Attachement A - SOW CODEX Twist Capsules RevB.pdf

Statement of Work for CODEX Twist Capsule National Aeronautics and Space Administration

Wallops Flight Facility Wallops Island, VA November 5, 2020

1.1 INTRODUCTION

The Wallops Flight Facility, Small Satellite and Special Projects Office, Code 850 is developing a pointed coronagraph science payload for the international space station. The Twist Capsule is required for the Coronal Diagnostic Experiment (CODEX). CODEX will operate from a platform on the ISS. This science instrument will help to understand solar wind sources and acceleration mechanisms to resolve overarching solar physics questions. This document defines the work to be performed by the Contractor in the design, development, fabrication, and delivery of the Twist Capsule.

1.2 SCOPE

NASA seeks to buy two twist capsules for the CODEX project. This Statement of Work (SOW) defines requirements that govern the management, development, testing, and delivery of the Twist Capsule. It defines the contractor tasks, deliverables, responsibilities, and schedule, either within this document or by reference. The twist capsules shall meet the following requirements in section 1.7. If vendor standards exceed NASA standards, then vendor standards will take precedent otherwise NASA standards shall be followed. In the event of a conflict between the SOW and the specification, please call the NASA Contracting Office Representative (COR) for confirmation.

1.3 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

1.3. A. Program management

The contractor shall provide the facilities, personnel, services, tools, equipment, and materials necessary to design, analyze, manufacture, test, and deliver the hardware and data in accordance with the requirements of this SOW and the documents referenced herein.

The contractor shall generate a matrix listing each section in this statement of work reflecting either compliance or non-compliance. Areas of non-compliance need to be addressed by the contractor showing how they plan to meet the requirement(s) or why it will remain non-compliant.

The contractor shall designate a single individual who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract and ensure that all objectives are accomplished within schedule constraints.

The contractor shall designate and identify by name a single individual to serve as a point of contact with the NASA/GSFC Contracting Officer’s Representative (COR) for all technical aspects of the twisted capsule.

The contractor shall establish and apply a program control system for managing all resources, controlling schedules, managing all engineering, manufacturing and procurement activities, configuration management, Quality Assurance, and documentation control.

1.3. B. Reporting

This section details the requirements for reporting to the NASA/GSFC COR.

a. Program Plan and Schedule

The contractor shall develop a detailed program plan and schedule to describe how the work will be conducted. The contractor shall develop the plans for these activities and the NASA/GSFC COR shall review and approve.

The contractor shall develop a Program Plan that includes the elements given below at a minimum.

• How the program is to be managed

• The key management, technical and quality people on the program

• All subcontractors and their role in the program

• How the contractor plans to manage their subcontractors

• The programmatic and technical risks

The contractor shall use the Program Plan described above to develop a detailed schedule for the program.

The contractor shall incorporate comments made at the Kick-off Meeting from the customer into the Program Plan document and submit a final document to the NASA/GSFC

COR for review and approval.

b. Monthly Program Status Update

The contractor shall prepare and present to the NASA/GSFC COR monthly technical status updates via teleconference or equivalent. These meetings should last no more than one hour. The status update shall be a summary presentation of the monthly progress to include topics such as schedule overview, accomplishments, technical performance measures, status of key milestones, risks, problem areas, challenges/issues, quality assurance issues/status, and on-going and planned activities. Meeting minutes and action items shall be submitted to the NASA/GSFC COR.

1.3. C. Kick-off Meeting

The Contractor shall organize and hold a Kick-off Meeting at the Contractor’s facility prior to any activity identified in this SOW. This meeting can be virtual and should last no more than two hours.

The Contractor shall provide to the NASA/GSFC COR a Kick-off Presentation Package and all other required deliverables. The Kick-off Meeting shall address program management and quality assurance activities outlined in this SOW, as well as the performance requirements outlined in the Twister Capsule Specification in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

• Program Management, program plan, and schedule

• Quality Assurance

• Twist Capsule Design Description

• Flight Heritage

• Facilities

• Mechanical Analysis

• Any long-lead items that need to be ordered

1.3. D. Design Review

The Contractor shall organize and hold a design review at the Contractor’s facility prior to fabrication of the design. This meeting can be virtual and should last no more than three hours.

The Contractor shall provide to the NASA/GSFC COR a Design Presentation Package and all other required deliverables. The design review shall address the technical requirements in Section 1.6 and how they are met. The design review will serve as an approval gate that the design meeting the requirements. At a minimum, the presentation package should cover the following areas:

• Twist Capsule Overall Design

• Mechanical Design

• Mechanical Analysis

• Electrical Design

• Electrical Analysis

• Materials list

1.4 CONCEPT OF OPERATIONS

NASA seeks a systemic solution for passing of electrical signals through two gimbal frames in direct support of an international Space Station bound mission named COronral Diagnosis EXperiment (CODEX). The system will be responsible for passing electrical connections in two areas: the azimuth hub, and elevation hub, pictured immediately below. The azimuth hub enables passing of electrical signals from the FRAM to the gimballed frame. The elevation hub enables passing of electrical signals from the gimballed frame to the internal of the coronagraph.

CODEX must point at the sun with a high degree of accuracy and precision. The system is an integral component of the overall pointing system – it must interact with the pointing system (brushless DC motors) in such a way as to be predictable and low opposition to rotation about its axis. The system is also responsible for both data and power transmissions. The system must accommodate a large range of motion. Full rotations, though not a requirement, is an acceptable solution.

The system will be required during all testing phases of CODEX. NASA will be subjecting the system to environmental testing including vibration, thermal vacuum and shock and as a result will not require this from the vendor prior to shipping the twist capsules. Once entering the system level testing phase, there is no opportunity for extensive maintenance or refurbishment

– the system must be able to progress through all testing and the flight mission without return to vendor.

1.5 SCHEDULE

Deliverables specified in shall be onsite at the Wallops Flight Facility no later than 310 calendar days from the vender’s notice to proceed.

Elevation hub Coronagrap h

FRAM

Gimbal frame

1.6 REQUIREMENTS

• Lifetime o The twist capsule shall be capable of moving greater than 15,000 cycles over the full range of motion with no degradation in function o The twist capsule shall be designed to survive 2 years in low earth orbit

(roughly 420km)

• Conductors o The twist capsule shall contain power and signal lines based on Table 1 o The twist capsule electrical interface shall have flying leads at least 30” long on both the static and rotating interfaces o The twist capsule lead wires will conform to the specifications where detailed in Table 1

• Physical o The twist capsule shall fit in a cylindrical volume no greater than 8” diameter by 5” in length o The twist capsule shall weigh no more than 6kg o The twist capsule shall have a clear through bore of at least ¾” diameter in the center o The twist capsule shall mount via a flange with pattern of 13 (TBR) – #10 holes with a TBD spacing

• Range of motion o The twist capsule shall have a range of motion of at least 290o total angle

• Friction o Static friction torque for the twist capsule shall be less than 30 oz-in over the full range of motion and operating temperature range

• Environment o Loads

▪ The twist capsule shall be designed to handle loads in any direction based on Table 2 o Frequency

▪ The twist capsule shall be designed to have a minimum frequency of greater than 100 Hz when hard constrained at its interface to the spacecraft structure o The twist capsule shall be able to operate in less than 1e-5 Torr o The twist capsule shall be able to operate over a temperature range -20oC to

+50oC o The twist capsule shall be able to survive a temperature range -40oC to +60oC

• Testing o No environmental testing is required o At a minimum acceptance testing will include:

▪ Range of motion

▪ Friction torque measurement over full range of motion at room temperature

▪ Electrical continuity

▪ Electrical impedance

▪ Testing of 120VDC lines to meet minimum DC isolation requirement as noted in Table 1

• Contamination Control o Twist capsule materials shall meet the low outgassing material where the total mass loss is less than 1% and condensable volatile materials collected are less than 0.1% via testing conducting according to the ASTM E595 standard o The unit shall have all components baked out at their maximum allowable temperature for 96 hours at a vacuum of at least 1e-5 torr

1.7 DELIVERABLES

• Kick-off Meeting

• Monthly Technical Status updates

• Design Review

• (2) Twist capsules

• End Item Data Package for twist capsule to include at a minimum:

o Mechanical Interface drawing(s) o Electrical Interface drawing(s) o Materials List and Certifications o Acceptance Test Report o Qualification by Similarity Report

Table 1: Signals, current capacities, lead wire types and notes

Item

Flex PCB Signal Name (Generic)

Signal Standard/Description

Trace Current Capacity

Wire Notes Notes

1 120VDC_HTR_UNFUSED(+)

Power

4A 1,5

2 120VDC_HTR_UNFUSED(-) 4A 1,5

3 120VDC_HTR_FUSED(+)

Power

4A 1,5

4 120VDC_HTR_UNFUSED(-) 4A 1,5

5 28VDC_MAIN1_OUT(+)

Power

13A 1

6 28VDC_MAIN1_OUT(-) 13A 1

7 28VDC_MAIN2_OUT(+)

Power

8A 1

8 28VDC_MAIN2_OUT(-) 8A 1

9 28VDC_SW1_OUT(+)

Power

3A 1

10 28VDC_SW1_OUT(-) 3A 1

11 28VDC_SW2_OUT(+)

Power

3A 1

12 28VDC_SW2_OUT(-) 3A 1

13 28VDC_SW3_OUT(+)

Power

3A 1

14 28VDC_SW3_OUT(-) 3A 1

15 28VDC_SW4_OUT(+)

Power

3A 1

16 28VDC_SW4_OUT(-) 3A 1

17 28VDC_SW5_OUT(+)

Power

3A 1

18 28VDC_SW5_OUT(-) 3A 1

19 28VDC_SW6_OUT(+)

Power

3A 1

20 28VDC_SW6_OUT(-) 3A 1

21 MTR_DRIVE_U Power 8A 1

Size trace based on max possible current through motor = 28V/3.5ohm = 8A

22 MTR_DRIVE_V Power 8A 1

Size trace based on max possible current through motor = 28V/3.5ohm = 8A

23 MTR_DRIVE_W Power 8A 1

Size trace based on max possible current through motor = 28V/3.5ohm = 8A

24 MTR_OVERALL_SHLD Motor Bundle Shield -- 1

25 75OHM_SIG1(+)

MIL-STD-1553B

1,2,3,4

26 75OHM_SIG1(-) --

27 75OHM_SHLD1

Differential Pair Shield

Shield termination point for 75 ohm Sig1 pair

28 75OHM_SIG2(+)

MIL-STD-1553B

29 75OHM_SIG2(-) --

30 75OHM_SHLD2

Differential Pair Shield

-- 1

Shield termination point for 75 ohm Sig2 pair

31 100OHM_SIG1(+)

Ethernet 10 Base-T

32 100OHM_SIG1(-) --

33 100OHM_SHLD1

Differential Pair Shield

Shield termination point for 100 ohm Sig1 pair

34 100OHM_SIG2(+)

Ethernet 10 Base-T

35 100OHM_SIG2(-) --

36 100OHM_SHLD2

Differential Pair Shield

-- 1

Shield termination point for 100 ohm Sig2 pair

37 100OHM_SIG3(+)

LVDS (100 Ohm)

38 100OHM_SIG3(-) --

39 100OHM_SHLD3

Differential Pair Shield

-- 1

Shield termination point for 100 ohm Sig3 pair

40 100OHM_SIG4(+)

RS422 (UART)

41 100OHM_SIG4(-) --

42 100OHM_SHLD4

Differential Pair Shield

Shield termination point for 100 Ohm Sig4 pair

43 100OHM_SIG5(+)

RS422 (UART)

44 100OHM_SIG5(-) --

45 100OHM_SHLD5

Differential Pair Shield

-- 1

Shield termination point for 100 Ohm Sig5 pair

46 100OHM_SIG6(+)

SpaceWire

47 100OHM_SIG6(-) --

48 100OHM_SIG7(+)

SpaceWire

49 100OHM_SIG7(-) --

50 100OHM_SHLD6

Differential Pair Shield

-- 1

Shield termination point for 100 ohm Spacewire signal group #1

51 100OHM_SIG8(+)

SpaceWire

52 100OHM_SIG8(-) --

53 100OHM_SIG9(+)

SpaceWire

54 100OHM_SIG9(-) --

55 100OHM_SHLD7

Differential Pair Shield

-- 1

Shield termination point for 100 ohm Spacewire signal group #2

56 100OHM_SIG10(+)

LVDS (100 Ohm)

57 100OHM_SIG10(-) --

58 100OHM_SHLD8

Differential Pair Shield

-- 1

Shield termination point for 100 Ohm Sig10 pair

59 DATA1(+) Bi-Level Discrete (0- 5V)

1,2

60 DATA1(-) --

61 DATA2(+) Bi-Level Discrete (0- 5V)

62 DATA2(-) --

63 DATA3(+) Bi-Level Discrete (0- 5V)

64 DATA3(-) --

65 DATA4(+) Bi-Level Discrete (0- 5V)

66 DATA4(-) --

67 DATA5(+) Bi-Level Discrete (0- 5V)

68 DATA5(-) --

69 DATA6(+) Bi-Level Discrete (0- 5V)

70 DATA6(-) --

71 DATA7(+)

Analog (0-5V)

72 DATA7(-) --

73 DATA8(+)

Analog (0-5V)

74 DATA8(-) --

75 CHASSIS_GND1 Bonding Ground 13A 1 Designed for max PCB trace current

75+N OVERALL_SHLDxN Overall Bundle Shield -- 1

N = number of flex tapes inside of twist capsule

Power

Data

Shield

Wire Notes:

1/ Wire type shall be of MIL-W-22759/33 grade or equivalent. Final wire gauge selection shall be confirmed with customer but shall meet associated trace current capacities.

2/ Wire leads for (+) and (-) pair shall be twisted.

3/ Wire leads for (+) and (-) pair shall be shielded.

4/ Wire impedance shall match associated signaling standard.

5/ Wire and trace shall be DC isolated from CHASSIS_GND1 (Line #75) by > 1 MΩ.

Table 2: Component Limit Loads – Mass Based

Component Mass (Kg)

Limit Load (G)

1 or less 67.9

2.5 58.0

5 49.0

10 39.8

15 34.7

20 31.2

30 26.8