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THEMIS INSTRUMENT SUITE FM2/FM3 PRE-SHIP REVIEW FM4/FM5 PRE-ENVIRONMENTAL REVIEW

THEMIS INSTRUMENT SUITE FM2/FM3 PRE-SHIP REVIEW FM4/FM5 PRE-ENVIRONMENTAL REVIEW Electric Field Instrument (EFI) John Bonnell EFI, IDPU, and II&T Teams University of California - Berkeley. Outline. Summary of EFI Status at FM2/3 PSR and FM4/5 PER Instrument Configuration by SN

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THEMIS INSTRUMENT SUITE FM2/FM3 PRE-SHIP REVIEW FM4/FM5 PRE-ENVIRONMENTAL REVIEW

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  1. THEMIS INSTRUMENT SUITE • FM2/FM3 PRE-SHIP REVIEW • FM4/FM5 PRE-ENVIRONMENTAL REVIEW • Electric Field Instrument (EFI) • John Bonnell • EFI, IDPU, and II&T Teams • University of California - Berkeley

  2. Outline • Summary of EFI Status at FM2/3 PSR and FM4/5 PER • Instrument Configuration by SN • Summary of End-Item Data Package • Final Test and Cal Results vs. Requirement Fulfillment • PFRs • Open Items • Bonus Content: • EIDP Table of Contents • Vibration Testing Summary • TVAC Testing Summary

  3. EFI Status at FM1 PSR • Requirements and Design: • No major changes to Requirements or Design since M-CDR (see Changes Since M-CDR and PFR Status for details). • All RFAs from previous reviews closed out. • Procurement: • All procurement is complete. • Personnel, Assembly and Test: • Team has done an amazing job. • 5 full FLT complements of SPBs and AXBs have completed functional and environmental testing, and either delivered to II&T or have completed II&T by the end of Aug ’05 (roughly 8 weeks per set). • BEB assembly complete in Dec ’04; bench testing through FM6 complete. • DFB assembly complete in Feb ’05; bench testing through FM5 complete. • Reduction in Force complete, Jun ‘05. • Final EFI team includes one half-time Scientist (Instrument Lead), one half-time MechE (shared with Probe I&T) and one half-time ElectE (shared with Probe I&T).

  4. Instrument Configuration

  5. FM2/3 End-Item Data Package (EIDP) • Same great content as FM1 EIDP, but now double the fun! • See Bonus Materials for Table of Contents. • Delivered Instruments: ~ 13.1 kg (x2). • End-Item Data Package: ~ 22.5 kg (x2; 72% margin!).

  6. EFI Mission Requirements Fulfillment: • FM2-FM4 MR fulfillment noted in THEMIS Verification Matrix (see MSE Presentation). • Integrated EFI and component parts compliant with mission requirements.

  7. Results of FM1-FM5 Testing • DC and AC Transfer functions agree within Flight sets to better than 1 % on non-critical functions (USHER, GUARD, AC SENSOR gain, etc.), and better than 0.2 % on critical, matched functions (BIAS, DC SENSOR gain). • Full 16-bit control of all bias functions demonstrated (control to better than 1 part in 1000, as per MRD). • V- and E-channel gains on DFB as per specification. • DFB Spectral (Filter Bank, FFT, and AKR) and Derived Quantities data products as per specification.

  8. EFI PFR Status

  9. PFR Status (1) • New PFRs since FM2/3 PER and FM1 PSR: 103, 105, 115. • Update on open PFR relevant to FM1 PSR: PFR-096.

  10. PFR Status (2) • PFR-103 (Cracked SPB Retainer Tube): • The SPB Door Retention Pin Retainer Tube on one FM4 unit was found to be damaged after actuation; the material around a fastener had yielded. • Analysis of the design showed that insufficient material was present to hold the fastener. • A retention clip was added to all units to properly retain the pin mechanism. • PFR-105 (FM4 Turns Counter Switch Failure): • The SPB turns counter switch on one unit was found to actuate at half the rate of other units. • It was found that the turns counter cam fastener sat proud of the cam surface on some of the units in a survey of all flight units, leading to unreliable switch actuation in the affected units. • The turns counter cam was reworked to assure that the fastener head would be below the cam surface in all units, and actuation was tested in all flight units.

  11. PFR Status (2) • PFR-115 (FM3 EFI V1 Failing AC Functional Test in TVAC) • One FM3 SPB unit displayed an anomalous response during AC Functional Testing during the cold soak portion of FM2/3 TVAC. • The anomalous response was traced to contact between the Sphere and Usher surfaces, which would affect pre-deployed testing of the sphere but would not affect deployed operation. • The contact between the Sphere and Usher was traced to an out-of-spec gap between the two surfaces, arising from tolerance stack up on the Preamp Enclosure and Sphere. • A 5-mil insulating kapton spacer anchored to the SPB Sphere Holder via transfer adhesive was added to all flight SPBs to increase the gap and eliminate the possibility of contact between the Sphere and Usher. • The gap under axial load and electrical isolation on all units was verified by measurement, and will be complete by F5 TVAC.

  12. Open Items

  13. Open Items • Instability of EFI Y IMON (PFR-096): • Source of 2 mA current consumption instability traced to EFI Preamps on affected units. • Suspect preamp boards swapped for Flight spares, and affected units re-integrated and re-calibrated. • Spare units consume nominal, stable current. • Suspect preamp PWBs subjected to bench tests to determine nature of current consumption instability. • Suspect preamp PWBs reworked to isolate source of problem to particular components (power supply bypass caps replaced). • Suspect parts sent for comparative DPA (suspect parts and parts from same lot and vendor); results pending (NOV 2005).

  14. Bonus Materials: • EIDP Table of Contents (note FM identifier is not valid) • Vibration Testing Summary • TVAC Testing Summary

  15. EIDP: Electrical • THEMIS EFI Preamp: F1 PWB: • Assembly Records. • Special TVAC Acceptance Test Data. • THEMIS EFI F1 SciCal: • SciCal Summary (calibration data summary). • DC Response Data (BIAS, SENSOR, FLGND, USHER, GUARD, BRAID). • AC Response Data (SENSOR, FLGND, USHER, GUARD, BRAID). • THEMIS BEB, S/N 004, FM1 (BINDER 1): • SCHEMATIC, ASSEMBLY AND RE-WORK RECORDS, BOARD-LEVEL TESTING RESULTS, MATE/DEMATE AND POWER LOGS. • THEMIS DFB, S/N 02, FM1 (BINDER 5): • SCHEMATIC, ASSEMBLY AND RE-WORK RECORDS, BOARD-LEVEL TESTING RESULTS, MATE/DEMATE AND POWER LOGS. • THEMIS Harness: EFI (F1-6; no Binder number assigned): • Schematic, assembly and re-work records. • THEMIS Harness: Enable Plugs, Coax Cables (F1-6; Binder 24): • Schematic, assembly and re-work records.

  16. EIDP: Misc. • THEMIS EFI Preamp PWB and Cable Loading Log (SPB and AXB): • CROSS-REFERENCED LIST BETWEEN BOOM UNIT, CABLE, AND PREAMP S/N. • THEMIS EFI: PA & Cable Drawings (Binder 35): • Mechanical Drawings of Preamp Enclosure and Cable Assembly fixtures. • Assembly and Re-Work records included in individual boom unit assembly records. • THEMIS EFI Deploy Data (F1-6): • Sphere/Fine Wire deploy data. • Duplicates of SPB Hi-Bay and TVAC Deploy Test Reports. • Duplicates of AXB Vertical and TVAC Deploy Test Reports.

  17. EIDP: SPBs • THEMIS SPB: Vibration Acceptance Testing (FM1-2; Binder 12): • Acceptance Vibration Test Reports. • THEMIS SPB Flight Documents: Hi-Bay Full Deployment Testing (F1-5; Binder 13): • Deploy Testing Reports (current consumption, length measurement and calibration, deploy rate). • THEMIS EFI: SPB Procs & Schematics (all; Binder 14): • Vacuum Motor Burn-In Test Report. • THEMIS EFI: SPB Mass Properties (F1-6; Binder 15): • SPB Mass Properties and ICD Conformance Reports. • THEMIS: SPB Master Mechanical Drawings, FM1 (Binder 27): • As-Built Mechanical Drawings. • SPB S90x: THEMIS (Assembly and Test Records; Binders 8, 9, 10, and 11): • Assembly and rework records for boom unit, preamp enclosure, and cable. • Electrical and mecahnical functional test records. • TVAC test records.

  18. EIDP: AXBs • THEMIS Axial Boom: Assembly Records, Flight1 Upper and Lower Booms, THM-AXB-FLT-001, -002 (Binders 29 and 28): • Boom Wiring Diagram, Assembly and Re-Work Records. • THEMIS Axial Boom: Test Records, Flight 1 Upper and Lower Booms, THM-AXB-FLT-001, -002 (Binders 31 and 30): • Mechanical and Electrical Functional Test records. • Vibration Test Results. • TVAC test Results. • ICD Conformance and Mass Properties. • THEMIS Axial Boom: Vibration test Data, All Flight Units (no Binder number assigned): • Acceptance Vibration Test Data.

  19. SPB Acceptance Vibration Protocol • Per UCB THEMIS Document THM-SPB-PRO-423 • All 3 Axes • Sine Survey, .25 G, 5 – 2000 Hz • Sine Strength per Swales TM2430-RevD, 29 November 2004 • Random • Per Swales Document TM2430-RevD • 7.09 G RMS • 1 min duration • All Vibration Testing Performed at Same Facility, Quanta Labs • Retesting (if required) • ‘Workmanship Shake’ • Validate any design changes following original Flight build shake • Validate rework of any failures on previous vibration test • Entire vibration protocol, single axis only Acceptance Sine Strength Specification Acceptance Random Specification 4X SPB Flight Units on Vibration Plate

  20. SPB Acceptance Vibration Tests Run

  21. SPB Vibration Testing Overview • Deviations from Test Specification (Notching/Force Limiting/Aborts) • None • SPB First Natural Frequency: 144 Hz (Requirement: >75 Hz) • Good Sine Sweep Consistency from Unit to Unit (within 15 Hz) • Retesting due to Hardware Failure • Backing out of bolts (2 X Bolts not torqued correctly at Flight Build) • Resolution: Bolts torqued and spot-bonded, single axis re-vibe completed • Single Strand of Cable pulled out of connector at Spool (Assy error) • Resolution: Wire repaired, single axis re-vibe completed • Retesting due to Hardware Redesign (FM1 Only) • Release Ring Spring Redesigned to Ensure Constant Force on Doors • Resolution: All springs Replaced in all units • Single Axis Retest Completed • Preamp Ferrule Crimp Redesigned (Contact discovered to be inconsistent during testing) • Resolution: Ferrule material changed and recrimped • Single Axis Retest Completed • Status • Flight Units F1-F5 Vibration Acceptance Testing Completed

  22. AXB Acceptance Vibration Protocol • Per UCB THEMIS Document THM-AXB-PRC-302 • All 3 Axes • Sine Survey, .25 G, 5 – 2000 Hz, 2 octaves/minute • Sine Strength per Swales TM2430-RevD, 29 November 2004 • Random per Swales Document TM2430-RevD • Qualification: 13.01 G RMS, 2 min duration • Acceptance: 9.21 G RMS, 1 min duration • All Vibration Testing Performed at Same Facility, Quanta Labs • Retesting (if required) • ‘Workmanship Shake’ • Validate any design/procedure changes following original Flight build shake • Validate rework of any failures on previous vibration test • Entire vibration protocol, single axis only

  23. AXB Acceptance Vibration Tests Run AXB X Axis AXB Y Axis Note: Jan 11 2005 testing was to qualification levels due to design modifications relative to the engineering test unit. AXB Z Axis

  24. AXB Vibration Testing Overview • Deviations from Test Specification (Notching/Force Limiting/Aborts) • Due to resonances in testing fixture, notching was required on the Y Axis to prevent overtesting of the booms • THM-AXB-FLT-001, 1570 Hz to 1670 Hz, input 0.0016 g2/Hz • THM-AXB-FLT-002, 1580 Hz to 1745 Hz, input 0.0016 g2/Hz • AXB Z First Natural Frequency: 300 Hz (Requirement: >75 Hz) • Good Sine Sweep Consistency from Unit to Unit (within 15 Hz) • AXB X & Y frequencies modeled fixture resonances, suggesting first natural frequency higher than 1800 Hz • Retesting due to Improper Test Procedure • Accelerometer was not located at the boom’s center of mass during vibration • Resolution: Accelerometer placed at center of mass and single axis test completed • Retesting due to Hardware Failure • Sensor door mount cracked during re-stow of boom (Assembly Error) • Resolution: Assembly replaced and single axis test completed • Status • Flight Units F1-F5 and Flight Spare F6 Vibration Acceptance Testing Completed.

  25. EFI PreAmp Thermal Testing Status • NO CHANGE SINCE FM1 I-PER.

  26. EFI SPB Thermal Testing Status • Updates since FM1 I-PER: • F4 and F5 SPB TVAC and Thermal Balance testing complete as of July 2005.

  27. EFI AXB Thermal Testing Status • Updates since FM1 I-PER: • AXB F3 thru F6 received 6 Suite-level TVAC cycles en masse July 25-28, ’05 in order to deliver AXB and AXT (tube) to Probe I&T . • AXB F2 and F3 units delivered to Swales to support Probe RCS buildup, Aug and Sep 2005.

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