MSD II 5/1/2015

P15310 – SATCOM on the MoveRev. A

Test Plan

SATCOM on the Move

Table of Contents

1.Introduction

2.Testing

2.1.Component Testing

2.1.1.PCB

2.1.2.Microcontroller

2.1.3.Mount and Driver Board

2.1.4.Batteries

2.1.5.Geo-PNT – Settings

2.1.6.Enclosure

2.2.System Testing

2.2.1.Mount Stability

2.2.2.System Error

2.2.3.Fade Data

1.Introduction

These results were found by following the test plan document.

2.Testing

2.1.Component Testing

2.1.1.PCB

The PCB had a few problems, but off the shelf regulators were purchased to replace the problem areas. The requirements were then met.

Table 1 - PCBTest Results

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.1.1.1 / 12 / Validate battery indicator ("fuel gauge") / 12V / +/- 0.5V / Volts / Adjust pot resistor (R6) such that right-most green LED is lit - inspect Power In LED / Pass, Fuel Gauge is accurate
4.1.1.2 / 12 / Validate +12V circuit / 12V / +/- 0.5V / Volts / Probe J2 - Pin 1 with reference to ground with meter / Pass
4.1.1.3 / 12 / Validate +6V circuit / 6V / +/- 0.5V / Volts / Probe J2 - Pin 2 with reference to ground with meter / Pass
4.1.1.4 / 12 / Validate +9V circuit / 9V / +/- 0.5V / Volts / Probe J2 - Pin 3 with reference to ground with meter / Pass

2.1.2.Microcontroller

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.1.2.1 / 1,2,5 / Power to all shields / Yes/No / NA / NA / Test voltage on outputs from all shields / Pass, all have visual LEDs that power
4.1.2.2 / 1,2,5 / Ethernet Shield / Yes/No / NA / NA / Test data receive / Pass
4.1.2.3 / 1,2,5 / Serial Shield / Yes/No / NA / NA / Test data transfer / Pass
4.1.2.4 / 1,2,5 / Memory Shield / Yes/No / NA / NA / Test file saving / Fail, deemed unnecessary
4.1.2.5 / 1,2,5 / Test program response times / Yes/No / NA / seconds / Run program and keep clock measurements / Pass, calculation negligible
4.1.2.6 / 1,2,5 / Power Microcontroller / 5 / +- 0.1 / Volts / Check USB power cable for correct voltage / Pass, Arduino functional
4.1.2.7 / 1,2,5 / Validate aiming algorithm / Yes/No / NA / NA / Input known coordinates with known offset data.
4.1.2.8 / 1,2,5 / Validate output signal to controller / Yes/No / NA / NA / Given a known input data set, ensure micro outputs correct motor positioning data. / Pass, 0, 90, 180, and 270 degrees checked

2.1.3.Mount and Driver Board

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.1.3.1 / 10 / Yaw Motion (>=360) / 0 to 360 / - 0, + inf / deg / Test program to evaluate motion / Pass, 360 degrees before loopback
4.1.3.2 / 2 / Yaw Degree per Click / <1.5 / - inf, + 0 / deg / Test program and protractor / Pass, average of ~1.5
4.1.3.3 / 11 / Pitch Motion (-90<x<90) / -90 to 90 / - 2, + 2 / deg / Test program to evaluate motion / Pass, 360 degrees, but math only allows 180
4.1.3.4 / 1 / Pitch Degree per Click / <1.5 / - inf, + 0 / deg / Test program and protractor / Pass, average of ~1.5
4.1.3.5 / 1 / Gear Backlash (Pitch) / <.1 / - inf, + 0 / deg / Physical test with protractor / Pass,
4.1.3.6 / 2 / Gear Backlash (Yaw) / <.1 / - inf, + 0 / deg / Physical test with protractor
4.1.3.7 / NA / Stall Torque (Pitch) / >500 / - 0, + inf / in-oz / Physical test with test program / Pass, fought hard, but never stalled
4.1.3.8 / NA / Stall Torque (Yaw) / >500 / - 0, + inf / in-oz / Physical test with test program / Pass, fought hard, but never stalled
4.1.3.9 / NA / Angular Velocity (Pitch) / >50 / - 0, + inf / deg/s / Test program, possibly oscilloscope / Pass, visual check
4.1.3.10 / NA / Angular Velocity (Yaw) / >50 / - 0, + inf / deg/s / Test program, possibly oscilloscope / Pass, visual check

2.1.4.Batteries

Table 2 - Battery Load Test Results

Figure 1 - Battery Testing Results

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.1.5.1 / 6,7,12 / Battery Duration/Life / 90 / -15, + inf / Minutes / Run System continuously until batttery dies and record time / Pass
4.1.5.2 / 6,7,12 / Validate Voltage Output / 12 / +/- 0.5V / Volts / Connect to voltmeter to confirm / Pass

2.1.5.Geo-PNT–Settings

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.1.6.1 / 3, 4, 5 / Check position offset settings to match mount / Yes/No / NA / NA / Visual check off of settings file. / Pass
4.1.6.2 / 3, 4, 5 / Check configuration XML files to ensure proper calibration / Yes/No / NA / NA / Compare current configuration files to new calibrated files. / Pass
4.1.6.3 / NA / Verify PNT is set up to output via ethernet with the correct packets / Yes/No / NA / NA / Check configuration XML files to ensure proper output. / Pass
4.1.6.4 / NA / Verify that the PNT is outputting data / Yes/No / NA / NA / Connect PNT to a known working port (laptop) and listen for output data after initializing PNT / Pass
4.1.6.5 / NA / Verify Power to PNT is correct / 12V, 2A / -2,+18; max 2 / Volts, Amps / Measure via multimeter / Pass

2.1.6.Enclosure

Water Resistance Test

Figure 2 - Enclosure, Wet Outside (Left), Dry Inside (Right)

Enclosure Temperature Test

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.1.7.1 / 12 / No signs of component damage / Yes/No / vib table for specific frequency / Pass
4.1.7.2 / 12 / No signs of connection damage / Yes/No / vib table for specific frequency / Pass
4.1.7.3 / 12 / No signs of mounting damage / Yes/No / vib table for specific frequency / Pass
4.1.7.4 / 12 / No signs of box damage / Yes/No / vib table for specific frequency / Pass
4.1.7.5 / 12 / No water within enclosure / Yes/No / Water resistant test / Pass
4.1.7.6 / 12 / Max temperature does not exceed max operating temperature of any component inside the enclosure / 60°C / + 0, -80°C / °C / Run previously recoreded test data and place thermocouple in the enclosure and monitor temperature for 4 hours / Pass

2.2.System Testing

2.2.1.Mount Stability

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.2.1.1 / 8 / Place system on vehicle and evaluate vibration / Yes/No / Visual confirmation if vibration is too much on video footage / Pass

2.2.2.System Error

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.2.2.1 / NA / Verify that entire system powers up, upon switch ON / ON/OFF / N/A / N/A / Flip the power switch / Pass
4.2.2.2 / 1, 2, 14 / Validate total system error (camera aiming angle) / 0.75 / +0.25, - inf / degrees / Image processing or small scale measurement at various distances (perhaps 200 ft, .5 miles and 2 miles). / Fail, pointing algorithm was skewed
4.2.2.3 / NA / Verify directionals of system / Yes/No / NA / NA / Turn clockwise, counterclockwise, or any other direction, make sure system responds correctly as expected. / Fail, System was close, but not correct

2.2.3.Fade Data

Fade data could not be completed because pointing exactly while GPS was connected could not be fully realized.

# / Eng Req # / Description / Nominal / Margin of Error / Units / "How to test" description (Notes) / Pass/Fail
4.2.3.1 / NA / Check receive data after fade / Yes/No / NA / NA / Receive data, remove GPS, check if data continuous / Fail
4.2.3.2 / 6, 7, 14 / Static test / TBD / NA / NA / Collect fade data while not moving / Fail
4.2.3.3 / 6, 7, 14 / Moving test / TBD / NA / NA / Collect fade data while moving / Fail
4.2.3.4 / NA / Check initial fade data output valid / TBD / NA / degrees / Measure error of PNT output with known coordinates either statically or on a given gps path with a gps signal simulator. / Fail
4.2.3.5 / 6, 7, 14 / Check that the system works overall during a fade / TBD / NA / degrees / Ensure that the data connections work via observing the system and ensuring proper movement with expected error due to PNT during a fade / Fail

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