Transcript HMI Peer Review - Stanford University

HMI00372
Integration, Test, and Verification
Michael Levay
Integration and Test Lead
[email protected]
650-424-4046
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 1
Integration and Test – Agenda
• Review of Driving Requirements
• Instrument Integration
• GSE
• Verification Approach
• Functional Test
• Environmental Test Flow
• Test Facilities
• Open Issues
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 2
Driving Requirements
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Provide facilities, equipment, and personnel to verify system functional
performance
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Demonstrate instrument compliance to environmental requirements: Vibration,
Acoustics, Shock, TB/TV, EMC
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Perform test/qualification of selected engineering model Subassemblies/Subsystems
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Mechanism life test (shutters and hollow motors)
Engineering Test Unit (ETU) filter oven performance test
(OP) Structure Model (SM) test
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Engineering model ISS
Perform testing and characterization of selected flight model Subassemblies/Subsystems
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SM Oven
SM Telescope
Prototype alignment mechanism (functional)
Prototype door mechanism (functional)
Telescope, ISS, filter oven with optics, focal planes
Support integrated spacecraft level testing at GSFC
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 3
Integration Approach
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Mechanical/Optical
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Telescope
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Filter Oven
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Focal Plane Assemblies
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ISS
Subsystems and sub-assemblies first integrated to an “identical” non-flight baseplate
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Bench is in clean tent
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Sub-assemblies and subsystems are aligned and focused on the NF baseplate
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Sub-assemblies and subsystems are transferred to OP with little additional adjustment
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Assembly sequence is rehearsed during SM build-up
Stimulus telescope system allows focusing to vacuum positions in air
Electrical
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Integrate major subsystems outside the OP
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
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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
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Regression testing if/when major software modifications occur during the test flow
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 4
Telescope Build-up
Window/Filter
Calibrate filter
Integrate &
align telescope
subsystem
Telescope structure
Optics fabrication
HMI Preliminary Design Review – Nov. 18 &19, 2003
Verify optics
performance
Integration and Test [Levay] Page 5
Filter Oven Build-up
Lyot element
fabrication
Assemble/align
Lyot cells
Michelsons
fabrication
Oven & controller
fabrication
Test oven &
controller
Fabricate
mechanisms
Test mechanisms
Fabricate
polarizers/procure
waveplates
HMI Preliminary Design Review – Nov. 18 &19, 2003
Test Waveplates and
Polarizers
Assemble/calibrate
Lyot filter
Assemble/test
filter oven system
Integrate mechanisms
and
waveplates/polarizers
Integration and Test [Levay] Page 6
Electrical and Software Build-up
BAE
Flight model integration
Develop SUROM
software
Procure EM
RAD6000
SUROM software
Test
Procure FM
RAD6000’s
Flight electronics
build and test
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
Design/Fabricate BB
Electronics
HMI Preliminary Design Review – Nov. 18 &19, 2003
Test flight boards
with BB electronics
Test BB electronics
Integration and Test [Levay] Page 7
Focal Plane Assembly Build-up
Sensor evaluation
GSE procurement
at LM
Flight sensor
evaluation at LM
Development
sensor program
(e2v)
Development
camera program
(RAL)
Flight focal plane
integration and
test at LM
Flight sensor
program (e2v)
Development
camera integration
and test (RAL)
Flight camera
program (RAL)
Flight camera test
(RAL)
Development
camera to LM for
electrical and
software test
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 8
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
HMI Preliminary Design Review – Nov. 18 &19, 2003
Ops and
Analysis
Integration and Test [Levay] Page 9
GSE
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Mechanical
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Optical
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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)
Stimulus telescope
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Supply a reference beam for locating optical component to their final vacuum positions
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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
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Spacecraft simulators (GFE)
EGSE workstations
IEEE control instrumentation
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 10
Verification Approach
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Verification items consist of
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Spacecraft driven resource limitations
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Science driven performance requirements
The approach is to demonstrate compliance to requirements at the integrated
instrument level
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Verification will show that the instrument is capable of producing the
measurements required to realize the science requirements
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Instrument level verification will demonstrate integrated optical, mechanical,
electrical and sensor performance using solar and synthetic targets.
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Measurements of individual elements and sub-assemblies will be performed to gain
confidence that the integrated instrument will perform as required
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The SM and Spacecraft Interface Simulator will be used to show compliance to
interfaces and resource limitations
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 11
Verification Approach
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HMI formal verification will be per the requirements in the functional
specification.
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The spec includes items that can be verified at the integrated instrument level
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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 subassembly level testing, life testing, etc.
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Most testing will occur at LMATC or other LM facilities
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Optical tables, heliostat feed, vacuum test facilities are already available
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Project specific equipment yet to be purchased include stimulus telescope, lifting and handling
fixtures, shipping containers, etc.
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Some environmental testing may be sub-contracted/purchased
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 12
Preliminary Verification Matrix
Parameter
Requirement
Method
Central wavelength
Filter bandwidth
Filter tuning range
Central wavelength drift
Field of view
Angular resolution
Focus adjustment range
Pointing jitter reduction factor
Image stabilization offset
range
Pointing adjustment range
Pointing adjustment step size
Dopplergram cadence
Image cadence for each
camera
Full image readout rate
Exposure knowledge
Timing accuracy
6173.3 Å ± 0.1 Å (Fe I line)
76 mÅ ± 10 mÅ FWHM
680 mÅ ± 68 mÅ
< 10 mÅ during any 1 hour period
> 2000 arc-seconds
better than 1.5 arc-seconds
± 4 depths of focus
> 40db with servo bandwidth > 30 Hz
> ± 14 arc-seconds in pitch and yaw
Test & Analysis
Test
Test
Test & Analysis
Test & Analysis
Test
Test
Test & Analysis
Test
> ± 200 arc-seconds in pitch and yaw
< 2 arc-seconds in pitch and yaw
< 50 seconds
< 4 seconds
Test
Test
Test
Test
< 3.2 seconds
< 4 microseconds
< 0.1 seconds of ground reference
time
> 4000 x 4000 pixels
0.50 ± 0.01 arc-second / pixel
To fit without loss in allocated
telemetry
< 60 minutes after eclipse end
5 years at geosynchronous orbit
Test
Test
Test & Analysis
Detector format
Detector resolution
Science telemetry
compression
Eclipse recovery
Instrument design lifetime
HMI Preliminary Design Review – Nov. 18 &19, 2003
Test
Test
Test
Test & Analysis
Test & Analysis
Integration and Test [Levay] Page 13
Functional Testing
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The tests will be run with controlled STOL procedures (STOL, Systems Test &
Operations Language).
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The aliveness test will require less than 30 minutes and will test the major
subsystems.
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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.
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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.
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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.
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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
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 14
T
T
A
T
T
T
Thermal Vacuum (# Cycles)
T
T
T
T
T
4
Comments
Thermal Balance
T
Thermal Cycle/Functional
Radiated Susceptibilty
Shock
Random Vibration
Acoustic
Structural Loads
Moments of Inertia
CG
Mass
Comprehensive Test
Mechanical Life Test
T
Radiated Emissions
PT
T
Conducted Susceptibilty
SM
T
Conducted Susceptibility
M
T
Conducted Emissions
PF
Characterization and Calibration
HMI
Alignment
I
PT = prototype)
Level of Assembly
Test Item
Unit Type (PF=protoflight,
Preliminary Environmental Test Matrix
T
Optics, Mounts, Mechanisms
A
Lyot Filter
PF
T
T
T
A
A
Filter Oven
PT/PF
T
T
T
A
T
A
Alignment System
PT/PF
T
T
T
A
T
A
Front Door
PT/PF
T
T
T
A
T
A
Hollow Core Motors
PT
T
T
T
T
A
T
T
A
Shutter
PT
T
T
T
T
A
T
T
A
Focus/Calibration Wheel
PT
T
T
T
A
A
Front Window
PF
T
T
T
A
Fold Mirrors
PF
T
T
T
P
Optical Performance
PF
T
S
Image Stabilization System
PF/PT
T
T
S
Telescope
PF/PT
S
Filter Oven (with Optics)
PF
T
T
T
Structural Systems
A
HEB
PF
T
T
A
T
A
OP
PF
T
T
A
T
HMI Preliminary Design Review – Nov. 18 &19, 2003
T
T
T
T
T
Integration and Test [Levay] Page 15
Levels of Assembly
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
Part
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 16
Environmental Test Flow
Special
performance
test dry runs
Comprehensive
Performance
Test
IT &
Cal
Long Form
Functional Test
EMI/EMC
Alignment and
Acoustics Prep
Cal
SFFT
Long Form
Functional Test
Acoustics
Long Form
Functional Test
SFFT
Thermal Balance
Alignment
Shock Prep
Alignment,
Vibration Prep
SFFT
SFFT
Sine Sweep
Long Form
Functional Test
Shock
Random
Vibration
Alignment and
TB/TV Prep
Chamber
Certification
Thermal
Vacuum
HMI Preliminary Design Review – Nov. 18 &19, 2003
Alignment,
TB/TV De-prep
Comprehensive
Performance Test
Special
performance
test in air
Special
performance
test in vacuum
•Delivery
Integration and Test [Levay] Page 17
Test Facilities
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LMSAL Sun Laboratory
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1500 sq ft room with 4 separate bays
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Blackout curtains separate the areas
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HMI will use about ½ the area
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Heliostat for natural sunlight testing
Includes class 10, 000 clean tent
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LMSAL Astro Lab - Vacuum Chamber
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1.5 m diameter x 5.5 m length vacuum chamber used for other projects
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Heliostat feed used for optical tests during thermal vacuum test
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Heliostat upgrade in progress (LM fixed asset)
Plan to use hot/cold box method rather than cold shroud
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Adequate for buildup on GSE bench and flight box
Method proven on other programs
LMSAL Optical Characterization Facilities and Equipment
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Cary Spectrophotometer - transmittance and reflectivity measurements
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Zygo Interferometer – wave front error and flatness measurements
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Eschelle Spectrograph - wavelength standard for filter calibration
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HeNe (6328 A) and tunable lasers
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 18
LMSAL Sun Laboratory
Clean
Room
Flight Buildup
Heliostat
Class 10,000
Non- Flight Base Plate
Clean Tent
Class 10,000
EGSE
Room 110
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 19
Heliostat
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 20
Class 10,000 Clean Tent
EGSE Consoles
Heliostat Fold Mirror
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 21
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
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 22
TV/TB Chamber in B252
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 23
Mechanical Model Fit Check in TV Chamber
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 24
Spacecraft
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I&T
HMI will have a presence at spacecraft integration and test sites
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We intend to participate in all significant test and integration activities that involve HMI
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There are no items that require late installation or reinstallation
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There is a purge port
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We expect to be able to purge whenever we choose
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We can supply the purge equipment but expect NASA to supply the purge gas
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We will supply whatever lifting and handling mechanical GSE that attaches
directly to HMI
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(Electrical) test connector will be used for troubleshooting only
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There are a few non-flight items (protective covers for radiators)
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There will be stimulus telescope system that we will use for optical health
checks
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We intend to use this through a window in vacuum
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HMI includes an LED for camera aliveness tests
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We understand that we will test HMI using our automated (STOL) test
procedures on our GSE during spacecraft testing.
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 25
Open Issues
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Integration, test, and verification concepts are at PDR level, so there are no
significant open issues.
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There are several items that require resolution prior to CDR. These include:
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Agreement with NASA on detailed contents of the specification
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Implement HMI verification database (modification to existing capability)
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Detailed description of the interface between Stanford and LMSAL supplied test and
calibration software
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Baseline design for stimulus system including air-to-vacuum adjustment capabilities
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Update Integration, Test, and Verification Plan
HMI Preliminary Design Review – Nov. 18 &19, 2003
Integration and Test [Levay] Page 26