SAMPLE CANISTER CAPTURE MECHANISM FOR MSR: CONCEPT DESIGN AND TESTING RESULTS INCLUDING 0-G ENVIRONMENT

Transcription

1 SAMPLE CANISTER CAPTURE MECHANISM FOR MSR: CONCEPT DESIGN AND TESTING RESULTS INCLUDING 0-G ENVIRONMENT Authors: Riccardo Carta, Daniele Filippetto, Politecnico di Milano Co-authors: Prof. Michèle Lavagna, Politecnico di Milano Mr. Filippo Mailland, CGS S.p.A. Dr Peter Falkner, ESA Mr Jonan Larranaga, Aurora Technology B.V. for ESA ASTRA 2015, Noordwijk, The Netherlands, 11 May 2015

2 Presentation Outline 2 1. Introduction to SCCM study 2. SCCM breadboard Manufacturing, Assembly, Integration and Test (MAIT) I. Manufacturing Assembly and Integration II. Test Plan and test facility III. Test results a. Functional Tests b. Thermal Vacuum Tests (TVT) c. Vibration Test (VT) 3. SCCM Parabolic Flight experiment I. Introduction II. Experiment Design III. Test Plan IV. Results 4. Conclusions

3 Mars Sample Return (MSR) architecture 3

4 Study Overview 4 Objectives: The Sample Canister Capture Mechanism (SCCM) is a feasibility Study to develop a technology concepts for a future Mars Sample Return (MSR) mission The SCCM will be in charge of capturing and securing an Orbiting Sample (OS) which accommodates the Martian soil samples Main goals of the Study: Build the Elegant Breadboard Model (EBM) Functional/ Environmental tests for TRL-4 Parabolic flight campaign for TRL-6

5 Study Critical Requirements 5 6 kg spherical OS: 230 mm diameter, Incoming relative velocity: 5-15 cm/s Angular misalignment: ±5 Radial offset: 10 cm Whole capture procedure within 90s Retention within 7 s Maximum stowed envelope 800 x 800 x 500 mm First natural frequency higher than 100 Hz Single point failure tolerance

6 Elegant Breadboard Model Design 6 EBM assembly Arm Hinge CAM Funnel Baseplate Support Tower Motor End Rotation Sensors Shims

7 High Level Test Plan 7 Test Plan Functional Tests Environmental Tests Thermal Vacuum Tests Mechanical Tests (Vibration)

8 Ground Test Objectives 8 Type of Test Test Article Test Objective Test facility Arm actuation functionalities Hold Down Release Mechanism functionality Functional Tests EBM OS detection Actuation chain performances Polimi (Including 0g GSE & OS Mockup) Motorization Factors assessment Motor Maximum Torque Estimation Thermal- Vacuum Tests EBM (excl. OS Mockup) EBM functionality at expected operative thermal conditions EBM survival at the expected non operative thermal conditions Serms srl Vibration test EBM (excl. OS Mockup) EBM withstanding of expected vibration levels Serms srl

9 Functional Test: Test Facility 9 Criticalities: OS swinging motion Funnel-OS position accuracy Requirement drivers: Cost Reusability Functionality Motorization factor EBM configuration PoliMi-DAST

10 Functional test 10 Functional tests results Test Article Test Objective Deployment Maximum torque Test Results Successful Duration: 17,70 17,84 s Successful Measured values: 10,85 10,94 Nm EBM Motorization factors Closure and reset Retention Successful Measured values: 60,28 60,68 Successful Duration: 17,61 18,15 s Successful Duration: 6,60 7,60 s Sensor failure simulation of test case 25/26 results in test failure

11 Environmental Test: Thermal-vacuum, cycles details 11 Temperature Minimum Non-Operational/Survival Temperature Minimum Operational Temperature Maximum Operational Temperature Maximum Non-Operational/Survival Temperature Values 248 K 252 K 322 K 335 K

12 Environmental Test: Thermal-vacuum, test facility 12 Thermal-vacuum chamber Thermocouples location

13 Thermal-vacuum tests 13 Funnel and Motor case temperature profile Temperature ( C) Time (min) Funnel Motor

14 Environmental Test: Vibration, Test Plan Details 14 # Run Test type Initial Conditions Characteristics 1 Resonance search test SCCM EBM in stowed configuration, not operative Band Hz Level: 0.2 g (Peak) 2 Sine vibration test X and Y axes SCCM EBM in stowed configuration, not operative Frequency 5 21 Hz ±5.7 mm Frequency Hz 10 g (*) Frequency Hz 6 g 2 Sine vibration test Z-axis SCCM EBM in stowed configuration, not operative Frequency 5 21 Hz ±11 mm Frequency Hz 20 g Frequency Hz 6 g 3 Random vibration test X and Y axes SCCM EBM in stowed configuration, not operative 9,03 g RMS 3 Random vibration test Z-axis SCCM EBM in stowed configuration, not operative 14,00 g RMS (*) Limit imposed by test facility equipment

15 Environmental Test: Vibration, test facility 15 Slip table Sensor MP15 MP17 MP20 MP21 MP23 MP31 MP42 MP65 Location Baseplate (Tower) Baseplate (Funnel) Arm tip Funnel top Arm shaft Lug top HDRM/arm Motor flange Shaker + head expander

16 Vibration tests 16 Resonance search results Mode ID FEM analysis [Hz] Before vibration test [Hz] (Reduction %) After vibration test [Hz] (Reduction %) (13.5%) 107 (13.5%) (12.8%) 117 (12.8%) (11.7%) 125 (11.7%) (8.1%) 136 (9.4%) (4.1%) 144 (4.8%) (10.4%) 201 (10.0%) 1 natural frequency higher than 100 Hz as required FEM increases stiffness Reduction percentage <15%

17 Parabolic Flight 17 ECSS standards for TRL-6 Testing full scale in relevant environment Microgravity operations Relative dynamics funnel-os OS capture operations Impact forces Aircraft manoeuvre allowing simulate weightlessness About 20 s microgravity each parabola Elliptic path relative to the centre of the Earth

18 Experiment Design 18 Experiment components: Elegant Breadboard Model Orbiting Sample (OS) OS Launcher Trap Safety brake Frame Structure Protective Layer Acquisition and Control System

19 Parabolic Flight Experiment Design: OS launcher 19 Fully manual OS launcher: Initial OS velocity, from 0.1 to 0.2 m/s; Easy 5 degree predefined attitude misalignment (included into attitude correction); Easy 10 cm predefined radial misalignment (included into initial offset correction; OS retention under an acceleration of 2g in all directions; Simple reset; Quick launch.

20 Parabolic Flight Test Objectives 20 Type of Test Test Article Test Objective Test facility Demonstrate of arm actuation functionalities in microgravity environment Demonstrate motor capability of withstanding OS impacts in capture configuration Demonstrate of OS detection in microgravity environment Parabolic Flight EBM Demonstrate of retention operation in microgravity environment Novespace Demonstrate transfer capability in microgravity environment Demonstrate funnel capability of withstanding OS impacts Raise TRL to 6

21 Parabolic Flight Test Plan 21 First Day The first set: verify the arm functioning (opening, closure and holding); The second set: verify retention maintaining with the OS inside funnel; The third set: verify the transfer operation; The fourth and fifth sets: verify OS launcher operations and OS trajectory; The sixth set: verify OS launch, sensor triggering and arm closure. Second and Third days Complete test execution. Set OS initial angle [deg] OS initial offset [cm]

22 Parabolic Flight Test Results 22 Test Day Test Case OS Initial Condition Speed Offset Angle Success [%] Success with triggered sensors [%] Success with OS inside funnel for more than 4s [%] [cm/s] [cm] [deg] INIT CAPT TRA LNC RET * (5/6) 100 (5/5) 100 (5/5) C (2/4) 100 (2/2) 100 (2/2) (4/4) 100 (4/4) 100 (4/4) (3/4) 100 (3/3) 100 (3/3) TOT (14/18) 100 (14/14) 100 (14/14) (8/10) 80 (8/10) 100 (8/8) C (2/4) 50 (2/4) 100 (2/2) (3/5) 75 (3/4) 100 (4/4) (7/9) 100 (7/7) 100 (7/7) TOT (20/28) 83 (20/24) 100 (20/20) Transfer completed within one parabola No pinching during transfer Launch affected by microgravity perturbations Successful execution of complete test within one parabola (~22 s) Failed test due to perturbations Occasional Arm/OS impacts before retention Retention successful even when the OS was manually delivered inside the funnel to react to perturbations

23 Parabolic Flight Test Results 23 DAY 2 Perturbations effects analysis Aircraft acceleration between OS launch and first impact with funnel Release time measured through the video analysis OS velocity: - acceleration measurements integrations - speed provided from launcher OS trajectory: - velocity integration. Successful test Failed test OS-funnel impact area

24 Parabolic Flight Test Results 24 DAY 2 Perturbations effects analysis OS-funnel edge impact at entering conditions Upward perturbation acceleration at launch (green vertical line)

25 Parabolic Flight Test Results 25 OS impacts Calculated from OS acceleration measurements OS-Funnel Forces higher than expected (design phase) cm/s Higher impact velocity Higher forces in Day 3 tests (higher OS speed) Impact duration as expected (design phase) ms No visible damage to protective layer Need for less stiff material or no protective layer at all OS-Arm Short Impact duration (~20 ms) Unknown impact distance from actuation chain Not directly comparable with maximum motor torque No motor synchronization loss recorded during impacts Force [N] Duration [ms] Day 2 Day 3 Day 2 Day 3 Mean Maximum Minimum Force [N] Day 2 Day 3 Mean Maximum Minimum

26 Parabolic Flight Test Results 26 Microgravity phase example OS-Funnel impacts OS-Arm impact

27 Parabolic Flight Test Results 27 Microgravity Perturbations Smooth parabola Low perturbations (first half) Successful test Disturbed parabola High perturbations: 0,05g peak Z acceleration; 0,02g mean Y acceleration during launch (first 5 seconds) Failed test

28 Conclusion 28 On-ground test campaign successfully completed Breadboard design effective both at system and component level in laboratory environment EBM able of withstanding mechanical and thermal loads induced during all mission phases Breadboard performances not affected from environmental loads TRL-4 achieved Parabolic flight test campaign successfully completed EBM full functionality in relevant 0-g environment Test cases doubled with respect to test plan Strong perturbations effect on OS during free floating phase resulting in some failed tests OS trajectory not rectilinear OS speed higher than requirements Testing condition more demanding with respect to design phase estimation Design concept robust and reliable Arm and funnel geometry Arm closure speed Detection sensors position Possible improvement: implementation of automatic release mechanism triggered by acceleration sensor TRL-6 achieved

29 Complete test example 29

30 ASTRA 2015, Noordwijk, The Netherlands, 11 May 2015 Thank you for the attention Questions?

31 ASTRA 2015, Noordwijk, The Netherlands, 11 May 2015 Backup

32 Parabolic Flight Test Results 32 DAY 1 Test ID Result Remarks 1 INIT 2 CAPT 3 - TRA 1 N/A Not available for tests 2 OK Only deployment 3 OK Only closure 4 OK Only deployment 5 OK Only closure 6 OK Only deployment 1 OK 2 OK 3 OK 4 OK 5 OK 1 OK First half of transfer 2 OK Transfer completion 3 OK 4 OK 5 OK Test ID Result Remarks 4 LNC 5 LNC 6 - RET 1 ENTER 2 ENTER 3 ENTER 4 ENTER 5 ENTER 1 ENTER 10cm offset 2 ENTER 10cm offset 3 ENTER 4 ENTER 5 ENTER 1 SUCCESS No arm/os impacts 2 SUCCESS Arm/OS impacts 3 FAIL 10cm offset 4 FAIL 10cm offset 5 SUCCESS 10cm offset Arm/OS impact No pinching during transfer OS Launch affected by microgravity perturbations

33 Parabolic Flight Test Results 33 DAY 2 attempting execution of complete test within one parabola Test ID Result Remarks 1 1 N/A Not available for tests INIT 2 OK RET 3 SUCCESS Arm/OS impacts TRA 4 OK RET 5 SUCCESS Arm/OS impacts TRA 6 OK 2 C-15 3 C-15 1 SUCCESS Arm/OS impacts 2 OK Transfer 3 FAIL 4 SUCCESS Arm/OS impacts 5 SUCCESS 1 FAIL 2 SUCCESS Switch to retention Arm/OS impacts 3 OK Transfer 4 SUCCESS Arm/OS Pinching 5 FAIL Test ID Result Remarks 4 C-15 5 C-15 1 SUCCESS 2 SUCCESS 3 SUCCESS 4 FAIL 5 SUCCESS 1 MISSED 2 SUCCESS Switch to retention 3 OK Transfer 4 SUCCESS Switch to retention Arm/OS impacts 5 SUCCESS Arm/OS impacts Successful execution of complete test within one parabola Failed test due to perturbations

34 Parabolic Flight Test Results 34 DAY 3 OS 20cm/s (not 10cm/s) because of perturbations Test ID Result Remarks 1 1 N/A Not available for tests INIT 2 SUCCESS C-20 3 FAIL C-20 4 SUCCESS C-20 5 SUCCESS C-20 6 SUCCESS Arm/OS impacts 2 C-20 3 C-20 1 SUCCESS 2 SUCCESS 3 SUCCESS 4 SUCCESS Arm/OS impacts 5 FAIL 1 SUCCESS 0 offset Arm/OS impacts 2 SUCCESS Arm/OS impacts 3 FAIL 4 SUCCESS Arm/OS impacts 5 FAIL Test ID Result Remarks 4 C-20 5 C-20 6 C-20 1 SUCCESS 2 FAIL 3 FAIL 4 SUCCESS 5 SUCCESS Arm/OS impacts 1 SUCCESS 2 FAIL 3 SUCCESS 4 FAIL 5 SUCCESS Arm/OS impacts 1 SUCCESS 2 SUCCESS 3 SUCCESS Arm/OS impacts 4 SUCCESS Arm/OS impacts 5 N/A N/A Failed test due to perturbations

35 Parabolic Flight Test Results 35 Retention test

36 Complete test example 36 Successful test

37 Complete test example 37 Failed test

38 Parabolic Flight Test Results 38 DAY 3 Perturbations effects analysis Aircraft acceleration between OS launch and first impact with funnel Release time measured through the video analysis OS velocity: - acceleration measurements integrations - speed provided from launcher OS trajectory: - velocity integration. Successful test Failed test OS-funnel impact area

39 Parabolic Flight Test Results 39 DAY 3 Perturbations effects analysis OS entered funnel close to nominal conditions Perturbation forced OS to escape funnel before arm reached retention configuration

40 Parabolic Flight Test Results 40 OS speed Number of frames between start and stop of OS support plate Speeds lower than mode value due to launcher components friction Video fps Piston stroke [cm] Measured speed [cm/s] Mode [cm/s] Expected speed [cm/s] Test Day Test Day Test Day

41 Vibration tests 41 Sine test Y-axis First resonance frequency amplification of arm tip response EBM rigid behaviour below 100HZ

42 Vibration tests 42 Random tests - 3σ rms response Location X [g] Y [g] Z [g] test FEM test FEM test FEM Arm tip Funnel top Arm shaft Lug top HDRM/arm Motor flange