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CALVI Students LIEGE 2011 6 PDF
CALVI Students LIEGE 2011 6 PDF
CALVI Students LIEGE 2011 6 PDF
An Overview
Spacecraft + launcher
Spacecraft Authority
Spacecraft
Spacecraft
Payload Contractor
Instruments/sub-systems
Other Contactors
Units/components/parts
Levels of Assembly
RPM
RFFE
Limit Loads - LL
x KQ
QL
x KA
x Coef. A
AL
Design Limit Loads
DLL
x Coef. B
x Coef. C
x KQ
x KA
AL
DYL
DUL
QL
Protoflight
Prototype
10
2. Mechanical environment
11
Transportation
Rocket Motor Ignition Overpressure
Lift-off Loads
Engine/Motor Generated Acoustic Loads
Engine/Motor Generated Structure-borne Vibration Loads
Engine/Motor Thrust Transients
Pogo Instability, Solid Motor Pressure Oscillations
Wind and Turbulence, Aerodynamic Sources
Liquid Sloshing in Tanks
Stage and Fairing Separation Loads
Pyrotechnic Induced Loads
Manoeuvring Loads
Flight Operations, Onboard Equipment Operation
12
Important consequences
Need for considering the actual (e.g. test or flight) boundary conditions
(e.g. for the purpose of notching)
Need for a valid F.E. model (e.g. to be used for force and stress recovery)
Spacecraft Loads Analysis - A. Calvi
13
Shocks
Loads (vibrations) are transmitted to the payload (e.g. satellite)
through its mechanical interface
Acoustic loads also directly excite payload surfaces
14
15
Acoustic Loads
During the lift off and the early phases of
the launch an extremely high level of
acoustic noise surrounds the payload
The principal sources of noise are:
Engine functioning
Aerodynamic turbulence
16
17
Shocks
Mainly caused by the actuation of pyrotechnic devices:
Release mechanisms for stage and satellite separation
Deployable mechanisms for solar arrays etc.
18
Shocks
[g]
[g]
Time [t]
Frequency [Hz]
19
20
21
22
23
Strength
Structural life
Structural response
Stiffness
Damping
Mass Properties
Dynamic Envelope
Positional Stability
Mechanical Interface
24
Requirements evolution
25
Some definitions
Design:
The process used to generate the set information describing the
essential characteristics of a product (ECSS-P-001A)
Design means developing requirements, identifying options, doing
analyses and trade studies, and defining a product in enough detail so
it can be built (T. P. Sarafin)
Verification:
Confirmation by examination and provision of objective evidence that
specified requirements have been fulfilled (ISO 8402:1994)
Verification means providing confidence through disciplined steps that
a product will do what it is supposed to do (T. P. Sarafin)
Note: we can prove that the spacecraft satisfies the measurable criteria
we have defined, but we cannot prove a space mission will be successful
26
27
28
29
Launch vehicle manuals specify minimum values for the payload natural
(fundamental) frequency of vibration in order to avoid dynamic coupling between
low frequency dynamics of the launch vehicle and payload modes
30
31
32
33
34
Mode shapes
Cantilever beam
Mode 1: 16.2 Hz
Mode 2: 18.3 Hz
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
Gen. mass
i-th mode
55
56
57
58
59
60
70
60
acceleration [m/s2]
50
40
30
20
10
0
-10
-20
0
0.1
0.2
0.3
0.4
0.5
t [s]
0.6
0.7
0.8
0.9
4
3
2
1
0
50
100
150
200
250
300
t, s
61
80
70
60
acceleration [m/s2]
50
40
30
20
10
0
-10
-20
0
0.1
0.2
0.3
0.4
0.5
t [s]
0.6
0.7
0.8
0.9
62
63
64
UPPER
COMPOSITE
EAP-
EAP+
EPC
Spacecraft Loads Analysis - A. Calvi
66
6. Z9 Ignition
67
CLA Output
LV-SC interface accelerations
Equivalent sine spectrum
Internal responses
Accelerations,
Displacements
Forces
Stresses
68
Lift-off
Main Fitting
I/F Force
X Dir. [N]
Lift-off
Main Fitting
I/F Force
Z Dir. [N]
Lift-off
Keel Fitting
I/F Force
Y Dir. [N]
Lift-off Force Resultant in X [lbf]
Spacecraft Loads Analysis - A. Calvi
69
70
ESI
SRS
Q
ESI
ESI
71
SRS
ESI
SRS [m/s2]
200
SRS
Q
ESI
150
100
SRS
Q2 1
SRS
50
ESI
0
0
10
20
30
40
50
frequency [Hz]
60
70
80
72
[m / s ]
SDOF
0.01
natural frequency 23 Hz
[m / s
2.41
Transient response
2DOF
Transient response
[s ]
[s ]
[m / s ]
1.97
0.01
natural frequency 23 Hz
[m / s ]
2.46
73
[Hz
[Hz
5. Spacecraft testing
5.1
5.1
Mechanical tests
Modal survey test
Sinusoidal vibration test
Acoustic noise test
Shock test
Random vibration test
5.2
74
75
Measurements
Force sensors, calibrated strain gauges
Accelerometers, velocity or displacement sensors
76
Qualification test
Show a design is adequate by testing a single article
Acceptance test
Show a product is adequate (test each flight article)
77
78
79
Environment
Sine vibration
Acoustic
Shock
Level
Longitudinal= 1 g on [5-10] Hz
Lateral = 0.625 g on [5-100] Hz
1.5 g at 20 Hz
1 g on [40-100] Hz
31.5 Hz = 130.5 dB
63 Hz = 133.5 dB
125 Hz = 135.5 dB
250 Hz = 135.7 dB
500 Hz = 130.8 dB
1000 Hz = 126.4 dB
2000 Hz = 120.3 dB
100 Hz = 50 g
700 Hz = 800 g
1000 Hz 1500 Hz = 2000 g
80
5. Spacecraft testing
5.1
5.2
Mechanical tests
Modal survey test
Sinusoidal vibration test
Acoustic noise test
Shock test
Random vibration test
5.3
81
82
Data consistency
Increasing effort
Hammer test
Vibration test data analysis
Dedicated FRF measurement & modal analysis
Full scale modal survey with mode tuning
83
Modal Survey Test vs. Modal Data extracted from the Sine Vibration Test
Modal Survey:
requires more effort (financial and time)
provides results with higher quality
84
85
86
Herschel on Hydra
87
88
89
90
91
Acoustic
air pressure excitation
better suited for S/C and large Subsystems with low mass / area
density
92
93
5. Spacecraft testing
5.1
5.2
Mechanical tests
Modal survey test
Sinusoidal vibration test
Acoustic noise test
Shock test
Random vibration test
5.3
94
Overtesting:
an introduction
(vibration absorber effect)
95
96
The excitation during the flight is not a steady-state sine function and
neither a sine sweep but a transient excitation with some cycles in a
few significant resonance frequencies
The objective of notching of the specified input levels is to take into
account the real dynamic response for the different flight events. In
practice the notching simulates the antiresonances in the coupled
configuration
Spacecraft Loads Analysis - A. Calvi
98
Notching
ESI
(equivalent sine)
Spacecraft Loads Analysis - A. Calvi
99
100
101
102
103
104
105
106
107
Natural frequencies
Mode shapes
Modal effective masses
Modal damping
108
109
110
T
mM
2
T
mr as
T
T
mr mr as as
MACrs
Note: COC and MAC do not give a useful measure of the error!
111
10
11
12
13
-2.94 13.37
-0.95 15.65
-1.73 16.90
-3.26 23.03
0.93
0.35
-1.16 23.95
0.34
0.93
-2.00 24.16
-1.98 24.86
-0.12 25.56
0.86
-0.95 26.34
0.22
10
-2.65 26.47
11
-0.40 27.42
12
-3.65 27.82
0.82
0.27
13
-6.00 28.38
0.46
0.89
15
1.19 30.91
17
1.63 33.26
-
-4.72 34.45
20
1.21 34.99
16
17
18
19
20
1.00
1.00
0.99
33.71
19
15
13.78 15.80 17.20 23.81 24.23 24.65 25.36 25.59 26.59 27.19 27.53 28.87 30.19 30.55 32.73 33.15 33.86 34.57 35.21 36.16
18
14
0.95
0.95
0.27
0.90
0.95
0.26
0.96
0.26
0.95
0.94
0.21
0.32
0.64
0.34
0.62
0.95
0.57
0.81
112
Err. % Freq. Hz
35.86
2.87
37.24
0.00
45.99
4.17
4.78
47.46
-3.39
49.82
0.96
53.19
56.65
2.10
58.67
60.24
3.30
64.30
66.40
67.50
68.73
69.68
71.69
72.71
3.30
73.34
74.78
75.63
78.77
82.12
7.72
84.51
5.54
86.31
88.64
7.21
89.29
5.45
94.44
97.15
99.56
F.E.M.
1
2
34.83 37.24
0.87
0.46
0.87
0.47
3
44.07
4
45.19
8
51.51
0.77
-0.33
0.24
0.76
9
52.68
10
55.46
15
62.18
21
70.92
26
77.99
29
81.53
30
82.25
31
84.42
0.87
0.75
0.22
0.79
0.21
-0.35
0.46
-0.28
-0.30
0.21
0.45
-0.22
-0.22
0.46
0.61
0.32
-0.43
-0.38
0.37
0.21
-0.33
0.85
-0.24
0.76
0.87
-0.23
0.64
-0.33
0.63
113
114
Scatter in manufacturing
Uncertainties in physical properties (geometry, tolerances, material properties)
115
116
7. Conclusions
117
118
Final Verification
Consist of:
Making sure all requirements are satisfied (compliance)
Validating the methods and assumptions used to satisfy
requirements
Assessing risks
119
120
121
Technical inconsistencies
Uni-axial vibration and shock test facilities
Low frequency transient often simulated at the subsystem and
system assembly level using a swept-sine vibration test
Infinite mechanical impedance of the shaker (and the standard
practice of controlling the input acceleration to the frequency
envelope of the flight data)
Vibro-acoustic environment often simulated at the subsystem
and units assembly level using a random vibration test
Test levels largely based on computational analyses (we must
validate critical load analyses!)
122
NEW TRENDS
Protoflight vs prototype
Testing (force limited vibration testing)
Computational mechanics
Vibro-acoustic analysis
Random vibration analysis
123
Bibliography
Sarafin T.P. Spacecraft Structures and Mechanisms, Kluwer, 1995
Craig R.R., Structural Dynamics An introduction to computer methods, J. Wiley
and Sons, 1981
Clough R.W., Penzien J., Dynamics of Structures, McGraw-Hill, 1993
Ewins D.J., Modal Testing Theory, practice and applications, Research Studies
Press, Second Edition, 2000
Wijker J., Mechanical Vibrations in Spacecraft Design, Springer, 2004
Girard A., Roy N., Structural Dynamics in Industry, J. Wiley and Sons, 2008
Steinberg D.S., Vibration Analysis for Electronic Equipment, J. Wiley and Sons,
2000
Friswell M.I., Mottershead J.E., Finite Element Model Updating in Structural
Dynamics, Kluwer 1995
Ariane 5 Users Manual, Arianespace, http://www.arianespace.com/
124
ECSS-E-HB-32-26
ECSS-E-ST-32
ECSS-E-ST-32-03
ECSS-E-ST-32-10
ECSS-E-ST-32-11
ECSS-E-ST-32-01
ECSS-E-10-02
ECSS-E-10-03
ECSS-E-ST-32-02
125
THE END!
Acknowledgements:
TAS France for the data concerning the project SENTINEL-3
ALENIA SPAZIO, Italy, for the data concerning the projects GOCE, COLUMBUS,
MPLM and SOHO
EADS ASTRIUM, UK, for the data concerning the project AEOLUS and
EarthCARE
ESA/ESTEC, Structures Section, NL, for the data concerning ARIANE 5 FE
model and LV/SC CLA
126