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AIT Flow Diagram
AIT Flow Diagram
Once all subsystems are developed, AIT activities commence! The process begins with performing FlatSat tests on both EM and FM. Following the verification of all FM FlatSat activities, Module Assembly procedures and Spacecraft Integration activities will be carried out before conducting Post Integration Tests for LI-Bus.
AIT Figure 6: AIT Flow Diagram
FlatSat
FlatSat
FlatSat is made in 3 parts: EM FlatSat, FM FlatSat, and FM FlatSat Backup.
Engineering Model (EM) FlatSat is made in phase C to help identify the bugs and problems with the EM hardware. Once these problems are identified, the hardware is debugged and modified. The modified hardware that are built in house (i.e. Power and CDH hardware) will be reordered for phase D, while COTs hardware (i.e. Communication's Transceiver) will be removed from from EM FlatSat and transferred to the FM FlatSat. All the other EM components will stay intact on the EM FlatSat for problem solving in the next phase and "Lessons Learned" for the future Projects.
Both Flight Model (FM) FlatSat and its backup are made simultaneously in phase D. In case of any faulty component or short circuit, components can be swapped with the FM backup. Further, in the worst case scenario of having faulty FM and FM backup components, the EM hardware can be used as the second backup.
Once all FlatSat verification activities are verified, FM FlatSat can be disassembled and the FM hardware is transferred to Module Assembly to be eventually assembled into LISSA.
AIT Figure 7: FlatSat Flow Diagram
FlatSat Test Plan
FlatSat Test Plan
The following diagram describes the FlatSat plan at subsystem-level. Power is the first subsystem activated in FlatSat and tested. Right After Power Communication and CDH are simultaneously activated and CDH commands Power to activate Deployables and AODCS. Lastly, Payload stand-in and Thruster subsystems are tested for their functionality.
AIT Figure 8: FlatSat Plan
Assembly and Integration
Assembly and Integration
Module Assembly:
Module Assembly:
All FM FlatSat components are disassembled from FlatSat and reassembled based on their modules assembly plans provided by each subsystem. Prior to full assembly, conformal coating is applied to all applicable components (more information on conformal coating and applications will be provided at subsystem level). In this step, modules are placed in their half or full shells before being completely assembled into LI-Bus.
Bus Assembly and Integration:
Bus Assembly and Integration:
This intertwined step of assembly and Integration happens with support from Structure and Harnessing team. In this step all the harnessing and CAN lines are connected to the half or full modules to integrate the components and the rails are attached to assemble the modules. Additionally, all the external components such as the solar panels, external thermistors, and deployables such as antennas and their deployment mechanisms are attached to the assembled LISSA.
AIT Figure 9: Assembly and Integration Step Flow Diagram
Post Integration Tests
Post Integration Tests
Once LISSA is fully integrated, Post Integration Tests are performed to verify the functionality of the designed bus before handing it off to Magellan Aerospace.
The First Test performed on LISSA post integration is Fit Inspection, Which will be done by inspecting the Bus against the ISISpace 6U deployer.
Right after Fit Inspection, the Bus is measured for its weight using a scale and sent for its first Full Functional Test. The Functional test verifies that the overall system is integrated and commands are relayed from CDH to the rest of the subsystems on board. This test also verifies the functionality of the the deployables.
An Over Air Radio Frequency Communication Test will be performed by pinging the communication transceiver to make sure that the Communication hardware is functional and capable of handing ground station commands before another full functional test is performed on the whole system.
Lastly, a Random Vibration Test will be performed on the Bus to verify compliance with the space debris guidelines and avoiding any loose connections. A Reduced Functional Test will be performed after the vibration test. The Reduced Functional test follows the same steps as the Full functional test with exclusion of the deployables as the vibration test has already verified that the release mechanisms for the deployables are properly secured.
AIT Figure 10: Post Integration Tests
Test Summary by Model
Test Summary by Model
Engineering Model (EM):
Engineering Model (EM):
FlatSat: FlatSat is done to ensure functionality of satellite components and interfaces. This may include functionality verification of various sensors such as sun sensor and magnetometers in addition to in-house developed boards such as CDH and PCU. In addition, various inter-module interface protocols such as SPI, RS485, and UART are tested during FlatSat. The components that are tested during EM FlatSat are CDH hardware, PCU and battery pack, ADCS board, Payload stand-in, GNSS module, and the star tracker.
Assembly Demo: Once the FlatSat test is completed, an assembly demo with the EM boards is performed with all available components to ensure proper assembly of all hardware and harnessing within the EM structure.
Fit and Mass Inspection: The assembled EM will be measured for dimensions and weighed. Note that the mass of the satellite at EM level would not reflect the final mass of the bus ad it will be missing some components. However, this would provide an estimate of the current weight of the bus.
System Power-Up + Wing Deployment: After fit and mass inspections, the system is powered through the umbilical cord and the wings are deployed after the hold time (100 s here).
Telemetry: After full deployment, flight software will ping the subsystems for telemetry through the umbilical cord.
Flight Model (FM):
Flight Model (FM):
FlatSat: FlatSat test will be repeated for FM components in a clean room environment. This test will include all of the bus components.
Full Assembly: Once the FlatSat functionality is verified, the components will be conformally coated and assembled into their shells with appropriate harnessing.
Fit and Mass Inspection: The assembled bus will be interfaced with the ISISpace dispenser for fit inspection. Mass and center of mass of LISSA will be measure experimentally using load cells.
Functional Test: Functional test includes various software activities to confirm flow of data between subsystems and deployment of the solar wings. the functional tests will be performed through the umbilical cord. A detailed test plan is provided at Functional and Reduced Functional Test.
Over Air RF Test + Functional Test: This test will be done to ensure functionality of the communications transceiver. To perform this test, Magellan Aerospace facilities will be used to enable radio communications inside the clean room. Once the radio communication is established, various flight software commands will be sent to acquire telemetry and data through the functional test.
Random Vibration Test: Random vibration test will be done to +3dB of the maximum expected flight levels of Falcon 9 for 60s per axis. the vibration profile will be randomly chosen from frequencies in the range of 20 - 2000 Hz.
Reduced Functional Test: After the vibration test, a reduced functional test will be performed wher the intermodule functionality of the satellite is tested through the umbilical cord. However, the deployable components won't be deployed after at this stage. A thorough inspection of the deployable mechanisms will be done to insure there is no damage to the mechanisms after the vibration.
Phase D Schedule
Phase D Schedule
The following is the proposed schedule for AIT phase of LISSA developement:
AIT Figure 11: Phase D Schedule
Finalize EM FlatSat & Finish FM Procurement
Finalize EM FlatSat & Finish FM Procurement
Following the completion of phase C and CDR, the remaining EM FlatSat tests, such as the hardware in the loop test for AODCS subsystem, is carried out. Also, any design modification is implemented reflecting the CDR feedback and the FM hardware is procured.
FM FlatSat
FM FlatSat
FM FlatSat carried out in the ASIF facility. The list of GSE required for FM FlatSat is shown below:
GSE
FlatSat MGSE
FlatSat Harnessing
Soldering Station
Power Supply
Logic Analyzer
Flight Software Computer
FlatSat Station
P/N
NA
NA
NA
Bin Number
NA
NA
NA
Owner
STARLab
STARLab
Magellan
STARLab
STARLab
NA
Magellan
Comments
Assembled in ASIF
For harness assembly and board modification
Requires clearance from Magellan Aerospace
FM Assembly and Integration
FM Assembly and Integration
FM Assembly and Integration is carried out in the ASIF facility. The list of GSE required for Assembly and Integration is shown below:
GSE
Handling MGSE
FM Harnessing
Soldering Station
Power Supply
Logic Analyzer
Flight Software Computer
P/N
NA
NA
Bin Number
NA
NA
Owner
STARLab
STARLab
Magellan
STARLab
STARLab
NA
Comments
Assembled in ASIF
For harness assembly and board modification
Requires clearance from Magellan Aerospace
Post Integration Tests
Post Integration Tests
Post integration tests are carried out in the ASIF facility. The list of GSE required for Post Integration Tests is shown below:
GSE
Z-Face handling MGSE
Deployer
Scale
Power Supply
Logic Analyzer
Flight Software Computer
S-Band Antenna Test Equipment
P/N
NA
Bin Number
NA
Owner
STARLab
Magellan
STARLab
STARLab
STARLab
NA
Magellan
Comments
Used for TVAC
Used for fit check and vibration test
For mass inspection
Requires clearance from Magellan Aerospace
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