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1 - ASP-05-STR1-263M054-1
Tous droits réservés © Alcatel Space Industries All rights reserved
Star One C1 - Insurance Presentation
8 - Satellite Test Plan and Philosophy
2 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
The STAR ONE C1 satellite is a protoflight model and will be submitted to qualification environmental conditions as specified in the environmental specification
The objective is to demonstrate that the performances specified are met before, during and after the environmental tests
Satellite Test Plan
3 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
AIT SEQUENCE
The AIT sequence in divided in phases: SM Integration Final integration Initial performance test (SPT1A) TV tests Pre environmental tests (SPT1B) Environmental tests Post environmental tests (SPT2B) Final performance tests (SPT2A) MCI Preparation for transport
Satellite Test Plan
4 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
MECHANICAL ENVIRONMENTAL TESTS (2)
SPT1 B
SC TV SPT1 A
SM/CMMATING
FINALINTEG.
BODYALIGNMENT
ASSY
ElectricalPerf. tests
comp.
EMCCE/CS
ESD
THERMALBALANCEASSY
THERMAL CYCLING
EAST &WEST
PANELS
ANTENNAEMOUNTING,ALIGNMENT
& DISMOUNT
THERMALINSTRUMENTATIO
N
T&C RF BAPTAM
IRES PSSH10N THRUSTERS
ASSY
REFLECTORS, FEEDS& MECHANISMS
INSTALL
PRE-TVTESTASSY
VIBADAPTOR
MLI
ACOUSTICTEST
ADAPTORFIT CHECK
SEP.SHOCK
TEST
TANKSDRAINING
SA INSTALLMAN.DEPLO
Y& CHECK
ASSY ASSYSA
FOLDING
SOLAR ARRAY
ANTENNADEPL. +
BODYALIGN.VERIF
.
SPT2 B
SA PYRO.DEPLOY.
ASSY
SOLAR ARRAY
PHYSICALPROPERTIES
REFLEC.PYRODEPLOY.ALIGN.
SATELLITE PREPARATION FOR FLIGHT
ASSY
SA INSTAL.MAN.
DEPLOY& CHECK
SAFOLDING
MASSPROP.
CHECKASSY SHIPMENT
PREPAR.
MLISOLARARRAY
FAR
TO LAUNCH SITE
SPT2 A
PIM's
ElectricalPerf. tests
2
MECHANICAL ENVIRONMENTAL TESTS (1)
TANKFILLING
SIMULATIONLIQUIDS
SINEVIBRATION
MECHANICALINSTRUMENTATION
EMCLAUNCH
EMC RE/RS
UPSTESTScomp.
IF NECESSARY
GNDVERIF.TEST
REFLECTORS & FEEDSALIGNMENTS vs S/C
TANKPRESSURISAT
ION
vibrationpreparation
UPSPerf.Tests PACK
CATRGLOBAL
LEAKCHECK
BODYALIGN.VERIF.
IF NECESSARY
IF NECESSARY
Satellite Test Plan
5 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
Assembly, Integration & Tests (AIT) Plan
Activities performed during AIT are detailed in the AIT plan which defines the scope of each phase
Each AIT phase is governed by reviews (Test Readiness Review -TRR and Test Review Board - TRB) and a leading procedure which calls modular tests execution.
The elementary tests which are performed all along the AIT Sequence are defined in the subsystem test matrices which summarize for each elementary test (defined by a test requirement) in which AIT phase it has to be performed.
Satellite Test Plan
6 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
INITIAL SYSTEM PERFORMANCE TEST: SYSTEM PERFORMANCE TESTS 1 PART A SPT1A
After SM/CM mechanical assembly, interface testing and S/C Final integration, the Satellite will be subjected to the reference system performance measurements.
The SPT1A will be as follows:
Body alignmentsElectrical performance testsUPS testsEMC CE/CS & ESD tests (can be postponed to SPT2A phase)Antennas mounting and alignmentFlight batteries installation, connection and beginning of charge
maintenance (ST3 option).
Satellite Test Plan
7 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
THERMAL VACUUM TESTS
Those tests occur in the ALCATEL 550 m3 thermal vacuum chamber and are composed of:
The Thermal Balance Test (TBT) applied to the PFM satellite The Thermal Cycling Test (TCT) applied to all models.
Objectives: To qualify the mathematical model in order to predict performances under flight
condition (TBT) To verify the validity of the thermal control concept chosen (TBT) To verify the thermal behaviour (dissipation's, gradients) of units (TBT) To verify the performances of units and Subsystems under environment
representative of external conditions encountered during all spacecraft lifetime (vacuum, cold and hot temperature, CORONA effect) (TCT).
To serve as a complete spacecraft burn-in. To perform eclipse discharge simulation. To verify the spacecraft contamination criteria (TCT)
Satellite Test Plan
8 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
THERMAL VACUUM TESTS
The hardware configuration of the satellite is similar to the flight configuration with the following exceptions:
The propellant tanks are empty, but are pressurised with about two bars of gaseous nitrogen
The Solar Arrays are not mounted E/W reflectors are not mounted, but the Earth antenna is installed
and both East/west feeds will be installed on test shim plates (ST8 option)
RF energy is dissipated into RF loads via non flight waveguides connected to input/output of the repeater
The flight PROM is not yet installed, replaced by an EM EEPROM (TBC)
Satellite Test Plan
9 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
THERMAL VACUUM TESTS The satellite is installed on the thermal adapter in the vacuum
chamber. The adapter is superinsulated and is thermally isolated from the satellite by insulating washers. The dolly interface frame is temperature controlled during all the test. In addition, spacecraft horizontality is also controlled during the test in order to have heat pipes in operating conditions.
During the thermal vacuum tests, the satellite temperature is controlled using :
the cold shrouds & cryopanels, thermocouples and S/C Telemetry (flight thermistors) satellite heaters test heaters installed on the satellite (if any)
IR heaters installed around the satellite when necessary. Each one is commanded and monitored independently in order to obtain the temperature required for the test.
The massive quantity of thermocouples allows the temperature monitoring of all units dissipating more than 10 W as well as every units described in the STAR ONE C1 performance specification. Some additional thermocouples (direct channel) are used for the monitoring of extra spacecraft hardware: thermal test adapter, I/F with test equipment’s.
Satellite Test Plan
10 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
Satellite Test Plan
11 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
THERMAL VACUUM TESTS
It is foreseen to submit the model to 3 cycles of thermal vacuum conditions and to perform all tests mentioned in the matrices. Tests are performed during the 2 first hot and cold plateaus. The third cycle will give opportunity to perform retest or investigation. For FM, a specific screening test will be performed (ST7 option).
The thermal cycling test is needed at system level but not specially for subsystem thermal control purpose. Nevertheless, the temperature level of the spacecraft during these tests is assured by thermal control subsystem, under his responsibility.
Contamination probes are installed in the vicinity of the satellite and analysed after test to determine outgazing products. After removal from the vacuum chamber, the satellite will be inspected.
Satellite Test Plan
12 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
PRE ENVIRONMENTAL TESTS SYSTEM PERFORMANCE TESTS 1 (part B)
SPT1B
The SPT1B will be sequenced as follows:
Body alignment verification
Antenna mounting, deployment and alignment verification
Solar arrays mounting, deployment, illumination & folding
Satellite Test Plan
13 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
MECHANICAL ENVIRONMENTAL TESTSThe aim of these tests is to demonstrate the ability of the Satellite to be submitted to the launch environment conditions (vibrations, acoustic noise and shock) with margins, without suffering performance degradation.
The sequence of tests will be split as follows:Tanks filling (simulation fluids)Sine vibration testPost sine vibration testAcoustic noise testPost acoustic verificationAdapter fit check and separation shock test (if
required)Tank draining.
Satellite Test Plan
14 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
MECHANICAL ENVIRONMENTAL TESTS
Tank fillingIn order to reach a representative satellite mass and dynamical behaviour, the tanks will be filled with simulation liquids and pressurised to an adequate pressure.
Satellite Test Plan
15 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
MECHANICAL ENVIRONMENTAL TESTS
Sine Vibration testThe satellite, in its launch configuration, clamped upon test adapter, and with tanks filled with simulation fluid will be subjected to vibration test along each one of the three orthogonal X, Y and Z axes.The sequence of events for each vibration axis will be as follows:
initial no-notched very low level runs (entry 0.05g) 5-150 Hz; no-notched low-level run (entry 0.2g) 5-150 Hz intermediate level (entry half protoflight level and half notching
level) 5-100 Hz STAR ONE protoflight level 5-100 Hz no-notched low-level verification sweep for comparison to initial
satellite signature.
Satellite Test Plan
16 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
Satellite Test Plan
17 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
Mechanical environmental tests
During the test, the satellite will be in electrical launch configuration and TM and TC RF links will be verified.
Post sine vibration testAfter the vibration tests a visual inspection will be performed on the satellite, then a short TM/TC verification will be carried out.
Satellite Test Plan
18 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
MECHANICAL ENVIRONMENTAL TESTS
Acoustic noise testThe Satellite will be installed into the chamber and submitted to the required acoustic environment as defined by arianespace.
The spacecraft will be in electrical launch configuration and will be controlled through TM and TC video links.
Post acoustic noise test verificationBefore the first run and after each subsequent run, a visual inspection will be carefully performed on secondary structures, thermal insulation and on outside equipment such as Solar Array wings and antennas.
Satellite Test Plan
19 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
Satellite Test Plan
20 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
MECHANICAL ENVIRONMENTAL TESTS
Adapter fit check and separation shock test (if required)The aim is to demonstrate the mechanical and electrical compatibility of the satellite with the adapter, and to verify that the separation shock does not damage the satellite. This test includes the pyrotechnic release of a flight representative clamp-band.
Tank drainingThe tanks will then be dried by flushing with hot and dry nitrogen. The heaters installed on the lower portion of the tanks are used. Dryness will be verified by gas chromatography.
Satellite Test Plan
21 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
POST ENVIRONMENTAL VERIFICATION SYSTEM PERFORMANCE TESTS 2 (part B)
SPT2B
The SPT2B will be sequenced as follows:
Solar array verification
Antenna pyro deployment and alignment verification
Satellite Test Plan
22 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
FINAL SYSTEM PERFORMANCE TEST SYSTEM PERFORMANCE TESTS 2 (part A)SPT2A
The SPT2A will be basically similar to the SPT1A and the test results will be compared to verify continued satisfactory performances of the Satellite.
SPT2A sequence is as follows:Body alignments verification,Electrical Performance Test,UPS tests,Ground Station compatibilityMCI
Satellite Test Plan
23 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
Compact Antenna Test Range (CATR) Test
This phase includes all activities done in the CATR environment:Antenna VSWR and DecouplingEMC RE Launch compatibilityS/C Radiated Auto-compatibilityAntenna patterns, EIRP, IPFDPIM’s (if necessary)
A test of the fully assembled protoflight satellite, except Solar Arrays, is performed on the compact indoor antenna range as a part of the Final System Performance Test. The compact indoor antenna range is capable of evaluating the far field RF performance of the satellite.
Satellite Test Plan
24 - ASP-05-STR1-263 All rights reserved © 2005-proprietary , Alcatel Space
FINAL OPERATIONS
The final operations will be sequenced as follows:
Solar array installation
Reference OMUX bandwith test
Final MCI (thruster’s adjustment)
Global leak test
Satellite Test Plan