11D-12-1807

www.dynetics.com

1D-12-1807

Barry KingDirector, Space Test & OperationsDynetics, Inc.256-713-5624barry.king@dynetics.com

Integration & Test of Complex Programs (Commercial Perspective)

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A Complex Commercial Program

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Integration 101 Questions

Where are we in the Program Life cycle Pre-Phase A – Phase F

What are we doing? Objectives/Requirements – Needs, Goals, and Objectives (NGOs)

When are we doing it? Schedule/Resources

Who is doing it? Program, System, Elements

How are we doing it? System/Element Relationships

Work Breakdown Structure

Where are we doing it? (Design, Factory, SIL, Field)

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Program Integration Road Map

Life Cycle Phases

Technical

Descriptions

Process

Pre-

Phase AConcept

Studies

Phase AConcept &

Technology

Development

Phase BPreliminary

Design &

Technology

Completion

Phase CFinal

Design &

Fabrication

Phase DSystem

Assembly,

Integration

Test, & Launch

Phase EOperations

&

Sustainment

Phase FCloseout

Key Decision

Points

Milestones

Guiding

Documentation

Major Events

Development, Verification, Test, Validation, Mission

KDP A KDP B KDP C KDP D KDP E KDP F

SRRMCR SDR PDR CDR SIR FRR

DoD

&

NASA

ORD, CRD, SEMP, SDD, IDD TEMP ITP/CEP

TRD

DAC Cycles

CONOPS

SEMP

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What are we doing?

Objectives/

Requirements

NGO’s

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Stakeholder Needs, Goals, and Objectives (NGOs)

Stakeholder NGO’s NGO Statement

NGO #1:

LV Class

To develop a launch system that delivers NLT XX lbm payload

NGO #2:

Ascent Options

To develop a launch system that provides multiple ascent target

options for the customers, including LEO, GTO, Polar-SSO

NGO #3:

Launch Site Flexibility

To develop a launch system that provides multiple launch site

options to the customers

NGO #4:

Responsiveness

To develop a launch system that is highly responsive to market

and customer needs – Launch turn around within XX hours

NGO #5:

Cost Ceiling

The program shall develop the system for less than $TBD

NGO #6:

Operability Date

The system shall achieve operability by the end of 20XX.

The NGO’s set the basis for answering the question of what we are trying to do!

It is the key starting point for a program and Level 1 requirements

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Integrated Test

Approach

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Need for Early Integration

Design Engineering Test Integration

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Documentation Relationships

SEISEMP

V&V Plan

Requirements

Integrated Test Design

System Safety

CONOPs

Test Plans

Flight & Ground Operations

Missions sequences and checklists

Range Safety, Procedures and

Limitations

ITO

The SEI-ITO

Integration Link

These documents and relationships must be mapped early in the

program, and executed in the SEMP, TEMP, ITP, etc.

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Complex Integration Deduction

SEI

ITO

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Integrated Test & Verification Flow

Element

#1

Testing

Transport

to MOB

Transport to MOB

Run

IVT

Ground/Air

Fuel LV

Flight Day

Conduct FRR

Mate

Elements

Mate

Elements

Run

IVT

Mate

Elements

System

Level

Testing

Element

#2

Testing

LV

Element

Testing

Payload

Element

Testing

Run

IVT

Element Level Testing – Performed as subsystems

and components are integrated to verify compatibility

and functionality across interfaces. Planned and

executed by Elements

Integrated Verification Tests – Performed as elements

are integrated with other elements to verify compatibility

and functionality. Planned and executed by SEIT.

System Level Tests –

Performed to verify and validate

the fully integrated system.

Transport to MOB

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Top Level Interfaces

GHE/

GSE

Element

Launch

Vehicle

Aircraft

Launch

Vehicle Aircraft

Electrical Umbilical

Mech / Lifting

Elec / Simulator

Elec / Simulator / Umbi

Propulsion Systems check out - ?

GPS / NAV

TM / H&S / BIT

Commanding / Arm

Payload H&S / Commanding - ?

Mechanical / Umbilical

Layout / Path

Connector / Umbi De-Mate

Attach Points

Release Mechanism

Propulsion

Fuel Dump

H&S / Top Off - ?

RF

Command & Control

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Test Levels

Element Level Testing ELTs will be performed as subsystems and components are integrated to

verify compatibility and functionality across interfaces

Planned and executed by the Element SE&I with delivery and approval of

Acceptance Data Packages (ADPs)

Integrated Verification Tests IVTs will be performed as elements are integrated to verify compatibility

and functionality across interfaces

Planned and conducted by the System Integration and Test Group

System Level Testing (Integrated Flight Elements) SLTs will be performed to verify and validate the fully integrated system

Planned and conducted by the System Integration and Test Group

V&V Report will define the specific details needed to document the

data and analysis necessary to close out the requirement Traceable to requirements in Requirements Database

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System Level Integrated Testing

Integrated Ground Vibration Test Verifies modal response in a controlled ground test environment

Captive Carry Integration testing to collect vibration, loads and modal data in order to

verify predictions and models

Taxi test to verify proper functionality and range operations procedures

Integrated Range Test (IRT) Test functionality and compatibility with the range (ground or air)

Ensures all data interfaces, tracking systems (C, S and UHF), and

communications are compatible/operational prior to mission

Countdown Demonstration Test (CDT) Exercise the complete system on the ground through a controlled,

pre-planned sequence of events

ALS System and all Range assets operated in a realistic countdown scenario

Flight Demonstration Tests (FDTs) Dress rehearsal executing the entire range of expected flight and

contingency operations

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Integrated

Operations

Approach

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Mission CONOPS

Launch Site Selection

Primary operating base

Secondary locations

Polar/Equatorial orbit insertion

DRM Design and Trades

Stage impact

Debris footprint

NOTAMS and aircraft/ship traffic

International Law

Ground Station Placement

Portable TM Stations

Infrastructure

Data transmission and handling

Mission Timeline

Ground ops

Taxi/Takeoff

Cruise and TSP establish

Launch and ascent

Return to base

Contingency Planning

Abort – scrub

Fuel dump – jettison

Divert locations

Site surveys

Security

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Mission Phases

Mission CONOPS or Phases Must Be Considered During

Design and Development

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Keys To Success

In order to have a successful program, all levels of requirements

must be linked and verifiable along the way Analysis, model or test

Most common and impacting mistakes Not base lining and/or having fluid requirements

• Treat them like LCCs

The design team must include integration and test personnel

Letting design engineers be involved too long

Using 65% of the schedule for development and 35% for ITO

Discipline and completeness is achieved from experience and not just

from a process or procedure• Getting “help” in the wrong areas following a failure

• Lack of real program integration and execution experience

If you have not screwed it up at lest once, then you have no experience

• SE, Quality, Safety areas are not the program, they are aspects of the process

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Back-Ups

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SIL Approach & Critical Uses

Element Interfaces - The SIL is necessary to simulate/replicate the elements software and/or hardware functionality in order to verify the interface and performance specs early in the program and throughout the life cycle.

Element and/or System Interaction - The SIL software and hardware is necessary to simulate the interactions and mission profiles between the elements and the system as a whole, in order to train the individual operators and the entire flight operations team

Flight Software Test & Verification- The SIL tests and verifies in a configuration controlled environment, the software delivered by the element teams prior to certification and use in a flight operations environment

Fault Insertion & Data Reduction (FDIR) - The SIL software and hardware can/will manipulate system and subsystem inputs in order to observe and analyze the results, leading to the establishment of limits and launch commit criteria.

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Integrated Test Flow