Virtual AIT

1
Virtual AIT

• Massimo Braghin
• ESA ESTEC
• TOS-MTC

2
Outline

• To extend the Virtual Mock-up environment to the
  AIT
• To complete the Virtual satellite Design RD with
  AIT
• Relevant technologies required
• Major RD activities envisaged

3
System level AIT process

• The accurate definition of the AIT process in the
  early phase of a project is the key for the
  following cost saving.
• AIT Planning should be concurrently connected to
  Engineering design activities
• The proper time for an AIT trade-off is at the
  project start

4
What is needed?

• Design definition
• gtSatellite physical and functional design
• gtSatellite interfaces
• External Interfaces
• gtLauncher
• gtOther system elements
• gtGround facilities (integration, test and launch
  operations)
• Programmatic constraints
• gtLaunch date
• gtCombined tests / launch operations with other
  elements

5
What must be achieved?

• Definition of the baseline process
• Identification of critical phases
• Definition of support equipment
• AIT sequences consolidated before manufacturing
  begins
• Input to engineering for design improvement
• Time and cost evaluation over the AIT phase

MOD.1 N
MOD 1 N1
MOD 2 K
MOD 2 K1
FIT CHK 12
MOD 2 K2
MOD 1 N2
ENGINEERING EVALUATION
6
Current Method

• AIT planning based on
• Design definition
• External Interfaces
• Programmatic constraints
• Personal experience
• AIT planning is modified after design change is
  completed
• Concurrence between engineering and AIT is still
  low (timing and priorities)

DESIGN DEFINITION
DESIGN CHANGE 1
7
Virtual Spacecraft

• New design technologies can be applied.
• By developing a virtual model of the spacecraft
  it is possible
• To make available a simulated spacecraft (DMU) in
  the early phases of the project
• In the same simulation environment, the AIT
  process can be defined and analysed

8
Virtual S/C and AIT
The early availability of a Digital Mock-up of
the S/C allows the AIT team to define the
assembly, integration and handling sequence,
electronically
9
Virtual Mechanical AIT (VMAIT)
SPACECRAFT DESIGN
ASSEMBLY CHECK ON DMU
FULL MECHANICAL AIT ANALYSIS
AIT SEQUENCE RUN (DMU BASED)
PROGRAM CONSTRAINTS
MECHANICAL AIT BASELINE PLAN
10
VMAIT Model Definition

• WHAT SHALL BE IN?
• Spacecraft, subsystem and equipment level
• Mechanical GSE
• Ground facilities including interfaces
• Transportation facilities
• Human factor including tooling

11
VMAIT Model
TEST (far objective)
DESIGN
INTEGRATION
TRANSPORTATION

• Accessibility analyses
• Workflow assessment
• AIT Plan
• Visual AIT Procedures
• MGSE and special mechanical tools

12
Integration with DMU

• Dynamic Link with DMU
• Limiting the detail to typical System AIT
• Units box level
• Assembled structure
• Separated access/unit panels
• etc.

• Physical properties are necessary
• Mass and inertia
• Harness flexibility
• Solid boundaries
• Degrees of freedom (also of the operator)
• Working tools and their interfaces
• etc.

13
VMAIT Analysis

• Assembly
• Test in advance assembly paths on access
  critical items
• Identify best posture for operators in difficult
  tasks
• Evaluate required working areas
• Assess need for special tools
• Provide the optimised assembly sequence
• Make immediately available the procedure
• Etc.

• Satellite AIT Flow
• Check clearances for transportation
• Define flows in Integration Halls
• Define installation of specimen, GSE and facility
  interface connections
• Verify MGSE design options, utilisation
  procedures in the operating location etc.
• Define required personnel for each task
• AIT Schedule
• Etc.

14
Envisaged Technologies

• 3-D modelling environment compatible with (or
  same as) DMU
• The same applies to test facilities VR modelling
• Physical properties modelling application SW
• Human operator modelling tool
• VR Lab. for visual procedures exploitation and
  verification

15
Envisaged RD

• VMAIT model should be developed in combination
  with the Virtual Mock-up
• GSTP WITH TOOL PROTOTYPING AS KEY ISSUE (AND
  COMPATIBILITY VERIFICATION WITH TEST CENTRE VR
  MODEL)
• Definition of test centre(s) VR model
• GSTP WITH TOOL PROTOTYPING AS KEY ISSUE
• The same or a compatible operating environment
  should be provided to assure easy data exchange