hoisting / transportation / handling for s/c modules...

BC.ASU.TN.00029Issue 1

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BC.ASU.TN00029.Iss1.AIT.doc

Hoisting / Transportation / Handling For S/C Modules during System AIT

Load Cases and Factors Technical Note

CI CODE: B3000

UK EXPORT CONTROL RATING: Not listed Rated By:

© Astrium Limited 2009

Astrium Limited owns the copyright of this document which is supplied in confidence and which shall not be used for any purpose other than that for which it is supplied and shall not in whole or in part be reproduced, copied, or communicated

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Astrium Limited, Registered in England & Wales No. 2449259 Registered Office: Gunnels Wood Road, Stevenage, Hertfordshire, SG1 2AS, England


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Astrium Limited owns the copyright of this document which is supplied in confidence and which shall not be used for any purpose other than that for which it is supplied and shall not in whole or in part be reproduced, copied, or communicated to any person without written permission from the owner.


INTENTIONALLY BLANK


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CONTENTS

1. SCOPE.......................................................................................................................................................................... 4

2. REFERENCES ............................................................................................................................................................ 5 2.1 REFERENCE DOCUMENTS.......................................................................................................................................... 5 2.2 ABBREVIATIONS....................................................................................................................................................... 5

3. LOAD FACTORS ....................................................................................................................................................... 6

4. LOAD CASES.............................................................................................................................................................. 9 4.1 GROUND OPERATION LOAD CASES .......................................................................................................................... 9

4.1.1 Hoisting and Handling ..................................................................................................................................... 9 4.1.2 Transportation.................................................................................................................................................. 9

4.2 S/C CONTAINER LOAD CASES ................................................................................................................................ 11 4.2.1 MTM and MPO Transport Container............................................................................................................. 11 4.2.2 MOSIF Transport Container .......................................................................................................................... 11

5. S/C SYSTEM AIT CONFIGURATIONS ............................................................................................................... 12 5.1 S/C HOISTING CONFIGURATIONS............................................................................................................................ 12 5.2 S/C TRANSPORT CONFIGURATIONS ........................................................................................................................ 29 5.3 S/C HANDLING CONFIGURATIONS.......................................................................................................................... 34


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1. SCOPE

This technical note defines the load cases and factors for various hoisting, transportation and handling cases for various configurations of spacecraft modules during System AIT. This document will evolve into a separate section to form part of the BepiColombo project ‘Load Synthesis Document’ (Ref: BC.ASU.RP.00009). The spacecraft System AIT configurations have been defined by Thales Alenia.


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2. REFERENCES

2.1 Reference documents

List of reference documents: within this technical note will be referred to as (AD-n).

AD Title Doc-No Iss.Rev Date

AD-1 General Design and Interface Requirements BC-ASD-SP-00001 3 20-6-2007

AD-2 System MGSE Specification BC-ASD-SP-00026 4 16-11-2007 AD-3 System Requirements Document BC-EST-RS-02100 1 4-6-2006

AD-4 Thales Alenia

Hoisting/Transportation/Handling Configurations for the BC

Modules during System AIT

- DRAFT 10-08-2007

2.2 Abbreviations

CofG Centre of gravity

F/H Flight Hardware

GSE Ground Support Equipment

HA Handling Adaptor

H/W Hardware

I/F Interface

IR Infra Red

LHA Lower Handling Adaptor

MCS Mercury Composite Spacecraft

MGSE Mechanical Ground Support Equipment

MMO Mercury Magnetosphere Orbiter

MOSIF MMO Sunshield and Interface Structure

MPO Mercury Planetary Orbiter

MPT Multi Purpose Trolley

MTM Mercury Transfer Module

N/A Not applicable

S/C Spacecraft

TBC To Be Confirmed

UHA Upper Handling Adaptor


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3. LOAD FACTORS

The following load factors are taken from AD-1 (Ref: GDI-3613) and are used for all hoisting, handling and transportation limit load cases defined in this technical note.

Limit Load (LL)(Flight, OS, VAIT)

Design Load (DL) Qualification Load(QL)

Yield Load (YL) Ultimate Load(UL)

x Design Factor FOSDx Uncertainty Factor FOSUNx Protoflight Factor FOSPF

x Yield Factor FOSY x Ultimate Factor FOSU

x Qualification Factor FOSQ

Figure 3-1: Definition of Loads Flowchart (Ref: AD-1, GDI-3613)

From Figure 3-1 above: Design Loads (DL) Design Load (DL) = Limit Load (LL) x FOSD x Kadd Where FOSD = 1.5 (Ref: AD-1, GDI-189) and (AD-3, SRD-1516) Kadd = 1.2 for Flight H/W (Ref: AD-1, GDI-206) Ultimate Loads (UL) For Flight H/W Ultimate Load (UL) = Design Load (DL) x FOSU Where FOSU = 1.25 (Ref: AD-1, GDI-3229 for Flight H/W, based on joints and inserts) For MGSE Ultimate Load (UL) = Design Load (DL) x FOSU Where FOSU is to be applied in accordance with Table 3-1 and Table 3-2 (Ref: AD-2, MGSE-2067 and MGSE-2113)


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Table 3-1: MGSE Safety Factors (Ref: MGSE-2067)

MGSE shall be designed with the safety, proof and test load factors as follows:

(1) National requirements have to be applied if they are more stringent. (2) Annual re-validation according to national and launcher site regulations.

Table 3-2: MGSE Safety Factors (Ref: MGSE-2113)

MGSE items used in (or with) F/H and/or MGSE shall meet the safety factors specified in the Table below:


Table 3-2 continues next page


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Table 3-2 cont.: MGSE Safety Factors (Ref: MGSE-2113)



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4. LOAD CASES

4.1 Ground Operation Load Cases

4.1.1 Hoisting and Handling

The load cases defined in Table 4-1 are for Hoisting and Handling and are taken from AD-2 (Ref: MGSE-4702). Note the load factors are limit cases only and will need to be factored in accordance with Section 3. The load cases defined in Table 4-1 are to be considered for the design of MGSE and S/C interfaces.

Table 4-1: Hoisting and Handling Load Cases

Load Case ID N° Load Factor [g], vertical

Load Factor [g], lateral Reference/Remark

1 S/C Crane Hoisting

1.0 g (gravity) ± 0.3 g

± 0.2 g DIN 15018-1

slow crane velocity

2 Handling Adapter (for S/C Handling)

1.0 g (gravity) ± 1.5 g

± 2.5 g

3 Ground Handling

1.0g (gravity) ± 0.5g

± 1.5g Multi purpose trolley Ref: MGSE-4918

Hoi

stin

g / H

andl

ing

4 Stack Vertical Transportation

1.0g (gravity) ± 3.3g

± 1.0g Ref: Soyuz User Manual Section 3.2.1.1 and Section 6.3.1.3 the transport loads in Guiana Space Centre.

4.1.2 Transportation

The load cases defined in Table 4-2 are for Transportation (Air, Road and Ship) and are taken from AD-2 (Ref:MGSE-4702). Note the load factors are limit cases only and will need to be factored in accordance with Section 3. The load cases defined in Table 4-2 are to be considered for the design of MGSE and S/C interfaces.


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Table 4-2: Transportation Load Cases

Load Case ID N° Frequency/Time Level [g] Remark

3.1 Sine excitation 3 axis ***)

(2) 5 Hz - 10 Hz

10 - 200 Hz

DA = 6 mm

1.2 g peak

The curve shall be extended to 2 Hz when H/W resonance below 5 Hz are expected ****)

3.2 Random (continuous)

2 Hz- 100 Hz

0.004 g²/Hz, 0.626 gRMS

Superimposed to sine ****) Roa

d Tr

ansp

orta

tion

3.3 Shock 3 axis T = 20 ms 10.0 g Saw Tooth

Load Case ID N° Frequency/Time Level [g] Remark

4.1 Sine excitation 3 axis ***)

2 Hz - 20 Hz

20 Hz - 50 Hz

50 Hz - 200 Hz

200 Hz - 1000 Hz

1000 Hz - 2000 Hz

DA = 0.53 mm

0.85 g

2.0 g

2.4 g

0.3 g

****)

4.2 Random (continuous)

2 Hz- 100 Hz 0.004 g²/Hz, 0.626 gRMS

Superimposed to sine ****)

Air

Tran

spor

tatio

n

4.3 Shock 3 axis T = 20 ms 6.0 g Half Sine / Crash Loads

Load Case ID N° Load Factor [g],

vertical Load Factor [g], lateral Reference/Remark

Ship

Tr

ansp

orta

tion

5 Quasistatic loads (low frequent waves)

1 g (gravity) +0.6 g/-1.4 g

± 0.5 g accelerations act simultaneously

Note: Vertical is the direction parallel to the gravity Remarks:

Down (+) / Up (-)

***) The worst case envelope (peak values) for short time sine dwell or sine sweep sequences are to be considered in the analysis (design, stress); no permanent excitation w.r.t. fatigue ( not as long-term stress).

****) The MGSE design has to protect the F/H to load levels below handling loads under the specified sine or random excitations. The TSCs need a low-frequent suspension with high damping in order to avoid high inputs to modes of the F/H. The loads acting on the container shall not exceed the S/C handling loads in any transport and handling case. The loads acting on the S/C C.o.G. shall not exceed 1.0 g ± 1.0 g in vertical direction and ± 1.5 g in lateral direction.


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4.2 S/C Container Load Cases

The following load cases are for transport containers that protect the S/C modules during transit.

4.2.1 MTM and MPO Transport Container

The transport containers shall protect the MTM and MPO flight hardware (e.g. shock absorption) such that the Ground Operation Load Environments as given in Table 4-1 and Table 4-2 do not induce loads on the S/C CofG greater than those defined in Table 4-3. Both vertical and horizontal loads shall be considered as acting simultaneously. These limit accelerations and requirements are taken from AD-2 (Ref: MGSE-4228 and MGSE-4239).

Table 4-3: Limit Accelerations for Ground Operations for MTM, MPO containers

Load case GROUND EVENT VERTICAL

Down (+) / Up (-)

HORIZONTAL

6 Ground Handling

(nominal handling loads)

1 g (gravity) ± 2.0 g ± 2.0g

4.2.2 MOSIF Transport Container

The transport container shall protect the MOSIF flight hardware (e.g. shock absorption) such that the Ground Operation Load Environments as given in Table 4-1 and Table 4-2 do not induce loads on the S/C CofG greater than those defined in Table 4-4. Both vertical and horizontal loads shall be considered as acting simultaneously. These limit accelerations and requirements are taken from AD-2 (Ref: MGSE-4449 and MGSE-4461).

Table 4-4: Limit Accelerations for Ground Operations for MOSIF containers

Load case GROUND EVENT VERTICAL

Down (+) / Up (-)

HORIZONTAL

7 Ground Handling

(nominal handling loads)

1 g (gravity) ± 4.0 g ± 2.5g


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5. S/C SYSTEM AIT CONFIGURATIONS

5.1 S/C Hoisting Configurations

The ‘worst-case’ quasi-static accelerations taken from AD-2 shall be considered for all hoisting configurations defined in this section. From Table 4-1, Load Case ID1 is applied to the following configurations.

Case ID Configuration Summary Total Mass Hoisted Applicable Load Case

A1 MPO Vertical Hoisting (+Z Down) MPO WET + MPO UHA + MPO LHA

A2 MPO + MTM Vertical Hoisting (+Z Down) MPO WET + MTM WET + MPO UHA + MTM LHA

A3 MPO Vertical Hoisting (+Z Up) MPO DRY + MPO LHA + MPO TTA / IR TTA

A4 MTM Vertical Hoisting (+Z Down) MTM WET + MTM UHA + MTM LHA

A5 MTM Vertical Hoisting (+Z Up) MTM DRY + MTM LHA + MTM TTA

A6 MOSIF Vertical Hoisting (+Z Down) MOSIF + MMO + MOSIF HA + Extended Poles

A7 MMO / MPO /MTM Vertical Hoisting (+Z Down)

MMO + MPO WET + Short Poles + MTM WET + MTM LHA + MPT / VIS

A8 MOSIF Vertical Hoisting (+Z Down) MOSIF + MMO + MOSIF TTA + Extended Poles

A9 MCS Vertical Hoisting (+Z Down) MCS WET + MTM LHA + Poles

A10 MCS Vertical Hoisting (+Z Down) MCS WET + LVA + LVA HA + Poles

A11 MPO Horizontal Hoisting MPO WET + MPO UHA + MPO LHA

A12 MPO Horizontal Hoisting MPO WET + MPO UHA + MPO LHA

A13 MTM Horizontal Hoisting MTM WET + MTM UHA + MTM LHA

A14 MTM Horizontal Hoisting MTM WET + MTM UHA + MTM LHA

A15 MOSIF Horizontal Hoisting MOSIF + MOSIF HA + MOSIF Horizontal Lifting Device

A16 MOSIF Sunshield Vertical Lifting MOSIF Sunshield

A17 MOSIF I/F Frame Vertical Lifting MOSIF Sunshield + Adaptor + Poles

Table 4-1 Load Case ID1


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Hoisting Configuration Case ID: A1

VERTICAL HOISTING MPO

+Z DOWNWARDS (MOSIF I/F UP) (MPO WET + MPO UHA + MPO LHA)

Flight I/F *

MPO WET

+ Z

MPO LHA

MPO UHA

Lifting Device

g + Z

I/F to MOSIF


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VERTICAL HOISTING MPO + MTM

+Z DOWNWARDS (MOSIF I/F UP) (MPO WET+MTM WET +MPO UHA+ MTM LHA)

Flight I/F*

MPO WET

+ Z

MTM LHA

MPO UHA

Lifting Device

MTM WET

I/F to MOSIF

+ Z g


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VERTICAL HOISTING MPO

+Z UPWARDS (NADIR FACE UP, THERMAL TESTS) (MPO DRY+MPO LHA+ MPO TTA (or MPO IR TTA)

Flight I/F *

MPO DRY

+ Z

MPO LHA

Lifting Device

g + Z

I/F to MTM

MPO TTA or MPO IR TTA


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VERTICAL HOISTING MTM

+Z DOWNWARDS (MPO I/F UP) (MTM WET+MTM UHA+ MTM LHA)

Flight I/F

MTM WET

+ Z

MTM LHA

MTM UHA

Lifting Device

g + Z

I/F to MPO


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VERTICAL HOISTING MTM

+Z UPWARDS (ME UP, TB TEST) (MTM DRY+MTM LHA+ MTM TTA)

Flight I/F Flight I/F

MTM DRY

+ Z

MTM LHA

Lifting Device

g + Z

I/F to LVA

MTM TTA


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VERTICAL HOISTING MOSIF

+Z DOWNWARDS (MMO I/F UP) (MOSIF + MMO+Extended poles + MOSIF HA)

I/F on MGSE

Lifting Device

g + Z

Poles + extension + rigid parts

MOSIF + MMO

I/F to MPO MOSIF HA


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VERTICAL HOISTING MMO / MPO / MTM

+Z DOWNWARDS (MMO I/F UP) (MMO + short poles + MPO WET) (Separation)

Flight I/F (to be replaced) Flight I/F(to be replaced)

Lifting Device g

+ Z

Poles + extension + rigid parts

MMO

I/F to Poles I/F to MPO

MPO WET

MTM WET

MTM LHA

MPT or VIS


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VERTICAL HOISTING MOSIF

+Z DOWNWARDS (MMO I/F UP) (MOSIF + MMO+Extended poles + MOSIF TTA)

I/F on MGSE

Lifting Device

g + Z

Poles + extension + rigid parts MOSIF +

MMO

I/F to Poles

MOSIF TTA I/F to MPO


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VERTICAL HOISTING MCS

+Z DOWNWARDS (MMO UP) (MCS WET +MTM LHA+ Poles)

Estimated MGSE Mass

MTM LHA 250 kg

Lifting Device

g + Z

POLES MMO

I/F to Poles

MPO WET

MTM WET

MTM LHA


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VERTICAL HOISTING MCS

+Z DOWNWARDS (MMO UP) (MCS WET +LVA +LVA HA+ Poles )

Estimated MGSE Mass

LVA HA 200 kg

g + Z

Lifting Device

POLES MMO

I/F to Poles I/F to MPO

MPO WET

MTM WET

LVA

LVA HA


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HORIZONTAL HOISTING MPO

(MPO WET +MPO UHA+ MPO LHA)

Flight I/F on MPO* Flight I/F on MPO

MPO WET

+ Z

MPO LHA

MPO UHA

Lifting Device

g

+ Z

I/F to MOSIF

I/F to MTM


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HORIZONTAL HOISTING MPO

(MPO WET +MPO UHA+ MPO LHA ) (MASS PROPERTIES/TURN-OVER FOR THERMAL TESTING)

Flight I/F on MPO * Flight I/F on MPO *

MPO WET

+ Z

MPO LHA

MPO UHA

Lifting Device

g

+ Z I/F to MOSIF

I/F to MTM


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HORIZONTAL HOISTING MTM

(MTM WET +MTM UHA+ MTM LHA)


MTM WET

+ Z

MTM LHA

MTM UHA

Lifting Device

g

+ Z

I/F to MPO

I/F to LVA


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HORIZONTAL HOISTING MTM

(MTM WET +MTM UHA+ MTM LHA ) (MASS PROPERTIES (tbc) /TURN-OVER FOR THERMAL TESTING(dry))


MTM WET

+ Z

MTM LHA

MTM UHA

Lifting Device

g

+ Z I/F to MPO

I/F to LVA


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HORIZONTAL HOISTING MOSIF

(MOSIF +MOSIF HORIZ LIFT DEVICE+MOSIF HA)

I/F on MGSE

MOSIF Horizontal Lifting

Device

MOSIF HA

+ Z

I/F to MPO

g


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VERTICAL LIFTING MOSIF Sunshield


VERTICAL LIFTING MOSIF I/F FRAME (FLIGHT I/F CROSS)

Lifting Device

g + Z

MOSIF Sunshield

Lifting Device

g + Z

MOSIF Sunshield


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5.2 S/C Transport Configurations

The ‘worst-case’ quasi-static accelerations taken from AD-2 shall be considered for all transport configurations defined in this section. From Table 4-1, Load Case ID5 is applied to the following configurations. In addition, to the quasi-static accelerations the transport dynamic loadings defined in Table 4-2, Loads Cases ID10 to 12 must also be considered. The following transport configurations shall also consider container load cases. The transport container shall protect the flight hardware such that the ground operation load environment s DO NOT induce loads on the S/C CofG greater than those defined in Table 4-3 and Table 4-4.

Case ID Configuration Summary Total Mass Transported Applicable Load Cases

B1 MPO Transportation MPO DRY + MPO LHA + MPO UHA Table 4-1, Load Case ID2

Table 4-2, Load Case ID3-5 Table 4-3 (Container Loads, Load Case ID6)

B2 MTM Transportation MTM DRY + MTM LHA + MTM UHA Table 4-1, Load Case ID2


B3 MOSIF Transportation MOSIF + MOSIF HA+ Poles (TBC) Table 4-1, Load Case ID2


B4 MCS Vertical Transportation MCS DRY and WET Table 4-1, Load Case ID4

Table 4-2, Load Case ID3-5 See Note

Note: The loads acting on the S/C CofG shall not exceed 1.0g ± 1.0g in the vertical direction and ± 1.5g in the horizontal direction in accordance with AD-2 (Ref: MGSE-4702). Vertical and Horizontal loads shall be considered acting simultaneously.


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Transport Configuration Case ID: B1

TRANSPORTATION MPO

(MPO DRY + MPO LHA+ MPO UHA (to reduce installations/removal activities)


Estimated MGSE Mass

MPO UHA 200 kg

MPO DRY

+ Z

MPO LHA

MPO UHA g

+ Z I/F to MOSIF

I/F to MTM


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TRANSPORTATION MTM

(MTM DRY + MTM LHA+ MTM UHA (to reduce installations/removal activities)


Estimated MGSE Mass

MTM UHA 200 kg

MTM DRY

+ Z

MTM LHA

MTM UHA g

+ Z I/F to MPO

I/F to LVA


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TRANSPORTATION MOSIF

(MOSIF + MOSIF HA)


+ Z

MOSIF HA

g + Z

I/F to MOSIF

I/F to MTM

I/F to Poles (for handling only , TBC, or through MOSIF HA)


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VERTICAL TRANSPORTATION MCS DRY AND WET @ CSG


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5.3 S/C Handling Configurations

The ‘worst-case’ quasi-static accelerations taken from AD-2 shall be considered for all transport configurations defined in this section. From Table 4-1, Load Case ID5 is applied to the following configurations.

Case ID Configuration Summary Total Mass Handled Applicable Load Cases

C1 MPO Tilting and Rotations MPO WET + MPO LHA + MPO UHA

C2 MPO Tilting and Rotations MPO WET + MPO LHA + MPO UHA

C3 MTM Tilting and Rotations MTM WET + MTM LHA + MTM UHA

C4 MTM Tilting and Rotations MTM WET + MTM LHA + MTM UHA

C5 MOSIF Tilting and Rotations MOSIF + MMO + MOSIF HA


C6 MCS Tilting and Rotations MCS WET + MTM LHA or LVA Table 4-1 Load Case ID3

C7 MPO Handling Case (Thermal Tests) MPO DRY + MPO TTA

C8 MTM Handling Case (Thermal Tests) MTM DRY + MTM TTA

C9 MOSIF Handling Case (Thermal Tests) MOSIF + MMO + MOSIF TTA

C10 Handling Case (Replacement of Fired Pyro-devices on MPO/MTM after Separation Test)

MMO + MPO WET + MTM WET

or

MMO + MPO DRY + MPO TTA



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Handling Configuration Case ID: C1

TILTING AND ROTATIONS MPO

(MPO WET + MPO LHA+ MPO UHA)


MPO WET

+ Z

MPO LHA

MPO UHA

g

+ Z

I/F to MOSIF I/F to MTM

Tilting and full rotation


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TILTING AND ROTATIONS MPO

(MPO WET + MPO LHA+ MPO UHA) (WET, TBC; DRY FOR TB TEST)

Flight I/F

Flight I/F

MPO WET

+ Z

MPO UHA

MPO LHA

g

+ Z

I/F to MOSIF I/F to MTM



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TILTING AND ROTATIONS MTM

(MTM WET + MTM LHA+ MTM UHA)

Flight I/F* Flight I/F*

MTM WET

+ Z

MTM LHA

MTM UHA

g

+ Z

I/F to MPO I/F to LVA



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TILTING AND ROTATIONS

MTM (MTM WET + MTM LHA+ MTM UHA)

(WET, TBC; DRY FOR TB TEST)


MTM WET

+ Z

MTM UHA

MTM LHA

g

+ Z

I/F to MPO I/F to LVA



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TILTING AND ROTATIONS MOSIF

(MOSIF +MMO+ MOSIF HA)

I/F on MGSE

MMO + Z

MOSIF HA or TTA

g

+ Z

I/F to MPO


MOSIF


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TILTING AND ROTATIONS

MCS (WET for Simulated STM;DRY for STM and PFM)

+ Z

MTM LHA or LVA

g

+ Z


MTM WET MPO

WET MOSIF +MMO

+ Z + Z


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HANDLING CASE (THERMAL TESTS)

MPO (MPO DRY + MPO TTA)

Flight I/F

MPO DRY

+ Z

g + Z

I/F to MOSIF

MPO TTA

360 DEGREES ROTATION


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HANDLING CASE (THERMAL TESTS)

MTM (MTM DRY + MTM TTA)

Flight I/F

MTM DRY

+ Z

g + Z

I/F to MPO

MTM TTA



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HANDLING CASE (THERMAL TESTS) MOSIF

(MOSIF + MMO + MOSIF TTA)

I/F on MGSE

+ Z

g + Z

I/F to MPO

MOSIF TTA


MOSIF


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HANDLING CASE (REPLACEMENT OF FIRED PYRO-DEVICES ON MPO/MTM AFTER

SEPARATION TEST) MMO / MPO / MTM

(MPO DRY + MPO TTA)

Lifting Device g

+ Z

POLES MMO

I/F to Poles

MPO WET

MTM WET

MPO/MOSIF/MMO STACK (and MOSIF/MMO/MPO/MTM STACK) support for replacement of separation pyro:


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