SYSTEM INTEGRATION DESIGN FACTORS,

PRE-FLIGHT TEST REQUIREMENTS AND

ENVIRONMENTAL LOADS.

BY
JAGADISH J (1AH17AS013)
AEROSPACE BRANCH
ACS COLLEGE OF ENGINEERING
SYSTEM INTEGRATION DESIGN FACTORS.
 INTRODUCTION

The integration of a satellite or spacecraft system consists of combining the mechanical and
electrical subsystem elements into a single entity through the application of logical processes,
and takes into account the physical and functional aspects of the subsystem interrelationships.
 INTEGRATION PROCESS AND PHILOSOPHY

The process consists of mechanical and electrical integration, qualification testing of the
basic design using the engineering, mechanical and electrical prototype models and acceptance
testing of the workmanship using the flight model.

The purpose of total integration was to ensure that all hardware would successfully function as
an integrated system to achieve the mission objectives.
SYSTEM LAYOUT

• Evolution of the subsystem layout.

• Functional and electrical considerations.
• Mechanical and environmental considerations.
 Each subsystem carried on the spacecraft has a large number of general interface
requirements which normally could be put into the following categories.
a) Mechanical interfaces
b) Environmental interfaces
c) Electrical interface based
d) Functional interfaces

The following interfaces were also considered for the successful completion of the prelaunch
and launch phase operations.
e) Spacecraft-ground support equipment interfaces
f) Spacecraft-launch vehicle interfaces
ELECTRICAL INTEGRATION
• Electrical distribution system

• Organisation of EDS

• Cable harness design

• Physical characteristics

• Environmental conditions

• Harness fabrication

• Integration sequence and tests

MECHANICAL INTEGRATION
• Subsystem boxes
• Subsystem mounting framework
• Principles of integration
 QUALIFICATION TESTING

1) Mechanical Testing.
2) Electrical Testing.
i. Testing in the process of integration
ii. Flight test using helicopter
3) Completion of the qualification program.
 CONCLUSION
The efforts of system integration were climaxed with the uninterrupted reception of the first signals
from Aryabhata consequent to its successful launching. Excellent performance of the onboard
technological subsystem in the subsequent orbital life indicated further the rigorous test philosophy,
procedures as well as documentation employed in the construction and integration of Aryabhata.
PRE-FLIGHT TEST REQUIREMENTS
 ACCEPTANCE TESTING OF FLIGHT
MODEL

The flight model was fabricated as an exact replica of the finalized prototype.
Acceptance standards for the flight model subsystems were based on their
performance characteristics as well as the inputs obtained from the
qualification testing of the previous models.
The following operations were made as part of the prelaunch operations:

i. Leak detection test on the spin-up system;

ii. Pressurizing the gas bottles of the spin-up system;
iii. Retransmission test at technological position;
iv. Ground checkout with cable checkout system as also RF retransmission test at the
launch pad;
 TEST TYPES
In this section, we look in some detail at the majority of the tests and
measurements that must be included in a qualification (Q) or acceptance (A)
test programme.
• Static Strength (Static Load) tests (Q) determine whether the design of load-
bearing structures will sustain quasi-static and dynamic accelerations,
induced by the launcher, boost motors and, if appropriate, its own spin. The
static load test is an early structure level qualification test.

. Fig : Orion Crew

model undergoing static
load test.
• Sinusoidal Vibration tests (Q, A) primarily validate mechanical modelling
and verify that the spacecraft can withstand the physical vibration
environment induced during launch. A vibrator, or ‘shaker’, subjects the
spacecraft to a ‘sweep’ of sinusoidal frequencies rising from 4 to 100 Hz or
150 Hz at prescribed levels and a sweep rate specified by the launch vehicle
manual, times a factor of 1.25 for qualification
Fig: Vibration test of the
CHEOPS satellite

• Modal Survey testing (Q) determines by experimental

methods the natural frequencies, mode shapes and
damping factors of the spacecraft. The modal survey is
investigative in nature, and to some extent a trial and
error approach is adopted.

Fig: modal survey test of the

CASSIOPE spacecraft.
• Random Vibration and Acoustic Noise tests (Q, A). The acoustic noise
environment is greatest at lift-off when noise is reflected from the launch
pad, and this can be of particular concern for large area, lightweight
structures. The structural response to acoustic noise is predicted in terms
of a random vibration. Random vibration tests using a vibrator/shaker are
usually performed only on small spacecraft.
Fig: Direct field acoustic

noise testing

• Shock test (Q)—the spacecraft is subjected to inputs representative

of the shocks induced into structures as a result of (a) shroud jettison
and spacecraft separation from the launch vehicle, and (b) release, by
pyrotechnic mechanisms, of appendages such as solar panels and
antennas, and their subsequent latching into operational orientation
Fig: shock testing
• Pressure test (Q, A). This subjects pressurized subsystems to 150% of
the maximum design pressure for at least 5 min, and the test is cycled
three times. Any system designed to contain fluids will undergo a
Leakage Test (Q, A), being pressurized at maximum design pressure for
20 min. During that time the leak rate is determined and all joints and
fittings individually checked for leaks.

Fig: Orion undergoing critical

pressure test

• Thermal vacuum/vacuum temperature cycling tests (Q, A). This is a

performance test that characterizes and verifies electrical functionality in
the vacuum of space under specified thermal conditions. The test is
performed at upper and lower temperature extremes and during transients.
The temperature profile is cycled between temperatures determined by the
qualification or acceptance test limits.

Fig: Galileo thermal vacuum

testing
 ENVIRONMENTAL LOADS

•
 ENVIRONMENTAL LOADS

• Natural Frequencies : The natural frequency is a governing design requirement for all
parts of the spacecraft. This requirement is imposed in order to limit the dynamic
coupling of the spacecraft with the launch vehicle.
• Semi-static and low frequency sinusoidal loads: The design of the primary structure to a
large extent by the semi-static and low frequency sinusoidal loads(up to approximately
50Hz)
• Sinusoidal and random loads :To a large extent, the sinusoidal and random loads
determine the design of secondary structures(solar panels, antennas, electronic boxes).
• Acoustic loads : Light structural parts with relatively large surface areas(such as solar panels and
spacecraft antennas)are more sensitive to acoustic loads than sinusoidal and random base
excitation.

• Shock loads : Deployable structures experience high shock loads. This is especially the case
when the deployment velocities are too high.

• Temperature: Temperature variations usually cause high thermal stresses in the structures. In
general, the various coefficients of expansion are accounted for in the choice of the structural
materials. Thermal deformations are taken into account when working with structures that must
be aligned with each other.

• Random Loads: The design of instruments and electronic boxes are determined by the random
base excitation
REFERENCES

• https://www.intechopen.com/books/satellite-systems-design-modeling-simulation-and-analysis/communication-su
bsystems-for-satellite-design

• Fortescue, Peter,‘ Spacecraft Systems Engineering’ John Wiley England,4 th edition, 2011,ISBN-13: 978-
0470750124

• System integration” by V A THOMAS, M N SATHYANARAYAN, V R KATTI, A A BOKIL, N R DATHATHRI, G

MOHANAKRISHNAN, K PATTABHIRAMAN, T K GOSWAMI, T L DANABALAN and I SELVARAJ ISRO Satellite Centre,
Peenya, Bangalore-560 058.
THANK YOU