Title: Agenda: LAT Environmental Test TIM, Day 1: Structural
1Agenda LAT Environmental Test TIM, Day 1
Structural
- Introduction ? 830 845
- Morning Planning Meeting ? 845 1200
- Sine Vibration Test Planning Meeting ? 845
1015 - Acoustic Test Planning Meeting ? 1030 1200
- Lunch ? 1200 100
- Facility Tour ? 100 315
- Acoustic Test Planning ? 100 145
- Sine Vibration Test Planning ? 145 245
- Mass Properties Planning ? 245 315
- Afternoon Planning Meeting ? 330 530
- Mass Properties Summary ? 330 345
- Sine Vibration Summary ? 345 415
- Acoustic Test Summary ? 415 445
- Action Item Review ? 445 530
2Agenda Morning Planning Meeting
- Sine Vibration Test Planning Meeting ? 845
1200 - Action Item List Status (JK) ? 845 900
- Status of the Test Plan (JK) ? 900 915
- Detailed Test Sequence and Current Test
Configuration (JK) ? 915 1000 - Other Logistics (All) ? 1000 1015
- Break ? 1015 1030
- Acoustic Test Planning Meeting ? 1030 1200
- Action Item List Status (JK) ? 1030 1045
- Status of the Test Plan (JK) ? 1045 1100
- Detailed Test Sequence and Current Test
Configuration (JK) ? 1100 1145 - Other Logistics (All) ? 1145 1200
3Sine Vibration Test Planning Updated Action Item
Status
4Sine Vibration Test Planning Updated Action Item
Status (cont)
5Sine Vibration Test Planning Test Plan Status
- 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
- Many technical details have been addressed in
previous meeting, and just need to be collected
and summarized many of these points will be
raised today, and agreements made will go
directly into plan - Instrumentation list is nearing completion, but
not finished yet - Internal accelerometers defined and CAD layout
complete - External accelerometer mathematical positions
defined, but CAD layout needed - Strain gauges (12 channels) on flexures expected,
but not defined yet (NRL can accommodate up to 40
channels, ¼ bridge) - Entrance/Exit criteria are well understood by all
- No failure or damage to the LAT assembly as
determined by physical inspection - No significant changes to the dynamic signature
as determined by the pre and post low-level sine
vibration inputs - No significant degradation of instrument or
system performance
6Sine Vibration Test Planning Test Plan Status
(cont.)
- 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 ManagerBill 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 Darren Marsh (or Doug
Bartholomew) (SLAC) - IT 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
7Sine Vibration Test Planning Test Plan Status
(cont.)
- 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 - EGSE Constraints
- Cables
- If harnesses are heavy, they should be
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?
8Sine Vibration Test Planning Test Plan Status
(cont.)
- Test Requirements
- MGSE Constraints
- Test Interface Plate
- Accommodates Spectrum-specified flexure mounting
procedures - Should not have any modes less than 225 Hz (1.5 X
150 Hz) - Should be one order of magnitude stiffer than the
flexures - Mass should be small enough to not significantly
impact Z-axis test - Light enough to allow for using GPR to lift
LATTIP within its current rated load (3000 kg) - CG should be in-line with LAT and should position
LAT CG through each drive axis - Sufficient strength to carry all test loads with
margin - Interface with NRL slip table and expander head
- Cable support structures
- Should allow free motion of cables between
vibration equipment and ground - Should be grounded well to prevent tipping
- Allow access to vibe equipment, connector panels,
blankets and externally mounted accelerometers - Test stand / handling dolly
- Should be grounded well to prevent rolling
- Should be located near shaker, and accessible by
the vibe lab crane - Radiator mass simulator needed?
9Sine Vibe Mechanical Issues
- Known issues to be worked
10Sine Vibe Test Configuration
Test Interface Plate fits completely on expander
head
LAT appears toclear rotationof expander head
Check on clearance to off-load frame
LAT on Expander Head (with auxiliary support)
LAT on Shaker Table
11Sine Vibe Test Configuration (cont.)
Check on total height of 4x4 Lift Fixture lifting
GPR over top of ACD
Check on clearance and access around underside of
GPR
LAT on Expander HeadShowing GPR Lift with 4x4
Lift Fixture
12Sine Vibe MGSE Concept
- Test Interface Plate
- Provides single interface for LAT in all test
configurations - Mimics SC top deck
- Ensures accurate alignment of SC flexures
Plate serves only to accurately position
brackets, not to carry vibe loads
Test Interface Plate with SC Flexures(on
expander head)
Mount brackets transfer load from flexure
directly to table
Test Interface Plate with SC Flexures(on slip
table)
13Sine Vibe MGSE Mount Detail
14Sine 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)
15Sine Vibration Test Planning Detailed Sequence
(cont.)
- Z-Axis Vibration Test (continued)
- Full-level run to 50 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 - Low-level Signature Sine Sweep to 150 Hz
- 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
16Sine Vibration Test Planning Detailed Sequence
(cont.)
- X-Axis Vibration Test
- 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 - Half-level run to 50 Hz
- Same steps as Z-axis test
- Give OK to proceed (SLAC), or decide alternate
action is needed - Full-level run to 50 Hz
- Same steps as Z-axis test
- Give OK to proceed (SLAC), or decide alternate
action is needed - Low-level Signature Sine Sweep to 150 Hz
- 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 - Lower LAT to slip table and torque bolts
- Perform vibration control system checkout (no
EGSE hook-up here)
Shaker
Slip Table
Shaker
Slip Table
17Sine Vibration Test Planning Detailed Sequence
(cont.)
- Y-Axis Vibration Test
- 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 - Half-level run to 50 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 - Low-level Signature Sine Sweep to 150 Hz
- 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
18Sine Vibration Test Planning Test Configuration
- Mechanical Configuration
- Radiators not attached
- Are mass simulators required to represent load
path from radiators? - Currently no mass simulators are baselined
- Mounted to GD/Spectrum Astro-provided test
flexures - 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
- Voltage type accelerometers have BNC connectors
to interface with NRL - Strain gauges do not have connectors (open leads)
- EGSE needed for LPTs between axes (Rich Baun to
define requirements) - Procedures
- 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
19Sine Vibration Test Planning Logistics and A/I
Closure Plans
- Many logistics can be discussed during the tour
- Any issues rotating shaker
- Verify slip table and expander head size, inserts
and pattern - CG Alignment / sensitivity of equipment to
offsets - Instrumentation patch panels and cable supports
- Floor space to set GPR and other GSE down
- Capability and benefit of using force gauges
- 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 - Complete and release drawings/model of slip table
and expander head - Complete detailed design and analysis of TIP and
flexure mount brackets - Check on hook height in vibe room to ensure we
can remove GPR when LAT is on expander head - Develop paper doll work-up to verify we have
floor space for 2 carts, GPR, and 4x4 Lift
Fixture - Develop requirements for Radiator simulator for
sine vibe - Lay out EGSE cable routing and locate EGSE crates
- Identify what contamination and humidity control
is needed in vibe facility - Verify response / control channel capability
- Is GN2 purge neccesary?
20Acoustic Test Planning Action Item Status
21Acoustic Test Planning Test Plan Status
- 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
- Many technical details have been addressed in
previous meetings, and just need to be collected
and summarized many of these points will be
raised today, and agreements made will go
directly into plan - Instrumentation list is nearing completion, but
not finished yet - Internal accelerometers defined and CAD layout
complete - External accelerometer mathematical positions
defined, but CAD layout needed - Strain gauges (12 channels) on flexures expected,
but not defined yet - Entrance/Exit criteria are well understood by all
- No failure or damage to the LAT assembly as
determined by physical inspection - Inspection of plastic sheet under LAT does not
produce any fibers, chips or fasteners - No significant changes to the dynamic signature
as determined by the pre and post low-level
acoustic vibration inputs - No permanent deformations in the LAT structure or
of any subsystem or component - No significant degradation of instrument or
system performance
22Acoustic Test Planning Test Plan Status (cont.)
- 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 ManagerBill 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 Darren Marsh (or Doug
Bartholomew) (SLAC) - IT 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
23Acoustic Test Planning Test Plan Status (cont.)
- 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 - EGSE Constraints
- Cables
- Must be long enough to reach LAT while mounted to
test stand - Cart with EGSE Hardware
- Portable, can be rolled into and out of the
chamber, if needed - If cart is moved, does EGSE system need to be
checked out again? - Power interface to lab?
24Acoustic Test Planning Test Plan Status (cont.)
- Test Requirements
- MGSE Constraints
- Test Interface Plate
- Should be one order of magnitude stiffer than the
flexures - Sufficient strength to carry all test loads with
margin - Can serve as SC top plate simulator
- Cable support structures
- Should allow free motion of cables between
vibration equipment and ground - Should be grounded well to prevent tipping
- Allow access to connector panels, blankets and
externally mounted accelerometers - Test stand / handling dolly
- Must accommodate mounting of radiators, with
lower strut supports simulated - The LAT should be positioned such that the flat
panels are a minimum of 15 from parallel to any
of the test cell walls (45 preferred) - Current strut design has rattle design to be
flight-like? - Radiator plane should be lined up with high flow
(2000 cfm) woofer to prevent air foil effect - Contamination is tenting needed humidity
- MGSE Concept being worked on at SLAC (Martin
Nordby)
25Acoustic Test Test Configuration and MGSE
This configuration is identical to EMI Test
configuration
Test Interface Plate mounts LAT to Test Stand
Facsimile SC struts support Radiators with
comparable stiffness
Need to establish required height off groundcan
be handled by a separate stand
LAT on Test Stand(one Radiator removed
26Acoustic Test Planning Detailed Sequence
- Pre-test Activities
- Chamber Setup and empty cell calibration
- 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 - Move LAT on dolly (radiators already installed)
into chamber and secure dolly to chamber floor
(orientation 45 TBD) - 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) - 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 ASDs and strain gauge SSDs
(NRL) - Review data (SLAC)
- Check for dead channels
- Review mic average for level and chamber
uniformity - Review Grms values for obvious anomalies
27Acoustic 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
- As level steps up to -3dB, check critical channel
linearity and record data - Hold at full level for 60 seconds
- 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 ASDs and strain gauge SSDs
(NRL) - Review data (SLAC)
- 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
28Acoustic 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
- Disconnect dolly from floor and move LAT out of
chamber
29Acoustic Test Planning Test Configuration
- Mechanical Configuration
- Radiators attached (with flight thermal joint)
- Need to ensure thermal joint has enough time to
cure (7 days RT) - Mounted to GD/Spectrum Astro-provided test
flexures - 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 (temporary scaffold
or ladder around MGSE) on X side - Layout needed to check cable run lengths
- Electrical Configuration
- Voltage type accelerometers have BNC connectors
to interface with NRL - Strain gauges do not have connectors (open leads)
- EGSE needed for LPTs before and after test (Rich
Baun to define requirements) - Procedures
- 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
30Acoustic Test Planning Logistics and A/I Closure
Plans
- Many logistics can be discussed during the tour
- Lip at threshold (how to transport into room)
- Mic placement / adjustability
- Cleanliness (need blanket?) is rating worse
than 100K? - Height off ground (Chris Fransen believes current
configuration should be okay, but need to check) - Placement in room (note any obstructions)
- Note flow rate of pneumatic horns and possible
currents in chamber - Instrumentation feedthrough and cable supports
- Floor inserts to secure LAT
- Is a dust tent needed around LAT in acoustic
chamber - What type of panels are needed in/around LAT to
simulate SC response - Accommodation for moving Test Stand over ½ door
sill - How high does Radiator need to be off the floor
affects Test Stand spacer height - A/I Closure plans
- Any action items unanswered by the end of the
meeting will be tracked on a weekly basis - Lets take a lunch break and come back for the
tour
31Agenda Facilities Tour
- Acoustic Test Planning ? 100 145
- Overview (BR) ? 100 110
- Run through test sequence described earlier (JK)
? 110 125 - Other things to discuss (All) ? 125 145
- Sine Vibration Test Planning ? 145 245
- Overview (BR) ? 145 155
- Run through test sequence described earlier (JK)
? 155 210 - Things to discuss (All) ? 210 230
- Control room (BR) ? 230 245
- Mass Properties Planning ? 245 315
- Overview (BR) ? 245 255
- Action Item List Status (JK) ? 255 300
- Run through test sequence (JK) ? 300 310
- Discuss capabilities of spin table and decide is
MOI is needed (All) ? 310 315
32Facilities Tour Mass Properties
- Mass Properties Planning ? 245 315
- Overview (BR) ? 245 255
- Action Item List Status (JK) ? 255 300
- Run through test sequence (JK) ? 300 310
- Remove non-flight instrumentation
- Move LAT and dolly into mass properties area
- Lift LAT onto MOI table and measure mass, Izz,
and Xcg and Ycg - Turn Dolly over to Z-horizontal configuration
- Attach three load cells beneath handling dolly
and measure mass and Z-cg - Turn dolly back to Z-vertical position
- Return LAT to Dolly
- Turn LAT and dolly over to Z-horizontal
configuration - Measure combined mass and Zcg
- Discuss capabilities of spin table and MOI
(pendulum) table and decide is MOI is needed
(All) ? 310 315
33Agenda Afternoon Planning Meeting
- Mass Properties Summary ? 330 345
- Agreements made today (JK) ? 330 335
- Items that still need to be worked out (All) ?
335 340 - Path to test (JK) ? 340 345
- Sine Vibration Summary ? 345 415
- Agreements made today (JK) ? 345 355
- Items that still need to be worked out (All) ?
355 405 - Path to test (JK) ? 405 415
- Acoustic Test Summary ? 415 445
- Agreements made today (JK) ? 415 425
- Items that still need to be worked out (All) ?
425 435 - Path to test (JK) ? 435 445
- Action Item Review 445 530
- Collect action items (JK) ? 445 500
- Read through action items (JK) ? 500 515
- Other? (All) ? 515 530
34Mass Properties Summary
- Agreements made today
- MOI Spin table is not ideal for our needs
- Static CG and Mass measurement can be
accomplished with load cells - If we want a 2mm CG resolution, then a 15lbf load
cell resolution is needed - Static LAT mass is up to 3000 kg (6614 lbf).
- If three load cells are used, each load cell
should be rated to 2205 lbf /- 15lbf - Items that still need to be worked out
- Check IRD MAR for CG requirement
- Reqmt is lt20mm for Xcg and Ycg
- Reqmt is lt185mm above LIP
35Sine Vibration Summary
- Agreements made today
- EGSE out of room if cables are long enough
(desirement, not requirement) - Verification of accels at SLAC using a 1g shaker
before mounting, tap check and touch check after
mounting - Keep full level vibe spectrum as is (with changes
in sweep rate) - Low level sine sweep up and down
- NRL to provide accel hookup to LAT
- QA managed by SLAC (Darren Marsh), but staffed by
SLAC and NRL - Proof Test MGSE at SLAC
- Items that still need to be worked out
- Structural analysis of TIP and associated MGSE
- Is mass simulator for radiators needed
- Determine need for force gauges
- Simulate LAT on fixture to check for fixture
modes - Path to test
- Force gauge decision by 3/25
- Release test plan by 3/25
- Plan for Mid to late April PDR (with most A/Is
closed) - Complete pretest analysis and release memo one
month prior to test
36Acoustic Summary
- Agreements made today
- No straps needed
- Radiators low to floor (3-5cm) is okay
- Line up radiator plane to main woofer output
- Omit mid-level run ? just monitor and collect
data - Go from full level to low level immediately (no
data review) - Use wheels instead of air bearings ? need to
decide on pneumatic or solid tires - Items that still need to be worked out
- Verify top plate adequately simulated with MGSE
- Path to test
- Release test plan by 3/25
- Complete pretest analysis and release memo one
month prior to test
37Action Item Review (New ones only)
38Dynamics Tests Action Item Form
- Topic / presentation slide number
- Submitted by
- Actionee
- Request
- Reason / Comment