Client Organization: Satellite Payload Integrator
Business Terms: Time & Material
Anticipated / Actual Engagement Duration: Indefinite / 16 months
Service Location: GTI Facility
Client Objective(s): Automate the cleaning and metrology of material to be incorporated into a satellite payload. Challenges: Space is hard. A chain is only as strong as its weakest link. The recognition of these principles in space craft development leads to very low tolerance of risk. Raw materials to be incorporated into a space flight payload must be thoroughly cleaned and measured. The measurement data should be preserved and documented within the systems engineering framework through which the spacecraft is being developed. Human error in cleaning, measuring, and recording data should be avoided.The material processing system should run unattended, have high reliability, and high availability. The system must generate and store data products containing upwards of 27,500 measurements per production cycle. The system must export the data product(s) from the industrial supervisory controller to a PC / Mac.Facilitate packaging of the processed & measured material in a clean environment, while preventing the re-introduction of contaminants. (The system operates in an uncontrolled / unconditioned environment, so ambient air quality would re-contaminate the processed material.)The data product would be used to inform the design of other payload elements; thus, the prioritization of system capabilities was fluid.
Implementation Strategy: Apply first principles of process automation to design to rapidly prototype a 1st gen automated metrology instrument. The 1st gen solution was built and generating data products in less than a month. Apply first principles of process automation, machine design, metrology, and critical cleaning to design and build a 2nd gen processing system in two phases.Due to severe time constraints, Phase 1 of the Gen-2 system development effort would incorporate only the necessary elements to generate metrology data products, which were gating the clients payload design and integration effort.Following the data product delivery milestone, the Phase 2 of the Gen-2 system development effort would realize the completion of the other processing functionalities.
Outcome: In total, QTY(3) systems were designed, built, and operated in the GTI facility. Data product and processed material were completed and packaged on-site at GTI, and the equipment was later delivered to the client.