Written By: Daniel Asante

Stage 1: Payload Deployment Functionality 

Test Description: The first stage of the test plan will evaluate the functionality of the payload deployment mechanisms using burn wire tests with the engineering model (EM). The test will focus on verifying successful deployment of the antenna's reflector and feed system, ensuring the mechanism operates as designed under standard and freezing (space-like) conditions (at -20 C).

Completed: 27/01/2025

Documented by: Daniel Asante [ Structure Lead ], Mitesh Patel [ Ex Lab Technician ].

Resources Required:

• Tools: Screwdrivers, wrenches, multimeter, burn wire.

• Hardware and Equipment: Engineering Model of the deployment mechanism, burn wire configuration components which include clamps, resistors and wire-locking screws.

• PPE: Personal protection equipment for tests and environment (clean room smock, face mask, gloves, etc.)

Verification Activities: 

• ARC-STR-0024

• ARC-STR-0025

Pass Criteria: PASS

Test Apparatus

1. A custom mounting frame to securely hold the engineering model during deployment tests. NOTE: There must be enough room beside the EM to allow for full deployment without damaging the reflector.

2.  Power supply and monitoring equipment to activate and monitor the burn wire, set to TBD Volts and TBD Amps.

Test Set-Up

Reflector Assembly

1.  Insert the hinge screws into the designated holes on the hinge body.

2.  Place the first torsion spring within the hinge, aligning it properly, and begin feeding the hinge pin through the spring.

3.  Position the reflector panel onto the hinge assembly. Insert one leg of the torsion spring into the corresponding hole on the reflector panel, then continue inserting the hinge pin through the reflector knuckle.

4.  Install the second torsion spring, ensuring one leg is inserted into the reflector’s corresponding hole. Feed the hinge pin through the second spring until it is fully seated within the hinge.

5.  With the satellite oriented on its side, align the hinge assembly at its designated location on the EM. Secure it in place using the screws and appropriate bolts.

General Test Set-Up:

1.  If testing in the freezing chamber, place EM in chamber for a minimum of 1 day prior to test.

2.  Inspect the engineering model for any pre-existing damage. 

3.  Orient satellite to be flat on its side to minimize gravitational influence on deployment motion. 

4.  Secure the EM to the mounting frame.

5.  Install and verify sensors to record the burn wire activation time, deployment motion, and final position of the reflector.

6.  Prepare data storage folders and test software for monitoring and logging results.

7.  Conduct a dry run to confirm all equipment is functional.

Test Procedures

1.  Connect the burn wire to the power supply.

2.  Secure the melt wires to their designated mounting screws and feed them perpendicular to the corresponding burn wires and through the tensioning geometry. 

Feed Arm

a) Locate the feed arm screw lock on the interior roof of the body chamber. Secure one end of the melt wire to the screw and partially tighten it.

b) Route the melt wire over the resistor positioned in front of the screw and beneath the tension clamp.

c) Place the arm in its stowed position and tie the melt wire to the arm using the feed holes. Tighten the screw lock further to apply additional tension as required.

Reflector

a) Locate the reflector screw lock on the right side of the satellite body. Attach the melt wire to the screw and partially tighten it.

b) Guide the melt wire over the resistor and through the second hole from the resistor.

c) With the reflector panel in its stowed position, pass the melt wire through the designated feed holes in the panel

d) Pass the melt wire through the hole opposite the initial body hole and tie it around a second screw lock located at the bottom of the left side panel.

e) Tighten both screw locks to increase wire tension as needed.

3.  Ensure the melt wires are taut against the burn wires and are secured to their respective deployable.

4.  Activate the burn wire and monitor the deployment motion.

5.  Record the deployment time and final position of the reflector relative to the feed.

6.  Repeat the test three times to verify consistency in both temperature conditions (room-temperature, and freezing).

Test Close-Out

1.  Compare the recorded deployment times and reflector positions to design specifications.

2.  Document any irregularities or failures.

3.  Store analyzed data in the project’s Wiki.

Data Analysis

1)    Burn wire activation time:

a) Determine average time taken for each burn wire to burn through melt wire. 

b) Verify that activation times remain consistent within a ±2-second window across all test trials for each temperature. 

2)     Post-burn movement:

a) Determine average time taken for each deployable to reach final position.

b) Verify that movement times remain consistent within a ±2-second window across all test trials for each temperature. 

3)     Final positioning:

a) Verify that the reflector and feed deploy to their final desired positions.

Parts List

• Following a freezing chamber test which revealed that the reflector hinge lacked sufficient torque for full deployment, two additional torsion springs will be tested to improve performance. 

Stage 2: Wing Deployment Functionality

Test Description: The second stage of the test plan will evaluate the functionality of the wing deployment mechanism using burn wire tests with the engineering model (EM). The test will focus on verifying successful deployment of the wings, ensuring the mechanism operates as designed under standard and freezing conditions (at -20 C).

Completed: N/A

Documented by: Daniel Asante [ Structure Lead ]

Resources Required:

• Tools: Screwdrivers, wrenches, multimeter, deployment mechanism testing tools

• Hardware and Equipment: Engineering Model of the deployment mechanism, burn wire configuration components, which include clamps, resistors and wire-locking screws.

• PPE: Personal protection equipment for tests and environment (clean room smock, face mask, gloves, etc.)

Verification Activities: 

Pass Criteria: PASS

Test Apparatus

1.   A custom mounting frame to securely hold the engineering model during deployment tests. NOTE: Ensure there is enough room around the EM to allow for full deployment without damaging the wings.

2.  Power supply and monitoring equipment to activate and monitor the burn wire, set to TBD Volts and TBD Amps.

Test Set-Up

General Test Set-Up:

1.  If testing in the freezing chamber, place EM in chamber for a minimum of 1 day prior to testing.

2.  Inspect the engineering model for any pre-existing damage. 

3.  Orient satellite to be in an upright position, reflector panel on the bottom of the model. 

4.  Secure the EM to the mounting frame.

5.  Install and verify sensors to record the burn wire activation time, deployment motion, and final position of the reflector.

6.  Prepare data storage folders and test software for monitoring and logging results.

7.  Conduct a dry run to confirm all equipment is functional.

Test Procedures

1.  Connect the burn wire to the power supply.

2.  Secure the melt wires to their designated mounting screws and feed them perpendicular to the corresponding burn wires and through the tensioning geometry. 

Repeat for each wing

a) Secure the melt wire to the wing by tying it to the feed holes located at the top of the wing. 

b) Place wing in stowed position and thread the wire underneath the closest resistor.

c) Locate the screw locks on the elevated platform above the resistor. Tie the melt wire to the adjacent screw and tighten until the tension is as desired.

3.  Ensure the melt wires are taut against the burn wires and are secured to their respective deployable.

4.  Activate the burn wire and monitor the deployment motion.

5.  Record the deployment time and final position of the wings.

6.  Repeat the test three times to verify consistency in both temperature conditions (room-temperature, and freezing).

Test Close-Out

1.  Compare the recorded deployment times and reflector positions to design specifications.

2.  Document any irregularities or failures.

3.  Store analyzed data in the project’s Wiki.

Data Analysis

1)    Burn wire activation time:

a) Determine average time taken for each burn wire to burn through melt wire. 

b) Verify that activation times remain consistent within a ±2-second window across all test trials for each temperature. 

2)     Post-burn movement:

a) Determine average time taken for each deployable to reach final position.

b) Verify that movement times remain consistent within a ±2-second window across all test trials for each temperature. 

3)     Final positioning:

a) Verify that the wings deploy to their final desired positions.