Biography Essex Fowlks V David Sgro

Transcription

1 Biography Essex Fowlks V Raytheon Integrated Defense Systems: Senior Manager Systems Engineering Systems ValidaHon Test and Analysis Directorate Staff (Present- 2007), Department Manager Air Defense System (ADS) Department ( ), Program Manager III ( ) Upgraded Early Warning Radar IntegraHon and Test Cross Product Team Lead, Senior Systems Principal Engineer THAAD radar integrahon and test ( ). Coleman Research CorporaHon: Senior Systems Engineer ( ), NaHonal Missile Defense Program Office; United States Army: Test and EvaluaHon Staff Officer Test and EvaluaHon Management Agency ( ), Test and EvaluaHon Staff Officer OperaHonal Test and EvaluaHon Command ( ), Test and EvaluaHon Officer Army Material Test and EvaluaHon Directorate ( ). EducaHon: DAWIA Level 3 Test and EvaluaHon, DAWIA 3 Systems Engineering, Command and General Staff College, M.S. Systems Management, Field ArHllery Officer Advance Course, Armor Officer Advance Course; Field ArHllery Officer Basic, M.S. Systems Management, Florida InsHtute of Technology, B.S. General Engineering United Military Academy. David Sgro Raytheon Integrated Defense Systems: Senior Mechanical Engineer. Has over 10 years of experience in mechanical engineering focusing on Environmental TesHng in the defense industry. His educahon includes a Bachelor's degree in Mechanical Engineering from Wentworth InsHtute of Technology in Boston, MA. He is a member of the InsHtute of Environmental Sciences and Technology (IEST) organizahon and is a working group and session chair for the shock and vibrahon test fixture design porhon of the IEST. David has published papers for both the IEST and internal Raytheon Symposiums. September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 1

2 How To Plan An Accelerated Reliability Growth Test Essex Fowlks V David Sgro Copyright 2014 Raytheon Company. All rights reserved. Customer Success Is Our Mission is a registered trademark of Raytheon Company September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 2

3 Goal Of This PresentaDon What Does It Takes To Plan An Accelerated Reliability Growth Test. Why ARGT TesDng? ARGT Drivers What Does It Take To Plan An ARGT? Lessons Learned Conclusions September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 3

4 Why Accelerated Reliability Growth TesDng? We need to determine a meaningful Reliability Measure (Ai) for the Unit Under Test (UUT). ARGT provides an efficient means to collect credible reliability data during early engineering research and development in a cost effecdve manner that will be used to understand and improve the product. September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 4

5 Current Business Environment UUT (CRAD, IRAD, POD, POM) Customer Requirements Schedule Resources ARGT Drivers CUSTOMERS WANTS PROOF OF RELIABILITY September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 5

6 Scope Team ObjecDves AssumpDons Resources Risks OpportuniDes What Does It Take To Plan An ARGT? PLAN ARGT JUST LIKE ANY OTHER TEST September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 6

7 Scope Subject one sample of each type UUT to accelerated environmental stresses thus aging and revealing life expectancies and design weaknesses The test is designed to simulate a pre- determined lifedme When failures occur, the UUTs will be repaired or, if necessary, spared to make condnued tesdng possible ModificaDons may be made to midgate the problem and permit test condnuadon ARGT provides life expectancy data and generates a list of potendal design changes that may contribute to increased product life and reliability ARGT will consist of repeddve thermal cycles incorporadng extended high temperature dwells, cyclic humidity, and random vibradon During the temperature and humidity phases of tesdng, the UUTs condnuously operates and undergo funcdonal tests A vibradon test phase is performed with the un- powered UUT OperaDonal checkouts will be performed a^er each axis The ARGT does not include supply- power- related stress factors September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 7

8 Customer Government Team Raytheon Program Management Office Engineering Management Business Unit Engineering VP Engineering Discipline Director Systems Engineers Mechanical Engineers Reliability Engineers Electrical Engineers CUSTOMERS MUST BE ON BOARD TRAIN EARLY September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 8

9 Finance FaciliDes Security Safety Team Cont d September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 9

10 ObjecDves DemonstraHng UUT reliability and maturity CollecHng data that proves UUT reliability and maturity September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 10

11 AssumpDons ü Labor budget approved ü Material budget approved ü Will use exisdng environmental chamber for ARGT ü Environmental lab will instrument UUTs ü ExisDng UUT vibradon fixtures are not sufficient ü Will switch UUT from environmental chamber fixture to vibradon fixture as required during ARGT ü Three chillers with headng capability required ü Purchase chillers ü Need to revise ARGT tesdng code and tools ü We can have breaks in ARGT to perform repairs ü Spare UUT and CCAs available for repair September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 11

12 AssumpDons? Program(s) provides vibradon and shock requirements flow down (TBD)? Customers concurs with ARGT thermal, humidity and vibradon profiles (TBD)? Customer concurs with electronics road vibradon requirements based on Aberdeen accelerometer data (TBD)? Automated UUT diagnosdcs checks conducted twice daily 7 days a week (TBD)? Automate UUT for unabended operadon (TBD)? AGRT approved for unabended 24/7 (TBD by Safety)? ARGT Facility will not require construcdon (TBD by FaciliDes) VALIDATE ASSUMPTIONS EARLY TO PRECLUDE DISCONNECTS September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 12

13 UUTs/Spares Test Profiles FaciliDes Materials Test StaDons So^ware/Firmware Data CollecDon Process InstrumentaDon Analysis Tools Staffing Resources September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 13

14 Environmental Chamber Layout Thermal Chamber September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 14

15 Chamber Test Fixture Design The test fixture will be used inside of an environmental chamber, which operates primarily at 115 C for long periods of Dme Thermal fixtures mimic gravitadonal orientadon. The UUTs are not air cooled as they are in the system but rather liquid cooled. Chiller carts will allow the proper adjustment to flow and cooling to best replicate fielded condidons. A UUT is mounted at one end of the test fixture and it dissipates heat into a heat sink located on the opposite wall of the test fixture and into thermal absorbent material, which covers the inside of the box The outside of the box is covered with 2 thick foam insuladon to protect from external chamber high temperatures Due to possible over headng of load boxes, condidoned air will be pumped into the load box at 21.1 C (70 F) or cooler which is supplied to the air plenum at the horn end of the box, circulates within the box to cool the absorbent material, then exhausts out the same side Air supply/return lines Environmental chamber Test Fixture Temperature condidoner Liquid nitrogen tanks (to cool air) Cooling of test fixture inside environmental chamber Return plenum Air exhaust Air inlet Supply plenum 2 foam insuladon Test Fixture September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 15

16 Test StaDon Layout September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 16

17 Risks Type Sub-IPT Title Description Mitigation/Capture Steps Risk Test/Analysis Test Facilities Facilities modifications to conduct ARGT Work with facilities to mitigate impact to schedule are not completed by test execution date. Risk Test/Analysis Unattended ARGT Testing Safety or security preclude 24 hour autonomous testing resulting in creased test cost for 24 hour staffing. Work with safety and security to establish means to test 24 per day without around the clock staffing. September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 17

18 OpportuniDes Type Sub-IPT Title Description Mitigation/Capture Steps Opportunity Test/Analysis Reuse Existing UUT Vibration Fixture Opportunity Test/Analysis Reuse Existing UUT Controller Opportunity Test/Analysis Reuse Existing UUT Firmware And Software Opportunity Test/Analysis Reuse Existing UUT Data Analysis and Collection Tools Opportunity Test/Analysis Reuse Existing UUT Environmental Test Pre/ Post Test Checkout Procedures ARGT UTT will require a vibration fixture. ARGT UTT will require a controller. ARGT UUT will require firmware and software to conduct test. ARGT UUT will required data analysis and collection tools. ARGT UUT will require procedures to establish baseline and identify changes resulting from test. Verify vibration fixture design does not require mechanical design changes to accommodate UUT. Purchase vibration fixture using existing drawing package. Verify controller design does not require electrical design changes to accommodate UUT. Purchase controller using existing drawing package. Verify existing UUT firmware and software does not require update to operate ARGT. Verify existing UUT data analysis and collection tools do not require update to support ARGT. Verify existing UUT DVT checkout procedures are adequate for pre/post checkout. ARGT IS NOT CHEAP USE RISK & OPPORTUNITIES September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 18

19 Lessons Learned Customer must understands why ARGT and not Highly Accelerated Life Test or, Environmental Stress Screening or, Highly Accelerated Stress Screening IdenHfy the number of UUTs and spare circuit card assemblies required to support ARGT early Use ARGT to target customer reliability concerns and drive to ground early September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 19

20 Conclusions TesHng has not begun but planning, design, and material procurement is well underway ARGT planning requires mehculous, systemahc and cost efficient approach ARGT provides excellent data capture / design validahon An ARGT is a complex undertaking requiring many different disciplines to plan, design and execute a credible and successful test CONDUCT ARGT EARLY IN DEVELOPMENT PROCESS September 8, 2014 ASTR 2014, Sep 10-12, St. Paul, MN 20