1 - asp-05-str1-263 m054-1 tous droits réservés © alcatel space industries all rights reserved...

1 - ASP-05-STR1-263M054-1

Tous droits réservés © Alcatel Space Industries All rights reserved

Star One C1 - Insurance Presentation

8 - Satellite Test Plan and Philosophy

2 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space

The STAR ONE C1 satellite is a protoflight model and will be submitted to qualification environmental conditions as specified in the environmental specification

The objective is to demonstrate that the performances specified are met before, during and after the environmental tests

Satellite Test Plan


AIT SEQUENCE

The AIT sequence in divided in phases: SM Integration Final integration Initial performance test (SPT1A) TV tests Pre environmental tests (SPT1B) Environmental tests Post environmental tests (SPT2B) Final performance tests (SPT2A) MCI Preparation for transport

Satellite Test Plan


MECHANICAL ENVIRONMENTAL TESTS (2)

SPT1 B

SC TV SPT1 A

SM/CMMATING

FINALINTEG.

BODYALIGNMENT

ASSY

ElectricalPerf. tests

comp.

EMCCE/CS

ESD

THERMALBALANCEASSY

THERMAL CYCLING

EAST &WEST

PANELS

ANTENNAEMOUNTING,ALIGNMENT

& DISMOUNT

THERMALINSTRUMENTATIO

N

T&C RF BAPTAM

IRES PSSH10N THRUSTERS

ASSY

REFLECTORS, FEEDS& MECHANISMS

INSTALL

PRE-TVTESTASSY

VIBADAPTOR

MLI

ACOUSTICTEST

ADAPTORFIT CHECK

SEP.SHOCK

TEST

TANKSDRAINING

SA INSTALLMAN.DEPLO

Y& CHECK

ASSY ASSYSA

FOLDING

SOLAR ARRAY

ANTENNADEPL. +

BODYALIGN.VERIF

.

SPT2 B

SA PYRO.DEPLOY.

ASSY

SOLAR ARRAY

PHYSICALPROPERTIES

REFLEC.PYRODEPLOY.ALIGN.

SATELLITE PREPARATION FOR FLIGHT

ASSY

SA INSTAL.MAN.

DEPLOY& CHECK

SAFOLDING

MASSPROP.

CHECKASSY SHIPMENT

PREPAR.

MLISOLARARRAY

FAR

TO LAUNCH SITE

SPT2 A

PIM's

ElectricalPerf. tests

2

MECHANICAL ENVIRONMENTAL TESTS (1)

TANKFILLING

SIMULATIONLIQUIDS

SINEVIBRATION

MECHANICALINSTRUMENTATION

EMCLAUNCH

EMC RE/RS

UPSTESTScomp.

IF NECESSARY

GNDVERIF.TEST

REFLECTORS & FEEDSALIGNMENTS vs S/C

TANKPRESSURISAT

ION

vibrationpreparation

UPSPerf.Tests PACK

CATRGLOBAL

LEAKCHECK

BODYALIGN.VERIF.

IF NECESSARY

IF NECESSARY

Satellite Test Plan


Assembly, Integration & Tests (AIT) Plan

Activities performed during AIT are detailed in the AIT plan which defines the scope of each phase

Each AIT phase is governed by reviews (Test Readiness Review -TRR and Test Review Board - TRB) and a leading procedure which calls modular tests execution.

The elementary tests which are performed all along the AIT Sequence are defined in the subsystem test matrices which summarize for each elementary test (defined by a test requirement) in which AIT phase it has to be performed.

Satellite Test Plan


INITIAL SYSTEM PERFORMANCE TEST: SYSTEM PERFORMANCE TESTS 1 PART A SPT1A

After SM/CM mechanical assembly, interface testing and S/C Final integration, the Satellite will be subjected to the reference system performance measurements.

The SPT1A will be as follows:

Body alignmentsElectrical performance testsUPS testsEMC CE/CS & ESD tests (can be postponed to SPT2A phase)Antennas mounting and alignmentFlight batteries installation, connection and beginning of charge

maintenance (ST3 option).

Satellite Test Plan


THERMAL VACUUM TESTS

Those tests occur in the ALCATEL 550 m3 thermal vacuum chamber and are composed of:

The Thermal Balance Test (TBT) applied to the PFM satellite The Thermal Cycling Test (TCT) applied to all models.

Objectives: To qualify the mathematical model in order to predict performances under flight

condition (TBT) To verify the validity of the thermal control concept chosen (TBT) To verify the thermal behaviour (dissipation's, gradients) of units (TBT) To verify the performances of units and Subsystems under environment

representative of external conditions encountered during all spacecraft lifetime (vacuum, cold and hot temperature, CORONA effect) (TCT).

To serve as a complete spacecraft burn-in. To perform eclipse discharge simulation. To verify the spacecraft contamination criteria (TCT)

Satellite Test Plan



The hardware configuration of the satellite is similar to the flight configuration with the following exceptions:

The propellant tanks are empty, but are pressurised with about two bars of gaseous nitrogen

The Solar Arrays are not mounted E/W reflectors are not mounted, but the Earth antenna is installed

and both East/west feeds will be installed on test shim plates (ST8 option)

RF energy is dissipated into RF loads via non flight waveguides connected to input/output of the repeater

The flight PROM is not yet installed, replaced by an EM EEPROM (TBC)

Satellite Test Plan


THERMAL VACUUM TESTS The satellite is installed on the thermal adapter in the vacuum

chamber. The adapter is superinsulated and is thermally isolated from the satellite by insulating washers. The dolly interface frame is temperature controlled during all the test. In addition, spacecraft horizontality is also controlled during the test in order to have heat pipes in operating conditions.

During the thermal vacuum tests, the satellite temperature is controlled using :

the cold shrouds & cryopanels, thermocouples and S/C Telemetry (flight thermistors) satellite heaters test heaters installed on the satellite (if any)

IR heaters installed around the satellite when necessary. Each one is commanded and monitored independently in order to obtain the temperature required for the test.

The massive quantity of thermocouples allows the temperature monitoring of all units dissipating more than 10 W as well as every units described in the STAR ONE C1 performance specification. Some additional thermocouples (direct channel) are used for the monitoring of extra spacecraft hardware: thermal test adapter, I/F with test equipment’s.

Satellite Test Plan


Satellite Test Plan



It is foreseen to submit the model to 3 cycles of thermal vacuum conditions and to perform all tests mentioned in the matrices. Tests are performed during the 2 first hot and cold plateaus. The third cycle will give opportunity to perform retest or investigation. For FM, a specific screening test will be performed (ST7 option).

The thermal cycling test is needed at system level but not specially for subsystem thermal control purpose. Nevertheless, the temperature level of the spacecraft during these tests is assured by thermal control subsystem, under his responsibility.

Contamination probes are installed in the vicinity of the satellite and analysed after test to determine outgazing products. After removal from the vacuum chamber, the satellite will be inspected.

Satellite Test Plan


PRE ENVIRONMENTAL TESTS SYSTEM PERFORMANCE TESTS 1 (part B)

SPT1B

The SPT1B will be sequenced as follows:

Body alignment verification

Antenna mounting, deployment and alignment verification

Solar arrays mounting, deployment, illumination & folding

Satellite Test Plan


MECHANICAL ENVIRONMENTAL TESTSThe aim of these tests is to demonstrate the ability of the Satellite to be submitted to the launch environment conditions (vibrations, acoustic noise and shock) with margins, without suffering performance degradation.

The sequence of tests will be split as follows:Tanks filling (simulation fluids)Sine vibration testPost sine vibration testAcoustic noise testPost acoustic verificationAdapter fit check and separation shock test (if

required)Tank draining.

Satellite Test Plan


MECHANICAL ENVIRONMENTAL TESTS

Tank fillingIn order to reach a representative satellite mass and dynamical behaviour, the tanks will be filled with simulation liquids and pressurised to an adequate pressure.

Satellite Test Plan



Sine Vibration testThe satellite, in its launch configuration, clamped upon test adapter, and with tanks filled with simulation fluid will be subjected to vibration test along each one of the three orthogonal X, Y and Z axes.The sequence of events for each vibration axis will be as follows:

initial no-notched very low level runs (entry 0.05g) 5-150 Hz; no-notched low-level run (entry 0.2g) 5-150 Hz intermediate level (entry half protoflight level and half notching

level) 5-100 Hz STAR ONE protoflight level 5-100 Hz no-notched low-level verification sweep for comparison to initial

satellite signature.

Satellite Test Plan


Satellite Test Plan


Mechanical environmental tests

During the test, the satellite will be in electrical launch configuration and TM and TC RF links will be verified.

Post sine vibration testAfter the vibration tests a visual inspection will be performed on the satellite, then a short TM/TC verification will be carried out.

Satellite Test Plan



Acoustic noise testThe Satellite will be installed into the chamber and submitted to the required acoustic environment as defined by arianespace.

The spacecraft will be in electrical launch configuration and will be controlled through TM and TC video links.

Post acoustic noise test verificationBefore the first run and after each subsequent run, a visual inspection will be carefully performed on secondary structures, thermal insulation and on outside equipment such as Solar Array wings and antennas.

Satellite Test Plan


Satellite Test Plan



Adapter fit check and separation shock test (if required)The aim is to demonstrate the mechanical and electrical compatibility of the satellite with the adapter, and to verify that the separation shock does not damage the satellite. This test includes the pyrotechnic release of a flight representative clamp-band.

Tank drainingThe tanks will then be dried by flushing with hot and dry nitrogen. The heaters installed on the lower portion of the tanks are used. Dryness will be verified by gas chromatography.

Satellite Test Plan


POST ENVIRONMENTAL VERIFICATION SYSTEM PERFORMANCE TESTS 2 (part B)

SPT2B

The SPT2B will be sequenced as follows:

Solar array verification

Antenna pyro deployment and alignment verification

Satellite Test Plan


FINAL SYSTEM PERFORMANCE TEST SYSTEM PERFORMANCE TESTS 2 (part A)SPT2A

The SPT2A will be basically similar to the SPT1A and the test results will be compared to verify continued satisfactory performances of the Satellite.

SPT2A sequence is as follows:Body alignments verification,Electrical Performance Test,UPS tests,Ground Station compatibilityMCI

Satellite Test Plan


Compact Antenna Test Range (CATR) Test

This phase includes all activities done in the CATR environment:Antenna VSWR and DecouplingEMC RE Launch compatibilityS/C Radiated Auto-compatibilityAntenna patterns, EIRP, IPFDPIM’s (if necessary)

A test of the fully assembled protoflight satellite, except Solar Arrays, is performed on the compact indoor antenna range as a part of the Final System Performance Test. The compact indoor antenna range is capable of evaluating the far field RF performance of the satellite.

Satellite Test Plan


FINAL OPERATIONS

The final operations will be sequenced as follows:

Solar array installation

Reference OMUX bandwith test

Final MCI (thruster’s adjustment)

Global leak test

Satellite Test Plan

1 - asp-05-str1-263 m054-1 tous droits réservés © alcatel space industries all rights reserved...

Documents

elementary tests

test requirement

system performance tests

thermal balance test

alcatel space ait sequence

thermal cycling test

alcatel space assembly

subsystem test matrices