Solar Orbiter

-
SPICE Door
Mechanism

ESA - Mechanism
Final Presentation
Days
30th March 2017
Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 1
 Content
1. Solar Orbiter and SPICE Instrument
2. SPICE Door Mechanism constraints
3. Development plan logic
4. Breadboard results
5. QM/FM successes and difficulties
6. QM2/FM2 test campaign
7. QM3
8. Lessons learned
Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 2
 Solar Orbiter and SPICE Instrument
Solar Orbiter:
‒ ESA mission Sun observation,
‒ Dedicated to solar and heliospheric physics,
‒ Orbit minimum at 0.28 AU (41’887’403.8 km),
‒ Lifetime 7+ year in space Credit ESA

SPICE:
The Spectral Imaging of the Coronal
Environment (SPICE) instrument is an EUV
imaging spectrograph designed to observe both
on the solar disk and out in the corona to
remotely characterize plasma properties at and
near the Sun. Credit CNES

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 3

 SPICE Door Mechanism constraints

Environment:
- High thermal fluxes,
- High solar radiation,
- High vibration loads
Constraints:
- Reduced allowed volume
- Stringent cleanliness and contamination requirement (EUV Instrument)

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 4

 SPICE Door Mechanism constraints
SPICE Door Mechanism Functions:
‒ Close the instrument flushing cavity on ground and during launch,
‒ Close / Open the field of view of SPICE (50 actuation in flight),
‒ Reject Solar flux / radiate to deep space for thermal control,
‒ Promote internal radiative heat exchange

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 5

 Development plan
Classical wise approach to limit project risks

 CDR
 PDR

 DRB
 QR
Risk

Justified Design

Proof of concept
- Analysis
Part samples
- Design qualification
Mature technology Mature technology
- Component - Component Breadboard
- Process - Process testing
Partial simulation Partial simulation Partial simulation
- Simplified model - Simplified model - Simplified model Qualification
- Critical fct. testing - Critical fct. testing - Critical fct. testing Model testing
Partial simulation Partial simulation Partial simulation Partial simulation Flight model
- Full rep. model - Full rep. model - Full rep. model - Full rep. model
- Full testing - Full testing - Full testing - Full testing acceptance
Workmanship error Workmanship error Workmanship error Workmanship error Workmanship error

Exploitation
Abuse loads Abuse loads Abuse loads Abuse loads Abuse loads Abuse loads
Project timeline
Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 6
 Development plan
Risk analysis:
The design includes feature that were completely new or not qualified:
- New thermal coating (high ε / low α ) on aluminum, range
[-60°C;+57°C],
- Not qualified Fractal black on aluminum for thermal range
[-60°C;+57°C],
- Linear bearings with no space heritage
- Ball screw with no space heritage
Uncertainties on analysis:
- Labyrinth seal gap and guessed amplification factor
- Global design from scratch
Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 7
 Development plan
Mitigation actions:
- Thermally cycled samples on the coatings
- Wet lub bearings & ball screw characterization
- First torque margin with wet lub parts
- Dynamic strength of bearings & ball screw
- Non gap closure of labyrinth seal during vibration

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 8

 Development plan
Model & Test Philosophy:
Model Objectives Representativity
Structural Model • Use for structural and mass properties tests at • Mechanical I/F
(SM) instrument level • Mechanical envelope
• Mass and CoG
• Thermo-mechanical properties
Bread Board Model • Demonstrate the structural integrity of the system • Mechanical I/F
(BBM) • Correlate FEM results with structural behaviour • Mechanical envelope
• Check system functionality at ambient temperature • Electrical I/F
• Check dynamic behaviour of ball recirculating items • Mass, CoG, MoI
(ball screw, linear bearings) • Thermo-mechanical properties
Qualification Model • Undertake the full suite of qualification tests • Mechanical I/F
(QM) • Fully assert the functionality of the system • Mechanical envelope
• Electrical I/F
• Mass, CoG, MoI
• Thermo-mechanical properties
• Tribology
• Optical behaviour
• Thermal behaviour
Flight Model (FM) • Flight use • Full flight layout and flight standard

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 9

 Development plan

Planning constraint:
Due do planning constraints, APCO T. and ESA have
decided to manufacture and test in parallel QM and FM.

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 10

 Breadboard results
Thermal coating samples (directly on aluminum & Ta6V) :

‒ No coating fracture after 100 cycles [-60°C;+157°C] -> success

‒ No adhesion defect during peel test (DIN ISO 9211) -> success
‒ Solar absorptivity α = 0.06 below 0.11 -> success
‒ IR emissivity ε = 0.50 above 0.55 -> fail*
‒ Ratio α/ε below 0.18 -> success
* Accepted as α/ε is below expectation.

A new innovative cold thermal coating is qualified for application on

curved surfaces, either on aluminum or titanium with the temperature
range [-60°C;+157°C]
Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 11
 Breadboard results
Fractal black (on aluminum & Ta6V) :

‒ No coating fracture after 100 cycles [-60°C;+157°C] -> success

‒ No adhesion defect during peel test (ASTM D3359) -> success
‒ IR emissivity ε above 0.95 -> success

Fractal black is delta qualified for application, either on aluminum or

titanium with a temperature range [-60°C;+157°C]

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 12

 Breadboard results
Functional test at ambient:

‒ Correct opening with end motion detection -> success

‒ Torque margin motion current 68 mA <70 mA -> success
‒ Full door opening in less than 50s -> success
‒ Launch lock torque =110 Nmm above 39 Nmm -> success

The Spice Door Mechanism with wet lub functional test results are in
accordance with expectation

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 13

 Breadboard results
Vibration Test outcomes:

‒ FE model correlated with test results

‒ Random qualification passed
‒ No drift in amplitude / frequency
‒ No change in launch lock torque
‒ No change in minimum motion current

The Spice Door Mechanism with wet lub parts sustains the vibration
loads with no degradation

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 14

 QM successes and difficulties
Functional test under nitrogen (<10% RH):

‒ Correct opening with end motion detection -> success

‒ Torque margin motion current -> success
‒ Full door opening in less than 50s -> success
‒ Launch lock torque above 39 Nmm -> success

This test is repeated just before the vibration test with same results.

The Spice Door Mechanism QM is ready for vibration test

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 15

 QM successes and difficulties
Vibration Test Results (QM &FM):
‒ Random qualification passed
‒ No drift in amplitude / frequency
‒ No change in launch lock torque
Test / Prediction correlation
‒ No change in minimum motion current
‒ NCR 41016: Slippage of micro-switches detected during functional
test

The micro-switch are fixed by fixed by screws M2 screws (0.5N.m). As

an increase of the torque deforms the switch, the switch is glued:
need to re-run the Y axis to confirm the validity of the repair

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 16

 QM successes and difficulties
Thermal Vacuum Test Results (QM/FM):
‒ Hot and cold functional tests -> success
‒ Non Op thermal cycling -> success
‒ Ambient & hot functional tests -> success
‒ Cold lifetime on QM (460 cycles) -> failure @120th cycles
‒ NCR 41018: irregular motion of motor and black dust on the motor
head

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 17

 QM successes and difficulties
Root cause analysis:
‒ High MoS2 degradation on high speed stage of gearbox
‒ Functional tests under N2 with 5-10% humidity by test chamber purge
‒ ESTL recommendation is humidity lower than 15ppm (~0.05%RH)
‒ Laboratory humid air enclosed in gearbox cannot be easily expelled
due to the labyrinth sealing of the motor

Conclusion:
Degradation caused by to high humidity during functional test

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 18

 QM successes and difficulties
Decision:
‒ Do all functional tests in vacuum
‒ Replace all MoS2 coated part of FM, already affected by functional
tests, by spare parts, rename it FM2 and re-run acceptance tests
‒ Replace QM motor by old FM one, rename it QM2
‒ Run Y axis vibration test and shocks on QM2 to close NCR 41016.
‒ Launch procurement of all MoS2 coated parts for QM3 and spare
‒ Run QM3 thermal and lifetime test
Outcome:
One year delay linked to CDA motors procurement and non conformity
during the manufacturing of the gearbox.

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 19

 QM successes and difficulties
Lesson learned:
Whereas ESTL Space Tribology Handbook states “The number of
operational cycles performed during assembly or testing in conditions
greater than 5% RH must therefore be kept to a minimum”.
The next statement in the book shall only be considered:
“ESTL advise that any operational cycles are performed under a dry
nitrogen purge of less than 15 ppm (0.05%RH) moisture content”

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 20

 QM2/FM2 test campaign
Vibration Test Results (QM2 & FM2):
‒ Random & shock qualification on QM, acceptance random on FM
passed
‒ No drift in amplitude / frequency
‒ No change in launch lock torque
‒ No change in minimum motion current (functional test)
‒ No slippage of micro-switches: NCR 41016 closed

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 21

 QM2/FM2 test campaign
Thermal Vacuum Test Results (FM2):
‒ Hot and cold functional tests -> success
‒ Non Op thermal cycling -> success
‒ Ambient & hot functional tests -> success

FM2 test campaign is considered successful pending the lifetime test of

QM3
The Spice Door Mechanism FM(2) is delivered for Instrument integration

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 22

 QM3 test campaign
Thermal Vacuum Test Results (02-03/2017):
‒ Hot and cold functional tests -> success
‒ Non Op thermal cycling -> success
‒ Ambient & hot functional tests -> success
‒ Cold / hot lifetime on QM (460 cycles)-> success
‒ Ambient functional test after lifetime -> success
‒ Strip down ongoing -> no anomaly detected
‒ NCR 41018: proposed for closure

The Spice Door Mechanism qualification activities are closed

successfully. QR/DRB scheduled in April.
Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 23
 Lessons learned
1. MoS2 lubricated mechanism should be
preferably operated in vacuum
2. In case of nitrogen operation, the 15 ppm limit
on humidity shall be respected for safe
operation (but difficult to reach)
3. Partially closed cavities shall be equipped with a
flushing port
4. Shortcuts in planning development does not
necessarily (rarely) lead to planning and cost
reduction
Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 24
 Thank you for your attention

Heurteau JP – Mechanism Final Presentation Days, Noordwijk, 30th March 2017 25