CASE GmbH Westendstrasse 125 80339 München Herschel PACS Test Procedure STM 1 Revision: -
i Document Approval Sheet Title: Herschel PACS Subtitle: Test Procedure STM Doc. No: 1 Revision: - Prepared:...... January 14, 2003 (Dr. G. Wanderer) Approved:...... (D.Kampf) Approved:...... (W.Zwick) Released:...... (Name) Released:...... (Name)
ii Document Change Record Iss./Rev. Date DCN-No. Pages Affected 1/- 13.01.2003
iii Contents 1 Introduction 1 2 Success Criteria 1 3 Applicable Documents 2 4 Identification of Test Article 2 5 Quality Assurance Instructions 2 6 Test Implementation 3 6.1 Personnel................................... 3 6.2 Measurement Equipment.......................... 3 6.3 Environmental Conditions.......................... 4 6.4 Test Tolerance................................ 4 6.5 Test Setup................................... 4 6.6 Special Precautions............................. 5 7 Test Program 6 7.1 Resonance Search Run........................... 6 7.2 Sinusoidal Load Run............................. 6 7.3 Random Load Run.............................. 7 7.4 Test Sequence................................ 8 8 Instrumentation 9 9 Proceeding in Case of Non-Conformances 10 10 Documentation 10 11 Step by Step Activity, Test Sequence Record 11
1 1 Introduction This test procedure defines the conditions and activities for the vibration test of the FPU structure thermal model. The STM consists out of the primary structure and mass dummies for all heavy components, like detectors mechanisms larger optical components This test is used to identify the fundamental modes of the FPU qualify the FPU assembly under vibration loads of sinusoidal and random loads at ambient temperature 2 Success Criteria The test will be considered as successful if the specified test loads have been applied and no physical degradation of visible parts is detected, i.e. no visually detectable damage of housing parts, struts or bolts, the deviation of the fundamental frequency of the FPU assembly are less than 10% comparing the search runs before and after the qualification level runs.
2 3 Applicable Documents AD1 PACS-KT-AN-005 Load Analysis AD2 CEA E-mail 15.05.2002 AD3 ESA E-mail Herschel FPU Vibrational Environment, 20.12.2002 AD4 SCI-PT-IIDA-04624 Herschel/Planck Instrument Interface Document IID Part A, Issue 3, Rev. 0, 1.7.02 AD5 PACS-KT-PL-012 PACS Vibration Test Plan, FPU Structure Thermal Model 4 Identification of Test Article Item Hardware/Drawing No Status Primary structures STM Filter wheel dummies Ge:Ga detector dummies FPU suspension struts Bolometer (Ph FPU) Grating dummy Chopper dummy Calibration source dummies Heavy optical components STM STM STM STM STM STM STM STM 5 Quality Assurance Instructions The instruments and equipments used for the defined test must be within the calibration cycles.
3 6 Test Implementation 6.1 Personnel Title Function Comp. Name Test Conductor overall responsible for the test KT Kampf and specimen handling Resp. Test Engineer release of test parameters and test runs, judgments of test results CASE Wanderer QA Responsible ensure QA requirements, implementation of test modifications KT Facility Engineer responsible for the reliable operation and control of the facility MPE 6.2 Measurement Equipment Equipment Ident. Nr. Shaker System Control System and Software Control and measurement accelerometer Control Charge Amplifier
4 6.3 Environmental Conditions The environmental conditions for preparations, handling and testing of the specimen shall be as followed: - Temperature: 22 o ± 5 o - Relative Humidity: 40% to 70% - Atmospheric Pressure: 980 ± 115 hpa - Cleanliness: Standard electronic integration room. 6.4 Test Tolerance The allowable tolerances shall be as indicated below. Resonance Search: Frequency ± 5 % Acceleration ± 10 % of maximum level Sweep Rate ± 5 % Random Vibration: Acceleration spectral density ± 3 db Filter band-width frequency band 10 Hz to 100 Hz 10 Hz or less 100 Hz to 350 Hz 25 Hz or less 350 Hz to 2000 Hz 50 Hz or less Overall rms level + 15 % / -5 % Frequency ± 2 % Test Duration in sec + 10 % / -0 % 6.5 Test Setup The FPU shall be vibrated in the tree satellite main axes. For the lateral axes the test specimen is mounted onto the slip-table of the shaker. To allow the longitudinal vibration on the small head expander of the shaker, a adapter plate is necessary. The test specimen is mounted on the adapter for all test. The adapter has to be mounted on the shaker before the test specimen is mounted, because the bolts under the test specimen are not accessible after putting the test specimen on the adapter.
5 6.6 Special Precautions The design of the screwed connections takes into account the loss of pretension due to cryogenic temperature. To test the capability of transferring shear loads under this conditions, the tightening of the M8 screws into the optical bench shall be reduced from 23 Nm to 17 Nm for the load axis Y and Z.
6 7 Test Program The following sections describe the test types. The test sequence is given in section 7.4 7.1 Resonance Search Run The acceleration level for all search runs shall be 0,5 g from 5 Hz to 2000 Hz, sweep rate 2 oct/min During the resonance search run the output level shall be limited to 18 g at sensor 1 (Top Optics) for vibration in X-direction and limited to 8 g at sensor 1 for vibration in Y- and Z-direction. The abort limit shall be set to 20 g at sensor 1 for vibration in X-direction and to 10 g at sensor 1 for vibration in Y- and Z-direction. 7.2 Sinusoidal Load Run The nominal qualification test levels for sinusoidal load runs are: Axis Range Level X 5-21 Hz 10 mm 5-100 Hz 18 g Y 5-14 Hz 10 mm 5-100 Hz 8 g Z 5-14 Hz 10 mm 5-100 Hz 8 g The sweep rate for the sine load runs shall be 2 Oct/min. During the sine load run the output level shall be limited to (18 g TBD) g at sensor 1 (Top Optics) for vibration in X-direction and limited to (8 g TBD) g at sensor 1 for vibration in Y- and Z-direction. The abort limit shall be set 10 % above the response limit at sensor 1.
7 7.3 Random Load Run The nominal qualification test levels for random load runs are: Axis Range Level X 20-100 Hz +3dB/Oct 100-150 Hz 0,05 g 2 /Hz 150-300 Hz 0,02 g 2 /Hz 300-2000 Hz -7 db/oct Y 20-100 Hz +3dB/Oct 100-150 Hz 0,02 g 2 /Hz 150-300 Hz 0,0125 g 2 /Hz 300-2000 Hz -7 db/oct Z 20-100 Hz +3dB/Oct 100-150 Hz 0,02 g 2 /Hz 150-300 Hz 0,0125 g 2 /Hz 300-2000 Hz -7 db/oct The duration for the random test is 2 minutes per axis. In order not to exceed the design limit loads the responses shall be limited to 18 g in axial and 8 g in lateral direction for the fundamental frequencies. The equivalent acceleration is determined by a = 4 0, 5 π W out f where W out = amplitude of the response frequency [g 2 /Hz] f = half-bandwidth of the response frequency Sensor 1 shall be used to determine the notching level. A abort limit shall be set at sensor 1 at a level 20 % higer than the expected response level in a small frequency band around the natural frequencies, if the input spectrum is notched.
8 7.4 Test Sequence Run Test Objectives Direction Excitation 1 Resonance Search X sec. 7.1 2 Intermediate Sinusoidal Run X half ampl. of sec. 7.2 3 Qualification Sinusoidal Run X sec. 7.2 4 Resonance Search X sec. 7.1 5 Low Level Random Vibration Test X sec. 7.3, -12dB 6 Intermediate Level Random Vibration Test X sec. 7.3, -6dB 7 Qualification Random Vibration Test X sec. 7.3 8 Resonance Search X sec. 7.1 1 Resonance Search Y sec. 7.1 2 Intermediate Sinusoidal Run Y half ampl. of sec. 7.2 3 Qualification Sinusoidal Run Y sec. 7.2 4 Resonance Search Y sec. 7.1 5 Low Level Random Vibration Test Y sec. 7.3, -12dB 6 Intermediate Level Random Vibration Test Y sec. 7.3, -6dB 7 Qualification Random Vibration Test Y sec. 7.3 8 Resonance Search Y sec. 7.1 1 Resonance Search Z sec. 7.1 2 Intermediate Sinusoidal Run Z half ampl. of sec. 7.2 3 Qualification Sinusoidal Run Z sec. 7.2 4 Resonance Search Z sec. 7.1 5 Low Level Random Vibration Test Z sec. 7.3, -12dB 6 Intermediate Level Random Vibration Test Z sec. 7.3, -6dB 7 Qualification Random Vibration Test Z sec. 7.3 8 Resonance Search Z sec. 7.1
9 8 Instrumentation The locations of the accelerometers are defined in AD5. The sensors at the suspensions shall be used for controlling. The input control shall use the average of the three accelerometers in the acceleration direction for controlling. Ch. Coordinates (mm) measure axis axis orientation Nr. Position within FPU x y z X Y Z X Y Z 1 Sensor 1 (Top Optics) 429 75 241 x x x 2 Sensor 2 (Photometer) 315-143 720 x x x 3 Sensor 3 (Collimator) 182 468 303 x x x 4 1 Axis Suspension 163-151 233 x x x 5 2 Axis Suspension 53 379-2 x x x 6 3 Axis Suspension 63 229 700 x x x 7 Bolometer Filter Wheel 158 55 688 x x x 8 Blue Spec. Detector Struct. x x x 9 Blue Spec. Detector Baffle x x 10 Red Spec. Detector Struct. x x x 11 Red Spec. Detector Baffle x x 13 Spectrometer Filter Wheel 76 151 179 x x x 14 Calib. Source 259 149 224 x x x 15 Grating Base 37 287 371 x x x 16 Vibration Adapter 0 0 0 x x x 17 Bolometer (External Wall) 104-122 720 x x x 18 Fold 1 Mirror 301 261 138 x x x 19 Collimator Mirror 259 272 600 x x x 20 Dichroic Beam Splitter 265-1 555 x x x 21 Chopper (Mass Dummy) 22 Bolometer blue cone tip x 23 Bolometer blue focal plane x 24 Bolometer 2K structure x 25 Bolometer Cooler x x x 26 Distribution Board blue x x x 27 28 29 30 Sensor 1 will be used for vibration test under cryogenic conditions.
10 9 Proceeding in Case of Non-Conformances 10 Documentation For every dynamic test the following information has to be documented: time, temperature humidity and ambient pressure control parameters input levels notch shape and reason for notch sine: acceleration versus frequency, sweep rate random: power spectral density versus frequency, effective grms, duration
11 11 Step by Step Activity, Test Sequence Record No. Activity Date AIV QA 1 Test Preparation apply test sensors according section 8 assemble FPU visual inspection of test specimen 1.1 Test Readiness Review 2 Vibration Test in X-Direction 2.1 Test Preparation mount test adapter on small head expander of shaker (tightening torque of bolts defined by test facility responsible) mount FPU on test adapter, tightening torque 23 Nm mark screw and suspension plate with brittle color connect and check the instrumentation to the data acquisition system 2.2 Vibration Testing 2.2.1 Search Run check the level and limiter according section 7.1 execute resonance search run
12 No. Activity Date AIV QA 2.2.2 Intermediate Sine Run check the level, notch values and limiter according section 7.2; input amplitude is 0,5 times the value in section 7.2 2.2.3 Sine Run check the level, notch values and limiter according section 7.2 2.2.4 Search Run check the level and limiter according section 7.1 execute resonance search run compare results with run 2.2.1
13 No. Activity Date AIV QA 2.2.5 Low Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at - 12 db 2.2.6 Intermediate Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at - 6 db 2.2.7 Qualification Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at 0 db
14 No. Activity Date AIV QA 2.2.8 Search Run check the level and limiter according section 7.1 execute resonance search run compare results with run 2.2.1 2.2.9 Post Test Activities visual inspect test specimen check completeness of test data dismount FPU from test adapter dismount test adapter 3 Vibration Test in Y-Direction 3.1 Test Preparation mount test adapter on slip table of shaker (tightening torque of bolts defined by test facility responsible) mount FPU on test adapter, tightening torque 17 Nm mark screw and suspension plate with brittle color connect and check the instrumentation to the data acquisition system
15 No. Activity Date AIV QA 3.2 Vibration Testing 3.2.1 Search Run check the level and limiter according section 7.1 execute resonance search run 3.2.2 Intermediate Sine Run check the level, notch values and limiter according section 7.2; input amplitude is 0,5 times the value in section 7.2 3.2.3 Sine Run check the level, notch values and limiter according section 7.2
16 No. Activity Date AIV QA 3.2.4 Search Run check the level and limiter according section 7.1 execute resonance search run compare results with run 3.2.1 3.2.5 Low Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at - 12 db 3.2.6 Intermediate Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at - 6 db
17 No. Activity Date AIV QA 3.2.7 Qualification Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at 0 db 3.2.8 Search Run check the level and limiter according section 7.1 execute resonance search run compare results with run 3.2.1 3.2.9 Post Test Activities visual inspect test specimen check completeness of test data dismount FPU from test adapter dismount test adapter
18 No. Activity Date AIV QA 4 Vibration Test in Z-Direction 4.1 Test Preparation mount test adapter on slip table of shaker (tightening torque of bolts defined by test facility responsible) mount FPU on test adapter, tightening torque 17 Nm mark screw and suspension plate with brittle color connect and check the instrumentation to the data acquisition system 4.2 Vibration Testing 4.2.1 Search Run check the level and limiter according section 7.1 execute resonance search run 4.2.2 Intermediate Sine Run check the level, notch values and limiter according section 7.2; input amplitude is 0,5 times the value in section 7.2
19 No. Activity Date AIV QA 4.2.3 Sine Run check the level, notch values and limiter according section 7.2 4.2.4 Search Run check the level and limiter according section 7.1 execute resonance search run compare results with run 3.2.1 4.2.5 Low Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at - 12 db
20 No. Activity Date AIV QA 4.2.6 Intermediate Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at - 6 db 4.2.7 Qualification Level Random Run check the level, notch values and limiter according section 7.3; level of acceleration at 0 db 4.2.8 Search Run check the level and limiter according section 7.1 execute resonance search run compare results with run 3.2.1
21 No. Activity Date AIV QA 4.2.9 Post Test Activities visual inspect test specimen check completeness of test data dismount FPU from test adapter dismount test adapter 5 Post Test Activities check the completeness of the test data complete filled in test procedure 5.1 Post Test Review