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Pre-Environmental Review PER SearchCoil Magnetometer FM4

Pre-Environmental Review PER SearchCoil Magnetometer FM4. D.ALISON(LPP). Outline. Introduction SCM Overview Subjects of the review Programmatics Requirements/Design Updates Verification Results Test Planning Assurance Activities. Block Diagram.

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Pre-Environmental Review PER SearchCoil Magnetometer FM4

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  1. Pre-Environmental ReviewPERSearchCoil MagnetometerFM4 D.ALISON(LPP) MMS SCM FM4 PER, 17 SEP 2012

  2. Outline Introduction • SCM Overview • Subjects of the review • Programmatics • Requirements/Design Updates • Verification Results • Test Planning • Assurance Activities MMS SCM FM4 PER, 17 SEP 2012

  3. Block Diagram • SCM interfaces to the CEB for power and data MMS SCM FM4 PER, 17 SEP 2012

  4. +Y -X +X -Y S/C Location SPACECRAFT DECK COMPONENTS DSS Mag boom (stowed) RF xnpdr Battery 3 2 4 C&DH Navigator 5 1 USO 8 SCM Pre-Amp 6 DPU 7 Star Sensors PSEES Mag boom (stowed) FEEPS S-Band Antenna MMS SCM FM4 PER, 17 SEP 2012

  5. S/C Location AFG SCM SDP CEB EDI SDP AEB ADP INSTRUMENT DECK COMPONENTS (BOOMS DEPLOYED) SDP EDI SDP DFG MMS SCM FM4 PER, 17 SEP 2012

  6. Subjects of the review • SCM FM4 setting-up: • Harness FM4 S/N FM4 • Preamp FM4 S/N FM5 • Sensor FM4 S/N FM3 FM2 SENSOR FM2 PREAMP FM4 PREAMP FM4 SENSOR MMS SCM FM4 PER, 17 SEP 2012

  7. 1. Programmatics • Organizational and staffing plans • RFA status • Status of drawings/engineering change orders and manufacturing planning documents • Schedule • Risk management status => no open risk MMS SCM FM4 PER, 17 SEP 2012

  8. 1.a) Organizational and staffing plans MMS SCM FM4 PER, 17 SEP 2012

  9. 1.b ) RFA status • All RFA AIs are in PIMS answered and concurred. MMS SCM FM4 PER, 17 SEP 2012

  10. 1.c) Status of drawings/engineering change orders and manufacturing planning documents • Manufacturing planning documents => sensor, harness and preamp in house. • Current configuration is flight configuration (one SCM instrument = 1 assembly Sensor + Harness + Preamp) FM2 SENSOR FM4 SENSOR MMS SCM FM4 PER, 17 SEP 2012

  11. 1.d) Schedule: manufacturing • Harness FM4 S/N FM4 manufactured • Preamp FM4 S/N FM5 manufactured • Sensor FM 4 S/N FM3 manufactured • Lacing tape • 2216 staking MMS SCM FM4 PER, 17 SEP 2012

  12. 1.d) Schedule: qualification • No Reserve for FM4 • FM4 FIT (FIELDS Interference and Timing) test at UNH => 11 DEC 2012 • Preamp + Sensor on schedule • Harness to be decided asap MMS SCM FM4 PER, 17 SEP 2012

  13. 2. Requirements/Design Update • Requirements and hardware/software design changes since CDR • Status of ICDs • Resource status MMS SCM FM4 PER, 17 SEP 2012

  14. 2.a) Requirements and hardware/software design changes since CDR • FM4 build as FM1 except for the torque values and glue (see below) • Requirement changes => No • Software design changes => N/A • The cables of the coils have been staked, using lacing tape and 2216 glue => NC closed, changes applied on FM1 and all subsequent FMs • FM4 S/N FM3 vibration => NCR ref MMS-SCM-NC-TRI-139_Iss1_rev1_FM4_SENSOR_cracks_after_vibration • Thermal Cycling between 22°C and 60°C performed with the tubes not fastened • Change of the torque value to hold sensors 0.35Nm instead of 1.2Nm • Thermal Cycling between 22°C and 60°C performed • Glue 2216 between the structure and the sensors • This set-up was qualified successfully in vibration atproto-flight levels on QM • Vibration at proto-flight levels 07 June 2012 successful (2 Post vibration thermal cycles at LPP ok • X-Ray inspection validation MMS SCM FM4 PER, 17 SEP 2012

  15. 2.b) Status of ICDs • SENSOR: • FIELDS SCM to Spacecraft Mechanical/Thermal ICD (101600025) => rev D from DEC 2011 (due to an update needed on the CAD model of the Sensor) • Mag Boom MICD => 2102850 rev A on May, 2011 • Orientation of the sensor on the mag boom changed since CDR, MICD of the mag boom not yet up to date • Change of Screwlock on pigtail SCM P213 and on harness SCMJ213 conformed with Mechanical/Thermal ICD (101600025) • PREAMP • FIELDS SCM to Spacecraft Mechanical/Thermal ICD (101600016) => rev D from DEC 2010 • The FIELDS ICD, UNH-MMS-FIELDSICD-01 is the Electrical interface document for SCM MMS SCM FM4 PER, 17 SEP 2012

  16. 3. Verification Results • Baseline performance/functional test results • Verification results of component and subcomponents • Analyses status • Mechanical • Thermal • Radiation => All parts are in PIMS and approved • Flight software/firmware status (if applicable) => N/A • Limited life items status => N/A MMS SCM FM4 PER, 17 SEP 2012

  17. 3.a) Baseline performance/functional test results • Electrical and Functional tests performed on the sensor after cabling of the pigtail • Functional test inside a mu-metal box with Helmholtz coils • Electrical tests will be used as baseline • Incoming inspection of the preamplifiers: • Power consumption (Feedback connector plugged, all inputs short-circuited) • Output offsets (each channel) • Transfer function (Preamp alone, each channel) => gain, cutoff frequencies • Input noise (Preamp alone, each channel) • Transfer function in field (Preamp + FM Sensor + FM Harness, each channel) => gain, cutoff frequencies • Calibration transfer function (Preamp + FM Sensor + FM Harness, each channel) => gain, cutoff frequencies • Trending parameters: • Power consumption • Transfer function (Preamp alone, each channel) => gain, cutoff frequencies • Total hours of operation log filled during testing • The sensitivity of the SCM depends mainly on: • The noise of the preamplifier • The gain of the assembly • The impedance of the primary coils MMS SCM FM4 PER, 17 SEP 2012

  18. 3.a) Logbook filled during FM4 S/N FM3 sensor Electrical and Functional tests Main trending parameter => Inductance of the primary windings MMS SCM FM4 PER, 17 SEP 2012

  19. 3.a) FM1 primary winding inductance monitoring during thermal vacuum • X is different from Y and Z due to its position in the chamber, close to the aluminum interface. • The baseline measurement for the thermal vacuum are performed just before closing the door. • No sharp drop during the cycles that could be a clue to detect a default in the ferrite core. MMS SCM FM4 PER, 17 SEP 2012

  20. 3.a) FM1 primary winding resistance monitoring during thermal vacuum MMS SCM FM4 PER, 17 SEP 2012

  21. 3.a) Logbook filled during FM4 S/N FM5 preamp Electrical and Functional tests • Trending parameters: • Power consumption • Cutoff frequencies • Gain MMS SCM FM4 PER, 17 SEP 2012

  22. 3.a) Tracking of the trending parameters during FM1 preamp qualification Vibrations (measurements after each axis in sinus and random) Thermal Vacuum (measurements during plateaus) MMS SCM FM4 PER, 17 SEP 2012

  23. 3.a) FM1 Preamp before and after qualifications MMS SCM FM4 PER, 17 SEP 2012

  24. 3.a) Functional test, Preamp alone FM4 MMS SCM FM4 PER, 17 SEP 2012

  25. 3.a) Functional test, Preamp alone FM4 MMS SCM FM4 PER, 17 SEP 2012

  26. 3.a) Functional test, Preamp alone FM4 MMS SCM FM4 PER, 17 SEP 2012

  27. 3.a) Functional test, FM4 S/N FM5 Preamp + Sensor FM4 S/N FM3 + Harness FMS MMS SCM FM4 PER, 17 SEP 2012

  28. 3.a) Functional test, FM4 S/N FM5 Preamp + Sensor FM4 S/N FM3 + Harness FMS MMS SCM FM4 PER, 17 SEP 2012

  29. 3.b) Verification results of components and subcomponents • SCM IRD last release 1016017 Issue 1 Rev 5, JULY 2011 • Instrument Suite Verification Plan used as a reference (rev 1.0, April 2011) • Verification matrix sent by Dave Rau (SCM IRD Verification Output-30Mar11.xlsx) • FM1 met the requirements after qualification and calibration => same results expected for FM4 following preliminary tests performed during incoming inspection (Gain, sensitivity, power consumption, frequency bandwidth) • Verification data to be checked withDave Rau after this presentation MMS SCM FM4 PER, 17 SEP 2012

  30. 3.c) Analyses status (Sensor) • Sensor Analyses • Random, Sinus, Shock, Thermal => 10C379_RT_MLCR_0053_11_ed02_mechanical_analysis_triaxe_update.pdf • SY00728_RP_1445_12_MMS_Mechanical_Analysis.pdf =analysis updated (see below) • Quasi static => Mechanical_Analysis_SCM-Sensor_UNH-Addendum_2011-08-23a.doc (John NOLIN, UNH) • FM1 qualification successful, at proto flight levels, one NC solved and closed => proposed solution: staking of the cables of the coils • S/N FM3 vibration at acceptance level 2-3 FEB 2012 => 2 cores cracked • NCR : MMS-SCM-NC-TRI-139_Iss1_rev1_FM4_SENSOR_cracks_after_vibration.doc • Change of the torque value to hold sensor 1.2Nm=>0.35Nm, 2216 glue added to hold sensors • This solution was applied on the QM and tested successfully in vibration 1 axis proto-flight level • New mechanical analysis done by Nexeya with thermoelastic coefficient corrected for Mapsil and new torque value: SY00728_RP_1445_12_MMS_Mechanical_Analysis.pdf • Shock qualification performed on the flight like EM4 SCM Sensor (sensors sent back to LPP, thermal cycle validation + X-Ray Inspection) MMS SCM FM4 PER, 17 SEP 2012

  31. 3.c) Analyses status (Sensor) Thermo elasticAnalysisupdated: SY00728_RP_1445_12_MMS_Mechanical_Analysis.pdf Temperature ranges as specified in the MICD MMS SCM FM4 PER, 17 SEP 2012

  32. 3.c) Analyses status (Preamp) • Mechanical and thermal analysis by BTS Industrie • Preamp Analyses • Random, Sinus, Shock, Thermal => 10C034_RT_LEBT_0210_10 _ed01_mechanical_analysis_MMS_box.pdf • Quasi static => Mechanical_Analysis_SCM-Preamp_UNH-Addendum_2011-08-23a.doc (John NOLIN, UNH) • Full QM qualification campaign in 2011 successful, FM1 also successful (acceptance levels): • vibration at qualification levels (sinus, random) • 1 thermal cycle between proto flight survival temperatures, with hot power and hot power off tests • 8 thermal cycles between operational temperatures with 4 hours plateaus Temperature ranges as specified in the MICD MMS SCM FM4 PER, 17 SEP 2012

  33. 4. Test Planning • Environmental test sequence and levels • Status of test procedures • Science calibration plan • Test as you fly exceptions • Support equipment readiness • Facility readiness/backup plans • Operating time status => N/A • Critical parameters for trending • Contamination control • Instrument/component safety MMS SCM FM4 PER, 17 SEP 2012

  34. 4.a) Flow diagram (Sensor+Harness) 2 cycles 22°C – 60°C BeforefasteningAfterfastening Current step MMS SCM FM4 PER, 17 SEP 2012

  35. 4.a) Temperature profile (Sensor + Harness in the chamber) Pumping Impedance of the primary winding of each coil measured each 30 min all along the test • Profile in procedure : MMS-SCM-PR-TRI-113-LPP-2.5_Cyclage thermique SENSOR • Need a verification by Dave Rau for the number of cycles MMS SCM FM4 PER, 17 SEP 2012

  36. 4.a) Sensor vibration levels (SCM IRD 1016017, rev 5) • FM1 tested at Proto Flight levels • FM2 tested at Acceptance levels • FM3 tested at Proto Flight levels • FM4 tested at Proto Flight levels MMS SCM FM4 PER, 17 SEP 2012

  37. 4.a) Spacecraft / Sensor coordinates +Zscm +Xscm . +Yscm MMS SCM FM4 PER, 17 SEP 2012

  38. 4.a) Flow diagram (Preamp) Current step MMS SCM FM4 PER, 17 SEP 2012

  39. 4.a) Temperature profile (Preamp alone in TV chamber) Cycling Pumping Transfer function and power consumption measured during plateaus Preamp always ON after the first cycle • Profile in procedure : MMS-SCM-PR-TRI-113-LPP-2.5_Cyclage thermique SENSOR • Need a verification by Dave Rau for the number of cycles MMS SCM FM4 PER, 17 SEP 2012

  40. 4.a) Preamp Vibration levels => Acceptance (SCM IRD 1016017 REV 5) MMS SCM FM4 PER, 17 SEP 2012

  41. 4.b) Bakeout/Outgassing certification • No TQCM monitoring for SCM Sensor and Preamp : -WaiverRef : MMS(Waiver-10160-60-CA)SCM SensorBakeout • Possibility to make the TQCM for SCM FM3 & FM4 Harnessduring the same test: • - With the 2 harness, canthe outgassingrate reach 20ng/sec/kg? MMS SCM FM4 PER, 17 SEP 2012

  42. 4.b) Status of test procedures • Each procedure includes a list of documents to be added to the Acceptance Data Package (log books, travelers, plots…) MMS SCM FM4 PER, 17 SEP 2012

  43. 4.b) Travelers MMS SCM FM4 PER, 17 SEP 2012

  44. 4. Test Planning 4.c) Science calibration plan Each assembly Sensor/Harness/Preamp will be identified and calibrated Calibration at Chambon la Forêt (quiet facility) Calibration outputs: • Transfer function (gain + phase) • Sensitivity • Axes orientation 4.d) Test as you fly exceptions => No 4.e) Support equipment readiness GSE ready (two split boxes + mu-metal boxes + QM Preamp) Equipments at LPP (main equipment is a Spectrum Analyzer) Software ready 4.f) Facility readiness/backup plans Old calibration facilities was used for FM1 and FM2. FM2 was tested in new and old Calibration to ensure continuity with FM1 measurements. FM4 will be only tested in the new Calibration facilities. 4.g) Operating time status => logbook filled each time the preamp is switched ON 4.h) Critical parameters for trending Sensor => Impedance measurement of the primary winding of the coils Preamp => High cutoff frequency, Gain in the flat band, Power consumption 4.i) Contamination control Cleanliness will be checked 4.j) Instrument/component safety Special case used during transportation Shock detector on the case Switch off limits on the power supplies Switch off limits on the thermal chambers (+5°C above MAX and -5°C below min temperatures) Switch off limits on the shaker (alarm = 3dB above the profile / switch off = 6dB above the profile) MMS SCM FM4 PER, 17 SEP 2012

  45. 5. Assurance Activities (Lionel MESLIER) • Reliability analyses status • QA planning for subsequent activities completion status • Non-conformance status • EEE Parts and Material status • Waiver status • Safety => N/A • End-Item Data Package (EIDP) plan MMS SCM FM4 PER, 17 SEP 2012

  46. 5. Assurance Activities • Objective To set up a Product Assurance system to guarantee required quality level • Implicit interests • Reproducibility & Productivity (5 models) • To control process & fabrication methods • To control parameters for product specified (procedures, specifications, …) • To check each information by recording, updating, & availability • Results reliability • To control analysis process • To meet requirements product by any tests or analysis MMS SCM FM4 PER, 17 SEP 2012

  47. 5. Assurance Activities • Executed tasks • System quality • PA documentation (PA Plan, CIDL, DML, DPL, Procedures, …) • Databases setting up (NCR, modifications, controls, …) • Configuration management (logbook, configuration files, …) • Product quality • Sub-contracting followed (claims, specifications, …) • Product validation & qualification (Metrology) • Cleanroom work environment management • Traceability for delivery elements • Project support • Project manager care (MAIV plan) • Conception & support vs. AIT • Logistic event (EIDP, expedition, packaging…) • UNH reporting and meeting • Internal team training at LPP (ESD precautions, handling…) MMS SCM FM4 PER, 17 SEP 2012

  48. 5.b) QA planning for subsequent activities completion status • PA documentation For SCM Instrument increased presence during manufacturing => increase PA documentation • AIT-QA Activities • More traceability (incoming records, historical records, NCR, waivers…) • Test activities (test witnessing, test readiness reviews, test procedures and reports…) • Cleanliness philosophy (cleaning procedure, laminar flow or hermetic boxes, UV lamp…) => cleanliness certificate • Mate and demate log (savers are used) =>PA responsible: Lionel MESLIER 30% FTE MMS SCM FM4 PER, 17 SEP 2012

  49. 5. Assurance Activities 5.a) Reliability analyses status SCM is fully qualified on environmental testing • FM1, FM2, FM3 Preamp => OK • FM1, FM2 Sensors => OK • FM3 (same design as FM4 with glue and reduced torque) => OK 5.c) Non-conformance status MMS-SCM-NC-TRI-623-LPP-1-0_FM2 alignment measurement out of specification 5.d) EEE Parts and Materials list status PIMS approval => OK All material certificates are added in the EIDP 5.e) Waiver status No waiver today MMS SCM FM4 PER, 17 SEP 2012

  50. 5.g) End Item Data Package (EIDP) plans 0. H/W EIDP Fore Section • CoC • CIDL/ABCL • RFW & NCRs • Test reports / Verification matrix • Logbooks • GSEs • Subunits EIDP • Handling, Packing, Unpacking • I/F Docs • Doc necessary for further work • Open / Spares/ Loose Items / Red tags / Hazardous • PA Doc (DML, DCL…) • Photos • Other datas & remarks MMS SCM FM4 PER, 17 SEP 2012

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