Acoustic Testing and Response Prediction of the CASSIOPE Spacecraft

A high intensity acoustic test in a reverberant chamber was conducted on the CASSIOPE spacecraft in the final stages of integration and test campaign to ensure that it would survive the acoustic loads during launch. This paper describes the acoustic test methodology, the details of the model used for analytical prediction of the structural response for acoustic excitation and discussion of the predicted response comparison with test results that provided confidence in the spacecraft structural design for acoustic loads. The objective of the spacecraft acoustic test was to demonstrate the ability of the structure and avionics to withstand the broadband random acoustic environment experienced within the launch vehicle payload fairing. The CASSIOPE spacecraft was tested in the reverberant chamber at overall sound pressure level up to 142.1 dB. The automatic spectral control system of the acoustic test facility, which used six control microphones, was able to achieve and the maintain target spectrum levels around the spacecraft within tolerances without manual adjustments to the noise generators’ controls. The dynamic response of the CASSIOPE spacecraft during the test was measured using a large number of accelerometers installed on critical locations of the structure. Low level pre-test and post-test structural response signatures as well as electrical integrity checks performed after the exposure to the proto-flight acoustic environment demonstrated the ability of the spacecraft to survive the launch. The acoustic response of the spacecraft was also predicted based on a finite element model analysis to identify the critical components, evaluate structural margins and assess the risks in proceeding with a proto-flight acoustic test based on the specified launch vehicle spectrum. The analysis method used to predict the responses combines the NX/NASTRAN solver and RAYON, a vibro-acoustic simulation software. The RAYON software functionality is based on a boundary element model that enables the creation of an accurate fluid loading on the structure, with consideration of fluid mass and damping effects. The study used a finite element model of the structure that was correlated through an experimental modal survey test and actual spectrum levels achieved during the acoustic test. Responses of most locations compared favourably with the predictions in critical locations such as the solar arrays. Due to the limited availability of the satellite as well as time and cost constraints in a spacecraft development program, it is important to perform both qualification tests as well as analytical predictions in an efficient and timely manner to validate structural designs of spacecraft.