Developments in test facility and data networking for the Altitude … · 2013-04-10 · Developments in test facility and data networking for the Altitude ... • Ancillary Systems/Electrical

11

Stennis Space Center

Developments in test facility and data networking for the Altitude Test Stand at the John C. Stennis Space Center

A General Overview

Phillip W. Hebert

SSC Electrical Design Engineering (EA-31)

(228) 688-2995

[email protected]

RELEASED - Printed documents may be obsolete; validate prior to use.

https://ntrs.nasa.gov/search.jsp?R=20080013489 2018-07-28T12:55:19+00:00Z

22


Developments in test facility and data networking for the Altitude Test Stand at the John C. Stennis

Space Center – A General Overview

RSRS--68 650 klbf68 650 klbf@ B1 Test Stand@ B1 Test Stand

Space Shuttle Main Engine TestSpace Shuttle Main Engine Test@ A2 Test Stand@ A2 Test Stand

Fastrac 60 klbfFastrac 60 klbf@ B2 Test Stand@ B2 Test Stand


33


NASA/SSCNASA/SSC’’s Mission in Rocket Propulsion Testing Is to Acquire s Mission in Rocket Propulsion Testing Is to Acquire Test Performance Data for Verification, Validation and Test Performance Data for Verification, Validation and Qualification of Propulsion Systems HardwareQualification of Propulsion Systems Hardware•• AccurateAccurate•• ReliableReliable•• ComprehensiveComprehensive•• TimelyTimely

Data Acquisition in a Rocket Propulsion Test Environment Is Data Acquisition in a Rocket Propulsion Test Environment Is ChallengingChallenging•• Severe Temporal Transient Dynamic EnvironmentsSevere Temporal Transient Dynamic Environments•• Large Thermal GradientsLarge Thermal Gradients•• Vacuum to 15k psi pressure regimesVacuum to 15k psi pressure regimes

SSC Has Developed and Employs DAS, Control Systems and SSC Has Developed and Employs DAS, Control Systems and Robust Instrumentation that Effectively Satisfies these ChallengRobust Instrumentation that Effectively Satisfies these Challengeses

The Following Presentation Reviews SSCThe Following Presentation Reviews SSC’’s Data Acquisition and s Data Acquisition and Controls Architectures Controls Architectures

Developments in test facility and data networking for the Altitude Test Stand at the John C. Stennis

Space Center – A General Overview


44


Agenda

Background Background –– SSC EE Org & Test FacilitiesSSC EE Org & Test Facilities

High/Low Speed Data Acquisition SystemsHigh/Low Speed Data Acquisition Systems

Control SystemsControl Systems

Video SystemsVideo Systems

Network ArchitectureNetwork Architecture


55


A-3 Project Team

Reach back into respective elements

A-3IBMT

SupportPA00

A-3Systems Engineer

LeadEA51

AA--3 Project Team3 Project Team

A-3Environmental

LeadRA02

JEProject

Manager

Independent Technical

Authority (ITA)

Matrix

Project Support

A-3Chief

EngineerEA00

A-3Project

ManagerPA20

A-3OperationsElectrical

Lead

EA21

A-3Design

ElectricalLead

EA31Philip Hebert

A-3Design

MechanicalLead

EA32

A-3Operations

FacilityLead

EA10

A-3Construction

Lead

RA10

A-3Safety and

MissionAssurance

LeadQA20

A-3Procurement

Lead

BA33

A-3OperationsMechanical

Lead

EA22

A-3Design

AnalysisLead

EA33

MSFCRepresentative


66


Design & Analysis Division

• Modeling and Analysis development and integration into RPT

• Fluid Mechanics/Thermal Analysis of Propellant Systems

• Liquid• Gas

• CFD• Structures/Loads Analysis• Thermal/Heat Transfer Analysis

Electrical Systems & Software

• Data Acquisition• Instrumentation & Signal Conditioning• Controls & Simulation • DACS Lab Management• Data Systems Management• Ancillary Systems/Electrical Power

Mechanical and ComponentSystems

• Cryogenic Propellant Systems • Storable Propellant Systems & HPIW• Hydraulics/pneumatics Systems• Press Gas/Purge Systems (TBA)• Components• Materials• Ancillary Systems

• TMS, Measurement Uncertainty• Standards & Specifications

Systems Analysis & Modeling

Design and Analysis Division

• Configuration Management• Records Retention DB Management

Organization Goal:• Develop and maintain propulsion test systems and facilities engineering competencies

• Unique and focused technical knowledge across respective engineering disciplines applied to rocket propulsion testing. e.g.,

• Materials selection and associated database management• Piping, electrical and data acquisition systems design for cryogenic, high flow, high pressure propellant supply regimes• Associated analytic modeling and systems analysis disciplines and techniques• Corresponding fluids structural, thermal and electrical engineering disciplines


77


AB-Complex

B-1/B-2 Full Scale Engine/Stage

Devt. & Cert

A-1 Full Scale Engine Devt. & Cert A-2

Components …Engines … Stages

J-2X SSME

SSC Test Facilities

RS-68/ARES


8


E-1Cells 1, 2, 3

High Press., Full Scale Engine Components

E-3Cell 1

E-2 Cell 2Low Press. Mid-Scale

& Subscale, Stage

E-3Cell 2

SSC Test Facilities (continued)

High Press. Small-Scale Subscale

TGV

J-2X J-2X

E-Complex

E-2Cell 1High Press.Mid-Scale

& Subscale


9



A-3

Conceptual View Conceptual View ––A3 Test StandA3 Test Stand


10



Nominal Vacuum Thrust

294,000 lbs

Nominal Vacuum Thrust

294,000 lbs


1111


Typical Test ArticlesTypical Test Articles

Integrated PowerheadDemonstrator

LR-89


1212


Test Facility Electrical Systems

Communications SystemCommunications System

Control SystemControl SystemFacility Fire Alarm SystemFacility Fire Alarm SystemFire & Gas Leak Detect SystemFire & Gas Leak Detect SystemGrounding SystemGrounding System

High Speed Data Acquisition SystemHigh Speed Data Acquisition SystemLighting SystemLighting SystemLightning Protection SystemLightning Protection System

Low Speed Data Acquisition SystemLow Speed Data Acquisition SystemAural Warning SystemAural Warning SystemPower Distribution SystemPower Distribution SystemUninterruptible Power SystemUninterruptible Power System

Video SystemVideo SystemInterconnecting NetworkInterconnecting Network


1313


Typical Test Facility Typical Test Facility Electrical System LayoutElectrical System Layout

Test Control Center Signal Conditioning BldgOr Hardcore

Test Article

Historical Overview of Systems at SSC

PLCE-NET

F/O F/O

ControlConsolesIncludes

PLCRacks

Instruments

CABLETERM. ENCL.

STE/TA InstrumentsSTE Valves

CABLE BOX(RB,TEB)

DRAG-ONS

FEED THROUGHCABLE COMPRESSION BOX

Collector

AnalogInputs

PLCs

Disc Vlv

Analog Vlv

FacilityS/C

Facility S/C: Programmable Signal Conditioners, Manual Filter Amps,

PCB and Dynamics Amps

LSDASDigitizer F/O F/O

HSDAS

F/O F/O


1414



A-3 Test Stand Electrical Systems & Interactions

Low Speed Data Acquisition

System (LSDAS)

High Speed Data Acquisition

System (HSDAS)

Control System (CS)

Low Speed Video System

(LSV)

High Speed Video System

(HSV)

Test Stand Lighting

Lightning Protection

SystemNetworksOFF-SITE

Grounding System

Control System (CS)

CommunicationsSystem(s) Lightning

Protection SystemNetworksOFF-SITE

Hazardous Gas Detection and

Protection System

Hazardous Gas

Detection and Protection

System

and Fire

DC PowerDistribution


1515



A-3 Test Stand Electrical Systems Software Data Flow & Interactions


System (LSDAS)


System (HSDAS)

Control System (CS)


(LSV)


(HSV)

NetworksOFF-SITE

Avionics Interface


System (LSDAS)


System (HSDAS)

Control System (CS)


(LSV)


(HSV)

NetworksOFF-SITE

Avionics Interface

J-2XENGINE

Hazardous Gas Detection and

Protection System

Hazardous Gas

Detection and Protection

System

and Fire


1616


Test Control Centers Test Control Centers ––Currently in PlaceCurrently in Place

A2 TCCTest

Conductor'sStation

E2 TCC


1717


Signal Conditioning Buildings (SCB) Signal Conditioning Buildings (SCB) ––Current Uses & InstallationsCurrent Uses & Installations

E2 SCB's

1 & 2

E2 Cell 1 SCB 1

Controls Racks

E1 SCB Signal

Conditioning Rack


1818


Signal Conditioning Buildings (SCB)Signal Conditioning Buildings (SCB)

A-3 Test Stand SCB Location


1919


High Speed Data Acquisition Systems

(HSDAS)


2020

Stennis Space CenterHigh Speed Data Acquisition SystemHigh Speed Data Acquisition System

• The High Speed Data Acquisition System is used torecord rocket engine or component data from a variety of dynamic sensors.

• Sampling rates are normally an order of magnitude in sample rates compared to the Low Speed Data Acquisition System.

• High speed data provides the Analyst with information about the dynamic environment/condition of a test article. The data feedsmodels that characterize the performance of the test article or allows the analyst to help determine the health of the hardware.

• The data is typically analyzed in the frequency domain.• Challenges to recording good high speed data include the

environment (high temperatures, vibration, high flow, cryogenic temperatures, high pressure), proper cabling, appropriate sensorselection, and numerous other considerations.


2121


High Speed High Speed Data Acquisition SystemsData Acquisition Systems

DataMAX IIDataMAX II (New to be used for A(New to be used for A--3)3)-- >= >= 200,000 Samples Per Second 200,000 Samples Per Second (Binary & (Binary & Decimal Sampling)Decimal Sampling)•• AB Complex (RSAB Complex (RS--68, J68, J--2X)2X)•• E ComplexE Complex•• Planned for use on APlanned for use on A--33


2222


Typical High Speed Data Acquisition Typical High Speed Data Acquisition System InstrumentationSystem Instrumentation

Typical Instrumentationnot always in the Catalog

• Special Ranges• Temp Compensation• Special Materials


2323


Typical High Speed Data Acquisition Typical High Speed Data Acquisition System InstrumentationSystem Instrumentation

StrainDynamic Pressure

AccelerometerSpeed


2424


Planned APlanned A--3 High Speed Data3 High Speed DataAcquisition SystemAcquisition System

SENSORS & TRANSDUCERS

INTERCONNECT CABLING

RECEPTACLE BOXES (RBs) &

TEBs

SIGNAL CONDITIONERS & AMPLIFIERS

RECORDER / CONTROL

WORKSTATION (TCC) A-3 TEST

FACILITY LAN HUB

HSDAS ETHERNET

SWITCH (SCB)

TEST STAND / TEST CELL

SIGNAL CONDITIONING BUILDING (UL)

PATCHPANELS

IRIG-B TIME SOURCE

CALIBRATION CONTROL

TEST CONTROL CENTER

FIBER OPTIC CABLE

A-3 LANSERVER

TO SDC

DATA PROCESSING

TRANSMISSION PC

FIBRE-CHANNEL

SSC LAN

HSDAS ETHERNET

SWITCH (SCB) MSFC

Slave

MasterRecorder

Slave

MasterRecorder Master

Recorder

Slave

MasterRecorder

PWR

T=0 FROM CS


2525


Low Speed Data Acquisition Systems


2626


SSC's Low Speed SSC's Low Speed Data Acquisition SystemsData Acquisition Systems

Data acquisition, recording, real time display, data Data acquisition, recording, real time display, data acquisitionacquisition•• Data types:Data types: Low frequency Analog Data, Discrete Low frequency Analog Data, Discrete

(event) Data, Pulse Data from flow meters and speed (event) Data, Pulse Data from flow meters and speed sensorssensors

EE--Complex DigitizerComplex Digitizer -- ~ 200 samples per second or ~ 200 samples per second or greatergreater

ABAB--Complex DigitizerComplex Digitizer -- ~ 200 samples per second or ~ 200 samples per second or greatergreater

AA--3 Test Stand 3 Test Stand –– ~ 200 samples per second or greater~ 200 samples per second or greater


2727


EE--Complex Low Speed DataComplex Low Speed DataAcquisition System ArchitectureAcquisition System Architecture

DIGITALINPUTSFOR

CONTROL SIGNALS, LIMITSWITCHES, ETC

INTER-CONNECT

CABLING RBs&

PATCH PANELS

SENSORSTRANSDUCERS

VALVES

SIGNALCONDITIONERS

&AMPLIFIERS

MULTI-SYSTEMCONTROLLER

(LOCAL COLLECTOR)

MASTERHIGH-LEVEL

MULTIPLEXOR

IRIG-BTIME

SOURCE

DISCRETEINPUT/OUTPUT

MODULE

SLAVEHIGH-LEVEL

MULTIPLEXOR

DAS SYSTEMCONTROLLER, CAL PC, AND DISPLAY

REMOTEDAS

DISPLAYS

GPIB

ETHERNET

FIBER OPTIC

HIGH LEVELINPUTS

HIGHLEVELINPUTS

TEST FACILITY SIGNAL CONDITIONING BUILDING TEST CONTROL CENTER

HUB HUB

REMOTEDAS

DISPLAYS

Historical Overview of LSDAS at SSC – E-Complex


2828


ABAB--Complex ArchitectureComplex ArchitectureLow Speed Data Acquisition System Low Speed Data Acquisition System

INTER-CONNECT

CABLING RBs&

PATCH PANELS

SENSORSTRANSDUCERS

SIGNALCONDITIONERS

&AMPLIFIERS

PRIMARYMULTIPLEXER

IRIG-BTIME

SOURCE

PRIMARYDISPLAY

PC

GPIB

ETHERNET

HIGH LEVEL INPUTS

INNER CORE of TEST STAND TEST CONTROL CENTER

DIGITAL INPUTS FOR CONTROL SIGNALS, LIMIT SWITCHES, ETC.

SECONDARY MULTIPLEXER

PRIMARYEVENTS

SECONDARYEVENTS

SECONDARYEVENTS PC

PRIMARY EVENT

LOGGER

SECONDARYEVENT

LOGGER

SECONDARYDISPLAY

PC

HUB HUB

HUB HUB

OUTER CORE of TEST STAND

PRIMARY DAS PC

CAL CONTROL

PC

PRIMARYEVENTS PC

PRIMARY DATA

LOGGER

SECONDARYDAS PC

SECONDARYDATA

LOGGER

GPIB

ETHERNET

FIBER

OPTIC

Redundant Data Recording

Historical Overview of LSDAS at SSC – AB-Complex


2929


ABAB--Complex Architecture Complex Architecture Low Speed Data Acquisition SystemLow Speed Data Acquisition System

The ABThe AB--Complex LSDAS consists of four test stand Complex LSDAS consists of four test stand systems:systems:•• A1, A2, B1, B2 (B1/B2 one structure with two distinct sides)A1, A2, B1, B2 (B1/B2 one structure with two distinct sides)

Systems contain >= 500 analog input channels and >= Systems contain >= 500 analog input channels and >= 700 digital input channels700 digital input channelsEach system contains a primary and secondary system Each system contains a primary and secondary system for redundancy. Data from the secondary system is only for redundancy. Data from the secondary system is only processed if a problem occurs on the primary system.processed if a problem occurs on the primary system.



3030



Fully populated Fully populated analog box analog box •• >= 200 analog input >= 200 analog input

channelschannels

Fully populated Fully populated discrete boxdiscrete box•• >= 400 digital input >= 400 digital input

channelschannels



3131



Model 8300Model 8300•• Programmable Programmable

Gain, filter, excitationGain, filter, excitation•• Automated calibrationAutomated calibration

Voltage InsertionVoltage InsertionShuntShuntRcalRcal

•• Various Mode CardsVarious Mode CardsStrain Gauge Strain Gauge Full Bridge , Half BridgeFull Bridge , Half BridgeRTDRTDThermocoupleThermocouple

•• MeasurementsMeasurementsStrain GaugesStrain GaugesPressure TransducersPressure TransducersRTDRTD’’ssThermocouplesThermocouples



3232


REMOTE DISPLAYS

REMOTE DISPLAYS

REMOTE DISPLAYS

REMOTE DISPLAYS

Proposed AProposed A--3 Low Speed Data3 Low Speed DataAcquisition System ArchitectureAcquisition System Architecture

A-3 Test Stand Proposed LSDAS




TEBs

SIGNAL CONDITIONERS & AMPLIFIERS

IRIG-B TIME SOURCE

DIGITAL INPUTS FOR CONTROLSIGNALS, LIMIT SWITCHES, ETC.

RECORDER / CONTROL

WORKSTATION (TCC)

A-3 TEST FACILITY

LAN SWITCH

LSDAS ETHERNET

SWITCH

DAS REAL-TIME TRANSMISSION

SERVER

LSDAS ETHERNET

SWITCH

TEST STAND / TEST CELL

VDC FROM CS

SIGNAL CONDITIONING BUILDING(s)

DIGITIZER / MULTIPLEXER(S)

RECORDER / CONTROL

WORKSTATION (SCB)

CALIBRATION CONTROL

TEST CONTROL CENTER

FIBER OPTIC CABLE

A-3 LANSERVER

TO SDCDATA

PROCESSING TRANSMISSION

PCFIBRE-CHANNEL

SSC LAN

DATA TO CS

T=0


3333


Existing functionality• All of the E-Complex Low Speed DAS software is developed in LabVIEW

LSDAS Operational and Control SoftwareDisplay ScreensCalibration SoftwareMeasurement System Analysis (MSA’s)“Near” real-time data transmissions

Proposed for A-3• Currently considering option of having vendor provided software or Pratt-

Whitney Rocketdyne developed Stennis Data Acquisition (SDAS) software for the following functions:

LSDAS Operational and Control Software“Near” real-time data transmissionsDisplay ScreensCalibration Software

• The Measurement System Analysis (MSA’s) function is planned to be developed in-house by NASA Engineering & Sciences Directorate (E&SD).

Low Speed Data Acquisition SystemLow Speed Data Acquisition SystemSoftwareSoftware

Software:


3434


Data Acquisition and RealData Acquisition and Real--time Displaytime DisplayProvides for the control of the data acquisition process and theProvides for the control of the data acquisition process and thedistribution of data for realdistribution of data for real--time displaytime display

Combines both the analog and discrete dataCombines both the analog and discrete data

Measurement System AnalysisMeasurement System AnalysisSoftware originally and methodology developed by RocketdyneSoftware originally and methodology developed by Rocketdyne

Purpose is to quantify a system precision for the LSDAS by Purpose is to quantify a system precision for the LSDAS by evaluating the drift over time of the data system.evaluating the drift over time of the data system.

It consists of a two point calibration performed every hour duriIt consists of a two point calibration performed every hour during an ng an eight hour time span. This is to simulate the maximum time eight hour time span. This is to simulate the maximum time between a prebetween a pre--test calibration and a test.test calibration and a test.

Software



3535


Low Speed Data Acquisition System Low Speed Data Acquisition System ––Calibration ControlCalibration Control

Calibration ControlCal Control PLC Master

Controller

Calibration Control

Function

Selector Control Panels

Voltage Standard

Function Generator

Cal Box

Programmable Interface

Digital MultiMeter

Short

Multiplexer / Digitizer

CONTROL

STATUS

CONTROL

CAL FLAGS

Test Control CenterDISCRETES

CAL FLAGS

Cal Select Relays

Test Stand Select Relay


3636


Provides computer controlled setups and Provides computer controlled setups and calibration of the Signal Conditioners.calibration of the Signal Conditioners.

Signal Conditioning SetupSignal Conditioning Setup•• Select gain, filterSelect gain, filter•• Setup and adjustment of individual signal conditioners and ampliSetup and adjustment of individual signal conditioners and amplifiersfiers

•• CalibrationCalibration•• Automatic calibrations on any number of selected signal conditioAutomatic calibrations on any number of selected signal conditionersners•• Calibrate all active measurements preCalibrate all active measurements pre--testtest•• Calibration TypesCalibration Types

Shunt CalibrationShunt CalibrationVoltage SubstitutionVoltage SubstitutionExcitation Power Supply CalibrationExcitation Power Supply CalibrationExternal CalibrationExternal Calibration

Calibration Software

ABAB--Complex Architecture Complex Architecture Low Speed Data acquisition SystemLow Speed Data acquisition System


3737


Typical Low Speed Data Acquisition Typical Low Speed Data Acquisition System InstrumentationSystem Instrumentation

FACILITY SPECIAL TEST EQUIPMENT TEST ARTICLE

Radiometer

Temperature

Flow

Static Pressure

Flow

Temperature

Static Pressure

Temperature

Flow

LVDT

LVDT

Strain

StrainLVDT

ProximitySpeed

• Standard Instrumentation - Not always in the Catalog• Special Ranges (Cryogenics, Hundreds of Degrees F )• Special temperature compensation circuits• Special Materials• Extremely High Pressures• Vacuum pressure transducers – Specific to the A-3 Test Stand

Level

Load Cell

Static Pressure


3838


Typical Low Speed Data AcquisitionTypical Low Speed Data AcquisitionSystem InstrumentationSystem Instrumentation

Pressure

Transmitter

Pressure

Delta P

Temperature

Thermocouples RTD’s

Transmitter

Strain

Strain Gauges

Speed

Speed Probe

Flow

VenturiFlowmeter

Turbine Flowmeter


http://www.omega.com/ppt/pptsc.asp?ref=Prewired_GP_Strain_KFG&nav=pree02

3939


Control Systems


4040

Stennis Space CenterControl SystemsControl Systems

• The Control System manages the test complex and rocket engine or component systems during day-to-day operations and testing while maintaining a safe environment allowing for orderly test shutdown and making facility systems safe in emergency situations. • Programmable Logic Controllers (PLCs) form the

backbone of the SSC Control Systems – New term Programmable Automation Controllers (PAC).

• PLCs primary functions are to sequence rocket engine or component tests and maintain daily operations.

• Hard-wired controls are provided as a backup to the PLCs.


4141

Stennis Space CenterControl Systems FunctionsControl Systems Functions

Day to Day OperationsDay to Day Operations•• Unloading cryogenics/propellants (Oxygen, Unloading cryogenics/propellants (Oxygen,

Hydrogen, Nitrogen, Methane, etc.)Hydrogen, Nitrogen, Methane, etc.)•• Propellant transfers from storage to run tanksPropellant transfers from storage to run tanks•• Pumping up bottle pressures (Nitrogen, Pumping up bottle pressures (Nitrogen,

hydrogen, helium etc.)hydrogen, helium etc.)•• Gas leak and fire detection.Gas leak and fire detection.•• Engine dryingEngine drying•• Facility Readiness Test (FRTs)Facility Readiness Test (FRTs)•• Redline cut checks (Redlines are Redline cut checks (Redlines are

measurements that are monitored by the PLC measurements that are monitored by the PLC for the purpose of initiating an immediate shut for the purpose of initiating an immediate shut down when out of tolerance.)down when out of tolerance.)


4242

Stennis Space CenterControl Systems FunctionsControl Systems Functions

Test Day OperationsTest Day Operations•• Propellant TransfersPropellant Transfers•• Engine chill down and prepEngine chill down and prep•• BlueBlue--line monitoring (Permissives to start test.)line monitoring (Permissives to start test.)•• Test stand valve sequencing and control during hot fire Test stand valve sequencing and control during hot fire

testtest•• Redline monitoring during hot fire testRedline monitoring during hot fire test•• Performs a controlled shutdown of the engine Performs a controlled shutdown of the engine

Critical valves are also wired to a backup PLC or timed Critical valves are also wired to a backup PLC or timed relaysrelays

•• For the AFor the A--3 Test Stand, proper control of the Chemical 3 Test Stand, proper control of the Chemical Steam Generator (CSG) system is also required.Steam Generator (CSG) system is also required.


4343


AA--3 Test Stand Control System3 Test Stand Control System

Seven PLC functions:Seven PLC functions:•• Facility ControlFacility Control•• CSG ControlCSG Control•• CSG Control BackupCSG Control Backup•• BlueBlue--Line and Redline Monitoring & Test Sequence ControlLine and Redline Monitoring & Test Sequence Control•• Fire and Hazardous Gas DetectionFire and Hazardous Gas Detection•• Dock Dock –– Propellant TransferPropellant Transfer•• Calibration ControlCalibration Control

Generic Ladder Logic is envisionedGeneric Ladder Logic is envisioned•• System is configured entirely through Excel or DatabaseSystem is configured entirely through Excel or Database•• Excel tables and/or Database can be configured in advance Excel tables and/or Database can be configured in advance

and downloaded on test day.and downloaded on test day.•• Excel tables and/or Database can be archived for historical Excel tables and/or Database can be archived for historical

referencereference


4444


E1 Control System LayoutE1 Control System Layout

Historical Overview of Controls System at SSC – E1

PLCE-NET

F/O F/O

ControlConsolesIncludes

PLCRacks

Instruments

CABLETERM. ENCL.

STE/TA InstrumentsSTE Valves

CABLE BOX(RB,TEB)

DRAG-ONS

FEED THROUGHCABLE COMPRESSION BOX

Collector

AnalogInputs

PLCs

Disc Vlv

Analog Vlv

FacilityS/C

Facility S/C: Programmable Signal Conditioners, Manual Filter Amps,

PCB and Dynamics Amps

LSDASDigitizer F/O F/O

HSDAS

F/O F/O


4545


E1 TCC Ethernet Switcher E1 SCB Ethernet SwitcherLower RateEthernet Hub

Workstations

PLCs

Eplex Ethernet Switcher

Serial Communications

Deluge Pump Station

Control Room SCB

F.O.

E1 PLC Network DesignE1 PLC Network DesignHistorical Overview of Controls System at SSC – E1


4646


Typical E1 SLC Programmable Logic Typical E1 SLC Programmable Logic Controller (PLC) InstallationController (PLC) Installation

• Dedicated STE PLC for Cell 2

DO AI

AO DI

• Shared Display PLC~

AI

DI

E1 PLCCabinet

Historical Overview of Controls System at SSC – E1


4747


Proposed AProposed A--3 Control System 3 Control System ArchitectureArchitecture

Controls Master Ethernet Switch

Red-line &Sequencer

PLC

CSGBackup

PLC*

DockPLC

CalibrationPLC

CSG Ethernet Switch

RemoteI/O

Chassis 1

FacilityPLC

RemoteI/O

Chassis 2

RemoteI/O

Chassis x

Ethernet…

CSG #xControl

CSG #2Control

CSG #1Control

CSGPLC

AvionicsInterface

J-2XENGINE

VSIM

Fire & GasDetectPLC

T=0


4848


Proposed AProposed A--3 Control System 3 Control System ArchitectureArchitecture

Timer B

EmergencyShut-Down

(Test Conductor’sConsole)

Timer C

Timer D

ImmediateBus A

PLCs

Watch-DogTimers

To Engine Controller

*HOLD

* If deemed necessaryFor specific valves

To Control Valves

VDC

S

Fail-Safe Solenoid


4949


• Migration to faster PLCsin a Distributed Architectureoutside the E1 Test Facility

• A-Complex Redline System

• A-Complex Fire & Gas Leak Detect

System

• B-Complex Redline System

• B-Complex Fire & Gas Leak Detect

System in design

• E3 Redline System

• A-3 Control System – ALL PLCs

Modernized PLC

SSC PLC Architecture ChangesSSC PLC Architecture Changes


5050


Test Control Center with GraphicalTest Control Center with GraphicalUser Interface (GUI) ScreensUser Interface (GUI) Screens

Hard WiredControls Controls

GUI


5151

Stennis Space CenterInTouch by Wonderware GUIInTouch by Wonderware GUI


5252


Video System


5353


AA--3 Test Stand Video System3 Test Stand Video System

• The A-3 Video System is envisioned to be a digital media video recording system. To this date at SSC, video recording system has been based upon a system that records to video tapes. • A-3 TEST STAND VIDEO REQUIREMENTS:

• Must record digital data to either hard drive or DVD.• Low Speed frame rate of ~30 frames per second (fps). High Speed frame

rate of ~200 fps or greater.• Recording time of >= steam generation time plus margin, minimum for both

Low and High-Speed Video Systems.• Recording must be remote from the camera.• Cameras and/or enclosures must operate at expected vacuum pressures.• Must digitally stream real time Low Speed test video off-site.• Must support Infrared (IR) video.


5454


AA--3 Test Stand Video System3 Test Stand Video System

T=0


5555


A-3 Test Facility NetworkArchitecture


5656


AA--3 Network Architecture3 Network ArchitectureDescriptionDescription

• The A-3 Network System is designed to provide overall network connectivity between all of the sub-networks required for the A-3 Electrical Systems.• A-3 TEST STAND NETWORK REQUIREMENTS:

• Test data network must be physically isolated from facility data network.• Transmission of “near” real-time data and video must use outgoing only

physical connections.• Provide method of transmitting post-test data outside of Test Facility network.• Provide a means of digitally transmitting “deterministic” LSDAS data to the

Control System.


5757


AA--3 Network Architecture3 Network ArchitectureBlock DiagramBlock Diagram

To SDC

To SSC LANTx

Acronyms

CS Control System SDC Stennis Data CenterLSDAS Low Speed Data Acquisition System SSC Stennis Space CenterHSDAS High Speed Data Acquisition System Tx TransmitDAS Data Acquisition System Rx ReceiveLAN Local Access Network TCC Test Control Center

4

4 LSDAS Deterministic DATA

A-3 Test Facility LAN

Rx

Test Network LAN Switch

LSDAS LANESK-A3-4071-FAC

HSDAS LANESK-A3-5071-FAC

Video LANESK-A3-7071-FACESK-A3-7571-FAC

A-3LAN

Server

CS LAN ESK-A3-2001-FAC

VideoTransmission

Server

DASTransmission

Server

BLACK & WHITEPRINTER COLOR

PRINTER

TCC


5858



Typical Control System Type Inputs




TEBs

SignalConditioning

Amplifier

To ControlsSystem

To LSDAS

To HSDAS**If necessary

Networked Control System Connection

DIGITIZER / MULTIPLEXER(S)

RECORDER / CONTROL

WORKSTATION (SCB)

LSDASDATA TO CS

ControlLogix Chassis

Processor Slot Ethernet for GUI

ReflectiveMemory I/O


5959



• Advantages of network connectivity:• Reduced Input modules to the controller:

• Reduce costs of acquiring unnecessary analog input modules• Reduce costs of wiring channels to the CS• Reduce effort of programming required for analog inputs• Reduce schedule by not requiring additional wiring, programming, and

activation time.• Reduce space required to house CS channels

• Reduced potential failure points with less hardware• Potentially increased scan speed with fewer modules to query• Data consistent between LSDAS and Controls Systems

• Disadvantages of network connectivity:• Lack of comparison of measurements between systems (Controls vs.

DAS)• Reduced independence of Controls operations.• Controls blindness if DAS fails.


6060


Summary

NASA/SSCNASA/SSC’’s Mission in Rocket Propulsion Testing Is to Acquire Test s Mission in Rocket Propulsion Testing Is to Acquire Test Performance Data for Verification, Validation and Qualification Performance Data for Verification, Validation and Qualification of of Propulsion Systems HardwarePropulsion Systems Hardware•• AccurateAccurate•• ReliableReliable•• ComprehensiveComprehensive•• TimelyTimely

Data Acquisition in a Rocket Propulsion Test Environment Is ChalData Acquisition in a Rocket Propulsion Test Environment Is Challenginglenging•• Severe Temporal Transient Dynamic EnvironmentsSevere Temporal Transient Dynamic Environments•• Large Thermal GradientsLarge Thermal Gradients•• Vacuum to high pressure regimesVacuum to high pressure regimes

AA--3 Test Stand Development is equally challenging with respect to 3 Test Stand Development is equally challenging with respect to accommodating vacuum environment, operation of a CSG system, andaccommodating vacuum environment, operation of a CSG system, and a a large quantity of data system and control channels to determine large quantity of data system and control channels to determine proper proper engine performance as well as Test Stand operation.engine performance as well as Test Stand operation.

SSC is currently in the process of providing modernized DAS, ConSSC is currently in the process of providing modernized DAS, Control trol Systems, Video, and network systems for the ASystems, Video, and network systems for the A--3 Test Stand to overcome 3 Test Stand to overcome these challenges.these challenges.


Documents

Developments in test facility and data networking for the Altitude … · 2013-04-10 · Developments in test facility and data networking for the Altitude ... • Ancillary Systems/Electrical