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This paper presents the shock test results achieved in the MER ARA/brush motor pyroshock qualification. The results of MER flight system pyrofiring tests in comparison with the ARA shock test requirements are discussed herein. Alternate test methods were developed in an effort to qualify the critical MER equipment for adequate performance in the actual flight pyroshock condition.
There are several methods of shock testing that are commonly used by the aerospace industry to qualify flight hardware to pyroshock environments. In some cases the shock results and in particular the shock response spectra computed from these tests were interpreted in such a way as to satisfy the testing requirements and were often considered successful for flight hardware qualification. However, close scrutiny of these acquired shock data suggest gross violation of the pyroshock qualification requirements. There are several issues, both in terms of the shock generation mechanisms and the shock signature acquisition and analysis that have led to improper qualification of flight hardware. In this paper some factors contributing to the misinterpretation of the shock data are reviewed. First, issues with the hardware fixturing and instrumentation that may lead to incorrect shock testing are discussed. Second, issues facing the shock simulation systems and pyrotechnic testing are reviewed. Finally, issues pertaining to the data acquisition and analysis are briefly discussed.
Motivation: (1) The activation of pyroshock devices such as explosives, separation nuts, pin-pullers, etc. produces high frequency transient structural response, typically from few tens of Hz to several hundreds of kHz. (2) Lack of reliable analytical tools makes the prediction of appropriate design and qualification test levels a challenge. (3) In the past few decades, several attempts have been made to develop methodologies that predict the structural responses to shock environments. (4) Currently, there is no validated approach that is viable to predict shock environments overt the full frequency range (i.e., ~100 Hz to 10 kHz). Scope: (1) Model, analyze, and interpret space structural systems with complex interfaces and discontinuities, subjected to shock loads. (2) Assess the viability of a suite of numerical tools to simulate transient, non-linear solid mechanics and structural dynamics problems, such as shock wave propagation.
Shock response spectra data from flight certification tests were analyzed to determine envelope variation with respect to mean values in each axis. An overall variation of + or - 8.61 dB or 169 percent exists for the data. This large variation may be attributed to one or more of the following: (1) Instrumentation problems may exist. (2) Variations in the source charge (blasting caps) such as shape or explosive load may exist. (3) Two blasting caps were used to excite the pyrotechnic plate tester. Delay time between charge firings may have varied. The cause or causes of the variations need to be identified and researched to prevent future pyroshock problems.
Resonant plate testing is a shock test method that is frequently used to simulate pyroshock events in the laboratory. Recently, it was discovered that if the unit under test is installed at an off-center location, a tri-axial accelerometer would record a shock response in three directions and the resulting shock response spectra implied that the test may have qualified the component in three directions simultaneously. The purpose of this research project was to evaluate this idea of multi-axis shock testing to determine if it was truly a multi-axis shock environment and if such a test could be used as an equivalent component qualification test. A study was conducted using generic, additively manufactured components tested on a resonant plate, along with an investigation of plate motion to evaluate the component response to off- center plate excitation. The data obtained here along with the analytical simulations performed indicate that off-center resonant plate tests are actually not three-axis shock tests, but rather single axis shocks at an arbitrary angle dictated by the location of the unit under test on the plate. This conclusion is supported by the fact that only one vectored shock input is provided to the component in a resonant plate test. Thus, the output response is a coupled response of the transverse plate vibration and the rotational motion of the component on the plate. Additionally, a multi-axis shock test defined by three single axis test environments always results in a significant component over-test in one direction.
An analytic approach is demonstrated to reveal potential pyroshock-driven dynamic effects causing power losses in the Thermo-Electric (TE) module bars of the Mars Science Laboratory (MSL) Multi-Mission Radioisotope Thermoelectric Generator (MMRTG). This study utilizes high-fidelity finite element analysis with SIERRA/PRESTO codes to estimate wave propagation effects due to large-amplitude suddenly-applied pyro shock loads in the MMRTG. A high fidelity model of the TE module bar was created with approximately 30 million degrees-of-freedom (DOF). First, a quasi-static preload was applied on top of the TE module bar, then transient tri-axial acceleration inputs were simultaneously applied on the preloaded module. The applied input acceleration signals were measured during MMRTG shock qualification tests performed at the Jet Propulsion Laboratory. An explicit finite element solver in the SIERRA/PRESTO computational environment, along with a 3000 processor parallel super -computing framework at NASA AMES, was used for the simulation. The simulation results were investigated both qualitatively and quantitatively. The predicted shock wave propagation results provide detailed structural responses throughout the TE module bar, and key insights into the dynamic response (i.e., loads, displacements, accelerations) of critical internal spring/piston compression systems, TE materials, and internal component interfaces in the MMRTG TE module bar. They also provide confidence on the viability of this high-fidelity modeling scheme to accurately predict shock wave propagation patterns within complex structures. This analytic approach is envisioned for modeling shock sensitive hardware susceptible to intense shock environments positioned near shock separation devices in modern space vehicles and systems.