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NASDAT & EIP Critical Design Review (CDR)

NASDAT & EIP Critical Design Review (CDR). ARRA Task 88 NASA ASF, 9/15/2011. Contents. Background Requirements Documents & Drawings Workmanship Experimenter Interface Panels (EIPs) NASA Airborne Science Data Acquisition and Transmission units (NASDATs) Aircraft Installations & Status

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NASDAT & EIP Critical Design Review (CDR)

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  1. NASDAT & EIPCritical Design Review (CDR) ARRA Task 88 NASA ASF, 9/15/2011

  2. Contents • Background • Requirements • Documents & Drawings • Workmanship • Experimenter Interface Panels (EIPs) • NASA Airborne Science Data Acquisition and Transmission units (NASDATs) • Aircraft Installations & Status • Future Work • Budget & Schedule • Hardware Management

  3. Background • Why are we doing this? Sensor Web – A distributed and coordinated network of sensors which collectively act as a single “macro- instrument.” (Delin, Sensors Magazine 4/1/2004)

  4. Background • How this work is funded & requirements: • American Recovery & Reinvestment Act (ARRA): • Build enough EIPs and NASDATs to support ER-2 and WB-57 • Task expires 10/31/11 • FY11 Overguide • Build out remaining, known hardware requirements for Global Hawk and other aircraft • Allocations & details at end of CDR

  5. Background • Highly-Simplified System Block Diagram:

  6. Key Requirements • EIP: • Match the capability in the ER-2 experimenters handbook, and… • Support legacy instruments • Monitor DC power & transmit over ethernet • Provide ethernet switch • Fit in existing ER-2 & WB-57 footprint • Easy to install in existing planes with skeleton crews • Pass customer QA & workmanship requirements

  7. Key Requirements • NASDAT:

  8. Documents & Drawings • Key EIP Design Documents: • Assembly Drawing (a9444-ASF11-342A) • Enclosure Drawing (a9444-ASF11-341A) • Ethernet Module (EIP-ASSY-001) • AC Distribution Card (EIP-ASSY-002) • DC Monitor Card (EIP-ASSY-003) • Solid State Power Controller Card (EIP-ASSY-004)

  9. Documents & Drawings • NASDAT:

  10. Workmanship • Not many houses build to the NASA 8739.x workmanship standards • No COTS board vendors build to 8739.x • How can we maintain quality, compatibility with the standards, and meet $ & schedule? • Many workmanship standards are compatible with the NASA 8739 standards • Ex. All flight Global Hawk PCBs built to IPC-610/III & inspected at DFRC

  11. Workmanship

  12. Workmanship

  13. Experiment Interface Panels

  14. EIP • EIP Versions: • Mark I: 1990s – Legacy ER-2 & WB57 units • Cabling patch-through with low-current relays to handle cockpit switch interface • Mark II: 2009 - Global Hawk • First cut at fleet-wide design, ended up being GH-specific • Mechanical relays, lots of wire, no ethernet switch inside • Mark III: 2011 – ER-2, WB-57 • Meets power requirements of MK1 design • Manned aircraft interface • Incorporates ethernet switch • Leverages technology not available during MK2 design

  15. EIP • Power Requirement (ER-2 Experimenter Handbook): (25A x 2 ckts) (79A) (50A x 2 EIPs) (72Ax2 EIPs) (79A) (30A) (30A) DC CURRENT REQUIREMENT: 79A per EIP (2.2kW) AC CURRENT REQUIREMENT: 50A / Ф, per EIP (17.25KVA)

  16. Replace J1-J4 with smaller connectors that only have switch/fail/interlock EIP Instrument Power connectors changes to 38999 21-16 (same as MK2) (MK1) Still supporting 35Ax2 output but on one connector Fuse circuits internally, use poly fuses where tempco is not an issue Replace J13 & J14 with Ethernet; leave aircraft wire in place & use as needed. Ship-side signals (DC, AC, Control input) connectors are drop-in compatible.

  17. EIP J6-J9: MIXED AC/DC CONNECTORS J2-J5: COCKPIT (“AIRCRAFT SIGNALS”) MK3 Proto Front Panel: J4: 35A X2 DC OUT Mission Critical 15A AC/DC & Control 15A AC/DC & Control 2x50A DC Output Control & Data Input Mission Critical J5: DATA (“AIRCRAFT SIGNALS”) EIP POWER (DCMON & ETHERNET SWITCH) Mission Critical 15A AC/DC & Control 15A AC/DC & Control 3Ф AC Input Legacy Output 8x100 Mb Ethernet 4x1Gb Ethernet J19-20: (4) 1Gb ETHERNET DC POWER (TRU) J16-17: (8) 10/100 ETHERNET

  18. EIP EIP Left Panel: Mission Critical DELETED FOR FLIGHT UNIT 15A AC/DC & Control 15A AC/DC & Control 2x50A DC Output Control & Data Input Mission Critical J18: COCKPIT, DATA, EIP POWER, EIP ID J15: 35A X2 DC INPUT J16: 3Ф AC INPUT (2 CKTS) Mission Critical 15A AC/DC & Control 15A AC/DC & Control 3Ф AC Input Legacy Output 8x100 Mb Ethernet 4x1Gb Ethernet

  19. EIP • Flight unit connector labeling will match existing ER-2 drawings:

  20. L1/L2/Omnistar GPS (coax) (Global Hawk only) 3Ф, 400Hz AC Circuit #1 (15A/Ф)* 3Ф, 400Hz AC Circuit #2 (15A/Ф)* 28VDC Circuit #1 @ 15A (H: Power) 28VDC Circuit #2 @ 15A (D: Power) IRIG-B (coax) Switch (from cockpit) (N.O. & COM) @ 5A EIP • J6-J9: Standard AC/DC Connector (Amphenol D38999/20WG16SN) • 16 x AWG #16 contacts, same pinout as Global Hawk EIP * - Recommended loading varies per plane & based on SAE50881 analysis

  21. EIP • MK2 & MK3 AC/DC Connector Differences: • No GPS splitter in MK3 units (pin M) • Command Relay (pins P & R) • MK2 relay is a mechanical relay – each pin is passive • MK3 relay is an active device (5A SSPC) • Input must be applied to ‘COM’ pin (P), output to ‘N.O.’ pin (R) • 3-Ф AC Circuits’ wire rating • GH rates circuits @ 10A/Ф, ER-2 & WB @ 15A/Ф • Both units use #16 wire, different rating philosophy

  22. EIP • MK1 vs. MK3 “Aircraft Signals” Connectors: • MK1 had 5, MK3 has 1 full (J1) + 4 small (J2-J5) • J1: Switch #1, Pin-for-pin compatible with MK1 J1 • Uses same M39016/19 relay as MK1: NC/NO/COM contacts, rated @ 1A resistive • Adds AD590/AC2626 temp sensor, read out in EIP status packet • Labeled “DATA” on MK3 • J2-J5 – Switches #2-5, WoW/Alt relays, interlock/fail • Switches are mirrored from J6-J9, but polyfused @ 2A nominal • Switches are NO/COM only and polarity sensitive • Labeled “COCKPIT” on MK3

  23. EIP • “Cockpit” Connectors (J2-J5): MIL-38999/III 13-98 • Grouping: • J6 & J2 (#2), J7 & J3 (#3), J8 & J4 (#4), J9 & J5 (#5) Cockpit Switch (2A) WoW N.O. COM N.O. Interlock COM COM GND Altitude N.O. FAIL “SPARE”

  24. EIP • Ethernet : MIL-38999/III 21-75 w/ quadrax inserts • ASF-MEMO-001 contains all pinouts & tooling for quadrax • Re-pin mating cable per mission (quadrax rated 500 cycles) • J19 for network, so 2x 1G & 8x 10/100 ports available for instruments, per EIP J19 & J20: 2x 1G per EIP J21 & J22: 4x 10/100M per EIP

  25. EIP • What ethernet connectors should experiments use? • RJFTV – easy, available, inexpensive • RJ45 in a MIL-38999/III shell • Global Hawk issues solved • Contact ASF for support re: use with Tensolite cable • Quadrax: expensive, low-loss, good for aircraft • Stay with Amphenol quadrax (ITT differs) • Part number support & spares available from ASF • ASF also has pressure bulkheads available

  26. EIP • Key MK3 EIP Technologies: • Solid State Power Controllers (Ametek Amphion) • DC relay, over-current and arc-fault breaker in 1.5in3 • Trip state, voltage & current monitor over SPI • Low power dissipation: Ron = 6mΩ @ 20A (120mW), no relay coil • Fails to ‘open’ state • -55ºC to 85ºC operation • Surge tolerant (48V @ 1s, 80V @ 100ms)

  27. EIP • Key MK3 EIP Technologies (cont’d): • 13-Port Ethernet Switch (Sixnet + ASF) • Developed for Alaska airlines entertainment network • Only COTS switch found that fit inside an EIP • ASF modified to match environment & connector req’s. • 12 ports over quadrax, one RJ45 (internal) • Microchip PIC18FxxJ60 • 8-bit microcontrollers with built-in Ethernet PHY • Surface mount and high-end PCB manufacturing

  28. EIP • Two prototype EIPs are built and tested. • Thermal & Altitude Tests: • 45C, sea level – operated, but near limits • Found & corrected thermal design issue • -75C, sea level – operated 1 hr (until LN2 ran out) • -55C, 70kft – test pending • Vibration Test: • Lockheed approved level reduction to ~0.45grms (GH/MK2 was 6grms, 7grms for qual) • Completed Z-axis unpowered vibe – no issues • Full powered 3-axis vibe pending

  29. EIP • EIP Test Flow: • Qualification test: • Electrical Performance • Powered vibe @ endurance levels & duration • Powered thermal / altitude

  30. EIP

  31. EIP • EIP 3-axis vibration • Profile based on worst-case WB-57 levels • Qualification Test: • Powered 3-axis test @ 0.5grms, 1 hour per axis • Workmanship Test: • Unpowered 3-axis test @ 0.5grms, 15 min/axis

  32. EIP • Discrepancies / Issues:

  33. EIP • Discrepancies / Issues:

  34. EIP • Flight EIP Status: • All subassemblies are in manufacturing and test.

  35. NASA Airborne Science Data Acquisition and Transmission units (NASDATs)

  36. NASDAT NASDAT Functional Block Diagram:

  37. NASDAT • NASDAT J1: Isolated Inputs • ARINC-429 (4 channels) • MIL-STD-1553 (1 dual-redundant channel) • RS-232 (2 channels) • RS-422 (2 channels) • Analog (8 channels) • GPS antenna (loop-through via internal splitter) • Power 28VDC

  38. NASDAT • NASDAT J2: Outputs; Configuration • 5 buffered outputs to 4 pair each, selected from: • (Isolated) Inputs: ARINC-429, RS-232, RS-422 • NASDAT-generated: ARINC-429, RS-232, • RS-422, IRIG-B, PPS • 2 full RS-232 for external payload support instruments • 1 full RS-422 for external payload support instruments • Configuration jumpers • KVM • Access to signals is useful for maintenance

  39. NASDAT NASDAT J3: Ethernet I/O – Quadrax NASDAT J4: USB Disk – attached or remote Amphenol Rugged USB Keys & Box Connectors (mated) Amphenol Rugged USB Keys & Box Connectors (de-mated)

  40. NASDAT • NASDAT Standard Data Products: • IWG1-formatted 1 Hz Nav/Housekeeping Data • UDP broadcast to aircraft LAN • UDP telemetry to ground • File recorded on-board • NTP, IRIG-B • Instrument status packet telemetry and monitoring • Instrument ad-hoc low-rate C3 UDP telemetry • “Kitchen Sink” file of most available data at 1 Hz • “Dynamics” file of attitude/accels/rates at 20 Hz

  41. NASDAT • NASDAT Optional Data Products: • Higher rate data • Other formats or parameters easily configurable • Can read or drive external instruments if needed • Can repeat or generate various signals if needed • NASDAT Legacy Data Products • ER-2 Nav Format • ER-2 Time Format • DC-8 ASCII Format • RS-232, ARINC-429, IRIG-B outputs

  42. NASDAT • NASDAT Internal Sensors: • Cabin Temp • Cabin RH • Cabin Pressure • Input Volts and Amps • Internal Temps • High-Precision GPS Clock • Miniature GPS/IMU • OmniStar-Capable GPS

  43. NASDAT NASDAT Internal Configuration Options: • SIM cards for the four Iridium modems • Miniature GPS/IMU installed: LandMark20, MIDG-II, None • Omnistar VBS service activated • Dataforth 5B S/C modules for A/D inputs • Software baseline load per aircraft VBS – Virtual Base Station

  44. NASDAT • NASDAT Front Panel Contents • J1: Inputs • J2: Outputs and per-aircraft configuration • J3: Ethernet • J4: USB • J5, J6, J7, J8: Iridium TNC Coax • Lamps: 5V “CPU” & 28V “Power” • RH probe • Pressure transducer port • Klixon 5A C/B - input power disable • Switch, guarded - Iridium Radio disable • J-hooks for ATR mounting

  45. NASDAT • NASDAT Back Panel Contents: • Mating bushings for ATR mounting pins • GoreTex vents for pressure EQ • NASDAT Mounting Tray: • Standard ARINC-404A “ATR ¾ Short” • No vibration isolation necessary • May want fan under tray in E-Bay

  46. NASDAT • Insert NASDAT box & model images here

  47. NASDAT • NASDAT Interface Card: 12 Layers • Prototype Status: Tested, installed • Flight Status: Submitted for fabrication (13 units)

  48. NASDAT • NASDAT PDU Card: Prototype tested, installed • Flight design revision completed, fab on hold • NASDAT Analog Card: • Flight units completed • NASDAT Iridium Power Card: • Prototype tested, installed • Flight design submitted for fab

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