THEMIS Mission PDR/CAR 1 UCB, November 12-14, 2003

Instrument Integration & Test

Dr. Ellen Taylor

University of California - Berkeley

THEMIS Mission PDR/CAR 2 UCB, November 12-14, 2003

Overview

Instrument Integration and Test at UCB• Responsibilities

• Requirements

• Facilities

• I&T Flow

THEMIS Mission PDR/CAR 3 UCB, November 12-14, 2003

Responsibilities

Responsibilities• Provide Clean Room Facility (Room 125)

• Access Control & Clean Room Training

• Develop MGSE– Instrument Harness Mockups & Test Platforms

• Fabricate Instrument Harnessing

• Support Instrument-Provided GSE– Mu-Metal Enclosures for FGM & SCM– N2 Purge Systems for ESA, SST– Sphere Sensor Boxes for EFI

• Integrate & Functional Test of EM, F1-F6

• Provide EMC, MAG, Vibration & TV Testing

• Daily Logistic Planning & “Standup” meetings

• Deliver & Support to Swales for Spacecraft I&T

THEMIS Mission PDR/CAR 4 UCB, November 12-14, 2003

Requirements

Requirements• Vibration / TV : GEVS SE

• EMC/EMI : MIL-STD-461

• Magnetics: Non-Magnetic Tooling Used for FGM/SCM

• Contamination: THEMIS Contamination Control Plan

• Metrology: Ongoing calibration program

• Tests:

Test Description Component InstrumentFunctional √ √Deployment √ √Self-Compatibility - √Cleanliness √ -EMC/EMI - √DC Mag Field √ -AC Mag Field - √ESC √ -Vibration √ -T/V (Cycles) √ (2) √ (6)

THEMIS Mission PDR/CAR 5 UCB, November 12-14, 2003

Facilities

Instrument Integration Lab• Secure Key-Coded Lock

• Class 100K Clean room

• Air Quality Monitored Weekly by Assurance

• Positive Air Flow

• Feed Thru’s to Adjacent Lab

• Gowning Area

• Storage Shelving for Component Storage

• Separate Flight and non-Flight Storage

• Oxygen Sensor (when Nitrogen Purge used)

• Used for HESSI, CHIPSAT, Stereo Impact

THEMIS Mission PDR/CAR 6 UCB, November 12-14, 2003

Environmental ChambersChamber Availability at SSL• Numerous Tanks• New Chamber for EFI Booms• Cal Chamber Upgrade for SST• Need 2 TQCM’s

TV Plan Design• 2 Component-Level TV Cycles Prior to Instrument-Level I&T• 6 Instrument Level TV Cycles at Instrument-Level

Chamber Usage During Relevant Performance Periods

Available Chambers TypeSLW 320 L1 TV EFW,EFI BoomsSLW 320 L2 TV NewSLW 320 T10 TV EFW DCDCSLW 320 Cal Vac FAST ESASLW 320 Tenney Thermal HESSI BlanketsSLW B20-Cal TV Shroud AvailableSLW B20-TV TV FAST InstrumentsSLW B20-Large Vac EUVESLW B20-Cal Vac

Comment

Chamber Availability # Weeks Usage 320-L1 320-L2 320-Cal B20-Cal B20-TV2.1.1 IDPU 20 31% 62.1.2 EFI SPB 30 73% 222.1.2 EFI AXB 35 17% 62.1.3 ESA 22 55% 122.1.4 SST 26 92% 242.1.5 FGM (Booms) 39 31% 122.1.6 SCM (Booms) 52 23% 122.1.7 F1-F5 I&T 22 46% 10Total Weeks 28 24 12 24 16Total Usage 90% 54% 55% 92% 77%

Facilities

THEMIS Mission PDR/CAR 7 UCB, November 12-14, 2003

Facilities

Deployment Min Max TargetFGM Boom 0 30 15SCM Boom 0 30 15AXB 0 30 15SPB 0 30 15

Environmental Test Chamber Requirements

• Pre-Test Clean

• Pre-Test Bakeout

• TQCM Monitoring

• Cryo-Pump

• Final Bakeout

• GN2 Backfill

Deployments in Vacuum

• SPB: Full Deploy w Takeup reel

• AXB/MAG: First Motion Hot&Cold

Unit Cold Hot Cold Hot Cold HotIDPU -30 40 -50 40 -50 65SST Sensor -55 40 -65 40 -65 65ESA -30 40 -50 40 -50 65EFI SPB -20 40 -50 40 -50 65EFI AXB -20 40 -50 40 -50 65SCM Boom -20 40 -75 65 -50 65SCM Sensor -50 65 -100 80 -100 80SCM Preamp -100 40 -50 40 -50 80FGM Boom -50 65 -75 65 -50 65FGM Sensor -80 80 -100 80 -100 120

OP LIMITS ECLIPSE OP LIMITS NON-OP LIMITSOperational

THEMIS Mission PDR/CAR 8 UCB, November 12-14, 2003

I&T Flow

THERMAL VACUUM (6 cycles)

TEST REVIEW

INST Functional Test

INST Self Compatibility

EMC/EMI/MAG VIBRATION

EFI Boom Deployments

IDPU-EFI Functional Test

IDPU-SST Functional Test

IDPU-ESA Functional Test

IDPU-FGM Functional Test

IDPU-SCM Functional Test

Platform FabHarness Fab &

BakeoutIDPU-Harness

Functional TestMag Boom

Deployments

Instrument Engineering Model I&T

THEMIS Mission PDR/CAR 9 UCB, November 12-14, 2003

I&T Flow

TEST REVIEW

IDPU-SCM Functional Test

INST Functional Test

INST Self Compatibility

VIBRATIONTHERMAL VACUUM

(6 cycles)

IDPU-EFI Functional Test

IDPU-SST Functional Test

IDPU-ESA Functional Test

IDPU-FGM Functional Test

Platform FabHarness Fab &

BakeoutIDPU-Harness

Functional TestMag Boom

DeploymentsEFI Boom

Deployments

Instrument Flight Model I&T