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MSD II 5/1/2015P15310 – SATCOM on the Move Rev. A
Test Plan
SATCOM on the Move
1
Table of Contents1. Introduction.............................................................................................................................3
2. Testing....................................................................................................................................3
2.1. Component Testing......................................................................................................................3
2.1.1. PCB.......................................................................................................................................3
2.1.2. Microcontroller....................................................................................................................5
2.1.3. Mount and Driver Board......................................................................................................6
2.1.4. Batteries...............................................................................................................................7
2.1.5. Geo-PNT – Settings..............................................................................................................8
2.1.6. Enclosure.............................................................................................................................8
2.2. System Testing.............................................................................................................................9
2.2.1. Mount Stability....................................................................................................................9
2.2.2. System Error........................................................................................................................9
2.2.3. Fade Data...........................................................................................................................10
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1. IntroductionThese 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
3
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
4
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 NATest 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 savingFail, deemed unnecessary
4.1.2.5 1,2,5Test program
response times Yes/No NA secondsRun program and keep
clock measurements
Pass, calculation negligible
4.1.2.6 1,2,5Power
Microcontroller 5 +- 0.1 VoltsCheck USB power cable
for correct voltage
Pass, Arduino
functional
4.1.2.7 1,2,5Validate aiming
algorithm Yes/No NA NA
Input known coordinates with known
offset data.
4.1.2.8 1,2,5Validate 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
5
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 degTest program to evaluate
motion
Pass, 360 degrees before
loopback
4.1.3.2 2 Yaw Degree per Click <1.5 - inf, + 0 degTest program and
protractor
Pass, average of
~1.5
4.1.3.3 11Pitch Motion (-
90<x<90) -90 to 90 - 2, + 2 degTest program to evaluate
motion
Pass, 360 degrees, but math
only allows 180
4.1.3.4 1Pitch Degree per
Click <1.5 - inf, + 0 degTest program and
protractor
Pass, average of
~1.5
4.1.3.5 1Gear Backlash
(Pitch) <.1 - inf, + 0 degPhysical test with
protractorPass,
4.1.3.6 2 Gear Backlash (Yaw) <.1 - inf, + 0 degPhysical test with
protractor
4.1.3.7 NA Stall Torque (Pitch) >500 - 0, + inf in-ozPhysical test with test
program
Pass, fought hard, but
never stalled
4.1.3.8 NA Stall Torque (Yaw) >500 - 0, + inf in-ozPhysical test with test
program
Pass, fought hard, but
never stalled
4.1.3.9 NAAngular Velocity
(Pitch) >50 - 0, + inf deg/sTest program, possibly
oscilloscopePass, visual
check
6
4.1.3.10 NAAngular Velocity
(Yaw) >50 - 0, + inf deg/sTest program, possibly
oscilloscopePass, 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 6,7,12Battery
Duration/Life 90-15, +
inf Minutes
Run System continuously until
batttery dies and record time Pass
4.1.5.2 6,7,12Validate Voltage
Output 12 +/- 0.5V VoltsConnect to voltmeter to
confirm Pass
7
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 NAVisual 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 NAVerify 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 NAVerify 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
8
#Eng Req
#Description Nominal
Margin of Error
Units"How to test"
description (Notes)Pass/Fail
4.1.7.1 12No signs of
component damage Yes/Novib table for specific
frequencyPass
4.1.7.2 12No signs of
connection damage Yes/Novib table for specific
frequencyPass
4.1.7.3 12No signs of mounting
damage Yes/Novib table for specific
frequencyPass
4.1.7.4 12No signs of box
damage Yes/Novib table for specific
frequencyPass
4.1.7.5 12No water within
enclosure Yes/No Water resistant testPass
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 Testing2.2.1. 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
ON/OFF N/A N/A Flip the power switch Pass
9
powers up, upon switch ON
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 DataFade 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 NACheck 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 NACollect fade data while
not movingFail
4.2.3.3 6, 7, 14 Moving test TBD NA NACollect fade data while
movingFail
4.2.3.4 NACheck 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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