美国麻省理工大学：《航天系统工程》（英文版） Spacecraft Manufacture and Test

Spacecraft Manufacture and Test Colonel John e Keesee 6/21/2004

6/21/2004 1 Spacecraft Manufacture and Test Colonel John E. Keesee

Lesson Objective e-To introduce and discuss manufacturing and test processes and philosophies 6/21/2004

6/21/2004 2 Lesson Objective [To introduce and discuss manufacturing and test processes and philosophies

Uniqueness of Satellite Manufacture sMall production runs o Extreme operational environments f Limited repair/replace options after launch e-High product cost and importance fHigh cost test environment eHighly coupled designs minimize weight and maximize performance but yield high comp plexity 6/21/2004

6/21/2004 3 Uniqueness of Satellite Manufacture [Small production runs [Extreme operational environments [Limited repair/replace options after launch [High product cost and importance [High cost test environment [Highly coupled designs minimize weight and maximize performance but yield high complexity

Overall Manufacturing Process o Prepare engineering data I Drawings, specifications, and processes f Manufacture component oo Qualify the component INtegrate and test rEpeat for other components and at higher levels of assembly 6/21/2004 4

6/21/2004 4 Overall Manufacturing Process [Prepare engineering data l Drawings, specifications, and processes [Manufacture component [Qualify the component [Integrate and test [Repeat for other components and at higher levels of assembly

Classic Manufacturing Processes drAw materials ordered from certified vendors eHigh reliability(S-level) electronic piece parts Group a, B, and C testing to ensure part quality a Project approved parts and materials lists fe Clean rooms for critical assemblies 6/21/2004

6/21/2004 5 Classic Manufacturing Processes [Raw materials ordered from certified vendors [High reliability (S-level) electronic piece parts l Group A, B, and C testing to ensure part quality [Project approved parts and materials lists [Clean rooms for critical assemblies

Clean rooms Facility/Operation Cleanliness Mechanical Not controlled Manufacturing Electronic assembly Class 10,000 ectromechanica Class 100 assembly Inertial instruments Class 100 Optical assembly Class 100 Spacecraft Assembly Class 100,000 and test 6/21/2004

6/21/2004 6 Clean Rooms Facility/Operation Cleanliness Mechanical Manufacturing Not controlled Electronic assembly Class 10,000 Electromechanical assembly Class 100 Inertial instruments Class 100 Optical Assembly Class 100 Spacecraft Assembly and Test Class 100,000

Classical Quality Assurance iDentify points in process flow where we can make sure the hardware construction complies with engineering data before the next steps prevent inspection o Test surveillance certifies test equipment and processes oo Quality assurance records all failures and anomalies 6/21/2004

6/21/2004 7 Classical Quality Assurance [Identify points in process flow where we can make sure the hardware construction complies with engineering data before the next steps prevent inspection [Test surveillance certifies test equipment and processes [Quality assurance records all failures and anomalies

Qualification Test Establishes that the design has suitable Performance Capacity to survive the operating environment inCludes vibration. shock. launch acoustics and the temperature extremes of space uNique functional performance tests in each environment 6/21/2004

6/21/2004 8 Qualification Test [Establishes that the design has suitable l Performance l Capacity to survive the operating environment [Includes vibration, shock, launch acoustics and the temperature extremes of space [Unique functional performance tests in each environment

Designing for Manufacturability tRaditional approach to quality( test/retest) is high cost and takes a long time PNew approaches use concurrent engineering and lean manufacturing processes to reduce cost and ensure quality 6/21/2004

6/21/2004 9 Designing for Manufacturability [Traditional approach to quality (test/retest) is high cost and takes a long time [New approaches use concurrent engineering and lean manufacturing processes to reduce cost and ensure quality

Lean Manufacturing Establishes and implements quality goals in the design phase A Focuses on the processes oe Minimizes wasted time and effort iNvolves manufacturing personnel in the design effort mInimizes work in progress 6/21/2004

6/21/2004 10 Lean Manufacturing [Establishes and implements quality goals in the design phase [Focuses on the processes [Minimizes wasted time and effort [Involves manufacturing personnel in the design effort [Minimizes work in progress