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BC.ASU.TN.00029Issue 1
Page 1 of 45
BC.ASU.TN00029.Iss1.AIT.doc
Hoisting / Transportation / Handling For S/C Modules during System AIT
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.
Astrium Limited, Registered in England & Wales No. 2449259 Registered Office: Gunnels Wood Road, Stevenage, Hertfordshire, SG1 2AS, England
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INTENTIONALLY BLANK
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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:
(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 continues next page
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(1) National requirements have to be applied if they are more stringent. (2) Annual re-validation according to national and launcher site regulations.
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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
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
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Hoisting Configuration Case ID: A3
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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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.
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.
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Hoisting Configuration Case ID: A7
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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Hoisting Configuration Case ID: A9
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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Hoisting Configuration Case ID: A11
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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Hoisting Configuration Case ID: A13
HORIZONTAL HOISTING MTM
(MTM WET +MTM UHA+ MTM LHA)
Flight I/F Flight I/F
MTM WET
+ Z
MTM LHA
MTM UHA
Lifting Device
g
+ Z
I/F to MPO
I/F to LVA
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Hoisting Configuration Case ID: A15
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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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
Table 4-2, Load Case ID3-5 Table 4-3 (Container Loads, Load Case ID6)
B3 MOSIF Transportation MOSIF + MOSIF HA+ Poles (TBC) Table 4-1, Load Case ID2
Table 4-2, Load Case ID3-5 Table 4-4 (Container Loads, Load Case ID7)
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: B3
TRANSPORTATION MOSIF
(MOSIF + MOSIF HA)
Flight I/F Flight I/F
+ 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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Transport Configuration Case ID: B4
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
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
Table 4-1 Load Case ID2
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Handling Configuration Case ID: C1
TILTING AND ROTATIONS MPO
(MPO WET + MPO LHA+ MPO UHA)
Flight I/F Flight I/F
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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Handling Configuration Case ID: C3
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
Tilting and full rotation
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Handling Configuration Case ID: C4
TILTING AND ROTATIONS
MTM (MTM WET + MTM LHA+ MTM UHA)
(WET, TBC; DRY FOR TB TEST)
Flight I/F Flight I/F
MTM WET
+ Z
MTM UHA
MTM LHA
g
+ Z
I/F to MPO I/F to LVA
Tilting and full rotation
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Handling Configuration Case ID: C5
TILTING AND ROTATIONS MOSIF
(MOSIF +MMO+ MOSIF HA)
I/F on MGSE
MMO + Z
MOSIF HA or TTA
g
+ Z
I/F to MPO
Tilting and full rotation
MOSIF
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Handling Configuration Case ID: C6
TILTING AND ROTATIONS
MCS (WET for Simulated STM;DRY for STM and PFM)
+ Z
MTM LHA or LVA
g
+ Z
Tilting and full rotation
MTM WET MPO
WET MOSIF +MMO
+ Z + Z
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Handling Configuration Case ID: C7
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 Configuration Case ID: C8
HANDLING CASE (THERMAL TESTS)
MTM (MTM DRY + MTM TTA)
Flight I/F
MTM DRY
+ Z
g + Z
I/F to MPO
MTM TTA
360 DEGREES ROTATION
BC.ASU.TN.00029Issue 1
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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.
BC.ASU.TN00029.Iss1.AIT.doc
Handling Configuration Case ID: C9
HANDLING CASE (THERMAL TESTS) MOSIF
(MOSIF + MMO + MOSIF TTA)
I/F on MGSE
+ Z
g + Z
I/F to MPO
MOSIF TTA
360 DEGREES ROTATION
MOSIF
BC.ASU.TN.00029Issue 1
Page 44 of 45
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.
BC.ASU.TN00029.Iss1.AIT.doc
Handling Configuration Case ID: C10
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:
BC.ASU.TN.00029Issue 1
Page 45 of 45
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.
BC.ASU.TN00029.Iss1.AIT.doc
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