.00 % 50.00 % 100.00 % 100.00 % 100.00 % 100.00 % 100.00 % 100.00 % 100.00 % 100.00 % 100.00 % 100.00 % 100.00 % 13:57:05, Wednesday, December 17, 2008 CTL/DEMAND (Peak) 0.036/ 2.000 gn 0.106/ 2.000 gn 0.378/ 2.000 gn 1.664/ 2.000 gn 1.980/ 2.000 gn 1.999/ 2.000 gn 1.962/ 2.000 gn 9.977/10.000 gn 19.076/20.000 gn 19.403/20.000 gn 19.519/20.000 gn 20.737/20.000 gn 20.540/20.000 gn 20.461/20.000 gn Controller 20.461/20.000 gn SOURCE DESCRIPTION User Command Controller Controller Controller Controller Controller Controller Controller User Command Controller Controller Controller Controller Controller Controller Controller Controller 'control(t),' Saved Signals Controller Start the Test Running in pre-test System paused after pre-test Run Scheduled Test Running in scheduled test All Panes saved to the disk. End of Test Full level elapsed 6 Total elapsed 14 END OF REPORT This report may not be reproduced except in full. It contains no corrections or erasures. Page 19 of 19