Presentation of the Astrium EGSEPresentation of the Astrium EGSE Validation System (EVS)

Compiled Clive Catley

Introduction

This presentation gives an overview of the Astrium EGSE V lid ti S t (k EVS)EGSE Validation System (known as EVS).The EVS is an ATE specifically designed for testing specialised spacecraft test equipment generically

. Its

con

tent

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d. specialised spacecraft test equipment – generically known as Electrical Ground Support Equipment (EGSE).

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( )The presentation provides background information on spacecraft testing (using the Gaia project as an

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example), which provides the justification for the EVS. Th ft i f th EVS H d d

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Software design is presented.

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Spacecraft testing (GAIA). I

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Spacecraft testing

The GAIA spacecraft is essentially a massive digital camera (1 billion pixels).Astrium (as prime contractor) leads a large European

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d. consortium building the spacecraft for the European Space Agency.

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The spacecraft will be placed 1.5 million km beyond earth orbit and over a 5 year period provide a census ( ) f l 1000 illi

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http://www.esa.int/esaSC/120377_index_0_m.html

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Spacecraft testing (GAIA). I

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Spacecraft testing

Typically for one-off science mission spacecraft, a “FlatSat” of the spacecraft is first built with a set of engineering model electronic units (identical to the fli ht d l )

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d. flight models).This is a test bed for validating the electrical i t f b d ft d l d l t l

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Spacecraft testing (GAIA). I

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Spacecraft testing

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Spacecraft testing

Typically a science spacecraft consists of a set of electrical units:The platform consisting of:

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ComputerElectrical interface

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Power control unitAttitude & orbit control (gyros, star trackers, sun

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(gysensors, propulsion)RF subsystem (transponders, antennas)

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Spacecraft testing

The platform consisting of:InstrumentInstrument support units

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Payload processors

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Spacecraft testing

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Spacecraft testing

To support ground testing of the spacecraft specialised test equipment is required, typically:

Solar array simulator

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d. Umbilical power & monitoringBattery simulator

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RF front endAvionics front end

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Spacecraft simulatorPayload front ends

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Checkout system

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Spacecraft testing. I

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Spacecraft testing. I

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Spacecraft testing. I

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Spacecraft testing

There is a requirement that such test equipment must be validated prior to use.That is: all electrical interfaces to the spacecraft (and

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d. corresponding functions) must be tested before connection.

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Spacecraft testing

One such test equipment is the Avionics front end which li i t f t th ft ttit d t l it dsupplies interfaces to the spacecraft attitude control units, and

in tandem with the spacecraft simulator is capable of simulating the units themselves.

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gThis equipment has over 600 I/O interfaces of various types:

Analog in/out

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Pulse generationPulse acquisitionRS422

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1553, SpaceWire BUS interfacesPower simulators

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Why do we need an EVS?Previously, 2 options have been employed to validate EGSE:

Procure EGSE with a built-in test facility.Validate manually using break-out boxes and stand-alone test equipment

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d. alone test equipment.Due to the extra software and hardware required for built-in test implementation option 1 can cost

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t. for built in test implementation, option 1 can cost typically upward of 50k€ per equipment (or some 100’s k€ per project).

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Option 2 can typically take in the order of 2-3 days for complex equipments. With EGSE often re-l t d b t i t l t t f iliti thi

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can prove very costly, as validation must be repeated following any shipment

This repeated following any shipment.

EVS overview

The EVS provides an option 3. It is designed to provide multiple generic test functions for validating spacecraft test equipment.

. Its

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EVS Hardware Design. I

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EVS overview

The EVS utilises PXI platform instrumentation where possible to provide a compact design.This is essential as the EVS may be located in sites

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d. with difficult access – such as inside thermal vacuum chambers or on the top of rocket launch t

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t. towers.The software platform is LabWindows/CVI, chosen f i f i i l d i

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familiarity as a development tool within Astrium.

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EVS Hardware Design. I

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EVS Hardware Design

At the core of the system is the switching. This is provisioned by a 128 way interface for mixed signal switching to the test instrumentation. This interface may also be re configured to 2 50 way interfaces

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d. be re-configured to 2 50 way interfaces.From this interface any 1 or 2 pairs from equipment cables can be selected and routed to the test instruments.

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A second interface is via a 12A matrix to allow signal routing for power testing.

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EVS Hardware Design

The EVS provides the following measurement facilities:7 ½ digit DMM – effectively doubling as an oscilloscope.Data Acquisition (digital, analog, isolated /non-isolated).D i l di d t

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d. Dynamic loading and measurement.Stimulation types:

Function generation

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t. Function generation.Data generation (digital, analog, isolated /non-isolated).Power sources

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Dynamic power sources.Special test types:

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1553Reflective memory

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Software Design

The software is designed such that the core system provides the majority of the test functionality required for multiple spacecraft projects, based on t d d I/O ifi d i ft GDIR d

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d. standard I/O specified in spacecraft GDIR and common functions, such as power, protection testing solar array simulation etc

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t. testing, solar array simulation, etc.This means any project utilising the system need only provide configuration information derived from

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the EGSE specifics and any specific development peculiar to the project

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Software Design

The software design is presented below. The core system consists of a Test Manager (MMI) reading test configuration in from project specific Excel files.

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Software Design

The tests are executed by core test modules providing common application based tests.

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Software Design

…or test modules designed specifically against project needs.

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Software Design

The test modules interface to an Instrument Driver Adaptation layer for specific instrument configuration (such as the switching)….

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This

Software Design

….or directly to the COTS Instrument Driver Layer as required.

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Software Design

Test results are processed against limits defined in the test configuration files, and test reports created.

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Software Design

Manual control is provided utilising intuitive front panel GUI’s, providing the capability of a general purpose test equipment.

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This

Software DesignEach project defines its test needs by providing Excel based configuration and limits files.

EGSE Validation Pro-Forma (Avionics SCOE)

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d. Avionics SCOE Cable Name Function ITB#

ITB (pos) ITB (neg) CCS Parameter1

1MPS-STAT-MPE-LV-PT-A Operator Connect Cable 26 Connect SCOE cable SK10P01 to ITB2 via 25WS

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1 MPS_LPTR-A.sig 6 2 13 25 MPE_MPS_LPTRA

1 MPS_HPTR-A.sig 6 2 11 23 MPE_MPS_HPTRA

1 MPS_HPLV-1A_OPEN.sig 2 2 2 15 MPS_HPLV1A_OPEN_PW

1 MPS_HPLV-1A_CLOSE.sig 2 2 1 14 MPS_HPLV1A_CLOSE_PW

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1 MPS_HPLV-1A_STAT.sig 4 2 16 24 MPS_HPLV1A_STAT

Test No Signal Type Config1a Config1b LowLim1 HiLim1

0 SHP-ACQ 28 0000 0 0640 0 0620 0 0660

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1 SHP-GEN 180.0000 0.0000 0.0590 0.0690

2 LV 28.0000 0.0640 0.0635 0.0645

3 FCV 28.00000 0.00100 0.00085 0.00115

4 RSA 0 0000 0 0000 0 0000 50 0000

This 4 RSA 0.0000 0.0000 0.0000 50.0000

Software Design

A separate Library is included which provides the i ti t l ith th ft t t i tcommunication protocols with the spacecraft test equipment.

Thus allowing the test modules to control and monitor the equipment functions (Normally spacecraft test equipment

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equipment functions. (Normally spacecraft test equipment communication protocols are based on packet messaging over LAN).

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The user front end is a simple GUI from which the operator simply selects the Excel file defining the test configuration and limits and starts the test

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The EVS includes a built in self-test which provides validation of all instruments, switching and test modules.

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This

Software Design. I

ts c

onte

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parti

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shal

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mun

icat

ed to

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p d

ocum

ent i

s th

e pr

oper

ty o

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rium

. Th

is

Conclusion

The EVS offers an efficient and cost effective solution to t th d f ft t t i t lid timeet the needs of spacecraft test equipment validation.

It provides accurate, repeatable validation testing in a time-effective manner, reducing setup times for spacecraft

. Its

con

tent

sha

ll no

t be

disc

lose

d.

, g p ptesting (particularly during intensive test periods on location). Example: The Avionics front end detailed here can be tested in less than 1 hour

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t. can be tested in less than 1 hour.It uses proven technology of which Astrium has widespread knowledge.

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otherwise built-in).It offers a test solution to existing equipment where

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m. It offers a test solution to existing equipment where

otherwise none exists.

This