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Payload Control System (NASDAT, EIP)

Payload Control System (NASDAT, EIP). ER-2 and WB-57 Implementation NASA ASF, 9/14/2010. Contents. Introduction Requirements Implementation EIP NASDAT Network Control System Test Plan Schedule / Milestones Conclusions / Action Items Acronym List (Appendix). Introduction.

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Payload Control System (NASDAT, EIP)

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  1. Payload Control System (NASDAT, EIP) ER-2 and WB-57 Implementation NASA ASF, 9/14/2010

  2. Contents • Introduction • Requirements • Implementation • EIP • NASDAT • Network • Control System • Test Plan • Schedule / Milestones • Conclusions / Action Items • Acronym List (Appendix)

  3. Introduction • This review will… • Cover the preliminary requirements & design for the ER-2 and WB-57 EIP and NASDAT units. • Demonstrate the ASF is ready to proceed with detailed design. • This review will not… • Be a review of the Global Hawk system (it’s different!) • Cover, in any significant detail, payload communications or the InMar-SAT system. ASF – Airborne Sensor Facility @ NASA ARC EIP – Experimenter Interface Panel; an instrument electrical interface. NASDAT – NASAAirborne Science Data Acquisition and Transmission unit

  4. Key Requirements • Level 1 (NASA Airborne Science / HQ): Sensor Web – A distributed and coordinated network of sensors which collectively act as a single “macro- instrument.” (Delin, Sensors Magazine 4/1/2004)

  5. Key Requirements • Level 2/3 (ER-2 & WB-57 Systems):

  6. Requirements (25A x 2 ckts) (79A) (50A x 2 EIPs) (72Ax2 EIPs) (79A) (30A) (30A) DC CURRENT REQUIREMENT: >80A per EIP (2.8kW) AC CURRENT REQUIREMENT: 50A / Ф, per EIP

  7. EIP Implementation EIP Functional Block Diagram:

  8. EIP Implementation • A modular, PCB-based design reduces wiring and simplifies assembly & maintenance w/rt to the Global Hawk version. SSPC Module (4) AC Distribution Module Legacy Module PRELIMINARY – FOR INFORMATION ONLY DC Distribution Module Ethernet Module (Monitor Module Not Shown)

  9. Support 5 experiments with 3 ‘Misison Critical’ and 1 (modified) ‘Air Data’ connector(s) Drop to 4 PWR connectors (5 command relays / EIP); EIP Implementation J6-J9 change to D38999/21-16 Provide analysis for 50A/circuit (same connector) Fuse internal circuit internally Replace J13 & J14 with Ethernet; leave aircraft wire in place & use as needed. Ship-side signals (DC, AC, Control input) connectors are unchanged.

  10. EIP Implementation EIP Front Panel: Mission Critical 15A AC/DC & Control 15A AC/DC & Control 2x50A DC Output Control & Data Input Mission Critical Mission Critical 15A AC/DC & Control 15A AC/DC & Control 3Ф AC Input Legacy Output 8x100 Mb Ethernet 4x1Gb Ethernet Adapter harnesses will be available to fold Mission Critical & Control into Legacy Output connectors

  11. EIP Implementation • Legacy EIP Power (Mixed AC/DC) Connector Using 3 #16 DC circuits, 2 with SSPCs @ 17.5A trip, 1 fused @ 10A Tie shields at backshell (TBD) • - GH safety circuit used for command circuit – lose NC contact (except for legacy connector) • GPS splitter designed-in but not installed; GPS socket removed in PWR connector • IRIG-B moved to PWR connector (GH style)

  12. L1/L2/Omnistar GPS (coax) (not provided for WB-57/ER-2) 3Ф, 400Hz AC Circuit #1 (15A/Ф)* 3Ф, 400Hz AC Circuit #2 (15A/Ф)* 28VDC Circuit #1 @ 15A 28VDC Circuit #2 @ 15A IRIG-B (coax) Command Relay (N.O. & COM) @ 10A EIP Implementation • Standard Instrument Power Connector (Amphenol D38999/20WG16SN) • 16 x AWG #16 contacts, same pinout as Global Hawk EIP * - Recommended loading varies per plane & based on SAE50881 analysis

  13. EIP Implementation

  14. EIP Implementation • DC In & Hi-Power Out connectors are same as prior design

  15. EIP Implementation • AC In/Out SAE50881 analysis • Dependent on aircraft wiring more than EIP • Aircraft circuit breakers have high maximum trip: • ER-2/WB-57 historical usage implies greater current ratings than SAE50881 analysis (based on 6TC breakers). • Recommendations: • Caution with high bundle counts & heavy loading • Update analysis with actual ER-2/WB-57 breaker unit data • Incorporate ER-2/WB-57 breakers in EIP environmental tests

  16. EIP Implementation • Modified Legacy Data Connector (page 1 of 2) NEW ASSIGNMENTS: ZJ: INTERLOCK #2 ZM: AIRCRAFT GROUND ZN: ALTITUDE SWITCH #2 N.O. ZP: ALTITUDE SWITCH #2 COM ZQ: LANDING GEAR #2 N.O. ZR: LANDING GEAR #2 COM ZS: FAIL LAMP DRIVE #2 ZT: SPARE

  17. EIP Implementation • Mission Critical / Aircraft Data Connector (page 2 of 2)

  18. EIP Implementation • Mission Critical Connector (Amphenol TVP06RW9-9S) • High-density D38999/III, 9x AWG #23 contacts • Will supply conversion adapters to legacy connector Redundant Interlocks Ground Landing Gear COM N.O. Redundant Fail Drive COM N.O. Altitude Switch

  19. EIP Implementation • Solid State Power Controllers (SSPCs): • DC relay, over-current and arc-fault breaker in 1.5in3 • Trip state, voltage & current monitor • Low power dissipation: • Ron = 6mΩ @ 20A (120mW), no relay coil • Inputs from command relays are opto-isolated on PCB (<20mA/input) • Fails to ‘open’ state • -55ºC to 85ºC operation • Surge tolerant (48V @ 1s, 80V @ 100ms) • Units for power circuits will be permanently ‘CLOSED’ • Status: Rev- PCB received; testing in process

  20. EIP Implementation • DC Monitor Module: • Revised form factor of Global Hawk design • UDP Status Packet Contents: • Voltage & Current for each 15A DC circuit (not for high-power) • Trip status for all SSPCs • Interlock & Fail line status for each payload • (1) External temperature (AD5626) • Humidity • EIP Internal Health Temperatures • Status: Schematic Design • Legacy Module: • Patches Control/Data input to Legacy Output and Mission Critical Connectors • Leverages PCB solder-tail connector technology • Status: Schematic Design Analog Devices AC2626 Temperature Probe

  21. EIP Implementation • AC Distribution PCB (Rev A): • Layer Stackup (0.125” Thick): • Top: Shield • Inner 1-2: Ckts. 1 & 2 ФA • Inner 3: Shield • Inner 4-5: Ckts. 1 & 2 ФB • Inner 6: Shield • Inner 7-8: Ckts. 1 & 2 ФC • Inner 9: Shield • Inner 10: Circuit 1 Neutral • Inner 11: Shield • Inner 12: Circuit 2 Neutral • Bottom: Shield • Layer Spacing: 4.15 mils (min) • Max Electric Field: 120.4 V/mil • FR4 DBV: 1100V/mil • Status: Ready for Fabrication DBV – Dielectric Breakdown Voltage

  22. EIP Implementation • Ethernet Module: Sixnet APSwitch • 8x 100Mbit ports, 4x Gigabit ports • 1x 100Mbit port internal to EIP (use for monitor) • Interconnects: MIL-DTL-38999/III Quadrax • Part #: 25-8 D38999/III (8 quadrax inserts) • Status: Functional & environmental evaluation.

  23. Network Implementation • Managed mesh w/ RSTP configured as 1G ring has two levels of fault tolerance: • Ring topology has built in redundancy • 1G over Cu = 2 quadrax (break one, down to 100Mbit) Image from Sixnet Ethertrak Software Users Manual RSTP – Rapid Spanning Tree Protocol – allows redundant connections in a managed network

  24. Network Implementation • Network impacts on system: • 1G ring means 4 quadrax / EIP & bulkheads • Cable: Tensolite NF24Q100 • Bulkheads: Amphenol TBD (19-18 pattern) • Ring network requires infrastructure power • 2 sets of 28VDC @ ~0.5A / EIP • Fused internally in each EIP • Spare pins available on control input harness

  25. Network Implementation • Worst-Case 1000BASE-T Cabling: • 2 Ethernet Switches, 4 ER-2 Bulkheads, all Tensolite NF24Q100 + Quadrax • TIA/AIA-568b (CAT6) vs. ER-2 Quadrax: • Conclusion: ER-2 IL meets worst-case CAT6 IL specification IL: Insertion Loss (i.e. attenuation)

  26. Control Implementation • Barebones Implementation (Now) • Low risk: Uses existing switch panel and wiring • Optimized Implementation (Later) • Uses Ethernet for indication and/or control • Requires additional electronics box to translate switches & lamp drives to/from network packets • (WB-57 only) FAIL => FAIL/STATUS • Logic Low: FAIL (red lamp on) • Logic High: RUNNING (red & blue lamps off) • Switching @ TBD kHz: STATUS (blue light on)

  27. Control Implementation BAREBONES OPTIMIZED #1 OPTIMIZED #2

  28. Test Plan • All unique designs will be qualification tested for vibration & thermal / altitude • Test procedures for each major assembly • EIP Test Bench • Developed for GLOPAC EIPs • Automated I/R/C “buzz-out” • Automated monitor calibration • DC & AC generators & loads I/R/C: Isolation / Resistance / Continuity test – finds unintended short or open circuits prior to first power -on

  29. Test Plan Ethernet switch integrated into EIP for WB/ER-2 Will need larger AC load (20kW) Will use 100A in-house TRU, not Champion Unit Need larger AC source; may have to go 60Hz

  30. Test Plan • Vibration – • Qualification Test per DRB 367-1100-121 (TBD) • 7.17grms, 3-axis,1 hour per axis • Fixture modification needed (new bolt pattern) • Thermal Altitude • Worst-case thermal & altitude combinations for pressurized and unpressurized areas • -55C -> 0C @ 70kft • 0C -> 45C @ 30kft • 0C -> 60C (TBD) @ sea level

  31. Test Plan May need to request waiver for infrastructure power cold start (TBD) Considering changing profile & dwell times to match DO-160F approach

  32. Schedule / Milestones • May 2010 – Materials funding issued • September 2010 – PDR • December 2010 – NASDAT Pre-Production • February 2011 – EIP Pre-Production • April 2011 – EIP & NASDAT Production • American Recovery and Reinvestment Act (ARRA) funds expire in June 2011

  33. Conclusion / Actions • The NASDAT, EIP, and associated hardware are ready for detailed design. • Review and record any actions flagged during the presentation.

  34. Payload Control System (NASDAT, EIP) ER-2 and WB-57 Implementation NASA ASF, 9/14/2010

  35. Acronym List • Ω - Ohms • Ф – Phase • 1G – Gigabit Ethernet • A - Amperes • AC – Alternating Current • AIA – Aerospace Industries Association • ASF – Airborne Sensor Facility • ATR – Air Transport Rack • C – Celsius / Centigrade • CAT6 – Category 6 • CPU – Central Processing Unit • DC – Direct Current • EIP – Experimenter Interface Panel • GLOPAC – Global Hawk Pacific • GRIP – Genesis and Rapid Intensification Processes • HQ - Headquarters • Hz – Hertz • IP – Internet Protocol • IRIG – Inter-range Instrumentation Group • IRIG-B – IRIG Code B • I/R/C – Isolation , Resistance, Continuity • k – Kilo (thousand) • kHz - Kilohertz • ms - Millisecond • NASDAT - NASA Airborne Science Data Acquisition and Transmission unit • PDR – Preliminary Design Review • RSTP – Rapid Scanning Tree Protocol • S/C – Signal Conditioning • SAE – Society of Automotive Engineers • SSPC – Solid State Power Controller • SSR – Solid State Relay • TBD – To Be Determined • TCP – Transmission Control Protocol • TIA – Telecommunications Industry Association • uC – Microcontroller • UDP – User Datagram Protocol • uP – Microprocessor • VAC – Volts, AC • VDC – Volts, DC • V – Volts • W - Watts

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