MAVENSWEA Assembly Integration Test AIT Contents AIT CESR

MAVEN-SWEA Assembly, Integration & Test (AIT) Contents • AIT: CESR Team • Facilities • Main subcontractors • Applicable documents • AIT documentation • Cleanliness & contamination issues • AIT flow chart • Schedule • Procurements & work in progress • Next activities • Conclusion March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 1

AIT: Staff § Mechanics: J Rouzaud (Irap) - G Peyre (Comat) § Integration, coatings, gluing, HV optocouplers : E Lecomte § Electronics, boards integration & tests: JJ Thocaven, P Rouger + TBD (CNES Technical Assistance for AIT) starting in April. § Calibrations: A Fedorov, P Rouger, C Mazelle § Procedures, anomalies, QA: D Moirin (BTS) § Harnesses, boards assembling: Microtec § Environmental tests : P Rouger + Microtec March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 2

Facilities § Class 1000 clean room for MCPs and detector assembly (IRAP) § New class 100 clean room for Maven and Exo. Mars AITs § Vacuum chamber storage for Maven and Exo. Mars parts or sub systems. § Heating chamber for Maven and Exo. Mars hardware sterilization. § Small clean room for electronics gluing and coating (IRAP) § Vacuum chamber and particles beam in class 10 000 clean room (see A. Fedorov presentation) § Thermal chambers (-60°C to +120°C) – IRAP § Class 100 K clean rooms available in sub contractors premices (Comat, Microtec) § EMC test facility: in Microtec (sub contractor) March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 3

Main sub contractors § COMAT Aerospace Mech. Fabrication & integration same as for STEREO (Toulouse) Tools for assembly same staff as for STEREO Assembly docs (procedures, as_built, control reports, QA, …) § CORIMA (Loriol-FR) Entrance grids fab & gold treatment same as for STEREO § Collini & Fluhmann(Swi) Black copper / Cu 2 S Gold same as for STEREO § SWIPELEC (Bordeaux-FR) MCP grids same as for STEREO § HIREX (Toulouse) EEE parts screening EEE parts procurement same as for STEREO (Tecnologica group) § CIRETEC (Toulouse) PCB fabrication CNES/ ESA qualified § MICROTEC (Toulouse) Parts & PCB welding, Harnesses same as for STEREO same staff § Mecano-ID (Toulouse) Environmental tests March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 4

Reference documents § MAVEN SWEA Performance Assurance Plan § MAVEN SWEA UCB to CESR/IRAP Interface Control Document § MAVEN PFP performance requirement § MAVEN PFDPU to instruments ICD § MAVEN – UCB Mission Assurance Implementation Plan (MAIP) § Maven harness specifications § Maven grounding specifications § Maven latchup LET criteria (tech. Note - UCB) March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 5

AIT documentation • As built lists (materials, EEE parts, processes) • As built assembling procedures • Environmental testing reports (if any) • Log books • Non conformity reports with appropriates corrective actions • Photographic documentation of FM hardware • Analysis reports (mechanical, electrical, …) • Tests reports March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 6

Cleanliness and contamination issues (1) § Microchannel plate cleanliness requirements (same as for Stereo) • Sensitivity to humidity, dust & hydrocarbons • 100 microns particles can create discharges and damage MCPs • Outgassing near MCP to be avoided • Special procedure to clean MCPs and restore properties § Permanent purging system installed on Swea with dry nitrogen at 5 liters/ hour • Plastic hermetic container filled with dry nitrogen acceptable for transportation (couple of hours) • few hours without purge flow is possble in clean room environment • MCPs or sensor equiped with MCPs is stored in vacuum at IRAP § Hermetic red tag cover on Swea analyser can be removed only in a class 1000 clean room and has to be kept on Swea analyser during I&T March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 7

Cleanliness and contamination issues (2) § All mechanical parts are cleaned with IPA § Storage vacuum chamber purchased for Swea parts during or after AIT. § Integration in clean rooms • In subcontractors clean rooms (Comat or Microtec) for tests or preliminary assemblies • Class 100 IRAP clean room with PP rules. • Class 1000 IRAP clean room for MCPs and analyser § Parts or sub systems bakeout before assembly in class 100 clean room §Unit bakeout for outgassing before first calibration tests § SWEA analyser stored in vacuum before calibration or before delivery to UCB § Bakeout of full Swea instrument at UCB (? ) March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 8

Cleanliness and contamination issues (3) • New ISO 8/ Class 100 vertical flux clean room purchased for Maven & Exo. Mars integrations. • Agreement to follow SSL planetary protection AIV rules (R Bartlett, Oct 4 th 2010) • For analyser coating, coated samples are made in the same time for contamination tests. • Document with specific AIV instructions wrt PP rules given to subcontractors. • First step of AIV @ subcontractors premices, then parts are sterilized when delivered to CESR. • Red protection cover redesigned for better use (Stereo experience) • Subsystems or Hw transported in sterile bags during AIV • Small vacuum storage purchased to store Hw or parts @1 mbar during AIV or before delivery • All steps in non conformity with PP reported on unit log book. March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 9

SWEA – MAVEN Protoflight AIT Flow Chart Processes modified to respect PP goal Note: Stereo-SWEA Engineering model analyser has been re-furbished according to Stereo to Maven changes and modifications indications have be validated and given to SSL (See Andrei Fedorov report) March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 10

SWEA sensor electronics and mechanics AIT steps Spheres + top cap coating Boards assembly, parts welding Harnesses @ Microtec Sterilization: 72 h @ 110°C Functionnal tests, tuning parts fixing Electronics integration, tuning parts welding Mechanical parts fabrication and control @ COMAT Mechanical verifications and tests (concentricity, mounting, ) @Collini with contamination samples delivered External parts coating Black Ni @SSL Cleaning / sterilization @ CESR Mechanical parts control and assembly test Quick functionnal test Thermal tests , tests reports Electronics ready for instrument assembly March 28, 2011 SWEA sensor mechanical assembly SWEA mechanics ready for instrument assembly MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 11

SWEA sensor final integration Electronics ready for instrument assembly SWEA sensor assembly internal connections SWEA mechanics ready for instrument assembly First vacuum tests @ CESR big vacuum chamber Electronics disassembly Gluing, coatings SWEA sensor final assembly Functionnal verifications Ready for delivery March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 12

AIT Schedule (2011) Delivery date to UCB TBD (late 2011) Previous schedule shifts due to open issues (Stereo to Maven changes) March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 13

AIT: procurements & work in progress Ø Assembly tools available at IRAP or in Comat Ø Stereo-SWEA engineering model available for « Maven modifications » ØFlight MCPs stored at Irap (delivered february 2010 : 1 pair) Ø Flight PCBs available stored at Microtec Ø Comat waiting for parts sent for coating to assemble mechanics. Ø Charge amplifiers A 111 F Amptek - GSFC screening (Option 1+) ØAll EEE parts delivered and available for boards assembly ØStereo parts re-screening: all available March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 14

Next activities o Update IRAP / UCB documents (ICD, QA) o Update EEE parts list , material list (cf David) o Fix most of Stereo to Maven changes issues with UCB o All flight parts received o High voltage optocouplers fabricated o Pinpullers delivered o Flight Model Mechanical parts fabricated o Some parts under treatment March 28, 2011 MAVEN SWEA instrument Pre-CDR Peer Review @ IRAP March 28 -29, 2011 15