CHAPTER 5 MECHANICAL AND ELECTRICAL INTERFACES
Contents
1. Section A A 1215 0 2 0 26 lt cn 91192 61134 0 5 150 25 L 20 R1 5 0 3 5 enuen sasn 2142A YOUNe SAEs 6 LM 3A Series Launch Vehicle User s Manual 5 3 2 3 1194A Interface Encapsulation on Pad The 1194A adapter for Encapsulation on Pad is a 650 mm high truncated cone see Figure 5 4 and Figure 5 5 Figure 5 4 Payload Adapter with 1194A Interface 5 3 2 4 1194A interface Encapsulation in BS3 The 1194A adapter for encapsulation in BS3 is a 450 mm high truncated cone see Figure 5 6 Issue 2011 5 5 9 1102 enss lt 5 Wy6LL 6 6 Springs 2 Microswitches section A A ae 1215 0 15 03 1184 28 0 5 1131 0 5 0 25 0 1 19 Detail A 2 Umbilical Connecters Detail A 0 2 45 0 5 0 3 enuen sasn 2142A YOUNe SALES 6 1102 5 2 9 659 9 6 Y 2 Umbilical Connecters Z 6 Separatio Springs Detail A 5 21 0 15 Section 1215 0 15 1184 28 0 5 01131 0 5 Detail om 1209 170 D 0 13 54 003 5 0 245 0 2x45 0 5 0 3 0 5 0 3 0 2x45 VA RO lt L 7 151 46 R3 1 6 enuen sasn 2149A YOUNe SAEs 6 LM 3A Series Launch Vehi2. SC Umbilical Cable Configuration Issue 2011 LM 3A Series Launch Vehicle User s Manual A RF Window gt 702 0 POTT P02 _ a 2 Umbilical Tower FER 852 Building 10607 350m KKI 44 BOX BOX2 TM TC Unit H Ethernet I 2 Connectors sires C Tobe provided by SC side Power Room Figure 5 9 SC RF Links amp Umbilical Cables 5 4 2 In Flight Disconnectors Two sets of In Flight Disconnectors IFDs are required and are symmetrically mounted outside the top ring of the Payload Adapter PLA The exact location and clocking will be coordinated between customer and CALT and defined in the ICD It is normal practice for customer to select the IFDs In such cases it is advisable that the customer supply the launch vehicle portion of IFDs including installation tools to CALT IFDs manufactured by DEUTSCH Engineered Connecting Devices are recommended see Table 5 1 while the Chinese made YF8 64 are also available if selected Table 5 1 IFDs LV Side SC Side 01 08179 7 401 D8174E37 OSN 02 D8179E37 OPY 402 D8174E37 OSY Notes The IFDs will be totally disconnected when the two halves have separated from each other by 13 5 mm The customer can also select other products by Deutsch as required e g the DBAS7061 which is manufactured by cold press processing 5 4 3
3. This separation signal will be sent to the launch vehicle telemetry system through the EY1 interface The break wires allow a maximum current of 100 mA and a maximum voltage of 30 V Figure 5 10 shows an example the break wire circuitry 5 16 Issue 2011 LM 3A Series Launch Vehicle User s Manual Break wire ce 01 SC Side Pot 32 LV Side Break wire Break wire Break wire we a6 ai se Site P02 LV Side Break wire Break wire Figure 5 10 An Example of Separation Signals amp Break wires There are also two micro switches on the PLA to give the mechanical separation signal which is also sent to the launch vehicle telemetry system 5 4 5 Ground Umbilical Cables a Configuration The ground umbilical cables are cables from the WXTC to COTE in the FER which are shown in Figure 5 9 and the functions are shown in Table 5 3 Issue 2011 5 17 LM 3A Series Launch Vehicle User s Manual Table 5 3 Ground Umbilical Cable Functions WXTC is the umbilical cable connector LV Ground whose female half socket is installed at the VEB while the male half pin is attached to the top end of ground cable The disconnection of WXTC is electrically controlled The disconnection is powered by the mean time forced disconnection is also used as a back up separation method Generally WXTC disconnects at about
4. 10 minutes WXTC prior to launch If the launch was terminated after the disconnection WXTC could be reconnected within 30 minutes The SC should switch over to internal power supply and cut off ground power supply at 5 minutes prior to WXTC disconnection Therefore during disconnection only a low current monitoring signal such as 30 V lt 100 mA is permitted to pass through the WXTC BOX1 is a box adapter for the umbilical cable that is located inside the SC Cable BOX1 Measurement Room on floor 8 5 of the umbilical tower If needed BOX1 can provide more interfaces for the connection with SC ground equipment FER BOX2 is another box adapter for the umbilical cable that is located inside the SC 2 FER on ground The SC ground support equipment are also located inside the b Ground Interface The customer determines the requirement for the ground interface but normally there are two ground interfaces for the satellite test console J11 amp J12 The detailed requirements for these ground interfaces shall be jointly agreed by customer and CALT See Table 5 4 CALT typically prepares short interface cables so the customer is required to provide the mating half of the connectors J11 amp J12 for the cables that interface with the satellite ground equipment Table 5 4 Ground Interfaces for Satellite Test LV side interfaces f To be defined by SC side If the customer cannot provide the connectors there are two
5. C60 is required between the lowest point on the satellite and the separation plane after installation If that cannot be achieved there should be a minimum clearance of gt 20 mm between the lateral restraining springs and the lowest point on the satellite 5 4 Electrical Interfaces 5 4 1 Summary CLTC and CALT provide the RF link and the umbilical link between the satellite and the satellite Electrical Ground Support Equipment EGSE after the satellite is mated with launch vehicle These links allow the customer to conduct pre launch testing and monitor the satellite during the launch count down The schematic of the umbilical cable and RF links between the satellite and the EGSE is shown in Figure 5 8 and Figure 5 9 The umbilical cable is designed and manufactured by CALT to meet the requirements of the customer based on their satellite platform The 350 m cable from FER to the Umbilical Tower and the hardware labeled EB26 EB36 BOX3 and Power supply 1 amp 2 are common to all missions The umbilical cable integral to the launch vehicle plus the ground facility cable from WXTC to ED10 ED12 ED13 ED14 BOX1 2 will be designed specifically for customer Issue 2011 5 13 5 14 013 aS A AA OR To BOX3 amp RF Link LM 3A Series Launch Vehicle User s Manual Figure 5 8 Provided by SC Umbilical Tower r BOX2 COTE le
6. options available provide the interface cables with each wire labeled with a number in accordance with the pin assignment of the connector for installation into the customer s connectors when available The second option is for the customer to manufacture this cable and provide it to CALT which case CALT will provide the mating set of connectors for BOX2 in Figure 5 8 The length of this cable is approximately 5 m 5 18 Issue 2011 LM 3A Series Launch Vehicle User s Manual 5 4 6 Shielding and Grounding 5 4 6 1 Shielding In order to protect against lightning and stray voltages the following measures have been implemented a The ground umbilical cable has two shielding layers The outer shielding is for protection against lightning and the inner shielding is for EMI protection b The ground umbilical cables from WXTC to BOX2 have a grounding point every 20 meters for the outer shielding layer to ensure that any charge buildup from a lightning strike or other inductance can be discharged immediately c After the umbilical connectors are mated the cable shielding is automatically connected to the launch vehicle shell structure d The inner shield has a single ground The inner shields of the umbilical cables onboard launch vehicle are connected to BOX2 e The inner and outer shields are insulated from each other within the cables 5 4 6 2 Continuity of Satellite Grounding The satellite s
7. In Flight Disconnectors Characteristics The customer shall specify all the characteristics of the IFDs including the pin assignments Issue 2011 5 15 LM 3A Series Launch Vehicle User s Manual usage maximum voltage maximum current one way maximum resistance type and pin assignment of connectors to be mated with the ground equipment etc CALT will design the umbilical cable according to the above requirements which will also be defined in the ICD 5 4 4 Umbilical Cable Onboard Launch Vehicle a Configuration The umbilical cables onboard the launch vehicle are cables from the IFDs P01 P02 to WXTC which will fly with launch vehicle See Table 5 2 Table 5 2 Umbilical Cable Mechanical technological interfaces between 2 PLA and LV Interface between umbilical cable and LV TM EY system through which the SC LV IFD J01 P01 J02 P02 separation signal is sent to LV TM system WXTC Umbilical cable connector type JF5 231 G Grounding points to connect the shielding of the wires to the shell of the LV b Separation Signal The separation signal is generated through break wires on the IFDs P01 amp P02 The satellite will receive the separation signals once the break wires are disconnected upon separation In addition there are another two break wires on the IFDs J01 amp J02 that will generate the separation signal for the launch vehicle once the break wires are disconnected upon separation
8. LM 3A Series Launch Vehicle User s Manual CHAPTER 5 MECHANICAL AND ELECTRICAL INTERFACES 5 1 Introduction This Chapter defines the mechanical and electrical interfaces between the satellite and the LM 3A Series launch vehicles The mechanical interface is to mate the satellite with the launch vehicle via the Payload Adapter PLA The electrical interface electrically connects the satellite with launch vehicle and satellite ground support equipment 5 2 Satellite Reference Axes The satellite coordinate system shall be aligned with the coordinate system of the LM 3A Series launch vehicle as shown in Figure 5 1 Center of Gravity 21 Figure 5 1 Series Launch Vehicle Coordinate System Issue 2011 5 4 LM 3A Series Launch Vehicle User s Manual 5 3 Mechanical Interface 5 3 1 Introduction The satellite is mounted on the launch vehicle through the Payload Adapter PLA which is mated with the VEB by bolts The top ring of the PLA Is the primary mechanical interface with the satellite which is attached to the PLA via a clampband The PLA also includes the separation springs separation sensors and the umbilical connectors 5 3 2 Payload Adapter LM 3A Series launch vehicle uses the international standard adapter types 937B 1194 and 1194A to interface with the satellite These are flight proven adapters and all include the separation system and umbilical brackets Oth
9. able tension force for cutters is 45 kN and for the explosive bolt the margin is much greater The V shoes which are made of high strength aluminum are used for clamping the interface ring of the satellite to the top ring of the Payload Adapter PLA The lateral restraining springs are used for restraining the outward movement of the clampband and the longitudinal restraining springs restrict the movement of the clampband toward the satellite after clampband release The two halves of the clampband are therefore restrained to the PLA below the separation plane to avoid re contact The separation spring assembly is mounted on the PLA providing a separation velocity of 0 5 m s or greater and can also provide a lateral axis spin rate of less than 3 0 deg s the spin rate being dependent on the customer s requirement 5 3 3 3 Installation Requirements During the installation of the clampband system 10 strain gauges are installed on each half 5 12 Issue 2011 LM 3A Series Launch Vehicle User s Manual of the clampband so that the strain and pretension at each measuring point can be monitored in real time A special purpose tool is used to apply the pretension which is normally in the range of 24 30 kN The pretension can however be adjusted to meet the specific requirements of the satellite and the results of the coupled load analysis For both C100 and C60 clampband a minimum clearance of 2 85 mm for C100 and 2 60 mm for
10. aration Mechanism Issue 2011 5 9 LM 3A Series Launch Vehicle User s Manual SC Bottom Line EEE oti i 1 a C60 Clampband 60 Figure 5 7b C60 Separation Mechanism Figure 5 7c C60 Mechanism 5 10 Issue 2011 LM 3A Series Launch Vehicle User s Manual Section Rotated 1155 section A A N Assembly Vx Restraining Springs gt C Back Ring Clampband Assembly LA 272 SC Interface Ring LV Payload Adapter LV Payloac Adapter Pushing Pod Separation Spring Before Separation Section A A Pushing Pole Separation Spring j Ue 4 2 LV Payload Adapter LV ag Adapter Micro Switch a After Separation 5 Separation Spring Issue 2011 5 11 LM 3A Series Launch Vehicle User s Manual Dynamic Envelope Clampband i 1495 mamas a Clampband Explosive Bolts Cutters Note The figure refers to the Dynamic Envelope of Clampband 1194 1194A Figure 5 7e 1194 1194A Clampband The non contamination explosive bolts and explosive cutters are fully redundant with each bolt or cutter having two igniters The maximum allow
11. cle User s Manual 5 3 3 Separation System 5 3 3 1 Satellite to Adapter Separation System The separation system uses a clampband to firmly install the satellite to the Payload Adapter PLA and reliably release the satellite from the launch vehicle upon separation The separation mechanism mounted on the adapter provides the relative separation velocity between the satellite and launch vehicle via separation springs The separation system is shown in Figure 5 7a Figure 5 7 0 Figure 5 7c Figure 5 7d and Figure 5 7 5 3 3 2 Separation Mechanism The separation mechanism consists of a clampband the non contamination explosive bolts or cutters V shoes and retention springs The clampband consists of two halves made of high strength steel There are two models of clampband available the C100 model which is 100 mm wide and uses two explosive bolts see Figure5 7a and C60 model which is 60 mm wide and uses two explosive cutters see Figures 5 7b and Figure 5 7c 5 8 Issue 2011 LM 3A Series Launch Vehicle User s Manual oc 5 S 95 8 55 Z m7 2 gt A lt 2 e 2 _ 2 2 oa 2 Jom 1 lt ss 3 of 5 5 Ot J om i Ts i WD Clampband Assembly Figure 5 7a 100 Sep
12. er interfaces can also be accommodated through technical coordination with 5 3 2 1 937B Interface Encapsulation on Pad The 937B mechanical interface is the upper part of 937B interface adapter which is a 900 mm high truncated cone Refer to Figure 5 2 The top ring which interfaces with the satellite is made of high strength aluminum alloy 5 3 2 2 1194 Interface Encapsulation on Pad The 1194 interface adapter is a 650 mm high truncated cone with top ring diameter of 1 215 mm Refer to Figure 5 3 The top ring which interfaces with the satellite is made of high strength aluminum alloy 5 2 Issue 2011 1102 anss 6 9 9 66 Z S 4 2 Umbilical 2 Switches Z 4 Separation Section A A 945 26 0 03 05 a a 025 L 045 A moe A A A LA 4 p gt G F in 4 2 y Ae etai LIS PPM a 2 vs y ee 5 es 4 4 foyer 4 2 2 r yy if NZ 0876 9 0 25 Detail A enuen sasn 2142A YOUNe SAEs 6 v S 1102 enss PELL 6 Separation Springs Z 2 Umbilical Connecters 7 2 Explosive Bolts
13. fication 5 8 1 Satellite AIT During the satellite AIT program and prior to final acceptance for delivery to the launch site a full mechanical and electrical fit check can be performed This interface verification or SC LV fitcheck is mandatory for all satellite platforms that have not previously been launched with the LM 3A Series launch vehicles The primary objective of the test is to verify that the mechanical interface is correct the electrical interfaces are compatible and all the connectors and arming plugs can be accessed This fitcheck can then be followed by a SC LV separation shock test to verify if the satellite could be separated from the Payload Adapter PLA properly within the required shock level The SC LV fitcheck and separation shock test is typically performed at the satellite manufacturers facility using the flight adapter and separation system provided by 5 8 2 Launch Site Interface Verification The electrical and RF interfaces between the satellite and each site for satellite processing including those where the satellite is mated to the launch vehicle shall be validated prior to the satellite moving to a new facility and after its arrival at a new facility This verification is to be performed whenever the umbilical connecters are disconnected and reconnected Issue 2011 5 21 LM 3A Series Launch Vehicle User s Manual 5 8 3 Satellite EGSE Interface Verification There are typically two sets
14. hall have a ground reference point close to the separation plane The resistance between all other metal parts of satellite shell structures etc and the reference ground shall be less than 10 mQ for a current of 10 mA In order to maintain the continuity of the grounding the bottom of satellite structure to be mated with the Payload Adapter PLA shall not be treated with any protective process that would affect its ability to meet the resistance requirements between the satellite and PLA 5 5 Satellite Constraints The satellite shall not transmit any remote signal that could be dangerous or interfere with the launch vehicle flight until the satellite has been completely separated from the launch vehicle The satellite shall not start its automated post separation program until it receives the separation signal from the launch vehicle 5 6 RF Links Issue 2011 5 19 LM 3A Series Launch Vehicle User s Manual 5 6 1 RF Relay Path The launch site can provide an link between the Satellite Test Equipment STE and the SC whenever the SC is in BS or at the launch pad The RF link equipment is set up between BS2 and the launch towers It provides uplink and downlink RF channels that can connect the STE with the SC and transmit the test and control signals when the SC is mated to the launch vehicle at the launch pad The RF system uses optical fiber to transmit and receive the signals 5 6 2 Characteristics and Interface of RF Lin
15. k a Frequency The optical fiber of the RF system allows the transmission of 350 MHz to 15 GHz signal while the microwave processing unit allows the transmission of signals in UHF L S C Ku and X bands b Signal Level The signal level interface between RF system and STE is shown in Table 5 5 Table 5 5 Signal level interface between RF system and STE Ku 5 7 Post Encapsulation Interfaces 5 7 1 Payload Usable Volume The payload usable volume is the area within the fairing that is available to accommodate 5 20 Issue 2011 LM 3A Series Launch Vehicle User s Manual the satellite when mounted on the Payload Adapter PLA of the launch vehicle This represents the total maximum envelope available for the satellite and includes all manufacturing tolerances thermal protection satellite appendages etc and also includes the dynamic tolerances based on results of the standard coupled loads analysis If the satellite has appendages that protrude to outside the usable envelope they shall be reviewed during the ICD and Mission Reviews If the protusions are found after these satellite appendages have been completed a special review shall be held to resolve the issue 5 7 2 Satellite Access The satellite can be accessed while in the fairing via special access doors on the fairing as agreed in the ICD The satellite can be accessed up until Launch 2 hours after which time the fairing is sealed 5 8 Interface Veri
16. of EGSE One set is permanently located in BS2 that is used as the primary system for controlling the satellite The second set moves with the satellite and functions as a remote test interface with the satellite The interfaces of this EGSE shall be verified prior to its arrival at the launch site and following each move at the launch site The interfaces with the launch site facility are defined in Chapter 7 5 22 Issue 2011
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