Flight Systems/ Test and Integration Laboratory

Environmental Test & Integration Facilities 

Altitude Simulation (Thermal Vacuum) Chambers

Vibration Laboratory with Mass Properties Instrument (Center of Gravity) 

Summary-Building 1250 Environmental Test and Integration Facilities

      Questions about facilities described on this page are best directed to Richard A. Foss P.E., unless otherwise specified.
 

Environmental Test and Integration Facility

The Environmental Test and Integration Facility comprised of facilities used to qualify components, subsystems, and small payloads intended for atmospheric and space fight. These facilities include several altitude simulation chambers (thermal vacuum chambers), three dynamic shakers, class 1000 and class 10,000 clean rooms, and a large structural backstop which is used for load testing and modal analysis. The laboratory is staffed by aerospace test engineers and engineering technical support personnel and utilizes other specialized support resources such as a chromatographic analysis laboratory to perform cleanliness evaluations, quality assurance, fixture design, photographic services, and electronic support personnel.

Altitude Simulation (Thermal/Vacuum) Chambers:

8' X 15' Cylindrical Thermal Vacuum Chamber
Open door veiw of vacuum chamberClick for full image

The largest of the facility vacuum chambers it has a usable volume of 6ft.8in. X 14 ft. and vacuum levels of 1 X 10-6 Torr.(mm Hg) are attainable using cryopump vacuum system to simulate orbital altitudes. This chamber utilizes a stainless steel internal LN2 shroud system and a circumferentially mounted 36Kw quartz heater array to produce a symmetrical thermal radiance. Thermal controls are PC intergrated allowing precise control of complex thermal profiles or quadrants about user selectable parameters. Test data and chamber thermal profiles are continually displayed and archived on a PC or storage disks. Thirty two (32) thermocouple channels are currently available to monitor customer payload thermal gradients. This facility can meet cleanliness criteria for space flight hardware, including a TQCM (Temperature-Controlled Quartz Crystal Microbalance) and Residual Gas Analyzer (RGA) to monitor and identify contamination spectra. A class 10,000 portable downflow provides a clean area for test preparation or transition from the Class 1000 clean room, prior to insertion into the test chamber.

OPERATION: Test items are normally configured on the stainless steel tray, which has the capability to be rolled out chamber door by an overhead trolley to a portable support frame for external access to the test item and tray. Thermocouple, electrical or fluid intergration to the payload are normally performed external to the chamber when possible. The tray is then rolled into the chamber for any final connections with chamber feedthrough penetrations and functional checks to support equipment are performed. Isolation valves provide for payload setup during cryopump cooldown (~2 Hr.). The chamber evacuation is achieved with 2 rotary piston mechanical pumps and crossover to ultimate pressure with the high-vacuum cryopumps.

CHAMBER SPECIFICATIONS:

INSTRUMENTATION:

6' X 6' Cylindrical Thermal Vacuum Chamber
Open door veiw of 6x6 vacuum chamber Click for full image

This medium sized, thermal vacuum chamber is capable of simulating altitude and thermal environments to orbital conditions. This facility is especially useful for qualifying payloads that may be sensitive to IR radiant heat sources. Use of 2 large capacity cryogenic pumps and a unique optically baffled, thermal shroud enables this facility to achieve vacuum pressures of 1 x 10E-7 Torr. (mm Hg). An external plenum tube is used to condition gaseous nitrogen within the range of -300deg.(F) to +250deg.(F). Thermal transfer to a payload is accomplished by pushing conditioned nitrogen through a closed loop, conductive platen and radiant thermal shrouds. Chamber control and data acquisition features can be automated to customer test parameters. There are normally 18 thermocouple channels available for monitoring payload temperatures. Numerous electrical and fluid, feedthrough penetrations are available for GSE (Ground support equipment) integration. The high vacuum capability, extreme cleanliness, TQCM and RGA instrumentation enable this facility to be used for low-level outgassing and mass loss measurement studies.

OPERATION: A class 10,000 portable downflow provides a clean area at test chamber door for payload preparation prior to insertion in chamber. The payload is placed on the chamber platten and instrumented with thermocouples, data and ground support equipment are connected with chamber feedthrough flanges. An overhead railway provides for optional mounting support. The cryopumps require 2 hour cool down time prior to chamber pump down, isolation valves provide for payload preparation during this period. The data acquisition and control system, can be programmed to customer setpoints, ramps and dwell period.
 

CHAMBER INSTRUMENTATION:


5' X 5' Cylindrical Thermal Vacuum Chamber
5 x 5 vacuum chamberClick for full image

A 5 by 5 foot thermal vacuum chamber which is capable of providing altitude vacuum and thermal simulation to approximately 10 E-7 Torr. A stainless steel Ln2 shroud provides a cold radiant source and a quartz heater array provides unidirectional radiant heating. Control and data acquisition systems are uniquely tailored for each application. This chamber does not meet stringent contamination requirements for space flight hardware. It is used primarily to qualify research or developmental components and for material outgassing or bakeouts.
 

OPERATTION: Test items are configured in the chamber and instrumented with thermocouples and connected with ground support equipment. Isolation value and door interlocks provide for test preparation in chamber during 2 hour cryopump cooldown. Control programs are suitable for atmospheric and space flight testing. Two rotary piston pumps with a cold trap provide roughing pressure for crossover to high vacuum with the cyropump.
 

Thermal/Vacuum Bell Jars

Bell Jar thermal vacuum facilities used to qualify components and small subsystems include two glass and one stainless steel Bell Jar. They are all similar in function and size and able to accommodate components up to approximately 1foot^3. Each has a cryogenic pumping system capable of attaining vacuum pressures of 1 by 10^-5mm (hg). Heating sources are uniquely configured to satisfy testing requirements and include both conductive and radiant sources. Conductive cold plates are available to produce temperatures as low as 250(F). When configured in conjunction with an appropriate heat source, a complex thermal profile can be established and maintained. Control and data acquisition features are automated and include both hardware and software fail-safe functions to allow continuous testing over extended periods. Fluid and electrical penetrations are available to meet interface requirements.

Vibration Test Facility

The vibration test facility is equipped to perform vibration testing, of aerospace components, subsystems, and small payloads.

Vibration capability consists of three dynamic shakers (listed below) sharing a common control and data acquisition system. Three thousand(3000), seventeen thousand five hundred(17500), and twenty-seven thousand(27000) force per pound dynamic shakers are used to qualify payload performance by simulating expected mission acceleration forces. Control software enables the application of complex frequency/amplitude spectra to include sine, random, shock, and various combinations of these spectra as may be required. Twenty four channels are available for control or data acquisition. Rotatable armatures, fixtures cubes, head expanders (T-4000 only), and slip tables permit adaptation to a variety of payload shapes and sizes and enables testing in three axis.
Link shaker table LING  Unholtz-Dickie T-1000 shaker tableT-1000 Unholtz-Dickie T-4000 shaker tableT-4000
Click Image to Enlarge 

Vibration Laboratory
Force Rating Peak
Size & Stroke(Peak to Peak)
LING Model 308V
3000 force-lb., sin
1-foot mounting cube, 1.5in. stroke
UNHOLTZ-DICKIE T-1000
17500 force-lb., sin
45in.x48in. slip table, 1in. stroke
UNHOLTZ-DICKIE T-4000
27000 force-lb., sin
48in.x61.5in. slip table, 1in. stroke

Modal Analysis

Equipment and trained personnel are available to conduct comprehensive modal analysis to identify resonant characteristics of complex structures and systems.
Modal Contact : Dr. Kenny B. Elliott (Kenny.B.Elliott@nasa.gov)

Model KSR1320 Mass Properties Instrument

  Mass properties, center of gravity instrument and data system Click for full image

Performance Specifications:

Center of Gravity:

Moment of Inertia:

Summary - Building 1250 Environmental Test and Development Facilities

High Bay

Medium Bay

Thermal Vacuum
Usable Test Volume
CHARACTERISTICS
Chambers:

5ft x 5ft

4ft.6in. x 4ft.3in. x 4ft.6in.
Quartz lamps, LN2 shrouds  <5x10E-6 Torr. (mm Hg)
PC control and data acquisition system High vacuum cryogenic pumps
GN2 thermal shroud 
<8 x 10-7 Torr(mm Hg.)
6ft x 6ft
3ft.6in. x 5ft. x 4ft.10in.
8ft x 15ft
6ft.8 in. x 14 ft.
Quartz lamps, LN2 shrouds,
<5 x 10-7 Torr(mm Hg.)
BELLJARS:
Glass
18in. Dia. x 30in. H
PC controlled and data acquisition system Variable heat sources High vacuum cryogenic pumps <5 x 10E-6 Torr(mm Hg.)
Glass
18in. Dia. x 18in. H
Stainless Steel
w/ 4" glass veiwport
24in. Dia. x 30in. H
Cryocycle Dip Tank
22in. x 22in. x 30in. H




Ln2 source, -185deg C(-300deg F)

 

Clean Room
40 Foot
36 ft. x 40 ft. , 26 ft. Hook height.
Class 10,000 (conditionally operated as a Class 100 clean room)

 

Clean Rooms
34 ft. x 15 ft.
(High bay)

 

26ft. x 16ft.
(Medium bay)

Class 1000

 



Class 1000

Laboratories

Vibration Laboratory-Shakers

LING Model 308V 3000 force-lb., sin
1-foot mounting cube, 1.5 in. stroke (p-p)
UNHOLTZ-DICKIE T-1000 17500force-lb.
45 in. x 48 in. slip table, 1 in. stroke (p-p)
UNHOLTZ-DICKIE T-4000 27000force-lb.
48 in. x 61.5 in. slip table, 1 in. stroke (p-p)


Back to SITB Home Page