Tim.honeycutt
- 1. KSC Constellation Ground Operations Project Office Integrated Testing at KSC between Constellation Systems Tim Honeycutt February 2008 Timothy.R.Honeycutt@nasa.gov 321-867-6567 321- 867-
- 2. KSC Constellation Project Office KSC Constellation Ground Operations Project Office KSC Constellation Project Office Business Staff Office Project Control Logistics Operations & Systems Engineering Integration & Integration (including IT&V) Crew Vehicle Ground Command, Systems (GS) Control, and Project Communications Launch Vehicle GS Project GS Project GS Project Support Management Integration & Office Requirements 2
- 3. Presentation Outline KSC Constellation Ground Operations Project Office • History of Multi-Element Integration Tests (MEITs) – MEIT Concept – Previous MEITs – Major Problems Found – Benefits • Integrated Testing at KSC for the Constellation Program – Integrated Tests • Multi-Element Integrated Tests (MEITs) • Flight Element Integrated Tests (FEITs) • Integrated Verification Tests (IVTs) • Summary 3
- 4. History KSC Constellation Ground Operations Project Office • “Ship and shoot” was the strategy for the International Space Station Program (ISSP) during the early 1990’s – It proposed transporting flight elements directly from the factory to the launch site and begin the mission without further testing. – Factory level testing and element interface verifications at the subsystem-level, and interface analysis were all that was planned. • Before the end of that decade a shift in testing strategy occurred within the ISSP – The ISSP adopted a more integrated approach for ground validation of it’s flight hardware. – Availability of elements at the launch site created a feasible opportunity to test multiple elements together. – The notion of validation testing on the ground was presented and accepted by the ISSP due to the criticality of the on-orbit functionality, including safety concerns for the crew . 4
- 5. History (cont) KSC Constellation Ground Operations Project Office • Multi Element Integration Tests (MEITs) and Integrated Systems Tests (ISTs) – Risk mitigation tests performed on the ground, used for validating the operation of the flight elements and their systems in an environment that is as flight-like as possible. – These tests were used to demonstrate the interoperability and functionality of Space Station elements as integrated “in-space” assemblies on the ground before they were assembled in space for the first time. • Space Station element-to-element interface capability was verified as well as systems end-to-end operability with hardware and software. • Mission Sequence Testing (MST), also known as “end-to-end” integration testing, included a full-up configuration with the Mission Control Center, Tracking Data Relay Satellite System (TDRSS), and the “station” operating on the ground. • Also verified limited on-orbit system compatibility. 5
- 6. KSC ISS MEIT/IST Experience KSC Constellation Ground Operations Project Office • Planned/developed and implemented the following for ISSP: – MEIT1: • U.S. Lab, Z1, P6, SSRMS, Node1 (emulated) – MEIT2: • S0/MT/MBS, S1, P1, P3/4, US Lab (emulated) – MEIT3: • JEM, Node2, US Lab (emulated) – Node2 Systems Test • Node2, US LAB & Node1 (emulated) 6
- 7. MEIT Configurations S RM SPDM 18 SS 18 31 18 18 MBS 18 External 31 Payload 24 31 ULC (or SLP) External CETA SLP (or ULC) Payload 30 CETA 30 30 MT 30 25 24 25 S-Band 17 17 17 17 26 26 23 32 24 24 12 12 25 25 16 14 14 14 16 14 16 16 S6 11 11 S5 8 11 11 S4 28 S3 22 22 S1 22 22 S0 22 22 P1 22 22 P3 28 P4 8 11 11 P5 11 11 P6 16 16 16 16 13 13 24 24 21 17 17 15 15 15 15 JEM ELM ES 17 17 15 15 24 29 External 29 Payload 24 JEM EF S0-to-Lab Struts External 29 Payload 5,7 5,7 29 5,7 5,7 MEIT-2 Uses 5,7 5,7 US Lab Simulation 9 8 8 9 JEM ELM PS SPP 27 5,7 5,7 RA 27 27 E 27 27 18 JEM PM 27 27 CUPOLA 9 8 8 6 re la Primary Orbiter 2 St 8 7 places 8 Docking 9 9 12 5,7 2 12 5,7 PORT 18 21 PORT Interface EFGF Z 4 ZENITH Progress 3 Service M1 3 4 A Module F 4 2 2 A FGB F 4 1 1 PMA1 PM 9 AFT FWD 9 8 8 9 U.S. LAB 9 8 8 9 AFT FWD 9 8 8 N 4 5,7 N 4 A3 PMA2 4 1 1 PM 1 sim 5,7 2 18 3 ula NADIR tion 27 2 3 Z NODE 1 Ku-Band NODE 2 DSM DC simulated CMGs (4) 12 RM-1 3 3 S P 3 3 3 -2 CRV#1 A P Universal Docking 1 8 9 NADIR ZENITH 9 8 8 N Z1 Z 11 MPLM 9 8 8 9 NADIR ZENITH 9 8 8 9 CAM Module 3 Alternate 1 F S 10 A F 3 RM-2 Soyuz CRV Orbiter Docking 3 3 TM adapt STBD STBD 9 18 9 Interface N 8 8 8 3 16 Beta Gimbal Assembly NTA 20 20 8 17 Solar Array Deployment 8 3 8 NTA 20 20 18 Power/Data Grapple Fixture (PDGF) LEGEND 8 9 9 Soyuz 19 Orbiter ‘D’ Hatch Remotely actuated mechanisms 9 9 8 TM OTA 20 20 AIRLOCK 20 NTA/OTA Attachment Mechanism 1 4 PMA3 AFT STBD EVA operated mechanisms 21 Lab Cradle Assy / MTSAS NODE 3 19 22 Segment to Segment Attach System (SSAS) IVA operated mechanisms 1 Modified APAS 8 9 NADIR ZENITH 9 8 OTA 20 20 23 Mobile Transporter Drive COF FWD PORT Articulating/Deployable mechanisms 2 Hybrid Docking Assembly (HDA) 24 Payload Attach System (PAS) 3 Probe and Cone (P&C) 9 9 27 25 ULC Attach System (ULCAS) Translation mechanisms Alternate MPLM 4 APAS Hatch Berthing Location 8 8 26 CETA Rollers passive active 5 RSA Solar Array Deploy Mechanism 8 9 U.S. 9 8 27 Window Shutter 6 RSA Radiator Deploy Mechanism 11 Rocketdyne Truss Attachment (RTAS) 28 Solar Alpha Rotary Joint (SARJ) MEIT 1 Completed 2/00 7 RSA Array Pointing Mechanism 12 Deployable Antenna HAB 29 JEM Berthing Mechanism MEIT 2 Completed 4/02 8 Common Berthing Mechanism (CBM) 13 Thermal Radiator Rotary Joint (TRRJ) 30 CETA Coupler MEIT 3 Completed 9/03 9 US Common Hatch 14 EPS Radiator Deployment 31 Common Attach System (CAS) 10 Manual Berthing Mechanism (MBM) 15 TCS Radiator Deployment 32 Trailing Umbilical System (TUS) (2)
- 8. MEIT 2 Hardware at KSC KSC Constellation Ground Operations Project Office P3 Truss P4 Truss P1Truss S0 Truss US Lab Emulator S1Truss 8
- 9. Problems Found in MEITs (Top Examples) KSC Constellation Ground Operations Project Office • P6 truss failed to power up due to Auxiliary Power Converter Unit (APCU) under voltage trip condition. – Impact: Unable to start P6 on Orbit. • US Lab critical activation took 36 hours during the first MEIT Power-up (computer/procedure problems), Requirement <2 hrs. During MEIT regression Mission Sequence Test, Critical Activation took 1 hr, 15 minutes. – Impact: Loss of Lab element during on-orbit activation due to thermal loading. • Command and Control (C&C) computers failed several times due to task overrun problems (CPU utilization problems). – Impact: Significant operational issues (Loss of Vehicle commanding, Vehicle health visibility, visibility to crew/ground) would occur because of continued loss of C&C computers. 9
- 10. Problems Found in MEITs (Top Examples) (continued) KSC Constellation Ground Operations Project Office • Video lines were swapped between Trailing Umbilical Systems 1, 2 (NASA) and Mobile Base System (Canadian Space Agency). – Impact: Significant operational impact to manually route video signals. Extra Vehicular Activity (EVA) would have been required to replace two harnesses to correct the problem. • C&C computers failed when performing synchronization to Global Positioning System (GPS) time. – Impact: Loss of accurate GPS capability, degraded attitude control capability until development /testing and on-orbit upload of new software patch. • Quality of Space to Ground Audio was unacceptable. – Impact: Operation and potential safety impact to crew due to lack of understanding between Crew/Ground. 10
- 11. MEIT Benefits KSC Constellation Ground Operations Project Office • Significant findings from MEIT have created an opportunity to correct major operational problems which would have resulted in: – Cost/Schedule Slip • Major milestone slippage in the Program – Critical On-orbit Operations impacts • Safety concerns for the crew • Loss of mission objectives • Loss of flight hardware – Nominal Operations impacts • Unknown operation risks (loss of redundancy capability) – Unplanned EVA’s The cumulative effect of identifying & resolving integrated hardware, software and procedure problems before flight has proven to save the International Space Station Program major on-orbit issues. 11
- 12. Integrated Testing at KSC for the Constellation Program (CxP) KSC Constellation Ground Operations Project Office • Testing that occurs between two or more individual Constellation Systems to verify the interfaces between those Systems and to validate the integrated Systems' functionality and interoperability. • Includes testing mechanical, electrical, data and fluid interfaces. • Integrated testing applies to the in-space flight and integrated vehicle stack configurations. – Multi-Element Integration Testing (MEIT) – Flight Element Integration Testing (FEIT) – Interface Verification Testing (IVT) 12
- 13. Constellation Architecture KSC Constellation Ground Operations Project Office Crew Exploration Vehicle – CEV/Orion Constellation Lunar Lander – Lander/Altair Crew Launch Vehicle – CLV/Ares I Architecture Cargo Launch Vehicle – CaLV/Ares V Crew Vehicles Launch Vehicles Ground & Mission & Systems & Systems Systems Ground CEV CLV Future Systems Lunar Mission CaLV Lander Systems EVA CLV Elements -1st Stage Systems -Upper Stage -Upper Stage Engine CxProgram Architecture Level 2 Flight Crew Project Level 3 CEV Elements System Equip. -Launch Abort System (LAS) -Crew Module (CM) Element Level 4 Lunar -Service Module (SM) Subsystem Level 5 Surface -Spacecraft Adapter (SA) Systems Subsystems: examples include Future data, power, thermal, etc. 13
- 14. Multi-Element Integration Test (MEIT) KSC Constellation Ground Operations Project Office MEIT: • An integration test between two or more flight systems that will be launched on separate launch vehicles and integrated together for the first time in space. – Interfaces between the flight systems, mission systems, and other appropriate CxP/ISSP and external systems may be also tested as part of each MEIT. • The primary objectives of MEIT are: – Demonstrate the interoperability, functionality, and stability of the flight systems, elements, and sub-systems as an integrated “in-space” vehicle assembly on the ground before they are assembled in space for the first time. – Validate critical mission sequence activities and flight procedures prior to their first-time execution in-flight. • A secondary objective of MEIT is: – To collect functional and performance data from the integrated flight systems to support validation of the different interface test tool sets, emulators, and simulators used by the Projects in accepting future serial numbers of those flight systems. 14
- 15. MEIT (continued) KSC Constellation Ground Operations Project Office • MEIT serves as a training ground for: – Flight crews and trainers – Mission Operations Division (MOD)/Mission Control Center (MCC) personnel – Constellation system engineers • MEITs are executed after all of the system-level requirements have been satisfied by the involved Project offices and those offices declare their system designs as verified for flight. • MEITs are one time tests with a potential for a follow-on regression test. – Performed prior to first crewed missions • Use of flight-like emulators and cables/connectors may be used when integration between the flight systems is not practical. • Planned MEITs: – CEV to International Space Station (ISS) (using ISS emulation) – CEV to Lunar Lander/Earth Departure Stage (EDS) (using EDS emulation) 15
- 16. MEIT 1 KSC Constellation Ground Operations Project Office MEIT 1 Test Configuration (performed in the Multi-Payload Processing Facility) 16
- 17. MEIT 1: CEV to ISS (Emulator) KSC Constellation Ground Operations Project Office • CEV-International Space Station (ISS) MEIT – To be performed in the year 2012, prior to first ISS flight. – Tests interoperability/functionality and all functional interfaces: data, audio, video, RF, power. – End-to-end test with Mission Control performed via TDRSS. – Uses emulation in place of ISS flight hardware. – Mated with flight-like cables and connectors. CEV ISS Flight Emulator LIDS 17
- 18. CEV-ISS Interfaces KSC Constellation Ground Operations Project Office – Mechanical • CxP will utilize newly developed Low Impact Docking System (LIDS) • LIDS is not compatible with ISS Docking System (APAS: Androgynous Peripheral Attach System) • CxP will construct two APAS To LIDS Adapter Segments (ATLAS) • ATLAS will be installed permanently on Peripheral Mating Adapters (PMAs) 2 and 3 • Provides power and data pass through capability – Power • ISS will provide 120 VDC to CEV via two redundant power feeds • CEV will convert 120 VDC ISS power to 28 VDC for internal buses – Fluids/Gases • Only requirements are for Inter Module Ventilation (IMV) air circulation – essentially same as for Shuttle orbiter 18
- 19. CEV-ISS Interfaces KSC Constellation Ground Operations Project Office – Avionics • Audio, video, and data are distributed internally to CEV over a Gigabit Ethernet network • CEV bus would connect to CxP provided Common Communications Adapter (CCA) which would provide conversion to legacy ISS networks. – CCA required for MIL-STD-1553 (ISS) and Gigabit Ethernet (CEV) data conversions – CCA installed on ISS – CCA or prototype would be integrated into ISS emulator and tested with CEV in MEIT • Separate CEV to ISS S-Band RF link would be implemented for rendezvous/proximity ops 19
- 20. MEIT 2 KSC Constellation Ground Operations Project Office MEIT 2 Test Configurations (TCs) (performed in the Space Station Processing Facility) 20
- 21. MEIT 2: Test Configuration #1 (TC1) KSC Constellation Ground Operations Project Office CEV to Lunar Lander with EDS Emulation EDS LIDS LIDS (Emulation) 21
- 22. MEIT 2: Test Configuration #2 (TC2) KSC Constellation Ground Operations Project Office CEV to Lunar Lander LIDS LIDS 22
- 23. Flight Element Integration Test (FEIT) KSC Constellation Ground Operations Project Office FEIT: – An integration test between the new or significantly modified systems and elements being assembled into an integrated launch vehicle for the first time. • Interfaces between the flight systems, ground systems, mission systems, and other appropriate CxP and external systems may be also tested as part of each FEIT. • The primary objectives of the FEIT are: – Demonstrate the interoperability, functionality, and stability of the flight systems, elements, and sub-systems as an integrated “launch vehicle” assembly prior to the first operational test flight of that particular launch vehicle configuration. – Validate critical mission sequence activities and flight procedures prior to their first-time execution. • A secondary objective of the FEIT is: – To collect functional and performance data from the integrated flight systems to support validation of the different interface test tool sets, emulators, and simulators used by the Projects in accepting future serial numbers of those flight systems. 23
- 24. FEIT (continued) KSC Constellation Ground Operations Project Office • FEITs are executed after all of the system-level requirements have been satisfied by the involved Project offices and those offices declare their system designs as verified for flight. • FEITs are planned and scheduled as part of the assembly and preparation of the integrated launch vehicle. • FEITs are currently planned for every test flight (except for Ares 1-X). • Planned FEITs: – CEV/CLV – Lunar Lander/EDS/CaLV 24
- 25. FEIT 1 KSC Constellation Ground Operations Project Office FEIT 1 Test Configuration (performed in the Vehicle Assembly Building) 25
- 26. FEIT 1 – Ares 1 Launch Vehicle Stack KSC Constellation Ground Operations Project Office • Test Configuration: – CEV/CLV Integrated Stack – Ground Systems – Missions Systems – SCaN (Space Communications and Navigation) CEV CLV Upper Stage CLV 1st Stage 26
- 27. FEIT 2 KSC Constellation Ground Operations Project Office FEIT 2 Test Configurations (TCs) (performed in the Vehicle Assembly Building) 27
- 28. FEIT 2 – Ares V Launch Vehicle Stack KSC Constellation Ground Operations Project Office E E D D S S Launch Vehicle TC2 TC1 • Test Configurations: • Both test configurations include: – Lunar Lander/EDS/CaLV (TC1) – Ground Systems • Integrated Stack – Missions Systems – Lunar Lander/EDS (TC2) – SCaN (Space Communications • On-orbit Configuration and Navigation) 28
- 29. Interface Verification Testing (IVT) KSC Constellation Ground Operations Project Office • Interface Verification Testing (IVT) verifies the mechanical and/or electrical interfaces between two or more flight systems after these systems have been mated. • IVT consists of the minimal set of activities to verify the integrity of all physical and functional interfaces between the systems involved for each specific vehicle stack configuration. • IVTs are performed as a subset of the FEITs during the flight tests and then performed for every flight after Full Operational Capability (FOC) has been obtained with the flight and ground Systems. • Performed in the Vehicle Assembly Building. • MEITs/FEITs would be required if any significant design upgrades or modifications have occurred. 29
- 30. Summary KSC Constellation Ground Operations Project Office • Based on the previous success of MEITs for the International Space Station Program, these type of integrated tests have also been planned for the Constellation Program: – MEIT • CEV to ISS (emulated) • CEV to Lunar Lander/EDS (emulated) • Future: Lunar Surface Systems and Mars Missions – FEIT • CEV/CLV • Lunar Lander/EDS/CaLV – IVT • Performed as a subset of the FEITs during the flight tests and then performed for every flight after Full Operational Capability (FOC) has been obtained with the flight and ground Systems. "Standing alone, components may function adequately, and failure modes may be anticipated. Yet when components are integrated into a total system and work in concert, unanticipated interactions can occur that can lead to catastrophic outcomes." (Columbia Accident Investigation Report (CAIB) Report 2003) 30