all logos, trademarks and images in this page are of their...

All logos, trademarks and images in this page are of their respective owners. AVC-BRC-722-001-en Rev. E July. 2013

PASSIVE THERMAL CONTROL ELECTRICAL SUB-SYSTEM

AEROSPACE

DESIGN

MANUFACTURING

INTEGRATION

MULTI LAYER INSULATION (MLI) BLANKETS

ELECTRICAL HARNESS

All logos, trademarks and images in this page are of their respective owners.

Designed for the extreme conditions

AVC-BRC-722-001-en Rev. E July. 2013


Since its beginning Aviotec supported Thales Alenia Space Italy in MLI and MDPS manufacturing for ISS Programs starting from Node 3 and Cupola. Today, Aviotec is a specialized company involved in design and manufacturing of:

About us

MLI blankets for Spacecraft’s Passive Thermal Control System

Micrometeroid and Debris Protection System bumpers

Manned Spacecraft’s internal items as: Cargo Transfer Bag Rack Internal Belts Nomex Mesh Net

Electrical Harness for Spacecraft and Aircraft application



The Aviotec manufacturing facilities are divided in two separated areas. One is for the Electrical Harness and the second one is dedicated for the Multi Layer Insulation blankets. Both areas are under environmental control concerning: contamination, humidity and temperature. The cleanliness level stays within ISO 14644-1 Class 8 particles concentration. The requirements are maintained under control by the monitoring of 0,5µm, 1µm and 5µm particle size using a TSI AEROTRAK® particle counter.

Manufacturing Area

AEROTRAK® Particle Counter MFG Multi Layer Insulation Area MFG Electrical Harness Area



The High-Quality of the Aviotec’s products is ensured by the experience acquired in several Space programs as:

Background Experience

NODE 3 • MDPS Bumpers

CUPOLA • MLI Blankets

PMM • MDPS Bumpers

ATV • MLI Blankets and MDPS bumpers

• Electrical Harness Flight Model Unit 5

CYGNUS PCM • MLI blankets and MDPS bumpers

• Electrical Harness Flight Model Unit 3

PRISMA PAYLOAD • MLI Blankets

FLPP IXV • Mock-up for electrical harness manufacturing

• Electrical Harness Flight Model Unit



ISS Cargo Transfer Bags ISS Retaining Belts

Node3 &

Cupola

NODE3 (2008) Manufacturing of Microeteorite and Debris Protection System (MDPS) composed of kapton nomex, nextel and kevlar layers.

CUPOLA (2008) we built Multi-layer insulation composed by aluminized beta cloth and kapton nomex.

PMM

PMM (Permanent Multipurpose Module) ex Leonardo MPLM: In 2009, Aviotec produces MDPS (Meteorite and Debris Protection System) for shielding improvement to satisfy the new requirement and stay additional 10 years in orbit with ISS.

Bags &

Belts

Customer:



Automated Transfer Vehicle

Manufacturing of MLI blankets & MDPS

Customer:



Automated Transfer Vehicle

Customer:

Manufacturing of MLI blankets & MDPS



CYGNUS PRESSURIZED CARGO MODULE

Customer: Manufacturing of MLI blankets & MDPS AVC-BRC-722-001-en Rev. E July. 2013


Prisma Payload

Customer:

Design & Manufacturing of

MLI blankets



Design and Development process on CATIA V5

Starting from Spacecraft structure 3D model step file and Thermal Requirement Specification delivered by the Customer, Aviotec develops the MLI blankets.

The design is focused to obtain the MLI blankets shape taking into account the minimization of thermal leaks, definition of fasteners points and grounding, as well as easy mounting and dismounting of the blankets for accessibility to required areas. On the basis of the 3D shape, Aviotec prepares the 2D Master Template Tool for MLI blankets Manufacturing.



Design & MFG Flow



3D Model STEP file (Input from customer)

MLI blankets 3D Model Design

(Catia V5)

Manufacturing 2D Template Tool

Blanket Manufactured

Hardware

Design

&

MFG

Flow



EVERY CRIMPING’S TOOLS ARE CALIBRATED AND SEALED

AVIOTEC PERFORM CRIMPING OPERATIONS IN ACCORDANCE WITH ESA “ECSS-ST-Q-70-26C”

DEDICATED STRIPPERS FOR EACH TYPE OF SPACE WIRE

ELECTRICAL HARNESS

CONTROL PROCESS

TEST

“GO NO-GO” GAUGE DAILY CHECK

TENSILE STRENGTH EVERY 100 CRIMPING OPERATION FOR EACH TOOL

VOLTAGE DROP TEST

MICRO-SECTION

ELECTRICAL TEST CHECKER:

INSULATION

CONTINUITY



ELECTRICAL HARNESS GALLERY

ESA CIRCULAR CONNECTOR 3401056 BASED ON MIL-C-38999 SERIES III CRIMPING - ESA ECSS-Q-ST-70-26C

3D HARNESS ROUTING HARNESS DURING MANUFACTURING IXV PDU HARNESS

IXV HARNESS BUNDLE



Customer:

FLPP IXV FLIGHT MODEL ELECTRICAL HARNESS MANUFACTURING

MANUFACTURING OF HARNESS ON MOCK-UP BUILT BY AVIOTEC IXV MOCK-UP IN AVIOTEC CLEAN ROOM



Customer: NASA PROJECT: RECYCLE FOR LIVING

AVIOTEC PROTOTYPE BAG IN AVIOTEC CLEAN ROOM

ISS CARGO TRANSFER BAG STANDARD

FORWARD OSMOSIS CTB INTERNAL BAG PLUMBING LAYOUT

UNFOLDED CTB INCORPORATED INTO WALL ELEMENTS SUCH AS DIVIDERS AND A CHAIR

INTERNAL LAYOUT SOLUTION POCKET FOR FORWARD OSMOSIS MEMBRANE



AEROSPACE QUALITY

• MLI IDENTIFICATION LABEL: Application of ID label made of kapton reporting P/N and

S/N according to customer CIDL • PACKAGING:

Double bag in anti-static nylon and hygroscopic salts MLI collocation in Transport Container and Shipping to the

customer • DOCUMENTATION DELIVERED FOR EACH MLI:

Worksheet with recording data of: P/N and Batch Number of material used Stamp of Date and ID operator step by step for all

operation Stamp of Quality Inspector ID step by step for all

operation Weight

Electrical conductivity test report Check List of all inspection performed during MIP Certificate of Conformity

The manufacturing process of MLI envisages the following on-ground validation activities: • VERIFYING OF INCOMING DOCUMENTATION AND CHECKING THE

REPRODUCTION SCALE OF MASTER TEMPLATE: analysis of the specifications and drawings for preparation

of worksheet checking the dimensional deviations by measuring the X and

Y ruler indicators on master template and recording the values

• MATERIALS ACCEPTANCE AND STORAGE: incoming inspection and acceptance report recording in company’s database software of all material

traceability features identification of materials through ID tags and Q.C. stamp

• MLI MANUFACTURING: Preparation of material kit according to part list recording of material traceability features (p/n and batch

number) in dedicated worksheet of MLI internal multilayer preparation according to part list and

recording in “Multilayer Preparation Sheet” (MPS) recording of all operations step by step and related Q.C.

inspection during MLI manufacturing • MLI FINAL ACCEPTANCE:

Notice to the customer and final Quality Inspection (MIP)

AVIOTEC Quality Management System is certificated EN 9100:2009 and ISO 9001:2008 with the following scope:

DESIGN, PRODUCTION AND INTEGRATION OF MULTI LAYER INSULATION BLANKETS (MLI) FOR AEROSPACE APPLICATION.

PRODUCTION OF ELECTRICAL HARNESS FOR AEROSPACE APPLICATION.

PRODUCTION OF FABRIC ARTICLES FOR AEROSPACE APPLICATION.



EVENTS:

PARIS, LE BOURGET AIR SHOW 2013 ILA BERLIN AIR SHOW FARNBOROUGH AIRSHOW

AEROSPACE & DEFENSE MEETINGS TORINO

JUNE 17-23 2013 MAY 2012 JULY 2012

OCTOBER 2013


All logos, trademarks and images in this page are of their respective owners. AVC-BRC-722-001-en Rev. E July. 2013

all logos, trademarks and images in this page are of their...

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