DESCRIPTION
Page No.
LIST OF AMENDMENTS
4
LIST OF ABBREVIATIONS
5
LIST OF FIGURES
6
LIST OF TABLES
7
1. SCOPE
8
2. CROSS REFERENCE DOCUMENTS
9
2.1.
LIST OF APPLICABLE STANDARDS
9
2.2.
LIST OF APPLICABLE DOCUMENTS
9
2.3.
LIST OF ENGINEERING DRAWINGS
10
3. DESCRIPTION & SPECIFICATION
3.1.
12
DESCRIPTION OF THE SYSTEM
12
13
3.1.2. GEAR TRAIN ASSEMBLY
13
3.1.3. LINEAR VARIABLE DIFFERENTIAL TRANSFORMER
13
3.1.4. DSP BASED ‘DUAL CHANNEL’ SERVO CONTROLLER
13
3.1.5. KINEMATIC MECHANISM
13
3.1.6. MIRROR IMAGE SENSOR
14
3.1.7. TACHO GENERATOR
14
3.1.8. BALL SCREW MECHANISM
14
3.2.
3.1.1. BRUSH LESS DC MOTOR
TECHNICAL SPECIFICATION
15
3.2.1. ACTUATOR SPECIFICATION
15
3.2.2. BRUSH LESS DC MOTOR
15
3.2.3. GEAR TRAIN ASSEMBLY
15
3.2.4. LINEAR VARIABLE DIFFERENTIAL TRANSFORMER
16
3.2.5. DSP BASED ‘DUAL CHANNEL’ SERVO CONTROLLER
16
3.2.6. MIRROR IMAGE SENSOR
17
3.2.7. TACHO GENERATOR
17
3.2.8. BALL SCREW MECHANISM
18
4. BILL OF MATERIAL
19
1
5. BILL OF MATERIAL FOR DIGITAL CONTROLLER
22
6. PROCESS FLOW
23
6.1.
PROCESS FLOW CHART
23
6.2.
PROCESS FLOW DESCRIPTION
24
7. INWARD GOODS INSPECTION
25
7.1 TEST PROCEDURE
25
7.2 TEST FORMATS
28
8. QUALIFICATION & ACCEPTANCE TESTS
8.1 INTRODUCTION
9.
35
35
SAFETY OF FLIGHT & ENVIRONMENTAL STRESS SPECIFICATION 36
9.1 RANDOM VIBRATION TEST
36
9.2 LOW PRESSURE,LOW TEMPERATURE & HIGH TEMPERATURE TEST
9.3 BURN IN TEST
37
9.4 DAMP TEST
38
9.5 ACCELERATION TEST
38
9.6 SHOCK TEST
39
9.7 EMI/EMC TEST
40
9.8 TEST PLAN
40
9.9 GUIDELINES IN CASE OF FAILURE DURING SOF
41
10. QUALIFICATION TESTS
42
10.1TEST PROCEDURES
42
10.1.1 GENERAL ASSESSMENT
42
10.1.2 FUNCTIONAL TESTS
42
10.1.3 ENVIRONMENTAL TESTS
43
10.1.4 EMI/EMC TESTS
44
11. TEST PROCEDURES
45
12.TEST FORMATS
47
13. ACCEPTANCE TESTS
51
13.1 TEST PROCEDURES
51
13.1.1 FUNCTIONAL TESTS
51
13.1.2 ENVIRONMENTAL TESTS
51
2
13.2 SPECIFICATIONS FOR ESS/AT
52
13.3 TEST FORMATS
53
14. FORMAT FOR QT/AT CONFORMANCE REPORT
55
15. SAFETY REQUIREMENTS AND REGULATIONS
57
16. PAKAGING & HANDLING
57
16.1HANDLING
57
16.2PACKAGING
57
17. FORWARDING/TRANSPORTING
57
18. STORAGE REQUIREMENTS
58
19. APPLICATION REQUIREMENTS
58
20. VITAL REPORTS TO BE ASSERTAINED
58
21. CONCLUSION
59
APPENDIX A
60
APPENDIX B
61
APPENDIX C
65
APPENDIX D
66
APPENDIX E
66
APPENDIX F
67
3
LIST OF AMENDMENTS
Serial No.
Description
Amendment no.
Authority
Date
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
P.S.: Information about amendment as and when received should be recorded
4
Page no.
LIST OF ABBREVIATIONS
Abbreviations
Expansion
DSP
Digital signal processor
FNC
Flex nozzle control
FRA
Frequency response analyzer
EMAS
Linear Electro-mechanical actuation system
LVDT
Linear variable differential transformer
MIS
Mirror Image sensor
OBC
On-board computer
PM-BLDC
Permanent magnet Brushless Direct Current Motor
QA
Quality assurance
QC
Quality control
Re-Co
Rare earth cobalt
5
LIST OF FIGURES
Figures
Description
Fig.1
Linear electromechanical actuation system
Fig.2
Kinematic connection of EM Actuator and MI Sensors
Fig.3
Diagrammatic details of ball screw for transmission
Fig.4
Electrical schematic of actuation system for ENTEST
Fig.5
Electrical schematic of actuation system for EMI/EMC
6
LIST OF TABLES
Tables
Details
Table-3.1
Technical specifications of ACTUATOR
Table-3.2
Technical specifications of Brush less DC Motor
Table-3.3
Technical specifications of Gear train assembly
Table-3.4
Technical specifications of LVDT
Table-3.5
Technical specifications of Digital controller
Table-3.6
Technical specifications of Mirror Image Sensor
Table- 3.7
Technical specifications of Tacho generator
Table-3.8
Technical specifications of Ball Screw
Table-4.0
Bill of material
Table-5.0
Process flow description
Table-6.0
Environmental tests
7
1.0 SCOPE
Control Systems Laboratory at Research Centre Imarat has taken the task of
design, development, testing and delivery of Linear Electro-mechanical Actuation
System for stage 1 Flex Nozzle based Thrust Vector Control of Nirbhay according to
the proposed specifications and the applicable military standards.
Linear electro-mechanical actuation system uses brush less dc motor with halleffect sensors and the reduction gear-train assembly along with a LVDT and DSP
based control electronics to meet required specifications
This QA plan has been prepared in association with the directorate of R & QA,
Research Centre Imarat to bring out the centered specifications, the inspection
requirements, QT/AT requirements and the formats for all these tests along with the
set of reports.
8
2.0 CROSS REFERENCE DOCUMENTS
2.1 LIST OF APPLICABLE STANDARDS
1.
IS 733/734: Specifications for Wrought Aluminum and aluminum alloy bars
2.
SAE-AMS-5659 L: Specifications for 15-5 PH steel
3.
MIL-STD-461E
4.
MIL-STD-810E
5.
JSS 55555
2.2 LIST OF APPLICABLE DOCUMENTS
1.
Preliminary Design Document Actuation System of Flex Nozzle Control
System: Doc. No. RCI/CSL/NIR/PDR/001, Dated Sept 2007
2.
SOF specifications issued by ADE Bangalore/ Project Nirbhay.
9
2.3 LIST OF APPLICABLE ENGINEERING DRAWINGS WITH ASSEMBLY
CHART:
10
11
3.0 DESCRIPTION & SPECIFICATION
3.1.
DESCRIPTION OF THE SYSTEM
Power to ALL
electronics
(28 V, 5 A)
Test PC/OBC
(Digital
Command)
FRA
(Analog
Command)
P-Axis
EMA & MIS
Controller
Y-Axis
EMA & MIS
Feedback data
from
EMA & MIS
Power to BLDC
motor
(56 V, 35 A)
Fig (1): Linear electromechanical actuation system
3.1.1. BRUSH LESS DC MOTOR
This uses RE-Co magnet of Sm2Co17 class for 8-pole rotor to give
rise to a radial flux patterns and has 3-phase wound stator of 24 slots from
core material of Co-Fe alloy Rotelloy3 class. While the Sm2Co17 magnet is
selected for its superior magnetic and thermal properties, the Rotelloy3
material has been chosen for its high saturation and permeability values.
12
3.1.2. GEAR TRAIN ASSEMBLY:
Gear train assembly consists of three spur gears. The train provides
two stage reductions with an overall gear ratio of 2.2. These gears have
been designed with sufficient factor of safety for mechanical strength,
surface durability and minimum backlash.
3.1.3. LINEAR VARIABLE DIFFERENTIAL TRANSFORMER:
The LVDT is used for position feedback in the electro mechanical
actuator. The principle of LVDT is based on Faraday’s law of induction.
The primary winding is excited by high frequency sinusoidal signal. The
secondary output is demodulated and converted into DC signal by a
dedicated IC AD698.
3.1.4. DSP BASED ‘DUAL CHANNEL’ SERVO CONTROLLER
The controller is designed as position servo-system with velocity
feedback, wherein LVDT acts as position sensor and 3-phase alternator
works as velocity sensors respectively. Three contact less linear output
hall-effect sensors measure the three phase currents independently.
The controller is built on the DSP processor that calculates the
velocity command as per the designed algorithm and outputs in direction
and magnitude format to generate necessary PWM signals, which are
optically isolated and buffered so as to drive, the MOSFETS.
3.1.5. KINEMATIC MECHANISM:
Two EMAs are mounted on the flex nozzle orthogonally in pitch and
yaw plane. Two MI sensors are mounted diametrically opposite to each
EMA to take care of the misalignment of Flex nozzle. The kinematic
configuration is given below:
13
MIS
EMA
Nozzle
Fig (2): Kinematic connection of EM Actuator and MI Sensors
3.1.6. MIRROR IMAGE SENSOR:
The MI sensor is used as external feedback device to correct the
misalignment due to flex seal compression. The LVDT used within the MI
sensor is a bought out item. Casing and assembly is made indigenously
according to the requirements.
3.1.7. TACHO GENERATOR:
The tacho generator is 3-phase permanent magnet alternator
designed to give desired voltage for rated speed that is used as a velocity
feedback device in the velocity loop of the electro mechanical actuator.
3.1.8. BALL SCREW MECHANISM
The ball screw is used as transmission mechanism in the actuator to
convert rotary motion from the motor to linear motion as required. The
efficiency of ball screw is very high. The ball screw has been designed to
have anti jamming feature.
14
3.2.
TECHNICAL SPECIFICATION
3.2.1 ACTUATOR SPECIFICATION
Table-3.1
Sl. No.
Parameter
Specifications
1.
Type of actuator
Electro Mechanical
2.
Operating Force
5000 N
3.
Stall Force
7000 N
4.
Null Length
220 mm
5.
Stroke
± 25 mm
6.
No Load Speed
150 mm/sec
7.
Band Width, -90°Ø, 10% FS Amp.
10 Hz± 2Hz
8.
Feed Back Element
LVDT
9.
Spherical Bearing dia
8 mm
10.
Spherical Bearing width
10 mm
3.2.2 BRUSH LESS DC MOTOR
Table-3.2
Type
Radial Flux PM BLDC motor
Rated voltage
56 V DC
Rated torque
2.0 N-m
Stall torque
3.0 N-m
Rated speed
4200 rpm
Rated current
35A
3.2.3 GEAR TRAIN ASSEMBLY
Table-3.3
Spur gears
3 nos.
Gear ratio
2.2:1
15
3.2.4 LINEAR VARIABLE DIFFERENTIAL TRANSFORMER
Table-3.4
Make
Sensorex or Equivalent
Stroke
 26 mm
Primary Sine Excitation
2.2 Vrms
Frequency
3.5 kHz
Linearity error
  0.5 % FSO
Operating temp range
 20°C to  125°C
Thermal sensitivity drift
 500 ppm/deg C
Shock Resistance
1000g / 5ms
Vibration survival
12g (PP) up to 2 kHz
Insulation resistance
 500 Mohm
Cable
6 tinned ETFE insulated,
Wire guage 24 & 2m long
3.2.5 DSP BASED ‘DUAL CHANNEL’ SERVO CONTROLLER:
Table-3.5
Type
Digital controller
Channel
Dual channel
Communication interface
Analog and 1553B
DSP processor
TMS320F2812
Power SC devices
200V/185A mosfets
PWM frequency
10 kHz
Rated voltage
56 V
Max.voltage
75 V
Rated current
35 A
Peak current
52.5 A
Position loop
1 m-sec sampling
Velocity loop
200 m-sec sampling
16
3.2.6 MIRROR IMAGE SENSOR
Table-3.6
Make
Sensorex or Equivalent
Stroke
 26 mm
Primary Sine Excitation
2.2 Vrms
Frequency
3.5 kHz
Linearity error
  0.5 % FSO
Operating temp range
 20°C to  125°C
Thermal sensitivity drift
 500 ppm/Deg C
Shock Resistance
1000g / 5ms
Vibration survival
12g (PP) up to 2 kHz
Insulation resistance
 500 Mohm
Cable
6 tinned ETFE insulated,
Wire guage 24 & 2m long
Housing
HE – 15 enclosure to house the LVDT
End fittings
Rod end bearing ID=5mm, width=8mm
3.2.7 TACHO GENERATOR
Table-3.7
Type
3-phase PM alternator
Winding connection
Star connected
Max. Voltage
2.5 V
Max. Speed
7500 rpm
Scale factor
333 mV/rpm
17
3.2.8.
BALL SCREW MECHANISM
Table-3.8
specifications
Parameter
8
Static load Limit
24,500 N
Buckling load of the shaft
66,880 N
Critical speed of the shaft
705,487 rpm
Stiffness
120,500 N/mm
Ball nut shaft outer Dia
27 mm
Ball nut shaft inner Dia
24 mm
Ball nut shaft thread size
M20x1.5
Ball nut shaft threads height
18.5 mm
Ball screw shaft threads height
7 mm
Ball screw shaft inner Dia
14 mm
Ball screw shaft thread size
M18x1.5
7
5
6
4
3
2
1
F
F
E
E
D
D
C
C
BALL THREAD DATA:PITCH (mm)
:
5
NO. OF STARTS
:
SINGLE
HAND OF START
:
R.H.
NO. OF CIRCUITS / NUT
:
3
BASIC
LOAD RATING
B
8
63 09 00 02
SHAFT
63 09 00 01
PART
No.
:
:
:
1220
1855
0.005
SUPPORTING METHOD
:
FIXED-FREE
MAX. ALLOWABLE SPEED (RPM)
:
6000
LUBRICATION
:
DRY LUBRICATION
CHD.
:
:
HRC 38 - 45
HRC 38 - 45
TRD.
:
± 0.004
SCREW (H925 CONDITION)
NUT (H925 CONDITION)
ACCU. REFERENCE LEAD ERROR (±E) (mm)
A
NUT & SLEEVE
1
AXIAL PLAY MAX. (mm)
HARDNESS OF
BALL GROOVE
DYNAMIC LOAD (KGF)
STATIC LOAD (KGF)
2
LEAD VARIATION OVER 300 LENGTH (e300) (mm)
:
0.005 (C1)
LEAD VARIATION OVER FULL LENGTH (e-TOTAL) (mm)
:
0.005
R. No.
DATE
AUTHORITY
ZONE
BRIEF RECORD
DESCRIPTION
DRG.No. / SPEC. No.
1
REV
DRN.
DATE
NAME
26-07-07
KM REDDY
MATL.
CHIEF D'MAN
FINISH
APPD. (DGN)
BALL SCREW
PART LIST No.
ASSY DRG. No.
DRG. No.
Research Centre Imarat
HYDERABAD
Fig (3): Diagrammatic details of ball screw for transmission
18
REMARKS
SCALE : NTS
COMP.
DATED
INITIALS
QTY
DRAWN TO SPEC. IS: 696
DEVIATION FOR UNTOLERANCED DIMENSIONS TO CONFORM TO
SPEC. IS : 2102 MEDIUM
ALL DIMENSIONS ARE IN mm.
B
1
MATL
SHEET
OF
APPD. (DRG)
PART No.
63 00 00 00
4.0 BILL OF MATERIAL:
4.1 Fabrication components for EMA:
Sl. No.
Description
Qty/Assy. Dwg. No.
1.
Body
1 No.
73 01 00 01
2.
Mid Plate
1 No.
73 02 00 01
3.
Eye End
1 No.
73 06 01 01
4.
Motor End Cap
1 No.
73 00 00 04
5.
Shaft End Cap
1 No.
73 10 00 01
6.
Cable Clamp
1 No.
63 00 00 06
7.
Gear
1 No.
73 04 00 01
8.
Idler Gear
1 No.
73 00 00 03
9.
Rotor Shaft
1 No.
73 05 00 01
10.
Rod End
1 No.
63 07 00 01
11.
Adaptor
1 No.
63 07 00 02
12.
Nut-1
1 No.
63 00 00 02
13.
Nut-2
1 No.
73 03 00 02
14.
Nut-3
1 No.
63 07 00 03
15.
Gear Key
1 No.
63 00 00 01
16.
Rotor Key
1 No.
73 05 00 02
17.
Ball Screw Key
1 No.
63 00 00 05
18.
Body Key
1 No.
73 01 00 03
19.
Screw M4
1 No.
73 05 00 03
20.
Tabwasher-1
1 No.
73 03 00 01
21.
Tabwasher-2
1 No.
73 05 00 04
22.
Wiper
1 No.
73 10 00 02
23.
Stator
1 No.
73 01 00 02
24.
Stator Tacho
1 No.
73 01 01 01
25.
Rotor
1 No.
73 05 01 01
19
Remarks
4.2 Bought out components for EMA:
Sl. No.
Description
Qty/Assy.
Dwg.
No./ Remarks
Part No.
1.
Ball Screw
1 No.
63 09 00 00
MTAR
2.
LVDT
1 No.
690100675x
sensorex
3.
Bearing -1 (ACB)
2 Nos.
SNFA EX25
SNFA
4.
Bearing -2 (DGBB)
2 Nos.
SKF619/5-2Z SKF
5.
Bearing -3 (DGBB)
1 No.
SKF6001-2Z
6.
Bearing -4 (DGBB)
1 No.
SKF619/8-2Z SKF
7.
FRE-8 (Spherical Bearing)
2 Nos.
FRE-8
8.
Magnet-1
4 Nos.
73 05 01 02
9.
Magnet-2
4 Nos.
73 05 01 03
10.
Magnet-1 (Tacho)
4 Nos.
73 05 01 04
11.
Magnet-2 (Tacho)
4 Nos.
73 05 01 05
12.
Dowel Pin (4X15)
2 Nos.
4X15
13.
Ch. Hd. Screw M2.5X -6 with 2 Nos.
IS: 1366 &
Spring Washer
IS:3063
Hex. Hd. Nut M6 with Spring 1 No.
IS:1364 Part-
Washer
3 & IS:3063
14.
15.
Allen
Socket
Hd.
Screw 3 Nos.
IS:2269
Hd.
Screw 4 Nos.
IS:2269
Hd.
Screw 8 Nos.
IS:2269
M2.5X -6 L
16.
Allen
Socket
M6X1-88 L
17.
Allen
Socket
M6X1-16 L
18.
Grub Screw M2.5X -8L
2 Nos.
19.
PCB (Taco)
1 No.
20.
Locktite
1 bottle
21.
Locking Wire dia 0.5 mm
2 meters
22.
Potting Compound
1 bottle
20
73 01 01 02
SKF
RWG
23.
Winding wire
Assorted
24.
Hall sensors
3 Nos.
25.
12 gauge PTFE Cables (3 1.5 meter
colors)
26.
each color
24 gauge PTFE Cables (9 1.5 meter
colors)
each color
27.
Shrinkable sleeves
1.5 meter
28.
EMI/EMC shields
1.5 meter
29.
Connector
1 No.
4.3 Fabrication components for MIS:
Sl. No.
Description
Qty/Assy. Dwg. No.
1.
FE Adaptor
1 No.
65 01 00 01
2.
LVDT Housing
1 No.
65 01 00 02
3.
Casing
1 No.
65 02 00 01
4.
Adaptor
1 No.
65 02 00 02
5.
Locknut-2
1 No.
65 02 00 03
6.
Bearing housing
1 No.
65 02 00 01
7.
Lock nut-1
1 No.
65 03 00 01
8.
Retaining ring
1 No.
65 03 00 02
21
Remarks
4.4 Bought out components for MIS:
Sl. No.
Description
Qty/Assy.
Dwg. No./ Part No.
Remarks
1.
LVDT
1 No.
690100675x
Sensorex/
Eq.
2.
Spherical Bearing
1 No.
EN2585 R05A
3.
Rod End bearing
1 No.
FSM 5-5N
4.
Journal Bearing
2 Nos.
EN2288-1515
5.
Ch. Hd. Screw M2.5X - 2 Nos.
IS: 1366 & IS:3063
8 with Spring Washer
6.
Hex. Hd. Nut M6 with 1 No.
IS:1364 Part-3 & IS:3063
Spring Washer
7.
Hex. Hd. Nut M5
1 No.
8.
Shrinkable sleeves
1.5 meter
9.
EMI/EMC shields
1.5 meter
10.
Connector
1 No.
5.0 Bill of Material for Digital Controller:
1. PCB
2. Electronic Components
Interface Details:
Differential/ .......
22
IS:1364 Part-3
RWG
RWG
6.0 PROCESS FLOW
6.1 PROCESS FLOW CHART
EMA, A1
CONTROLLER with
Software, A3
MI SENSOR, A6
QC, A2
QC, A4
QC, A7
LINEAR ELECTROMECANICAL
MIRROR IMAGE SENSOR, A8
ACTUATION SYSTEM, A5
EMAS
WITH MIS, A9
CORRECTIVE ACTION,
IF ANY, A11
QC, A10
INITIAL FUNTIONAL TEST, A12
EVALUATION &
SUGGESTION, A14
ENTEST, A13
ANALYSIS, A?
ANALYSIS, A?
ANALYSIS, A?TEST, A15
FINAL FUNCTIONAL
ANALYSIS, A?
ANALYSIS, A?
A?
CLEARANCE ANALYSIS,
FOR APPLICATION,
A16
ANALYSIS, A?
END
23
6.2 PROCESS FLOW DESCRIPTION
Table - 5.0
Activity Description
Tools Used
A1
EMA:
Availability of
1. Specification/Requirements
2. Design doc. & Review report
3. Material list & sources
4. Quality assurance plan
5. Cost/Time estimate & sanction
6. Mode of proto unit deployment
A2
QC:
Verification of
1. Materials inspection report
2. Components screening report
3. Inward goods inspection report
4. Sub-system level test report
5. Clearance from QC division
A3
Controller:
Availability of
1. Specification/Requirements for
both software and hardware
2. Design doc. & Review report
3. Material list
4. Cost/Time estimate & sanction
5. Mode of proto unit deployment
A4
QC:
Verification of
1. PCB inspection report
2. Sub-system level test report
3. Clearance from QC division
A5
EMAS:
1. System functional test
2. Review & Recommendation
A6
MI Sensor:
Availability of
1. Specification/Requirements
2. Design doc. & Review report
3. Material list & sources
4. Cost/Time estimate & sanction
5. Mode of proto unit deployment
A7
QC:
Verification of
24
Remarks, if any
Work center jointly with
R&QA, RCI as per this QA
plan
R & Q A, RCI with the
counter part of
the manufacturer
Work center jointly with
R & QA, RCI as per this
QA plan. Work center jointly
with SQAG on software
clearance.
R & Q A, RCI with the
counter part of
the manufacturer
Work center jointly with the
manufacturer
Work center jointly with
R & QA, RCI as per this
QA plan
A8
A9
A10
A11
A12
A13
A14
A15
A16
1. Materials inspection report
2. Sub-system level test report
3. Clearance from QC division
MIS:
1. System functional test
2. Review & Recommendation
EMAS with MIS:
1. Limited functional test
2. Study of compatibility
QC:
1. Visual inspection of the system
2. Checking of other deliverables
Corrective Action, if any:
1. For functional correction &/or
2. For dimensional modification
Initial Functional Test:
 EMA with MIS
(When assembly is correctly done)
Entest:
 Functionality study
 Response analysis
Evaluation & Suggestion:
 If any waiver advised (or else)
 Any design changes called for
Final Functional Test:
 EMA with MIS
(After the entest is confirmed ok)
Clearance for Application:
 EMA with MIS
(Set wise with certification given)
25
R & Q A, RCI with the counter
part of the manufacturer
Work center jointly with the
manufacturer
Applicable Work center jointly with the
s/w
manufacturer
simulation
R & Q A, RCI jointly with the
Work-center
Work center jointly with the
manufacturer
Test set-up asR & Q A, RCI jointly with the
applicable Work-center & the
manufacturer
--DoR & Q A, RCI jointly with the
Work-center and the
manufacturer
--DoR & Q A, RCI jointly with the
Work center and the
manufacturer
Test set-up asR & Q A, RCI jointly with the
applicable Work-center & the
manufacturer
R & Q A, RCI jointly with the
Work-center & the
manufacturer
7.0 INWARD GOODS INSPECTION
As stated earlier, the EMA system has sub assemblies as follows:
1.
2.
3.
4.
5.
6.
7.
Ball screw mechanism
Gear Train
BLDC motor
Tacho Generator
LVDT
Dual channel digital controller
MI sensor assembly
7.1 TEST PROCEDURE:
 Ball screw mechanism should undergo following inspection tests
A.
General Inspection
a.
b.
Dimensional Inspection
Material verification

Gears should undergo following inspection tests
A.
General Inspection
a.
b.
Dimensional Inspection
Material verification
 BLDC motor should undergo following inspection tests
A.
General Inspection
a.
b.
B.
Insulation resistance check
Armature resistance check
Performance tests
a.
b.
No load test
Load test
26
 Tacho Generator should undergo following inspection tests
A.
General inspection test
a.
b.
B.
Insulation resistance check
Armature resistance check
Performance test
a.
Scale factor test
 LVDT should undergo following inspection tests
A.
General inspection test
a.
b.
c.
Insulation resistance test
Dimensional inspection
Inspection of COC
 Dual channel digital controller should undergo following inspection test
A.
General Inspection test
a.
b.
c.
Dimensional inspection
Pin configuration check
Test Certificates for all PCBs with group B Certification
B . Performance test
a.
b.
c.
1553 response test
Health check
Card level test procedures
 MI sensor assembly should undergo following inspection test
A.
General inspection test
a.
b.
Dimensional inspection
Material verification
27
7.2 TEST FORMATS:
Inspection report for Ball Screw mechanism
SYSTEM:
ELECTROMECHANICAL ACTUATOR
Tested on:
Make
:
Report no.
Sl. No.
: EMA No.__________________
Project : NIRBHAY
A. GENERAL INSPECTION:
Tested for
Resulted in
Remarks
a. Dimensional inspection
b. Material verification
Note: This ball screw assembly for said EMA is passed/not passed through the
inspection conducted
Tested by
Verified by
28
Inspection report for Gear train
SYSTEM:
ELECTROMECHANICAL ACTUATOR
Tested on:
Make
:
Report no.
Sl. No.
: EMA No.__________________
Project : NIRBHAY
A. GENERAL INSPECTION:
Tested for
Resulted in
Remarks
a. Dimensional inspection
b. Material verification
Note: This Gear train for said EMA is passed/not passed through the inspection
conducted
Tested by
Verified by
29
Inspection report for BLDC motor
SYSTEM:
ELECTROMECHANICAL ACTUATOR
Tested on:
Make
:
Report no.
Sl. No.
: EMA No.__________________
Project : NIRBHAY
A. GENERAL INSPECTION:
Tested for
a. Insulation resistance check
>50MΩ at 100 VDC
b. Armature resistance check
0.5Ω±10%
Resulted in Remarks
Note: This BLDC motor for said EMA is passed/not passed through the inspection
conducted
Tested by
Verified by
30
Inspection report for Tacho generator
SYSTEM:
ELECTROMECHANICAL ACTUATOR
Tested on:
Make
:
Report no.
Sl. No.
: EMA No.__________________
Project : NIRBHAY
A. GENERAL INSPECTION:
Tested for
a. Insulation resistance
>50MΩ
A. PERFORMANCE TEST:
Tested for
a. Scale factor tests
0.33mV/rpm±10%
Resulted in
Remarks
Resulted in
Remarks
Note: This Tacho generator for said EMA is passed/not passed through the inspection
conducted
Tested by
Verified by
31
Inspection report for LVDT
SYSTEM:
ELECTROMECHANICAL ACTUATOR
Tested on:
Make
:
Report no.
Sl. No.
: EMA No.__________________
Project : NIRBHAY
A. GENERAL INSPECTION:
Tested for
Resulted in
Remarks
a. Insulation resistance test
b. Dimensional inspection
c. Inspection of Certificate of
conformance
Note: This LVDT for said EMA is passed/not passed through the inspection conducted
Tested by
Verified by
32
Inspection report for Dual channel Digital controller
SYSTEM:
ELECTROMECHANICAL ACTUATOR
Tested on:
Make
:
Report no.
Sl. No.
: EMA No.__________________
Project : NIRBHAY
A. GENERAL INSPECTION:
Tested for
Resulted in
Tested for
Resulted in
Remarks
a. Dimensional inspection
b. Pin configuration check
c. PCB test certificates
B. Performance test:
Health of total
controller
a. Health test
through analog
and digital
interface
Note: CARD level test procedures should be submitted by VENDOR.
Note: This Dual channel digital controller for said EMA is passed/not passed through
the inspection conducted
Tested by
Verified
33
Inspection report for MI sensor assembly
SYSTEM:
ELECTROMECHANICAL ACTUATOR
Tested on:
Make
:
Report no.
Sl. No.
: EMA No.__________________
Project : NIRBHAY
A. GENERAL INSPECTION:
Tested for
Resulted in
Remarks
a. Dimensional inspection
b. Material verification
Note: This MI sensor assembly for said EMA is passed/not passed through the
inspection conducted
Tested by
Verified
34
8.0 QUALIFICATION AND ACCEPTANCE TESTS:
8.1
Introduction
‘NIRBHAY’ is an airborne system, which can be ground launched, ship launched
and air launched. It will encounter various natural and induced environmental
conditions during its life cycle. The basis for this document is JSS 55555 and
MIL-STD-461E and is tailored for this document purpose. Method reference
number to be followed is mentioned in each of the test. The environmental tests
levels and conditions described in this document may be updated after initial
flight trials. Summary of all the Safety of Flight (SOF) Test specifications,
which includes the Environmental Stress Screening (ESS), is given in Appendix
‘F’.
In all the following sections when the term “standard Ambient” is specified, use
the values shown below. If no specific values are called for any test method,
conduct the test at “ Standard Ambient
“ conditions.
Temperature
Relative Humidity (RH)
Atmosphere Pressure
:
:
:
25 ± 10º C
20 to 80 %
Site pressure
The following SOF tests shall be carried out for one set of EMA system as
Qualification test:
Pre –temperature Random vibration
Three temperature cycles
Post –temperature Random vibration
Burn-in
Damp Heat
Acceleration
Shock
EMI/EMC
35
9.0
SAFETY OF FLIGHT & ENVIRONMENTAL STRESS SCREENING
PROCEDURES
9.1
Random Vibration Test
The test shall be done to determine the suitability of electronic and electrical
equipment to withstand the vibration levels
9.1.1 The characteristics of the Random vibration equipment shall be as given
clause 2.2, Test No. 28 of JSS 55555.
under
9.1.2 Test Procedure
9.1.2.1 Mounting: The mounting procedure for the EUT shall be as given under clause
3.1 Test No. 28 of JSS 55555.
9.1.2.2 Initial measurements: The EUT shall be visually examined and shall be
electrically and mechanically checked without opening the unit.
9.1.2.3Vibration Test: Vibration test shall be carried out on the EUT in all three axes
and for a period of 10 minutes. Performance monitoring shall be done on
the unit, during the vibration.
9.1.2.4 Post measurements: The EUT shall be visually examined and
electrically and mechanically checked.
9.2
shall
be
Low Pressure Low Temperature & High temperature Test (Three cycles):
The test shall be done to determine the suitability of electronic and electrical
equipment for use under simultaneously applied service
conditions of low air
pressure and high low temperature.
9.2.1 Test chamber
9.2.1.1 A combined cold and hot chamber meeting the requirements stated under clause
2 of Test No. 20 (Low Temperature) of JSS 55555 and clause 2 of Test No. 17
(High Temperature) shall be used.
9.2.1.2 In addition, the cold chamber shall have the capacity to go up to -40ºC and
create a pressure corresponding to 9000m altitude and maintain the pressure at
least for a duration of 30 minutes.
36
9.2.2. Test procedure
9.2.2.1 The Equipment Under Test (EUT) shall be introduced into the
ambient temperature.
chamber
at
9.2.2.2 The chamber temperature shall be decreased to the required severity of -40ºC at
the rate of minimum 3ºC/minute. After attaining the temperature , soak the unit
for a period of two hours.
9.2.2.3 Wherever low pressure test has been called for, the pressure shall be maintained
for duration of 30 minutes.
9.2.2.4 The temperature of the chamber shall then be brought up - 20ºC and the
performance test called low pressure shall be carried out. After giving due time
for warm up of the EUT after switching ON the EUT.
9.2.2.5 After completion of the performance test at low temperature and low pressure
test, the EUT shall be switched OFF and the chamber shall be taken to the high
temperature at the rate of minimum 3ºC/min.
9.2.2.6 After attaining the desired high temperature of +70ºC, EUT shall be switched ON
and the unit shall remain ‘ON’ for the stipulated period of two hours.
9.2.2.7 The temperature of the chamber shall then be lowered to +55ºC. Performance
test shall be carried out at the end of stipulated period. Then the equipment shall
be switched OFF and the chamber brought to ambient temperature.
9.2.2.8 The steps given above constitute one temperature cycle. Two more temperature
cycles shall be carried out on the EUT.
9.2.2.9 At the end of the third cycle let the chamber be brought to room temperature.
9.2.3 Recovery: At the end of the third cycle let the unit be kept under
ambient condition for about 2 hours and performance tests shall be carried out.
9.3
Burn-in-Test
9.3.1 Test Chamber: The hot chamber to be used for burn-in-test shall have the
characteristics as given clause 2 of test No. 17 of JSS 55555.
37
9.3.2 Test Procedure:
9.3.2.1 Introduce the EUT into the chamber. Initial performance test shall be carried out
on the EUT. After completion of performance test, raise the temperature
to the stipulated value of 70ºC at the rate of minimum 3ºC/minimum. After
attaining the required temperature, switch ON the unit.
9.3.2.2 Maintain the unit under ON condition for duration of 4hours.
9.3.2.3 At the end of the stipulated period of time, performance tests shall be carried out.
9.3.2.4 Bring the chamber to ambient temperature.
9.4
Damp Test
The damp heat test is intended to determine the ability of electronic
and
electrical equipment to withstand the stresses occurring in a climate of high
relative humidity with or without condensation.
9.4.1 Test chamber: The characteristics of the humidity chamber shall generally
conform to clause 2 of Test No. 10 of JSS 55555.
9.4.2 Test procedure:
The EUT shall be introduced into the chamber. Performance test shall
be
carried out before the start of the test and let the unit be switched “OFF”. Adjust
the chamber temperature to 40ºC and RH to 95% and expose the test item to
10-hour cycle
During the last 30 minutes of the stipulated duration, performance test shall be
carried out with EUT in ON condition. At the end of damp heat test the unit shall
be switched “OFF”.
9.5
Acceleration Test
This test shall be performed to assure that material could structurally withstand
the steady state inertia loads induced during service environments. This test is
also required to ensure the functioning of test item without degradation following
exposure to these forces.
9.5.1 Test equipment: The characteristics of the centrifuge shall be given under clause
2, Test No.1 of JSS 55555.
38
9.5.2 Mounting: Let the method of mounting the EUT shall be as given in clause 3.1
of Test No.1.
9.5.3 Test Procedure
9.5.3.1 Let the EUT be physically inspected and mounted on the centrifuge. Let the
performance test be carried out before acceleration.
9.5.3.2 Let the unit be acceleration tested to a level of 15 g for duration of one minute
in each of the three axes (both directions).
9.5.3.3 Let the EUT be physically examined after the acceleration test and performance
test be carried out.
9.6
Shock Test
Shock test shall be carried out to evaluate the physical functional performance
of material / components likely to be exposed to mechanically induced shocks in
its lifetime. Mechanical shock has the potential for producing the adverse effects
on the physical and functional integrity of all material.
9.6.1 Test Equipment: Let the characteristics of the shock test machine shall generally
conform to that given under clause 2.2 Test No. 24 of JSS 55555.
9.6.2 Test Procedure
9.6.2.1Mounting arrangement: As per clause 3.11 to 3.1.4, Test No. 24 of JSS 55555.
9.6.2.2 Initial measurement.
The EUT shall be visually examined and shall be electrically tested.
9.6.2.3 Test Procedure
The EUT shall be subjected to one, half sine wave shock, in each direction,
along each of the three mutually perpendicular axes (up and down) to al
level of 15 g duration of 15 milliseconds.
9.6.2.4 Visual inspection and electrical performance test shall be carried out after the
shock test.
39
9.7
EMI/EMC
This test shall be conducted to establish interface and associated verification
requirements for the control of the electromagnetic interference (emission and
susceptibility) characteristics of electronic, electrical and electromechanical
equipments. MIL-STD-461 E shall be referred for description of test set up and
various procedures for finer details.
Following coding system is used:C
R
E
S
CE
RE
CS
RS
Conducted
Radiated
Emission
Susceptibility
Conducted emissions
Radiated emissions
Conducted susceptibility
Radiated susceptibility
The units shall be subjected to the following three tests and performance test shall
be ensured during these tests.
9.8

Radiated emission test (RE 102)

Conducted susceptibility test (CS 115)

Radiated susceptibility (electric field) test (RS 103)

Conducted susceptibility (Spike) test (CS 106)

Electrostatic discharge test (ESD)
Test Plan
One each of all the airborne subsystems of NIRBHAY shall be tested as per the
following sequence.
a.
Functional tests
b.
SOF Tests (Tests: 1 – 8 as per Appendix F)
Unless otherwise specified the test item shall be installed in the test facility in a
manner that will simulate the service conditions. Subsequent to each
environmental test, a functional test shall be performed if complete performance
checks are not carried out during the actual environmental tests.
The first unit (prototype) of each line Replaceable Unit (LRU) shall be subjected
to both the functional tests and Safety of Flight (SOF) tests. The SOF tested items
40
shall be yellow banded and not used for flight. However, these yellow-banded
units can be used for ground applications.
The other LRUs will undergo only Functional Tests and ESS (Tests: 1-3 as per
Appendix F) tests.
9.9
Guidelines in case of failure of the unit during SOF
In case of failure of the EUT during Pre-temperature cycle test in any axis, the
unit will be rectified and the vibration test will be carried out in all the three axes.
In case of failure of the EUT during any of the Temperature cycles, the unit shall
be rectified and shall undergo minimum of two temperature cycles.
In case of failure of EUT during the post temperature cycle vibration tests, the
unit will undergo pre-temperature cycle vibration test, minimum of one
temperature cycle and the post-temperature cycle vibration tests.
In case of failure of the EUT in Damp heat, acceleration or shock tests, unit will
be rectified and subjected to that test in which it had failed.
In case of failure of the EUT during the Burn-in or EMI/EMC tests, the unit shall
be returned to the designer for the required modifications and then the unit is resubjected to the SOF tests.
41
10.0 QUALIFICATION TESTS
There are four stages in the qualification tests for EMAS with MIS:
1.
General assessment
2.
Functional tests
3.
EMI / EMC tests
4.
Environmental tests
10.1
TEST PROCEDURE:
10.1.1 GENERAL ASSESSMENT:
Each unit should undergo the following tests:
1. Size and weight check
2. Crack and denting check
3. Valuing the workmanship
The test procedures to be followed are given in APPENDIX-A
10.1.2 FUNCTIONAL TESTS:
Each unit should undergo the following tests:
1. Frequency response test (no-load)
2. Frequency response test (on-load)
3. Step response test (no-load)
4. Step response test (on-load)
5. Polarity checking
6. Threshold test
7. Scale factor test
8. Electrical to mechanical null test
9. Linearity (absolute)
The test procedures to be followed are given in APPENDIX-B
42
10.1.3 ENVIRONMENTAL TESTS
Each unit should undergo the following tests:
1.
P.R.E.E.T.
: Pre-Environmental Test
2.
I.N.S.E.T.
: Insitu Environmental Test
3.
P.O.E.T.
: Post-Environmental Test
The following is the electrical schematic of actuation system during ENTEST
Fig (4): Electrical schematic of Actuation system during ENTEST
Below are the list-out tests to be carried out:
Table-6.0
Type of test
P.R.E.E.T.
I.N.S.E.T.
P.O.E.T.
1.
Health test



2.
Burn In

x

3.
Acceleration - functional



4.
Random vibration (Pre Temp) test



5.
Temperature & Pressure Cycle



6.
Random vibration (Post Temp) test



7.
Damp Heat

x

8.
Shock test

x

Where   Applicable & x  Not applicable
Follow the test procedure for health check as given in APPENDIX-C and the test procedures
planned for 2 to 9.
43
10.1.4 EMI / EMC TESTS
Qualification unit should undergo the following tests:
1.
Radiated emission test (RE 102)
2.
Conducted susceptibility test (CS 115)
3.
Radiated susceptibility (electric field) test (RS1 03)
4.
Conducted susceptibility (Spike) test (CS 06)
5.
Electrostatic discharge test (ESD)
Follow the test procedure for health check as given in APPENDIX-D
FRA
Recorder
Unit Under Testing
EMA-P &
MIS-P
PC with
1553 Software
Digital
Controller
Power Supply
28V, 5A
EMA-Y &
MIS-Y
Power Supply
56V, 60A
Fig (5): Electrical schematic for actuation system during EMI/EMC
44
11.0
TEST PROCEDURES:
11.1 Initial Performance Tests:
The following functional tests shall be conducted for acceptance of EMA,
at 56 V input voltage. The test set up block diagram is shown in fig.(1).
11.2 No load Current:
The EMA is powered on and the current is measured from the power
supply. The EMA is at no load. Maximum no load current drawn by EMA and
Digital Controller should not be more than 4 Amps.
11.3 Sign convention:
The EMA is powered on. Command is issued through FRA/PC to the
controller. The direction of movement of piston is observed physically and the
position feedback and command are measured in recorder. The movement of the
piston should be outwards for positive command and should be inwards for
negative command. The direction of position feedback should match with the
position command in the recorder.
11.4 Null offset:
EMA is powered on and Enabled by an external power supply. Position
command of zero value is issued to EMA through FRA. The Position feedback of
EMA is measured by recorder/ multimeter. The feedback value is equivalent to
the Null offset of the actuator. The null offset should be less than 100 mV.
11.5 Scale factor:
EMA is powered on and Enabled by an external power supply. Step
command is issued to DADI. The displacement of piston of actuator is measured
by vernier. The ratio of commanded voltage to physical displacement is the scale
factor of the actuator.
11.6 Threshold voltage:
EMA is powered on and Enabled by an external power supply. Command
is given to EMA system. The position feedback is measured. The input voltage
45
corresponding to a change in position feedback from the value of Null offset is
measured as threshold voltage.
11.7 Linearity:
Linearity test is done to get the non linearity and gain of the actuator.
Linearity command is a ramp command consisting of small step commands. After
issuing each step command actuator feedback is measured and the gain of the
actuator is computed. At the end of the linearity command the % non linearity of
the actuator is found by calculating the max, min and average gain of the actuator.
The % non linearity of the actuator should be less than 10%.
11.8 Frequency Response Test:
The Frequency response of EMA is carried out at no load using frequency
response analyzer. The sinusoidal position command equivalent to 2.5mm (10%
of full scale stroke of actuator) is issued to the actuator with frequency varying
from 0.5 Hz to 15 Hz. The gain plot and phase plot is derived. Frequency at -90
deg phase will be measured. The frequency at -90 deg phase is stated as
Bandwidth of the actuator and should be =10 Hz± 2 Hz. The frequency response
on the actuator is carried out with and without load.
11.9 Load Test:
EMA is powered on and Enabled by an external power supply. The EMA
is connected to a simulated spring load system. The commands are given to EMA
and the EMA system is loaded by the load system. The load is measured through
a load sensor. Position feedback, velocity feedback and current feedback are
measured through a recorder.
11.10 Step response Test:
EMA is powered on and Enabled by an external power supply. Step
command of 0.5V is given to actuator and Settling time, Overshoot and speed are
measured. The test is carried out on the actuator with and without load.
46
12.0
TEST FORMATS
QUALIFICATION TEST REPORT FOR EMAS WITH MIS
SYSTEM:
EMAS with MIS
Tested on:
Make
:
Report no.:
Sl. No.
Sl. No.
: EMAS No. ___________________
: MIS No. ___________________
Project : NIRBHAY
A. GENERAL ASSESSMENT:
Required
Achieved
Remarks
a. Size and weight check
b. Crack and denting check
c. Valuing the workmanship
NOTE: The said EMAS with MIS are passed/not passed through the qualification test
conducted.
Tested by
Verified by
47
QUALIFICATION TEST REPORT FOR EMAS WITH MIS
SYSTEM:
EMAS with MIS
Tested on:
Make
Report no.
:
Sl. No. : EMAS No. ___________________
Sl. No. : MIS No. ___________________
Project : NIRBHAY
B. FUNCTIONAL TESTS:
Required
Achieved
a. Frequency response test (no-load)
= 10Hz± 2Hz
b. Frequency response test (on-load)
= 10Hz± 2Hz
c. Step response
test (no-load).
(cmd is 10% of
FS).
Settling time
Overshoot
 130 m-sec
 10%
d. Step response
test (on-load)
Speed
Settling time
Overshoot
 170mm/sec
 150 m-sec
 10%
Shaft moving
outward for +
ve cmd
0.4V/mm± 5
%
e. Polarity checking
f. Scale factor test
g. Threshold test
 100 mV
m. Electrical to mechanical null test
 ±100 mV
n. Non- Linearity (absolute)
≤ 10 %
Remarks
NOTE: The said EMAS with MIS are passed/not passed through the qualification test
conducted.
Tested by
Verified by
48
QUALIFICATION TEST REPORT FOR EMAS WITH MIS
SYSTEM:
EMAS with MIS
Tested on:
Make
:
Report no.
Sl. No.
Sl. No.
: EMAS No. ___________________
: MIS No. ___________________
Project : NIRBHAY
C. ENVIRONMENTAL TESTS:
Required
a. Health test
Health check
b. Burn In ( Unit under ON condition)

c. Random Vibration ( Pre Temp) test

d. Temperature Cycle

e. Random Vibration ( Post Temp) test

f. Shock

g. Acceleration

h. Damp Heat

Achieved
Remarks
NOTE: The said EMAS with MIS are passed/not passed through the qualification test
conducted.
Tested by
Verified by
49
QUALIFICATION TEST REPORT FOR EMAS WITH MIS
SYSTEM:
EMAS with MIS
Tested on:
Make
:
Report no.
Sl. No.
Sl. No.
: EMAS No. ___________________
: MIS No. ___________________
Project : NIRBHAY
D. EMI / EMC TESTS:
Required
a. Conducted susceptibility (CS 115)
Health
check
b. Radiated emission test (RE 102)

c. Radiated susceptibility test (RS 103)

d. Conducted susceptibility spike test (CS 106)

e. Electro Static discharge test (ESD)

Achieved
Remarks
NOTE: The said EMAS with MIS are passed/not passed through the qualification test
conducted.
Tested by
Verified by
50
13.0
ACCEPTANCE TESTS:
There are two stages in the acceptance tests for EMAS with MIS:
1)
Functional tests
2)
Environmental Stress Screening
13.1 TEST PROCEDURE:
13.1.1 FUNCTIONAL TESTS:
Each unit should undergo the following tests:
1)
Frequency response test (no-load)
2)
Step response test (no-load)
3)
Polarity checking
4)
Electrical to mechanical null test
5)
Linearity (absolute)
6)
Scale factor test
7)
Threshold test
The test procedures to be followed are given in APPENDIX-B
13.1.2 ENVIRONMENTAL TESTS
Each unit should undergo the following tests:
1.
P.R.E.E.T.
: Pre-Environmental Test
2.
I.N.S.E.T.
: Insitu Environmental Test
3.
P.O.E.T.
: Post-Environmental Test
Below are the list-out tests to be carried out:
1.
2.
Type of test
P.R.E.E.T. I.N.S.E.T.
P.O.E.T.
Health test



Random vibration



Thermal cycling



Random vibration



ESS
Where   Applicable & x  Not applicable
51
Follow the test procedure for health check as given in APPENDIX-C
13.2
SPECIFICATIONS FOR ENVIRONMENTAL STRESS SCREENING
(ESS) OR ACCEPTANCE TESTING (AT)
ESS (AT) shall consist of thermal cycling as in figure below proceeded
and followed by three axes random vibration. The unit under test (UUT) will be
subjected to a total number of 03 thermal cycles. The UUT will be switched on
during the 1st cycle (at +70°C) for the stipulated period of two hours. The
temperature shall be lowered to +55°C and performance test shall be carried out at
the end of stipulated period. Then the UUT shall be switched OFF. During the
cycle, the UUT will be soaked at +70°C and -40°C for 2 hrs respectively. The
performance parameters will be monitored towards the end of high temperature
(+70°C) and low temperature (-40°C) soaking.
Temp.
3°C per minute
2 Hrs
2 Hrs
+ 70°C
+ 55°C
UUT Power ON
UUT Power OFF
Ambient
No. of Time Cycles
- 10°C
- 20°C
2 Hrs
- 40°C
1 Cycle
52
13.3
TEST FORMATS:
ACCEPTANCE TEST REPORT FOR EMAS WITH MIS
SYSTEM:
EMAS with MIS
Tested on:
Make
:
Report no.
Sl. No.
Sl. No.
: EMAS No. ___________________
: MIS No. ___________________
Project : NIRBHAY
A. FUNCTIONAL TESTS:
Required
a. Frequency response test (no-load)
=10 Hz± 2 Hz
b. Step response
test (no-load)
 150 m-sec
 10%
Shaft moving
outward for +
ve cmd
Settling time
Overshoot
c. Polarity checking
d. Electrical to mechanical null test
 100 mV
e. Linearity (absolute)
 95 %
f. Scale factor test
0.4V/mm
±5%
g. Threshold test
 100 mV
Achieved
Remarks
NOTE: The said EMAS with MIS are passed/not passed through the qualification test
conducted.
Tested by
Verified by
53
ACCEPTANCE TEST REPORT FOR EMAS WITH MIS
SYSTEM:
EMAS with MIS
Tested on:
Make
:
Report no.
Sl. No.
Sl. No.
: EMAS No. ___________________
: MIS No. ___________________
Project : NIRBHAY
B. ENVIRONMENTAL TESTS:
Required
a. Health test
Health check
b. ESS
Random vibration

Thermal cycling

Random vibration

Achieved
Remarks
NOTE: The said EMAS with MIS are passed/not passed through the qualification test
conducted.
Tested by
Verified by
54
14.0
FORMAT FOR QT/AT CONFORMANCE REPORT
SYSTEM:
EMAS with MIS
DTR/DIV: CSL
Make
:
QAP REF.:
Sl. No.
Sl. No.
: EMAS No. __________________
: MIS No. __________________
Project : NIRBHAY
Sl. No. Test Description
1
Initial functional tests
Parameters
Remarks
Monitored
As per QAP
(Results to
be enclosed)
A
A
A
NA
NA
NA
A
A
A
A
--Do--
NA
A
A
A
A
--Do--
NA
A
A
A
A
--Do--
A
NA
A
NA
A
--Do--
A
NA
A
NA
A
--Do--
A
NA
A
A
A
--Do--
Burn In
A
NA
A
A
A
--Do--
EMI/EMC tests
A
NA
A
A
A
--Do--
A
As per QAP
(Results to
be enclosed)
ESS
Random
vibration
Thermal
cycling
Random
vibration
Damp Heat
Shock
Acceleration
3
QT AT Preet Inset Poet
Final functional tests
A
A
NA
55
NA
Where
NA
A
Preet
Inset
Poet
->
->
->
->
->
Not Applicable
Applicable
Pre- Environmental Test
During Environmental Test
Post Environmental Test
It is certified that the EMAS Sl. No. ______ with MIS Sl. No. ______ is cleared / not
cleared as qualification model/acceptance model.
Rep Work center
Sys Mgr - R & QA/RCI
Place:
Date:
56
Rep Missile project
15.0
SAFETY REQUIREMENTS AND REGULATIONS
The safety requirements should be followed as per MIL-STD-1378F.
However, it is vital to comply the following as it is or else is minimum.
1.
The controller should not be connected by reverse polarity.
2.
Regulated power supply should have a current range to 60 A.
16.0
PAKAGING & HANDLING
Packaging and handling requirements should be as per MIL-STD-2073.
However, it is projected that the procedure to be known is as follows.
16.1 HANDLING

Safety procedures should be followed during connection & testing, both at
the supply points and at the system.

The unit (EMAS with MIS) should be switched OFF if the current drawn
from supply is greater than 60 Amps.

Only current limited power supplies with maximum current = 1.5 rated
current should be used in all test procedure.
16.2 PACKAGING

Connectors must be confined from rust and damage by putting proper
plastic covers, bubble sheets etc. on them.

Each said unit should be properly placed in cardboard box and covered
with packing cloths and bits on all its sides.
17.0
FORWARDING/TRANSPORTING
The following information should be available on the transporting case:

Product name:

Product ref number:

Manufacturer name:

Quantities in:
57
18.0
STORAGE REQUIREMENTS
The storage requirements should be as per MIL-STD-108E.
19.0
APPLICATION REQUIREMENTS

The unit (EMAS with MIS) must have gone through the QC requirement

The unit (EMAS with MIS) must get the approval from QA department
20.0
VITAL REPORTS TO BE ASSERTAINED
20.1
QC fulfillment:

1st instance verification:


Specification/Requirements

Design doc. & Review report
nd
2 instance verification:

Materials inspection report

Components screening report

Inward goods inspection report

Sub-system level test report

Software requirements specification Document

Software Interface document

Hardware Interface document
20.2
QA fulfillment:

Qualification test reports


General assessment report

Functional test report

Environmental test report

EMI / EMC test report
Acceptance test reports

Functional test report

ESS report
58
21.0
CONCLUSION:
This QA Plan has been prepared by control systems laboratory in
association with, R&QA of RCI, Hyderabad for Linear Electro Mechanical
Actuation System (EMAS) and Mirror Image Sensor (MIS) for Flex Nozzle
Control of 1st Stage TVC of NIRBHAY Flight Vehicle. The plan has been
prepared to cover all aspects of the system beginning at design and ending at
delivery of the hardware systems.
59
APPENDIX-A
For EMAS with MIS (Qualification test):
GENERAL ASSESSMENT
A.1.1
Size and weight check
Aim of this
test
To observe the system size and weight
Instruments
required
N/A
Test method
Reference: dimensional drawings
To be
observed
A.1.2
Overall size  250 x 115 x 65 mm; Overall weight  3.0 kg
Crack and denting check
Aim of this
test
To observe the surface for crack or denting if any
Instruments
required
N/A
Test method
Reference: nil
To be
observed
A.1.3
No crack nor should there be any denting appear
Valuing the workmanship
Aim of this
test
To observe the value of workmanship
Instruments
required
N/A
Test method
Reference: nil
To be
observed
No unit should be observed unpleasant/loosely fit
60
APPENDIX-B
For EMAS with MIS (Qualification test):
FUNCTIONAL TESTS
B.1.1
Frequency response test (no-load)
Aim of this
test
To measure the frequency response of the actuator on no-load
Instruments
required
Test method
Regulated power supply (DC), Frequency response analyzer, Graph
plotter.
1. Actuator is installed on the test rig without the spring load
2. DC Voltage of 56 V is applied
3. Sine wave of amplitude 0.707 Vrms is given as command for 0.5 Hz
to 15 Hz in steps of 1 Hz. Gain magnitude Vs Frequency & Phase
angle Vs Frequency are plotted.
To be
observed
Bandwidth =10 Hz± 2 Hz (Freq. at -90° Phase)
B.1.2
Frequency response test (under load)
Aim of this
test
To measure the frequency response of the actuator under load
Instruments
required
Test method
Regulated power supply (DC), Frequency response analyzer, Graph
plotter
1. Actuator is installed on the test rig with the spring load attached.
2. DC Voltage of 56 V is applied
3. Sine wave of amplitude 0.707 Vrms is given as command for 0.5 Hz
to 15 Hz in steps of 1 Hz. Gain magnitude Vs Frequency & Phase
angle Vs Frequency are plotted.
To be
observed
Bandwidth =10 Hz± 2 Hz (Freq. at -90° Phase)
B.1.3
Step response test (no-load)
Aim of this
test
To measure the step response of the actuator on no-load
Instruments
required
Regulated power supply (DC), Function generator, Chart recorder
Test method
1. Actuator is installed on the test rig
2. DC Voltage of 56 V is applied
3. Square wave of amplitude of 2.5V at 0.25 Hz is given as command.
61
4. Both the input & the output signals are recorded
5. Speed, Rise time, Settling time, % peak overshoot are recorded
To be
observed
Settling time  130 ms
Overshoot  10% of FS
B.1.4
Step response test (under-load)
Aim of this
test
To measure the step response of the actuator under load
Instruments
required
To be
observed
Regulated power supply (DC), Function generator, Chart recorder,
Spring load.
1. Actuator is installed on the test rig with the spring load attached.
2. DC Voltage of 56 V is applied
3. Square wave of amplitude of 2.5V at 0.25 Hz is given as command.
4. Both the input & output signals are recorded
5. Speed, Settling time, % peak overshoot are recorded
Settling time 150 ms
Overshoot  10% of FS
B.1.5
Threshold test
Aim of this
test
To observe the maximum value of input command below which the
actuator does not respond.
Instruments
required
Regulated power supply [DC], Function Generator, Chart recorder
Test method
1. Position command to actuator is given in steps of 20 mV.
2. The input & the position feedback are recorded
3. The input command where the output changes by 20 mV-null offset
is recorded.
To be
observed
Threshold  100 mV
B.1.6
Polarity checking
Aim of this
test
To observe the polarity of the actuator movement
Instruments
required
Regulated power supply [DC], Function Generator, Chart recorder
Test method
1. Actuator is installed on the test rig
2. DC Voltage of 56 V is applied
3. Give the input command signal of + 1 V, see the direction of
movement of actuator output shaft
Test method
62
4. Give the input command signal of – 1 V, see the direction of
movement of actuator output shaft
To be
observed
For a + ve command, shaft should move outside or should extend
B.1.7
Electrical to mechanical null test
Aim of this
test
To ensure the correctness of electrical & mechanical zeros of the
actuator
Instruments
required
Regulated power supply [DC], CRO, Digital multimeter, Vernier scale
Test method
1. The actuator is nulled mechanically by using the dial gauge or
Vernier scale.
2. It is then tested for null in closed loop
3. When the input signals are as zero, the actuator shaft should be at
mechanical null.
4. Under this condition, the electrical null (i.e. actuator feedback)
should be   100 mV
To be
observed
Voltage at null   100 mV
B.1.8
Scale factor test
Aim of this
test
To relate the mechanical displacement and electrical command.
Instruments
required
Regulated power supply [DC], CRO, Digital multimeter
Test method
1. Actuator is powered on through controller.
2. Commands are issued to actuator in steps of 0.5 V DC
3. Mechanical displacement is measured at every command.
4. Ratio of command issued to mechanical displacement over the fullscale displacement is measured and averaged to give the scale factor.
To be
observed
S.F = 0.4V/mm ±5%
B.1.9
Linearity (absolute)
Aim of this
test
Absolute linearity is the maximum permissible deviation of the actual
output curve from an ideal reference line.
Instruments
required
Regulated power supply [DC], Function generator, Chart recorder
63
Test method
To be
observed
1. Run the actuator in closed loop.
2. Give a command signal of triangular wave, 1 V peak to peak at 1
Hz
3. Observe the command signal and feedback signal on the recorder
The deviation of the feedback signal from the reference line should be
 10 %
64
APPENDIX-C
For EMAS with MIS (Qualification test):
ENTESTS
Health test
Aim of this
test
To check the health during ENTESTS
Instruments
required
Regulated power supply [DC], Function generator, Strip chart recorder
Test method
1. Run the actuator in closed loop
2. Give a command signal of sine wave 2.5 Vrms, 1 Hz.
3. Observe the command signal and feedback signal on strip chart
recorder
To be
observed
The deviation  10 %.
65
APPENDIX-D
For EMAS with MIS (Qualification test):
EMI / EMC TESTS
Health test
Aim of this
test
Instruments
required
Test method
To be
observed
To check the health during EMI / EMC TESTS
Regulated power supply [DC], Function generator, Strip
chart
recorder
1. Run the actuator in closed loop
2. Give a command signal of sine wave 2.5 Vrms, 1 Hz.
3. Observe the command signal and feedback signal on strip chart
recorder
The deviation  10 %.
APPENDIX-E
Health test for Controller
Health test for controller
Aim of this
test
To perform Health test for the controller
Instruments
required
Regulated power supply [DC], Oscilloscope
Type of tests
To be
observed
1.
2.
3.
4.
5.
LVDT Excitation voltage and frequency
Hall supply
Down load check
DAC check
ADC Check
Health of all modules.
66
APPENDIX-F
SAFETY OF FLIGHT SPECIIFCATIONS SOF-Serial No. 1-8
ENVIRONMENTAL STRESS SPECIFICATIONS ESS-Serial No. 1-3
S.No. Performance checks conducted after soaking units for the duration as mentioned
below
Random Vibration
6 g(rms) (20 Hz to 2000 Hz) in 3 axes, duration of
1
(Pre Temperature)
vibration 10 minutes in each axis as per Random profile
curve given in the document.
Temperature Cycle
High: + 70 C soaking for 2 hours.
2
+ 55 C for performance checks.
Low: - 40 C and pressure corresponding to 9000 m
altitude, soaking for 2 hours
( 3 Cycles)
- 20 C for performance checks.
Random
Vibration
6
g(rms)
(20 Hz to 2000 Hz) in 3 axes, duration of
3
(Post Temperature)
vibration 10 minutes in each axis as per Random profile
curve given in the document.
Burn in (Unit under ON At + 70 C for 4 hours
4
condition)
Damp Heat
+ 40 C , RH > 95 % for 10 hours
5
6
7
Acceleration
15 g for 1 minute duration in each 3 axes (Both direction)
Shock
8
EMI/EMC
Specifications
15 g, 15 milli sec, half sine wave in each of 3 axes (up and
down), one shock each.
As per MIL STD 461 E in respect of
1.
Radiated emission test (RE 102)
2.
Conducted susceptibility test (CS 115)
3.
Radiated susceptibility (electric field) test (RS 103)
4.
Conducted susceptibility (Spike) test (CS 106)
5.
Electrostatic discharge test (ESD)
67