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RBSP Electric Field and Waves Instrument (EFW). Boom Systems Mechanical Overview, Testing, and Thermal Design Paul Turin Lead Mechanical Engineer SSL/UCB. EFW Structural/Mechanical Sub-System. Topics: EFW Mechanical Overview Personnel Suite configuration Boom introduction Heritage

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Rbsp electric field and waves instrument efw

RBSPElectric Field and Waves Instrument(EFW)

Boom Systems Mechanical Overview, Testing, and Thermal Design

Paul Turin

Lead Mechanical Engineer

SSL/UCB

EFW INST+SOC PDR


Efw structural mechanical sub system
EFW Structural/Mechanical Sub-System

Topics:

  • EFW Mechanical Overview

    • Personnel

    • Suite configuration

    • Boom introduction

    • Heritage

    • Design requirements

    • Mass budget

    • Schedule

  • Environments and Testing Overview

    • ETM

    • Vibration

    • TV

    • Deployments

  • Instrument Thermal Modeling

EFW INST+SOC PDR


Efw overview personnel
EFW Overview:Personnel

  • Lead Mechanical: Paul Turin

  • SPB Mechanical: Greg Dalton

  • AXB Mechanical: Jeremy McCauley

  • IDPU Mechanical: Bill Donakowski

  • Thermal: Chris Smith

  • Dynamics, Mechanical Greybeard: David Pankow

EFW INST+SOC PDR


Efw overview configuration on the rbsp spacecraft
EFW Overview:Configuration on the RBSP Spacecraft

REVISED

Spacecraft +Z

EFW INST+SOC PDR


Efw overview configuration on the rbsp spacecraft1
EFW Overview:Configuration on the RBSP Spacecraft

NEW

+Z

AXB mounting tube

AXB mounting tube

AXB sensor sphere

IDPU

AXBs

SPBs

SPBs

EFW INST+SOC PDR


Efw overview boom numbering
EFW Overview:Boom Numbering

EFW INST+SOC PDR


Efw overview spin plane booms
EFW Overview:Spin Plane Booms

REVISED

Stowed

  • Four Spin Plane Booms (SPBs)

    • Orthogonal pairs 80m/100m tip-to-tip

    • Sensor spheres at end

    • Preamps 3m inboard

Deployed

Doors

Wire(40/50m)

Fine wire (3m)

Preamp

Sensor sphere

EFW INST+SOC PDR


Efw overview axial booms
EFW Overview:Axial Booms

Sensor sphere/preamp

Whip

Two booms in mounting tube

Whip hinge

Mounting tube

Deployed Stacer

Single boom stowed

  • Two Axial Booms

    • 12m Tip-to-tip maximum

    • Sensor spheres at tips, Preamps in spheres

    • Lengths individually adjustable (longer only) on orbit to allow compensation for SC charging

Fully deployed

EFW INST+SOC PDR


Efw overview ucb ssl boom heritage
EFW Overview:UCB/SSL Boom Heritage

Spacecraft SPB’s Stacers

S3-2 4

S3-3 4 2

ISEE 2

VIKING 4

FREJA 6

FIREWHEEL* 2

CRRES 2

POLAR 4

FAST** 4 2

CLUSTER I* 16

CLUSTER II 16

THEMIS 20 10

SPARES 26 6

Demeter 4

STEREO 8

(Sounding Rockets) (~60)

----- -----

Total built and qualified 110 36 (+ 60)

Flown to orbit: 92 36

Successfully deployed: 91 35

Broken wires: 0

* LAUNCH FAILURE

** Double-sphere SPB failed to deploy. This design retired.

One AXB was not deployed until end of mission. Firing circuit optocouplers failed due to 10 yr radiation exposure.

EFW INST+SOC PDR


Efw overview design requirements
EFW Overview:Design Requirements

  • References, Standards, and Requirements

    • RBSP 7417-9013 Mission Requirements Document

    • RBSP-EFW-SYS-001D Instruments Requirements Document

    • RBSP 7417-9019 Environmental Design and Test Requirements Document

    • RBSP 7417-9018 Electro-Magnetic Environments

    • GSFC-STD-7000 General Environmental Verification Specification

    • NASA-STD-5001 Structural Design And Test Factors Of Safety

    • GSFC-STD-1000 Golden Rules

EFW INST+SOC PDR


Efw overview design drivers
EFW Overview:Design drivers

  • Load factors

    • APL required limit load = 30g

    • We feel should be based on 5s: 10.4grms x 5s = 52g (Themis test data)

      • 52g x 1.4SF = 78g -- Our design starting point is 100g

  • Required structure stiffness – first mode over 50Hz

    • We design for 100Hz min

  • Torque/force margins per GSFC-STD-7000 (GEVS) 2.4.5.3 (typically >3@PDR)

  • Conductive exterior surfaces per RBSP 7417-9018 EME

  • Magnetically shielded motors per RBSP 7417-9018 EME

    • Same design as THEMIS which had a stricter spec

  • Redundant locking features on fasteners

    • We use combinations of torquing, Spiralock,

      locking inserts, and staking

  • Design safety factors per RBSP 7417-9019 table 5-6

EFW INST+SOC PDR


Efw overview mass budget
EFW Overview:Mass Budget

REVISED

EFW INST+SOC PDR


Efw overview boom pdr milestones
EFW Overview:Boom PDR Milestones

EFW INST+SOC PDR


Efw environmental test overview
EFW Environmental Test Overview

REVISED

  • Instrument Level

    • Functional testing

      • Deployments

      • Torque margins

    • Vibration testing

      • Waiver for unpowered testing (we’re off for launch)

      • We prefer to test ETUs to qual levels and flight units to acceptance (asuming no significant changes). APL has specified protoflight tests. To be resolved by MPDR.

    • TV

      • Hot and cold deployments

    • Mass props

      • Knife edge CG determination +-.25in.

      • Torsional pendulum for MOIs +-10%

    • Pressure profile testing

      • We use 1in2 vent area per 1ft3 box volume rule of thumb, no analysis or test. Will request waiver

    • Self-induced shock

      • At the instrument level, not at observatory level due to deployment limitations. Will request waiver

    • No acoustics testing – no acoustically sensitive components

  • Suite level

    • No boom deployments at suite level – use simulators to exercise electrical services

  • Observatory Level

    • Observatory shock test

      • Waiver for boom walkout requirement – not practical for Stacers

      • Simulators incorporating Frangibolts will be provided for end-to-end electrical service tests

      • A partial deployment of the SPBs will be performed at EMC -- Doors opened, ~5m of wire deployed

EFW INST+SOC PDR



Efw vibration testing
EFW Vibration testing

  • Test levels per RBSP 7417-9019

  • Pre and post sine surveys (1/4g)

  • Sine sweep per table 5-9

  • Random currently per tables 5-11 & 12

    • APL has specified protoflight tests. We prefer to test ETUs to qual levels and flight units to acceptance (assuming no significant changes). Under negotiation.

  • AXBs will be vibrated individually.

    • Mounting tube and mass dummies will be provided to APL by Fall 2009 for inclusion in SC structural loads testing.

  • We will use force limiting for all tests

    • Testing performed at Quanta Labs, Santa Clara, CA

    • Performed >70 tests for THEMIS

  • All units powered off during tests

    • Waiver required. Off during launch.

EFW INST+SOC PDR


Efw thermal vacuum testing
EFW Thermal Vacuum Testing

  • Test levels per RBSP 7417-9019

  • AXB stacer unit and whip to be tested separately because of deployment offloading reqm’ts

  • Preamps tested separately prior to boom testing because of much wider temp swings

  • Hot and Cold Deploys

  • No thermal balance tests

    • All units have thermally conductive interfaces

    • Balance done at observatory level

EFW INST+SOC PDR


Efw deployment testing
EFW Deployment Testing

REVISED

  • ETU and Flight Deployment testing

    • Post assembly – ambient functional deployments

    • Force margin tests

    • Thermal Vacuum -- Hot and cold deploys (post vibe)

  • Observatory level

    • Spacecraft/Observatory test plan under discussion with APL, a waiver will be required

    • Due to impracticality of SC level full deployments:

      • Partial deployment of SPBs during EMC for radiated emissions test

      • Simulators for SPB doors and motors, AXB whip and stacer deployments in TV

      • This scheme followed on POLAR, FAST, CLUSTER, THEMIS

      • Following deployment, SPBs removed, restowed, spheres cleaned or replaced if surface marred

  • Additional tests

    • SPB Wire length calibration

    • SPB Fine wire pullout force profile and margin check

    • Wire EOT switch test

    • Motor, pinpuller current profile

EFW INST+SOC PDR


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