Publications

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Before a spacecraft can be considered for launch, it must first survive environmental testing that simulates the launch environment. Typically, these simulations include vibration testing performed using an electro-dynamic shaker. For some spacecraft however, acoustic excitation may provide a more severe loading environment than base shaker excitation. Because this was the case for a Sandia Flight System, it was necessary to perform an acoustic test prior to launch in order to verify survival due to an acoustic environment. Typically, acoustic tests are performed in acoustic chambers, but because of scheduling, transportation, and cleanliness concerns, this was not possible. Instead, the test was performed as a direct field acoustic test (DFAT). This type of test consists of surrounding a test article with a wall of speakers and controlling the acoustic input using control microphones placed around the test item, with a closed-loop control system. Obtaining the desired acoustic input environment - proto-flight random noise input with an overall sound pressure level (OASPL) of 146.7 dB-with this technique presented a challenge due to several factors. An acoustic profile with this high OASPL had not knowingly been obtained using the DFAT technique prior to this test. In addition, the test was performed in a high-bay, where floor space and existing equipment constrained the speaker circle diameter. And finally, the Flight System had to be tested without contamination of the unit, which required a contamination bag enclosure of the test unit. This paper describes in detail the logistics, challenges, and results encountered while performing a high-OASPL, direct-field acoustic test on a contamination-sensitive Flight System in a high-bay environment.

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Signal and power harnesses on spacecraft buses and payloads can alter structural dynamics, as has been noted in previous flight programs. The community, however, has never undertaken a thorough study to understand the impact of harness dynamics on spacecraft structures. The Air Force Research Laboratory is leading a test and analysis program to develop fundamental knowledge of how spacecraft harnesses impact dynamics and develop tools that structural designers could use to achieve accurate predictions of cable-dressed structures. The work described in this paper involved a beam under simulated free boundary conditions that served as a validation test bed for model development.

This paper presents experimental results and modeling aspects for electrical power and signal cable harnesses used for space applications. Dynamics of large precision structures can be significantly influenced by subsystems such as electrical cables and harnesses as the structural mass of those structures tends to become smaller, and the quantity of attached cables continues to increase largely due to the ever increasing complexity of such structures. Contributions of cables to structural dynamic responses were observed but never studied, except for a low scale research effort conducted at the Air Force Research Laboratory, Space Vehicles Directorate (AFRL/VSSV). General observations were that at low frequencies cables have a mass loading effect while at higher frequencies they have a dissipative effect. The cables studied here adhere to space industry practices, identified through an extensive industry survey. Experimental procedures for extracting structural properties of the cables were developed. The structural properties of the cables extracted from the extensive experimental database that is being created can be used for numerical modeling of cabled structures. Explicit methods for analytical modeling of electrical cables attached to a structure in general are yet to be developed and the goal of this effort is to advance the state of the art in modeling cable harnesses mounted on lightweight spacecraft structures.

A top level overview of the effect cables have on the dynamic response of precision structures is presented. The focus of this paper is on precision, low-damping, low-first modal frequency space structures where cables are not implicitly designed to be in the load path. The paper presents the top-level, Phase I results which include pathfinder tests, an industry/government/academia survey, modeling and testing of individual cable bundles, and modeling and testing of cables on a simple structure. The end goal is to discover a set of practical approaches for updating well defined dynamical models of cableless structures. Knowledge of the cable type, position and tie-down method is assumed to be known. Simulation sensitivity analysis of the effect cables have on a precision structure has also been completed. Each section of the paper will focus on the details of each area.

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