Payload Vibration Test Plan

In order to ensure that the samples survive the expected launch loads, we must ensure that the samples do not move relative to the sample plate. However, we cannot use adhesives, which could affect the sample material properties. Instead, we are using disc springs to prevent relative movement between the samples and sample plate. Since the samples are brittle and of variable thicknesses we will use aluminum support disks underneath the samples to concentrate the compressive load along the edge of each sample, preventing shear stresses in the samples. Using this method, the samples should only be held in compression between the support disk and sample plate lid along their edges.

Therefore, to ensure that the samples do not fail or create debris, we have conducted two rounds of random vibration testing on candidate samples in phase B and plan to do at minimum one more round in phase C. These tests use an engineering model of the sample plate and are conducted at Magellan Aerospace.

Phase B

1st Vibration Test

Introduction:

Test Description: The following test shall subject an engineering model (EM) of the ManitobaSat-1 payload sample plate assembly to the mission’s expected random vibration profile. This test will be used to validate the clamping mechanism used to hold payload samples in place and quantify how much (if any) debris is emitted by the samples during vibrations.

Completed: 19 Aug. 2019

Documented by: Matt

Resources Required:

Tools: Torque screwdriver, Camera, Pens and paper for test notes, Flashlight, Sample storage container(s), Clean room approved storage box
Hardware and Equipment: Front and Rear supports, Vibration interface plate, Fasteners, Vibration Table Control Computer, Kapton Tape, Super Glue, Vibration Table, Accelerometers, Sample Plate
PPE: Hearing protection, CSA approved steel toed shoes, CSA approved safety glasses, Clean room attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axis for both soft and hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axis for both soft and hard mount vibration profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.
The resonance search (sine sweek) shows a major mode frequency shift no greater than +/-5%, and +/-30% for major mode amplitudes.

Sample Plate Soft Mount Vibration Test Procedures:

The following test procedures are to be performed by two people, Test Conductor 1 and Test Conductor 2. For each stage within the procedures, one test conductor will perform the activity and the second will verify that this activity has been performed correctly.

1.1. Install interface plate onto vibration table:

Wipe down the vibration test table surface and interface plate with kimwipes and isopropyl alcohol until kimwipes come away clean
Place the interface plate onto vibration table and loosely fasten in place using ½-13 DEPTH OF THREAD fasteners, as indicated on the figure below.
Tighten all ½-13 fasteners to 600 inch pounds using a calibrated torque wrench.

Figure 1: Interface Plate Fastener Locations

1.2. Attach Accelerometers onto the Sample Plate:

Clean the surfaces of the sample plate where accelerometers will be installed (as indicated in red in Figure 2) using kimwipes and isopropyl alcohol until the kimwipes come away clean.
Place kapton tape strips onto the cleaned areas and carefully press down from one edge of the strip to the opposite side to remove any air bubbles or wrinkles in the kapton tape.
Using adhesive supplied by Magellan Aerospace, adhere the accelerometers onto the kapton-taped areas.

Figure 2: Accelerometer Mounting Locations (Red)

1.3. Install Sample Plate onto Interface Plate:

Place the dust containment box onto the interface plate so that the holes in the bottom of the box align with the holes as seen in Figure 3.
Place the sample plate assembly in the dust containment box so that the sample plate mounting holes align with the holes in the bottom of the box and the accelerometer wires come out the notch.
Loosely fasten the 8-32 ¾” fasteners as shown in Figure 4.
Tighten the 8-32 fasteners to 20 inch-pounds using a torque screwdriver.
Place the lid onto the dust containment box.
Loosely fasten the dust containment lid fasteners to the dust containment box.
Tighten the dust containment lid fasteners to 5.2 inch pounds.
Place Kapton tape over where the accelerometer wiring exits the dust containment box.
Wire the accelerometers onto the data collection computer.

Figure 3: Dust Containment Mounting Location

Figure 4: Sample Plate Assembly Mounting

1.4. X-Axis Vibration Testing

Put on hearing protection.
Begin random vibration testing to the profile below in Table 1.

1.5. Y-Axis Vibration Testing

Remove the bolts attaching the interface plate to the vibration table.
Rotate the interface plate 90 degrees so that the Y axis of the plate is now in-line with the vibration table’s test axis.
Loosely reattach the bolts attaching the interface plate to the vibration table.
Using a torque screwdriver, tighten the bolts attaching the interface plate to the vibration table to 124 foot pounds.
Put on hearing protection.
Begin random vibration testing to the profile in Table 1

1.6. Z-Axis Vibration Testing

Rotate the vibration table for Z-axis testing.
Put on hearing protection.
Begin initial Sine Sweep.
Once the initial Sine Sweep is done, begin random vibration testing to the profile below in Table 1.
Once the random vibration test is completed, perform the second Sine Sweep.
Save recorded test data.
Rotate the vibration table back to its upright configuration.

Table 1: Soft-stow Random Vibration Test Profile

1.7. Inspection and Tear-Down

After vibration testing is complete, carefully remove the lid from the debris containment box and place it so the open face is facing up. Watch closely for any debris or material that may have come off of the sample plate.
Inspect the sample plate, retention box, and area surrounding the sample plate for dust and debris. If dust and/or debris is found, photograph the dust/debris and record where the dust/debris was located.
Remove the fasteners attaching the dust containment box to the interface plate and carefully place the sample plate assembly into a clean-room approved box.
Use Kapton tape to seal the bottom of the dust containment box.

1.8. Detailed Sample Plate Inspection

Move the clean-room approved box, containing the sample plate assembly, and the debris containment box into the designated inspection area.
Using isopropyl alcohol and kimwipes, clean the surface of the inspection area until kimwipes wipe away clean.
Using a flashlight, inspect the inside of the debris containment box for dust and debris. Take pictures and notes of any identified debris.
Carefully remove the sample plate from the box and onto the designated workbench.
Using a flashlight, re-examine the sample plate assembly for damage to the assembly and to the samples within. Take pictures and notes of any suspected damage.
Carefully remove the sample plate lid.
Again inspect the sample plate, sample plate lid, and the samples for damage. Take pictures and notes of any suspected damage and wipe the surfaces of components (BUT NOT SAMPLES) with isopropyl alcohol and kim wipes and observe if any material collects on the kimwipe.
Carefully remove each sample and examine it for damage. Take pictures and notes of any suspected damage. Once inspected, place the sample in its designated storage container.
Examine the inside of the sample plate for any signs of debris or damage. Wipe the surface with isopropyl alcohol and kim wipes and observe if any material collects on the kimwipe.
Reassemble the sample plate assembly.

2. Sample Plate Hard Mount Vibration Test Procedures:

2.1. Attach Accelerometers onto the Sample Plate:

Clean the surfaces of the sample plate where accelerometers will be installed (as indicated in red in Figure 5) using kimwipes and isopropyl alcohol until the kimwipes come away clean.
Place kapton tape strips onto the cleaned areas and carefully press down from one edge of the strip to the opposite side to remove any air bubbles or wrinkles in the kapton tape.
Using adhesive supplied by Magellan Aerospace, adhere the accelerometers onto the kapton-taped areas.

Figure 5: Accelerometer Mounting Locations (Red)

2.2. Install Sample Plate onto Interface Plate:

Place the dust containment box onto the interface plate so that the holes in the bottom of the box align with the holes as seen in Figure 6.
Place the sample plate assembly in the dust containment box so that the sample plate mounting holes align with the holes in the bottom of the box and the accelerometer wires come out the notch.
Loosely fasten the 8-32 ¾” fasteners as shown in Figure 7.
Tighten the 8-32 fasteners to 20 inch-pounds using a torque screwdriver.
Place the lid onto the dust containment box.
Loosely fasten the dust containment lid fasteners to the dust containment box.
Tighten the dust containment lid fasteners to 5.2 inch pounds.
Place Kapton tape over where the accelerometer wiring exits the dust containment box.
Wire the accelerometers onto the data collection computer.

Figure 6: Dust Containment Mounting Location

Figure 7: Sample Plate Assembly Mounting

2.3. X-Axis Vibration Testing

Put on hearing protection.
Begin random vibration testing to the profile below in Table 2.

2.4. Y-Axis Vibration Testing

Remove the bolts attaching the interface plate to the vibration table.
Rotate the interface plate 90 degrees so that the Y axis of the plate is now in-line with the vibration table’s test axis.
Loosely reattach the bolts attaching the interface plate to the vibration table.
Using a torque screwdriver, tighten the bolts attaching the interface plate to the vibration table to 124 foot pounds.
Put on hearing protection.
Begin random vibration testing to the profile in Table 2.

2.5. Z-Axis Vibration Testing

Rotate the vibration table for Z-axis testing.
Put on hearing protection.
Begin initial Sine Sweep.
Once the initial Sine Sweep is done, begin random vibration testing to the profile below in Table 2.
Once the random vibration test is completed, perform the second Sine Sweep.
Save recorded test data.
Rotate the vibration table back to its upright configuration.

Table 2: Hard-mount Random Vibration Test Profile

2.6. Inspection and Tear-Down

After vibration testing is complete, carefully remove the lid from the debris containment box and place it so the open face is facing up. Watch closely for any debris or material that may have come off of the sample plate.
Inspect the sample plate, retention box, and area surrounding the sample plate for dust and debris. If dust and/or debris is found, photograph the dust/debris and record where the dust/debris was located.
Remove the fasteners attaching the dust containment box to the interface plate and carefully place the sample plate assembly into a clean-room approved box.
Use Kapton tape to seal the bottom of the dust containment box.
Remove the interface plate from the vibration table.

2.7. Detailed Sample Plate Inspection

Move the clean-room approved box, containing the sample plate assembly, and the debris containment box into the designated inspection area.
Using isopropyl alcohol and kimwipes, clean the surface of the inspection area until kimwipes wipe away clean.
Using a flashlight, inspect the inside of the debris containment box for dust and debris. Take pictures and notes of any identified debris.
Carefully remove the sample plate from the box and onto the designated workbench.
Using a flashlight, re-examine the sample plate assembly for damage to the assembly and to the samples within. Take pictures and notes of any suspected damage.
Carefully remove the sample plate lid.
Again inspect the sample plate, sample plate lid, and the samples for damage. Take pictures and notes of any suspected damage.
Carefully remove each sample and examine it for damage. Take pictures and notes of any suspected damage. Once inspected, place the sample in its designated storage container.
Examine the inside of the sample plate for any signs of debris or damage.
Place loose components (BUT NOT SAMPLES) into storage bags and clean the work area.
Once the work area is cleaned and all parts and assemblies are in their proper storage containers, pass the parts and assemblies through the pass box and exit the clean room.

2nd Vibration Test

Introduction:

Completed: 30 Sep. 2019

Documented by: Matt

Resources Required:

Tools: Torque screwdriver, Camera, Pens and paper for test notes, Flashlight, Sample storage container(s), Clean room approved storage box
Hardware and Equipment: Front and Rear supports, Vibration interface plate, Fasteners, Vibration Table Control Computer, Kapton Tape, Super Glue, Vibration Table, Accelerometers, Sample Plate
PPE: Hearing protection, CSA approved steel toed shoes, CSA approved safety glasses, Clean room attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axis for both soft and hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axis for both soft and hard mount vibration profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.
The resonance search (sine sweek) shows a major mode frequency shift no greater than +/-5%, and +/-30% for major mode amplitudes.

1. Sample Plate Hard Mount Vibration Test Procedures:

1.1. Install interface plate onto vibration table:

Wipe down the vibration test table surface and interface plate with kimwipes and isopropyl alcohol until kimwipes come away clean
Place the interface plate onto vibration table and loosely fasten in place using ½-13 DEPTH OF THREAD fasteners, as indicated on the Figure 8.
Tighten all ½-13 fasteners to 600 inch pounds using a calibrated torque wrench.

Figure 8: Interface Plate Fastener Locations

1.2. Install Sample Plate onto Interface Plate:

Place the dust containment box onto the interface plate so that the holes in the bottom of the box align with the holes as seen in Figure 9.
Place the sample plate assembly in the dust containment box so that the sample plate mounting holes align with the holes in the bottom of the box and the accelerometer wires come out the notch.
Loosely fasten the 8-32 ¾” fasteners as shown in Figure 10.
Tighten the 8-32 fasteners to 20 inch-pounds using a torque screwdriver.
Place the lid onto the dust containment box.
Loosely fasten the dust containment lid fasteners to the dust containment box.
Tighten the dust containment lid fasteners to 5.2 inch pounds.
Place Kapton tape over where the accelerometer wiring exits the dust containment box.

Figure 9: Dust Containment Mounting Location

Figure 10: Sample Plate Assembly Mounting

1.3. X-Axis Vibration Testing

Put on hearing protection.
Begin random vibration testing to the profile below in Table 3.

1.4. Y-Axis Vibration Testing

Remove the bolts attaching the interface plate to the vibration table.
Rotate the interface plate 90 degrees so that the Y axis of the plate is now in-line with the vibration table’s test axis.
Loosely reattach the bolts attaching the interface plate to the vibration table.
Using a torque screwdriver, tighten the bolts attaching the interface plate to the vibration table to 124 foot pounds.
Put on hearing protection.
Begin random vibration testing to the profile in Table 3.

1.5. Z-Axis Vibration Testing

Rotate the vibration table for Z-axis testing.
Put on hearing protection.
Begin initial Sine Sweep.
Once the initial Sine Sweep is done, begin random vibration testing to the profile below in Table 3.
Once the random vibration test is completed, perform the second Sine Sweep.
Save recorded test data.
Rotate the vibration table back to its upright configuration.

Table 3: Hard-mount Random Vibration Test Profile

1.6. Inspection and Tear-Down

After vibration testing is complete, carefully remove the lid from the debris containment box and place it so the open face is facing up. Watch closely for any debris or material that may have come off of the sample plate.
Inspect the sample plate, retention box, and area surrounding the sample plate for dust and debris. If dust and/or debris is found, photograph the dust/debris and record where the dust/debris was located.
Remove the fasteners attaching the dust containment box to the interface plate and carefully place the sample plate assembly into a clean-room approved box.
Use Kapton tape to seal the bottom of the dust containment box.

1.7. Detailed Sample Plate Inspection

Move the clean-room approved box, containing the sample plate assembly, and the debris containment box into the designated inspection area.
Using isopropyl alcohol and kimwipes, clean the surface of the inspection area until kimwipes wipe away clean.
Using a flashlight, inspect the inside of the debris containment box for dust and debris. Take pictures and notes of any identified debris.
Carefully remove the sample plate from the box and onto the designated workbench.
Using a flashlight, re-examine the sample plate assembly for damage to the assembly and to the samples within. Take pictures and notes of any suspected damage.
Carefully remove the sample plate lid.
Again inspect the sample plate, sample plate lid, and the samples for damage. Take pictures and notes of any suspected damage and wipe the surfaces of components (BUT NOT SAMPLES) with isopropyl alcohol and kim wipes and observe if any material collects on the kimwipe.
Carefully remove each sample and examine it for damage. Take pictures and notes of any suspected damage. Once inspected, place the sample in its designated storage container.
Examine the inside of the sample plate for any signs of debris or damage. Wipe the surface with isopropyl alcohol and kim wipes and observe if any material collects on the kimwipe.
Reassemble the sample plate assembly.

Phase C

3rd Vibration Test

Introduction:

Test Description: The following test shall subject an engineering model (EM) of the Iris payload sample plate assembly to the mission’s expected random vibration profile. This test will be used to validate the clamping mechanism used to hold payload samples in place and quantify how much (if any) debris is emitted by the samples during vibrations.

Completed: 16 Sep. 2020

Documented by: Ali

Resources Required:

Tools: Torque screwdriver, Camera, Pens and paper for test notes, UV light, Sample storage container(s)
Hardware and Equipment: Front and Rear supports, Vibration box, Vibration interface plate, Fasteners, Vibration Table Control Computer, Kapton Tape, Vibration Table, Sample Plate
PPE: Hearing protection, CSA approved steel toed shoes, CSA approved safety glasses, Clean room attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axis for both soft and hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axis for both soft and hard mount vibration profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.

1. Sample Plate Hard Mount Vibration Test Procedures:

1.1. Payload sample plate assembly:

Inspect each sample and take an image of its front and back using the STAR Lab’s digital microscope.
For each sample and sample support, using the sample layout shown in Figure 11:

a. Place a UMS-0007 disc spring in the center of the designated sample well within the payload sample plate

b. Taking care not to disturb the disc spring, place the sample support in the well

c. Place the sample in the well on top of the sample support

Carefully place the UMS-0004 sample plate lid on top of the sample plate.
Apply UMS-0085 Loctite 242 and loosely install the fasteners shown in Figure 12 onto the sample plate. All 2-56 fasteners (UMS-0016) are to be tightened to 0.28 Nm and all 4-40 pan fasteners (UMS-0008, UMS-0013, UMS-0016) to 0.59 Nm.
Alternately tighten the fasteners into the sample plate by 90 degree turns using a calibrated torque wrench until each fastener reaches the desired installation torque. DO NOT TIGHTEN ANY FASTENERS COMPLETELY WITHOUT ALTERNATING BETWEEN THEM AS THIS MAY CAUSE SAMPLES TO CRACK!
Assemble the UMS-0002 Gnomon pin and base by threading the pin through the back of the base. Apply UMS-0085 Loctite 242 to the pin threads before installing it to 0.28 Nm using a calibrated torque wrench.
Install the UMS-0002 Gnomon into the UMS-0019 Sample Plate Assembly using four UMS-0011 fasteners. Apply UMS-0085 Loctite 242 and install fasteners loosely before tightening each fastener in 90 degree increments, cycling between fasteners, using a calibrated torque wrench to 0.47 Nm.

helicoil

Figure 11: Sample Locations

Figure 12: Sample Plate Assembly Fastener Positions

1.2. Install interface plate onto vibration table:

Wipe down the vibration test table surface and interface plate with kimwipes and isopropyl alcohol until kimwipes come away clean
Place the interface plate onto vibration table and loosely fasten in place using ½-13 DEPTH OF THREAD fasteners, as indicated on the Figure 13.
Tighten all ½-13 fasteners to 600 inch pounds using a calibrated torque wrench.

Figure 13: Interface Plate Fastener Locations

1.3. Install Sample Plate onto Interface Plate:

Place the dust containment box onto the interface plate so that the holes in the bottom of the box align with the holes as seen in Figure 14.
Place the sample plate assembly in the dust containment box so that the sample plate mounting holes align with the holes in the bottom of the box and the accelerometer wires come out the notch.
Loosely fasten the 8-32 ¾” fasteners as shown in Figure 15.
Tighten the 8-32 fasteners to 20 inch-pounds using a torque screwdriver.
Place the lid onto the dust containment box.
Loosely fasten the dust containment lid fasteners to the dust containment box.
Tighten the dust containment lid fasteners to 5.2 inch pounds.

Figure 14: Dust Containment Mounting Location

Figure 15: Sample Plate Assembly Mounting

1.4. X-Axis Vibration Testing

Put on hearing protection.
Begin random vibration testing to the profile below in Table 4.

1.5. Y-Axis Vibration Testing

Remove the bolts attaching the interface plate to the vibration table.
Rotate the interface plate 90 degrees so that the Y axis of the plate is now in-line with the vibration table’s test axis.
Loosely reattach the bolts attaching the interface plate to the vibration table.
Using a torque screwdriver, tighten the bolts attaching the interface plate to the vibration table to 124 foot pounds.
Put on hearing protection.
Begin random vibration testing to the profile in Table 4.

1.6. Z-Axis Vibration Testing

Remove Interface Plate from Table
Rotate the vibration table for Z-axis testing.
Reattach Interface Plate to Vibration Table.
Put on hearing protection.
Begin random vibration testing to the profile below in Table III.
Save recorded test data.
Rotate the vibration table back to its upright configuration.

Table 4: Hard-mount Random Vibration Test Profile

1.76. Inspection and Tear-Down

After vibration testing is complete, carefully remove the lid from the debris containment box and place it so the open face is facing up. Watch closely for any debris or material that may have come off of the sample plate.
Inspect the sample plate, retention box, and area surrounding the sample plate for dust and debris. If dust and/or debris is found, photograph the dust/debris and record where the dust/debris was located.
Shine UV light into the retention box and inspect for dust and debris under UV-light. If dust and/or debris is found, photograph the dust/debris and record where the dust/debris was located.
Remove the fasteners attaching the dust containment box to the interface plate and carefully place the sample plate assembly into a clean-room approved box.
Use Kapton tape to seal the bottom of the dust containment box.

1.8. Detailed Sample Plate Inspection

Move the clean-room approved box, containing the sample plate assembly, and the debris containment box into the designated inspection area.
Using isopropyl alcohol and kimwipes, clean the surface of the inspection area until kimwipes wipe away clean.
Using a flashlight, inspect the inside of the debris containment box for dust and debris. Take pictures and notes of any identified debris.
Carefully remove the sample plate from the box and onto the designated workbench.
Using a flashlight, re-examine the sample plate assembly for damage to the assembly and to the samples within. Take pictures and notes of any suspected damage.
Carefully remove the sample plate lid.
Again inspect the sample plate, sample plate lid, and the samples for damage. Take pictures and notes of any suspected damage and wipe the surfaces of components (BUT NOT SAMPLES) with isopropyl alcohol and kim wipes and observe if any material collects on the kimwipe.
Carefully remove each sample and examine it for damage. Take pictures and notes of any suspected damage. Once inspected, place the sample in its designated storage container.
Examine the inside of the sample plate for any signs of debris or damage. Wipe the surface with isopropyl alcohol and kim wipes and observe if any material collects on the kimwipe.
Reassemble the sample plate assembly.

Phase D

4th Vibration Test

Completed: June 2021

Documented by: Ali

Resources Required:

Tools: Torque screwdriver, Camera, Pens and paper for test notes, UV light, Sample storage container(s)
Hardware and Equipment: Front and Rear supports, Vibration box, Vibration interface plate, Fasteners, Vibration Table Control Computer, Kapton Tape, Vibration Table, Sample Plate
PPE: Hearing protection, CSA approved steel toed shoes, CSA approved safety glasses, Clean room attire

Verification Activities:

Pass Criteria:

The sample plate EM will pass this test if:

The plate assembly and components have not visibly plastically deformed and the samples have not fractured after random vibration testing in all three axis for both soft and hard mount vibration profiles.
There is no debris created by the samples after random vibration testing in all three axis for both soft and hard mount vibration profiles.
The test input levels match the given test profiles to within +/- 1.5 dB.

Test Procedure

This test shall use the same procedure as used for the 3rd Vibration Test.

Page updated

Google Sites

Report abuse