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ECSS-P-00C(22March2013)-page=1
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ECSS-P-00C(22March2013)
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ECSS-P-00C
22 March 2013
ECSS
Standardization objectives, policies
and organization
ECSS Secretariat
ESA-ESTEC
Requirements & Standards Division
Noordwijk, The Netherlands
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2
Foreword
This document (ECSS-P-00C) presents the objectives, policy and organization of ECSS together with
its architecture and documents.
This Standard has been prepared by the ECSS Technical Authority and approved by the ECSS
Steering Board.
Published by:
ESA Requirements and Standards Division
ESTEC, P.O. Box 299,
2200 AG Noordwijk
The Netherlands
Copyright:
2013© by the European Space Agency for the members of ECSS
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Change log
ECSS-P-00A
4 April 2000
First issue
ECSS-P-00B
Never published
ECSS-P-00C
22 March 2013
Second issue
-
ECSS objectives and policies updated, in particular the following
was added:
o
Concepts of Handbook, Technical Memorandum and
Adoption Notice
o
Policy for establishing ECSS documents
o
Policy for certification, training and promotion
o
Policy for cooperation with other SDOs
o
Policy for application of the ECSS system
o
Policy for the maintenance of the ECSS system
o
Policy for the translation and use of the ECSS System by
non-ECSS members
-
Roles of the different types of ECSS participants and process for
accessing and changing status clarified
-
ECSS Structure updated to reflect actual structure
-
ECSS decision making process defined
-
ECSS documentation structure clarified, including addition of the
new branch “Space sustainability” to the ECSS system
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Table of contents
Change log ................................................................................................................. 3
Introduction ................................................................................................................ 6
1 Scope ....................................................................................................................... 7
1.1
General ..................................................................................................................... 7
1.2
Applicability............................................................................................................... 7
2 Normative References ............................................................................................ 7
3 Terms, definitions and abbreviated terms ............................................................ 8
3.1
Terms and definitions from other documents ............................................................ 8
3.2
Terms specific to the present document ................................................................... 8
3.3
Abbreviated terms..................................................................................................... 9
4 ECSS objectives ................................................................................................... 10
5 ECSS policies ....................................................................................................... 11
5.1
General ................................................................................................................... 11
5.2
Policy for establishing ECSS System ...................................................................... 12
5.2.1
General ..................................................................................................... 12
5.2.2
Policy for establishing ECSS documents ................................................... 12
5.2.3
Policy for cooperation with other SDOs ..................................................... 13
5.3
Policy for application of the ECSS System .............................................................. 14
5.4
Policy for maintenance and configuration management of the ECSS System ......... 14
5.5
Policy for certification and training .......................................................................... 15
5.6
Policy for promoting the ECSS system ................................................................... 15
5.7
Policy for translation of ECSS documents by ECSS members ................................ 15
5.8
Policy for use of ECSS System by non-ECSS members ......................................... 16
6 ECSS organization ............................................................................................... 17
6.1
Participation ............................................................................................................ 17
6.1.1
General ..................................................................................................... 17
6.1.2
Full members ............................................................................................ 17
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6.1.3
Associates ................................................................................................ 17
6.1.4
Observers ................................................................................................. 18
6.1.5
Accession by new participating organizations ........................................... 18
6.1.6
Termination of participation ....................................................................... 18
6.1.7
Change of status ....................................................................................... 19
6.2
ECSS Developer Structure ..................................................................................... 19
6.2.1
Overview ................................................................................................... 19
6.2.2
Mission statements of the ECSS bodies .................................................... 20
6.3
ECSS decision making process .............................................................................. 21
7 ECSS Documentation ........................................................................................... 23
7.1
Overview ................................................................................................................ 23
7.2
Documentation for developers ................................................................................ 23
7.3
Documentation for users (ECSS System) ............................................................... 24
Bibliography ............................................................................................................. 26
Figures
Figure 6-1: ECSS developer structure .................................................................................. 20
Figure 7-1: Architecture of ECSS documentation for developers .......................................... 23
Figure 7-2: General Architecture of ECSS documentation for users ..................................... 25
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Introduction
Standardization is an important tool to reduce risks, cost and improve both
quality and communication between parties during the preparation and
execution of programmes. European Space Agencies and industry have in the
past individually developed standards and applied them to their projects. The
European Cooperation for Space Standardization ECSS) was initiated to
harmonize the requirements from existing Standards for space projects, and to
provide a single, coherent set of standards for use in all European space
systems development and operation.
The goal of the ECSS Standardization System is to develop a common set of
consistent standards for hardware, software, information and activities to be
applied in space projects, so that life cycle cost are minimized, while continually
improving the quality, functional integrity, reliability and compatibility of all
elements of the project.
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1
Scope
1.1
General
This document states the objectives, policies and organisational structure for
establishing, implementing, and maintaining a coherent set of standards for
space systems development and operation, created through the European
Cooperation for Space Standardization.
ECSS documents are prepared for space projects and applications addressing
aspects of:
•
Project management,
•
Engineering
•
Product Assurance, and
•
Space sustainability
NOTE
For space sustainability definition, see 3.2.3.
ECSS documents include standards and supporting documents (handbooks,
technical memoranda, general support documents such as glossary), together
referred to as the ECSS system.
1.2
Applicability
This document, being the top level ECSS document, applies to all ECSS
activities and products.
2
Normative References
None.
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3
Terms, definitions and abbreviated terms
3.1
Terms and definitions from other documents
Standardized definition of terms for the ECSS Standards are defined in
ECSS-S-ST-00-01 “ECSS system - Glossary of terms”.
For example, the following terms, defined in ECSS-S-ST-00-01, apply to this
document:
•
Standard
•
Handbook, and
•
Technical memorandum
3.2
Terms specific to the present document
3.2.1
European Cooperation on Space Standardization (ECSS)
co-operative arrangement comprising nominated representatives of European
space agencies and industries set up to achieve the objective of developing a
comprehensive and coherent set of space standards for direct use in the
implementation of space programmes/projects and the development of space
products
3.2.2
ECSS developer
organisational structure of ECSS set up to develop and maintain the ECSS system
3.2.3
ECSS system
set of standards, handbooks and technical memoranda for ECSS users,
organised in the following branches, for direct use in the implementation of
space programmes and projects:
•
Space project management
•
Space product assurance
•
Space engineering
•
Space sustainability, which encompasses all standards and handbooks
for the development of space products, contributing to the long term
sustainability of space activities, including orbital debris mitigation,
space situation awareness, and planetary protection.
Space sustainability refers to the ability for all countries to continue to
use space for peaceful purpose and socio-economic or scientific benefit
over the long term.
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3.2.4
ECSS developer documents
set of internal ECSS documents defining the organisational structures, roles and
responsibilities, processes and rules required to define and implement the ECSS
policy and to develop, publish and maintain the documents that make up the
ECSS system
3.2.5
standards development organization (SDO)
organisation establishing and/or publishing standards (national, regional,
international, sectorial …) which are also available to users outside the
standards developing organisation itself
3.3
Abbreviated terms
The following abbreviated terms are used in this document:
Abbreviation
Meaning
CEN
European Committee for Standardization
CENELEC
European Committee for Electrotechnical
Standardization
ECSS
European Cooperation for Space Standardization
EN
European standard
ES
Executive Secretariat
ETSI
European Telecommunications Standards Institute
HB
Handbook
ISO
International Organization for Standardization
SB
Steering Board
SDO
standards development organization
ST
Standard
TA
Technical Authority
TM
Technical Memorandum
WG
Working group
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4
ECSS objectives
European Cooperation for Space Standardization (ECSS) goal is to provide a set
of documents, which have the overall objectives to:
•
be recognized and accepted by the European space community for use in
space programmes/projects;
•
achieve more cost effective space programmes and projects in Europe in
terms of technical performance, life cycle cost-effectiveness and on-time
deliveries;
•
improve the competitiveness of European space sector;
•
improve the quality and safety of space projects and products;
•
reduce risk and guarantee interoperability and interface compatibility by
applying proved and recognized requirements and methods;
•
facilitate clear and unambiguous communication between all parties
involved in space systems development and operation, in a form suitable
for inclusion in legally binding documents;
•
reflect user needs and feedback of experience from programmes, projects
and other appropriate sources to improve ECSS Standards, while
preserving internal coherency of ECSS system;
•
account for new practices, products, technology and missions.
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5
ECSS policies
5.1
General
In order to meet the objectives stated in clause 4, the ECSS policy is to:
•
produce an integrated and coherent set of management, engineering,
product assurance and space sustainability standards
covering all activities, phases and levels for the development and
operation of a space system, and
based on consensus amongst the ECSS members;
•
ensure that these standards are structured in such a way that they:
are directly applicable in business agreements;
take into account continual improvement of methods, techniques
and technologies;
define requirements in such a way that they bear on the need to be
fulfilled rather than on the means to be used to fulfil that particular
need, whenever possible;
are based on proven and validated approaches, methods and
solutions;
avoid duplication with other standards by incorporating into the
ECSS system where appropriate, available documents from other
sources;
take into account all valid sources of information, expertise and
feedback in the preparation and maintenance of ECSS documents;
make the best use of all available research, including the
technology programmes of European space agencies and industry;
take into account in the course of their development, the potential
negative impact of space systems, during their complete life cycle,
on human life, the environment, public and private property, space
and ground investments;
•
evaluate the benefits resulting from the use of a standard prior to its
initiation;
•
promote the wider usage of ECSS standards. Therefore, ECSS published
documents are made freely available worldwide.
ECSS does not provide any warranty nor accept any liability with respect to the
use of its documents.
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5.2
Policy for establishing ECSS System
5.2.1
General
The core of the ECSS System is the complete set of ECSS standards.
Standards can be developed entirely within ECSS or in cooperation with other
SDOs.
ECSS standards can be supported/complemented by HBs and TMs.
5.2.2
Policy for establishing ECSS documents
5.2.2.1
Policy for establishing ECSS standards
ECSS policy is to ensure that ECSS Standards:
•
respond to a need clearly expressed by the space community, taking full
account of the state of the art;
•
are designed for ease of application by their users and in particular, they
shall be as complete as necessary, concise, consistent, accurate and
unambiguous;
•
are comprehensible to qualified persons who have not participated in
their preparation and be structured in a way that facilitates essential
tailoring for application to specific projects;
•
contain requirements which benefit the whole space community, which
are specific, achievable, relevant, uniquely identified and verifiable, and
which do not give exclusive advantage to any individual European
organisation;
•
are not to be considered as stand-alone documents but rather as part of a
complete set of normative and reference documents;
•
avoid duplication of requirements inside and amongst documents;
•
are developed taking into account contributions from all relevant sources;
•
are subjected to public review open to all interested parties, before they
can be approved;
•
are structured in such a way that they:
can directly support the formal customer-supplier interfaces and
relationships, and address all the levels of the customer-supplier
chain;
can be tailored to the technical, cost, schedule, programmatic and
economic characteristics of individual space programmes and
projects;
address all phases and activities from start to finish of a project;
•
are drafted, approved and published in English.
In order to ensure uniformity of structure, style and terminology within the full
ECSS system, ECSS has established and applies processes and drafting rules
(see ECSS-D-00). In addition, in establishing the ECSS glossary, internationally
agreed terms and definitions are used, where appropriate.
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5.2.2.2
Policy for establishing ECSS handbooks
ECSS policy is to ensure that ECSS Handbooks:
•
are developed when need exists to support the application of ECSS
standard(s);
•
describe solution that comply with existing ECSS requirement(s).
5.2.2.3
Policy for using documents developed by other
SDOs
When an already approved and published non-ECSS document (e.g. ISO IS,
EN) exists, and is considered useable to fulfil an ECSS objective, this document
is either:
•
copied in whole or in part, with permission, in an ECSS document;
•
in case of standard, directly called up as normative reference, by ECSS
standard(s) and therefore made applicable by the ECSS system;
•
adopted through an adoption notice in the case where modification,
addition, and/or deletion of part of the adopted document is necessary to
ensure proper integration of that non-ECSS standard in the ECSS system.
Non-ECSS documents can be adopted as standards or handbooks.
The adoption notices follow the same approval process as ECSS
standards.
5.2.3
Policy for cooperation with other SDOs
The ECSS policy is to establish co-operation with other SDOs consistent with
ECSS objectives, in order to:
•
achieve international consensus and recognition where essential to allow
global interoperability, mission success, safety, protection of the earth,
space and their environments, or common policies or treaties;
•
influence, as early as possible, documents from other SDOs, which could
impact ECSS or which are intended to be adopted by ECSS;
•
maximize cost effectiveness and technical validity for ECSS by
incorporating output or expertise from other SDO.
Co-operation between ECSS and other SDOs may fall into one of three
categories, as follows:
•
formal cooperation: cooperation with another organisation conducted
under the control of a formal agreement, approved by both parties;
•
ad-hoc cooperation: activities to interface or cooperate with another SDO
or organisation, as a result of a specific SB decision and associated
mandate;
•
liaison: relation with another organisation, typically SDOs, to provide
mutual visibility of the activities of ECSS and another organisation. In the
frame of liaison level agreements collaborative activities are not
necessarily conducted.
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5.3
Policy for application of the ECSS System
ECSS documents are made applicable to a project only through a legal
document such as business agreement (e.g. contract) and/or internal directives.
When made applicable:
•
it is the responsibility of the party imposing a particular standard to
tailor it to ensure that it meets the intended need.
•
all parties using a standard are advised to acquaint themselves with the
intended scope and applicability of the standard to prevent inappropriate
usage.
•
the party imposing the use of an ECSS document, or a part thereof, is
responsible for monitoring and assuring its correct application.
•
all users of ECSS documents are encouraged to inform the ECSS
Secretariat about experience gained from application of ECSS Standards,
so that inadequacies in the documents can be corrected and
improvements made.
Details concerning application of the ECSS system are provided in ECSS-S-ST-00.
5.4
Policy for maintenance and configuration
management of the ECSS System
ECSS implements a maintenance policy which includes:
•
a fully documented and recorded baseline for the ECSS system and its
individual documents.
•
A change system based on the use of traceable change requests, change
request dispositions and their implementation.
•
a 5 year maintenance cycle at the end of which all standards of the ECSS
system shall be re-assessed with respect to the need for updating and
reissuing them with a common incremented issue index. During that
period, only modifications (technical or editorial) which are strictly
needed to guarantee correct application of the standard or to adapt to
new factors shall be implemented.
•
a process to collect feedback and lessons learned from users and
developers as a prime source for maintenance of the ECSS system.
•
a systematic checking of compatibility of modifications introduced in
new revisions or issues of documents with already published
requirements to maintain internal coherency of the ECSS system.
•
a configuration management system for ECSS documentation in line with
the following principles:
Establish and maintain a Configuration Management index
containing current issue and revision status of all ECSS documents
and make this available to all interested parties.
apply the configuration management procedure, as defined in
ECSS-D-00.
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•
Nomination of Document and Discipline Focal Points to support the
Technical Authority for correct understanding and application of the
standards and assessment of feedback and Change Requests.
5.5
Policy for certification and training
5.5.1.1
Certification
ECSS neither provides nor recognizes any certification process of supplier or of
product according to ECSS requirements, by any party.
5.5.1.2
Training and users information
ECSS promotes usage of ECSS system in European space projects and beyond
through information and, as far as practical, through training of potential users.
In addition, ECSS does not endorse the development of third party training
courses related to ECSS system.
5.6
Policy for promoting the ECSS system
ECSS will promote worldwide usage of ECSS system through all appropriate
means: e.g. conference papers, organization of users’ day, dedicated
presentations to space related projects or organizations, liaisons with standards
development organizations.
In particular, ECSS has developed and maintains a user friendly website
enabling both ECSS standards developers and users to get fully up-to-date
information.
5.7
Policy for translation of ECSS documents by ECSS
members
ECSS documents are written and published in English language only. Any
ECSS member wishing to translate, at its own expense, an ECSS document into
another language may do so, provided that such intent is made known to the
ECSS Secretariat and this ECSS member remains the sole responsible for the
coherence between the English version and the translated one. Such translated
documents are not part of the ECSS system. They shall bear a different
identification number than the original ECSS document and shall separately
identify which ECSS Standard has been used. In no way shall approval of the
ECSS Steering Board, nor any duty of distribution by the ECSS Secretariat, be
stated or implied for such translations, nor may such documents be sold.
ECSS does not recognize nor maintain translated version of the ECSS original
documents in English.
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5.8
Policy for use of ECSS System by non-ECSS
members
The European Space Agency, on behalf of the participating members, holds
copyright for all ECSS documents. No ECSS document may be reproduced in
any form without the explicit consent of ESA. However, this consent is granted
to ECSS members for their own use, for their contractors and subcontractors.
In case of request by non-ESA members or non-ECSS members for using ECSS
documents in whole or in part in their own documentation, the following policy
shall be applied:
•
direct use of ECSS standards themselves should be made rather than
rewriting using quotation of ECSS standards. This could avoid
incoherencies with ECSS system due to partial imports of ECSS
requirements, modified quotations or quotation of obsolete versions.
•
ECSS members are informed of requests addressed to the ES. Final
version of the proposed agreement to grant use and/or translation should
be submitted to SB approval and, when approved, signed by the SB
chairman on behalf of ECSS members (Copyright on ECSS standards
being held by ESA on behalf of ECSS members, final agreement are also
to be signed by ESA appropriate official).
•
when ECSS documents text is used, ECSS copyright is acknowledged,
quotations clearly identified in the document together with exact
reference/version and potential modifications of ECSS standards used as
source. This applies also to any derived document.
•
when translation of ECSS standard(s) is performed by the beneficiary,
this translation should be made available to ECSS members.
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6
ECSS organization
6.1
Participation
6.1.1
General
ECSS is open to participation from all European space sector and associated
organizations. Participating entities in ECSS can have a role of Members,
Associates or Observers.
Agreement to work in the interest of ECSS, to pursue the ECSS objectives and
policies and to follow rules as set out in the ECSS Operating Documents (ECSS-
P-00 and ECSS-D-00) is required from all participating organizations.
6.1.2
Full members
ECSS Full members are European space sector stakeholders that indicate their
intention to actively participate in ECSS document production, maintenance,
use and the associated feedback. They commit to:
•
provide an adequate level of support for all these activities,
•
ensure the implementation of ECSS system in their respective projects
when applicable.
Any member from the European space industry will participate through
Eurospace.
Only Full members take part in the consensus process within ECSS, as specified
in 6.3a.
At the time of the approval of this issue of ECSS-P-00, the following
organisations were Full members: Agenzia Spaziale Italiana, Centre National
d’Etudes Spatiales, Deutsches Zentrum für Luft- und Raumfahrt e.V., European
Space Agency, Eurospace, Netherlands Space Office, Norwegian Space Centre,
UK Space Agency.
6.1.3
Associates
ECSS Associates are those European space sector stakeholders that indicate a
desire to participate in ECSS document production but at a reduced level of
effort or limited to some specific aspects/disciplines, and that commit to
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implement ECSS system in their respective projects when applicable for those
documents whose preparation they were involved in.
Associates are encouraged to provide feedback on their use of the ECSS
standards by CR’s or other means.
Associates will be given access to specific ECSS body as per ECSS Technical
Authority proposal and when approval is given by the ECSS Steering Board.
At the time of the approval of this issue of ECSS-P-00, the following
organisations were Associates: Canadian Space Agency.
6.1.4
Observers
Observers are those European space sector stakeholders desiring a formal tie
with the ECSS through which they can observe the development process of
technical documentation and through which they can contribute to the ECSS
system (e.g. need for new standards, return of experience related to ECSS
system application in projects).
Their participation to the production, review of documents is not envisaged but
not excluded.
Observers will be given access to specific ECSS body as per ECSS Technical
Authority proposal and when approval is given by the ECSS Steering Board.
At the time of the approval of this issue of ECSS-P-00, the following
organisations were observers: EUMETSAT, European Defence Agency,
CEN/CENELEC.
6.1.5
Accession by new participating
organizations
Request for participation or change of status shall be sent in writing to the ECSS
Secretariat, stating the formal acceptance of the conditions laid out in the
relevant clauses 6.1.1 to 6.1.4. The Steering Board decides on such requests by
consensus of its members. Accession or change of status takes place on the date
of notification by the ECSS Secretariat that the Steering Board has approved
their participation.
6.1.6
Termination of participation
A participating organization may terminate its participation in ECSS by written
notification to ECSS Secretariat, who informs the ECSS Steering Board. The
termination becomes effective three months after receipt of the notification in
the ECSS Secretariat. Such participating organization shall endeavour to
minimize the effects of the termination on ECSS.
If, in the opinion of two thirds of all members, a participant no longer complies
with relevant clauses 6.1.1 to 6.1.4, its participation is terminated with
immediate effect.
|
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"document_id": "ECSS-P-00C(22March2013)",
"page_number": 18
}
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6.1.7
Change of status
A participating organization may change its status according to the following
rules:
a.
For changing status from Observer to either Associate or Full Member or
from Associate to Full Member, the principles laid down in 6.1.5 shall be
followed.
b.
For changing status from Full Member to either Associate or Observer or
from Associate to Observer, the principles laid down in 6.1.6 shall be
followed.
6.2
ECSS Developer Structure
6.2.1
Overview
The ECSS activities are organized through a number of bodies, collectively
known as the ECSS Developer, whose main functions are as follows:
•
Steering Board (SB): Define ECSS objectives, policy and strategy and
endorse the work plan
•
Technical Authority (TA): Implement the objectives, policy and strategy
defined by the SB; setup, approve, implement and monitor the Work-
plan endorsed by the SB
•
Executive Secretariat (ES): Support the TA and WGs, enforces drafting
rules, provide administrative support to the TA and SB, and ensure
promotion of ECSS and interface with other SDOs.
•
Working Group (WG): Convened as necessary by TA and in charge of
producing/modifying the standards as required by the endorsed Work-
plan.
•
Network of Expert (NoE): Document and Discipline Focal Points that,
with the addition of ad hoc experts, support TA and ES in specific tasks.
Figure 6-1 presents the ECSS developer structure.
In addition to the above and in line with the bodies responsibilities, task forces
may be created by the SB or TA, to assist in executing their responsibilities, and
are normally used to investigate and make recommendations on a particular
aspect or issue related to ECSS activities. Their mandate is usually of limited
duration.
The organisation of ECSS bodies, together with ECSS developer responsibilities,
documentation and processes is addressed in ECSS-D-00.
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20
Steering
Board (SB)
Technical
Authority (TA)
Executive
Secretariat (ES)
Network of
Experts (NoE)
Steering
Board (SB)
Executive
Secretariat (ES)
Technical
Authority (TA)
Network of
Experts (NoE)
Working
Group
W
G
W
G
Working
Group
Working
Group
Working
Group
Figure 6-1: ECSS developer structure
6.2.2
Mission statements of the ECSS bodies
6.2.2.1
Steering Board (SB)
The SB is mandated by the participating member organizations to define the
objectives, policy and strategy for the ECSS system and for providing overall
leadership of the ECSS bodies.
The SB decides whether ECSS shall cooperate with other SDOs, which type of
cooperation, and endorses the cooperation agreement prepared by the TA.
6.2.2.2
Technical Authority (TA)
The activity of the TA is guided and monitored by the SB.
The TA is the technical approval authority for the initiation and release of new
ECSS documents as well as for all changes to existing ECSS documents.
It is in charge to setup and implement the Work-plan with the support of the
ES. Furthermore, TA proposes the Work-plan to SB for endorsement.
Following interest expressed by any ECSS partner or other SDO for a co-
operative agreement, the TA:
•
assesses the impact of formal cooperation, and submit recommendation
to the SB, including the proposed methodology and process for
implementation;
•
if endorsed by the SB, set-up cooperation agreement, liaising with the
other parties as necessary.
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6.2.2.3
Executive Secretariat (ES)
The mission of the ES is composed of four items:
•
Programme function in support to TA to:
build the Work-plan to be endorsed by the SB (e.g. programmatic,
resources);
monitor and support the implementation of the Work-plan
including finalization and notification of the publication of ECSS
documents/events;
ensure implementation and perform monitoring of the ECSS
processes (including those to gather feedback from users and
lessons learned).
•
Support WGs and enforce drafting rules.
•
Custodian and configuration control of the ECSS documents;
•
Ensure the promotion of ECSS and interface with other SDOs;
•
Provide administrative support to SB and TA.
6.2.2.4
Working Group (WG)
The mission of an ECSS Working Group is to carry out the tasks necessary to
draft or update an ECSS Document in line with its Terms of Reference, against
an agreed planning and schedule. They are built on a case by case basis,
managed by the TA through a limited duration mandate.
6.2.2.5
Network of experts (NoE)
The network of experts is a pool of experts appointed by the TA and supported
by the ECSS organizations nominating them. They act for specific
mission/action through the sponsorship of the TA members or their nominating
organization.
The NoE is composed by the Document and Discipline Focal Points and ad hoc
experts, providing support in specific tasks. The NoE are not an advisory body
intended for the general public. Their support is restricted to the SB, TA and ES.
6.3
ECSS decision making process
In this document consensus is defined as not only a way to seek the agreement
of most participants, but also to resolve or mitigate the objections of the
minority to achieve the most acceptable general agreement. As a consequence,
minority views are considered to a greater degree than where a majority can
take a decision and enforce it without any further consideration of the minority
views.
a.
The ECSS governing bodies (i.e. the ECSS SB and TA) make decisions on
the following basis:
1.
After having considered the position of all Full members,
associated and observers, the governing body works on the basis
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22
of achieving consensus of the voting members (i.e. full members).
2.
If consensus as stated in a.1 above cannot be achieved, decisions
are made by the vote of the full members, with a simple majority
subject that a quorum of 50% of the voting rights is reached.
Votes are weighted in accordance with the following principles:
(a)
One (1) vote for each ECSS full member National Space
Agency.
(b)
Four (4) votes for the European Industry, represented by
Eurospace.
NOTE
Eurospace
can
decide
to
appoint
four
Eurospace voting representatives, with one
voting right each, or to concentrate the four
votes with a voting representative, or any
intermediate solution.
b.
ECSS WGs make all decisions on the following basis:
1.
by achieving consensus of all the WG members officially approved
by the ECSS TA.
2.
If consensus, cannot be achieved on a particular issue, the matter is
escalated to the TA for resolution.
Implementation details of these principles can be found in Chapter 4 of ECSS-
D-00 “ECSS organization and processes”.
|
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7
ECSS Documentation
7.1
Overview
ECSS documentation is divided into 2 categories:
•
Documents for developers of standards specifying objectives, policies,
processes, rules, standard forms;
•
Documents for users, composed of standards and supporting documents,
which collectively form the ECSS System, addressing the aspects of:
ECSS system description and implementation,
Space project management,
Space product assurance
Space engineering, and
Space sustainability.
NOTE
For space sustainability definition, see 3.2.3.
7.2
Documentation for developers
Architecture of ECSS documentation for developers of standards is depicted in
Figure 7-1:
Figure 7-1: Architecture of ECSS documentation for developers
ECSS standardization
policies
(ECSS-P-00)
ECSS processes
(ECSS-D-00)
ECSS configuration
management
ECSS-SDO cooperation
agreements
(e.g. CEN, CCSDS)
ECSS drafting rules
and template for
ECSS standards
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The present document (ECSS-P-00: Standardization policy) is the highest level
document providing objectives and policies applicable to the development,
maintenance and deployment of standards, handbooks and technical
memoranda, and defining the ECSS structure. The cooperation agreements
between SDOs and ECSS are kept/archived by ES and constitute essential
elements for the implementation of the actual ECSS policy.
All the ECSS internal processes are specified in ECSS-D-00. This document also
identifies all the items which are under configuration control by ECSS, together
with the stage at which they have to be put under configuration control.
The ECSS drafting rules and template for ECSS standards and for handbooks
are specified in ECSS-D-00-01 and ECSS-D-00-02 respectively. They specify all
the editorial rules necessary to guarantee high quality and maintainability of
the ECSS system.
An ECSS configuration management document specifies the configuration
control system and processes for the ECSS system.
In order to keep consistency between the two documentation sets, the
document for users: “ECSS Glossary of terms” described in 7.3 is also applicable
to developers.
7.3
Documentation for users (ECSS System)
The architecture of the ECSS system, shown in Figure 7-2, is composed of:
•
A System description and implementation standard (ECSS-S-ST-00)
which specifies how to use the ECSS system in a given project;
•
A Glossary of terms (ECSS-S-ST-00-01) which provides definition of
terms common to several ECSS standards (terms specific to a standard
are defined locally in that standard);
•
Standards (ST), Handbooks (HB) and Technical Memoranda (TM)
organized to cover: space project management, space product assurance,
space engineering and space sustainability. Inside each branch, the three
types of documents are classified in disciplines. For each discipline, a top
level standard provides all the general requirements related to that
discipline, while other documents cover specific aspects, processes,
products within a given discipline.
Detailed descriptions of the architecture, content and ECSS disciplines are
provided in clause 5.3 of ECSS-S-ST-00.
|
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ECSS-S-ST-00
ECSS System – Description, implementation
and general requirements
ECSS-ST-00-01
ECSS System – Glossary of terms
ECSS M Standards, HBs and TMs
External standards or handbooks “adopted”
or called up by ECSS documents
ECSS U Standards, HBs and TMs
ECSS E Standards, HBs and TMs
ECSS Q Standards, HBs and TMs
Figure 7-2: General Architecture of ECSS documentation for users
|
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"page_number": 25
}
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Bibliography
ECSS-D-00
ECSS – ECSS processes
ECSS-D-00-01
ECSS - Drafting rules and template for ECSS Standards
ECSS-D-00-02
ECSS - Drafting rules and template for ECSS Handbooks
ECSS-S-ST-00
ECSS system - Description, implementation and general
requirements
ECSS-S-ST-00-01
ECSS system – Glossary of terms
|
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"page_number": 26
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Space product
assurance
Crimping of high-reliability electrical
connections
ECSS Secretariat
ESA-ESTEC
Requirements & Standards Division
Noordwijk, The Netherlands
Corrigendum 1
The following editorial errors were identified in the published version of this
document and corrected:
• Requirement 5.1.2.1h (page 16)
• Requirement 5.3.2a.1 (page 27)
• Requirement 5.4.3.2c (page 30)
• Annex A.1 (page 46)
ECSS Executive Secretariat, 1 June 2017
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Foreword
This Standard is one of the series of ECSS Standards intended to be applied together for the
management, engineering and product assurance in space projects and applications. ECSS is a
cooperative effort of the European Space Agency, national space agencies and European industry
associations for the purpose of developing and maintaining common standards. Requirements in this
Standard are defined in terms of what shall be accomplished, rather than in terms of how to organize
and perform the necessary work. This allows existing organizational structures and methods to be
applied where they are effective, and for the structures and methods to evolve as necessary without
rewriting the standards.
This Standard has been prepared by the ECSS Executive Secretariat, endorsed by the Document and
Discipline Focal points, and approved by the ECSS Technical Authority.
Disclaimer
ECSS does not provide any warranty whatsoever, whether expressed, implied, or statutory, including,
but not limited to, any warranty of merchantability or fitness for a particular purpose or any warranty
that the contents of the item are error-free. In no respect shall ECSS incur any liability for any
damages, including, but not limited to, direct, indirect, special, or consequential damages arising out
of, resulting from, or in any way connected to the use of this Standard, whether or not based upon
warranty, business agreement, tort, or otherwise; whether or not injury was sustained by persons or
property or otherwise; and whether or not loss was sustained from, or arose out of, the results of, the
item, or any services that may be provided by ECSS.
Published by: ESA Requirements and Standards Division
ESTEC, P.O. Box 299,
2200 AG Noordwijk
The Netherlands
Copyright:
2017 © by the European Space Agency for the members of ECSS
2
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Change log
ECSS-Q-70-26A
13 February 2001
First issue
Transforming ESA PSS-01-726 into an ECSS Standard
ECSS-Q-70-26B
Never issued
ECSS-Q-ST-70-26C
31 July 2008
Second issue
Changes to ECSS-Q-70-26A are:
• Redrafting of ECSS-Q-70-26A in conformance with ECSS drafting
rules and new template.
• The requirements of the original clauses 4, 5, 6, 7, and 8 were moved
to the clause 5.
• New clause 5.6 “Document requirements“.
• Informative material moved to clause 4 and informative Annex A
“Crimp configurations and tools”.
ECSS-Q-ST-70-26C Rev.1
15 March 2017
Second issue, Revision 1
Changes with respect to the previous version are identified with revision
tracking.
Main changes are::
• Implementation of Change requests
• Several Figures replaced by new ones
• Clause 3 "Terms, definitions and abbreviated terms" updated
• Nomenclature added as clause 3.4
• Titles of clauses 5.1.2.3, 5.2, 5.2.4, 5.2.5, 5.3, 5.3.2, 5.4.3.2, 5.4.3.3
changed
• Several changes in the Clause 5.3 “Requirements for crimp
configuration qualification”
• Several changes in clause 5.4 “Test methods”
• Clause 5.5.2 “Personnel training and certification” updated
• Clause 5.5.4 “Visual inspection “updated
• Several changes in clause 5.5.5 “Shift performance inspection and test
for harness manufacturing”
• Clause 5.5.9 "Special crimping activities at spacecraft level,
modifications and repairs” added
• All Figures from Issue C replaced
• Annex A "Crimp configurations and tools" updated
• Annex B "Examples of typical ultimate axial strength" added
3
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Added requirements:
5.1.2.1i; 5.1.2.2f; 5.2.1k; 5.2.4g-h; 5.2.5g-i; 5.2.6d-f (where f was moved
from 5.2.6c); 5.2.7i-j; 5.3.1d-g; 5.3.2d-e; 5.3.4.1a; 5.3.4.2a-c; 5.4.3.1e;
5.4.3.2c-e; 5.4.3.3b; 5.4.3.4a-e; 5.4.3.5a-c; 5.4.4j; 5.5.2.2e; 5.5.4.3a-c; 5.5.5k-o;
5.5.9a-l.
Modified requirements:
5.1.1.2a-c and e; 5.1.1.4b and c; 5.1.2.1a-d and f-g; Figure 5-1 called from
added Note in 5.1.2.1a added; 5.1.2.2b; 5.1.2.3b and e; 5.1.2.4a; Table 5-1;
5.2.1a-c, e and h; 5.2.2a-b, d-g; 5.2.3a-c; 5.2.4a, c-f; 5.2.5a; 5.2.5c Note
deleted; 5.2.5d Note modified; 5.2.5e-f; 5.2.6a-b; 5.2.7a,b, d-f, h (Note
modified); 5.3.1a-b; 5.3.2a-c; 5.4.1a; 5.4.3.1d; 5.4.3.2a; 5.4.3.3a; 5.4.4a and i;
5.5.2.1a; 5.5.3d; 5.5.4.1a and d; 5.5.4.2a-c; 5.5.6.1a; 5.5.6.2c and d; 5.5.6.3c;
5.5.7c; 5.5.8a; 5.6a.
Deleted requirements:
5.1.2.3d; 5.2.1j; 5.2.6c (moved to 5.2.6f); 5.2.7g; 5.3.1c; 5.4.2a-c; 5.4.3.2b;
5.2.2a; 5.5.5a-j.
Corrigendum 1 of Second issue Revision 1:
• 5.1.2.1h: text reworded to remove second "shall be"
• 5.3.2a.1: reference to Table A-1 to Table A-6 put into a new NOTE
• 5.4.3.2c: text reworded to remove second "shall"
• Annex A.1: Text of first paragraph reworded from "(in conformance
with Table A-1 to Table A-6) " to "Typical settings for the crimping tool are
given in A.2."
This corrigendum was approved by the ECSS Technical Authority at
TA#58 (1 June 2017).
4
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Table of contents
Change log ................................................................................................................. 3
1 Scope ....................................................................................................................... 8
2 Normative references ........................................................................................... 10
3 Terms, definitions and abbreviated terms .......................................................... 11
3.1
Terms defined in other standards ........................................................................... 11
3.2
Terms specific to the present standard ................................................................... 11
3.3
Abbreviated terms................................................................................................... 12
3.4
Nomenclature ......................................................................................................... 13
4 Principles .............................................................................................................. 14
5 Requirements ........................................................................................................ 15
5.1
Preparatory conditions ............................................................................................ 15
5.1.1
Facilities .................................................................................................... 15
5.1.2
Tools and equipment ................................................................................. 16
5.2
Crimping operations for different types of interconnections ..................................... 18
5.2.1
General ..................................................................................................... 18
5.2.2
Material selection ...................................................................................... 19
5.2.3
Process review and documentation ........................................................... 20
5.2.4
Contact barrel and single wire crimping ..................................................... 20
5.2.5
Contact barrel and multiple wire crimping .................................................. 21
5.2.6
Ferrule shield crimping .............................................................................. 23
5.2.7
Lug and splice wire crimping ..................................................................... 23
5.3
Requirements for crimp configuration qualification .................................................. 26
5.3.1
General ..................................................................................................... 26
5.3.2
Qualification process test procedure ......................................................... 27
5.3.3
Sealing and marking ................................................................................. 29
5.3.4
Batch to batch variation ............................................................................. 29
5.4
Test methods .......................................................................................................... 29
5.4.1
General ..................................................................................................... 29
5
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5.4.2
<<deleted>> .............................................................................................. 29
5.4.3
Tensile strength ........................................................................................ 30
5.4.4
Metallography ........................................................................................... 31
5.5
Quality assurance ................................................................................................... 32
5.5.1
General ..................................................................................................... 32
5.5.2
Personnel training and certification ........................................................... 32
5.5.3
Workmanship ............................................................................................ 35
5.5.4
Visual inspection ....................................................................................... 37
5.5.5
Shift performance inspection and test for harness manufacturing ............. 39
5.5.6
Calibration of crimping tools ...................................................................... 40
5.5.7
Records .................................................................................................... 41
5.5.8
Nonconformance ....................................................................................... 42
5.5.9
Special crimping activities at spacecraft level, modifications and
repairs ....................................................................................................... 42
5.6
Document requirements.......................................................................................... 45
Annex A (informative) Crimp configurations and tools ....................................... 46
Annex B (informative) Examples of typical ultimate axial strength .................... 53
Bibliography ............................................................................................................. 55
Figures
Figure 1-1: Example of interconnections described in this Standard ....................................... 9
Figure 5-1: Example of crimping tools .................................................................................. 17
Figure 5-2: Example of a typical connector barrel and single wire crimping .......................... 21
Figure 5-3: Example of a typical connector barrel and multi-wire crimping............................ 22
Figure 5-4: Example of a typical ferrule shield crimping ........................................................ 23
Figure 5-5: Examples of typical lug and splice wire crimping (1 of 2) .................................... 25
Figure 5-6: Examples of typical lug and splice wire crimping (2 of 2) .................................... 26
Figure 5-7: Qualification process test procedure flow chart .................................................. 28
Figure 5-8: Quality control during crimping operation ........................................................... 34
Figure 5-9: Visible workmanship standards .......................................................................... 36
Figure 5-10: Workmanship examples and crimp micro-sections ........................................... 37
Figure 5-11: Shift performance test flowchart ....................................................................... 44
Figure A-1 : Confined irregular-octagon crimp (compactive) ................................................. 47
Figure A-2 : Dimpled confined octagon crimp (compactive) .................................................. 47
Figure A-3 : Regular-hexagon crimp (compactive) ................................................................ 47
Figure A-4 : Semicircular one- or two-indent crimp (dispersive) ............................................ 47
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Figure A-5 : Four-indent crimp (dispersive) ........................................................................... 47
Figure A-6 : Typical test fixture for testing lug and splice crimps ........................................... 52
Tables
Table 5-1: Equipment for verification process ....................................................................... 18
Table A-1 : Guideline for selector setting - Four-indent crimp (dispersive) - Single wire ........ 48
Table A-2 : Guideline for selector setting - Four-indent crimp (dispersive) - Two wires ......... 49
Table A-3 : Guideline for selector setting – Four-indent crimp (dispersive) – Two
different wires ..................................................................................................... 50
Table A-4 : Guideline for selector setting – Four-indent crimp (dispersive) – Single wire ...... 50
Table A-5 : Guideline for selector setting – Four-indent crimp (dispersive) – Two
identical wires .................................................................................................... 50
Table A-6 : Guideline for die selection – Regular hexagon (compactive ) – Ferrule
coaxial shield crimp ............................................................................................ 51
Table B-1 : Typical ultimate axial strength for compactive and dispersive crimped joints
manufactured using qualified ESCC wires .......................................................... 53
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
1
Scope
This Standard specifies:
•
Requirements for the following crimping wire connections intended for
high reliability electrical connections for use on spacecraft and associated
equipment operating under high vacuum, thermal cycling and launch
vibration:
removable contacts, single wire
removable contacts, multiple wires
coaxial contacts, ferrules
lugs and splices.
NOTE
These are the most commonly used crimping
wire connections and are represented in Figure
1-1.
•
The general conditions to be met for the approval of connections other
than the above mentioned ones.
NOTE
Additional forms of crimps, not covered in this
standard, are listed (not exhaustively) in the
informative Annex A.
•
Product assurance provisions for both the specific and the generic
connections mentioned above.
•
Training and certification requirements for operators and inspectors
(clause 5.5.2), additional to those specified in ECSS-Q-ST-20.
This standard may be tailored for the specific characteristics and constraints of a
space project, in conformance with ECSS-S-ST-00.
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Normal socket
Normal male
Enlarged socket
Enlarged male
MDM socket
MDM male
Coax socket
Coax male
Power socket
Power male
Butt splice
Parallel splice
Lug
Figure 1-1: Example of interconnections described in this Standard
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2
Normative references
The following normative documents contain provisions which, through
reference in this text, constitute provisions of this ECSS Standard. For dated
references, subsequent amendments to, or revisions of any of these publications
do not apply. However, parties to agreements based on this ECSS Standard are
encouraged to investigate the possibility of applying the most recent editions of
the normative documents indicated below. For undated references the latest
edition of the publication referred to applies.
ECSS-S-ST-00-01
ECSS system - Glossary of terms
ECSS-Q-ST-10-09
Space product assurance - Nonconformance control
system
ECSS-Q-ST-20
Space product assurance - Quality assurance
ECSS-Q-ST-60
Space product assurance - Electrical, electronic and
electromechanical (EEE) components
ECSS-Q-ST-60-05
Space product assurance – General requirements for
hybrids
ECSS-Q-ST-70
Space product assurance - Materials, mechanical parts and
processes
ECSS-Q-ST-70-08
Space product assurance - Manual soldering of high-
reliability electrical connections
ECSS-Q-ST-70-38
Space product assurance - High-reliability soldering for
surface-mount and mixed technology
ECSS-Q-ST-70-71
Space product assurance - Data for selection of space
materials and processes
SAE-AS-22520,
24 October 2011
Crimping tools, , wire termination, General specification
for
SAE-AS-7928B
10 March 2011
Terminals, lugs, splices, conductor, crimp style, copper,
general specification for
ISO 7500-1:2004
Metallic materials - Verification of static uniaxial testing
machines - Part 1: tension/compression testing machines -
Verification and calibration of the force-measuring system
ESCC 3901, Issue
2 May 2013
ESCC generic specification No. 3901 Wires and cables,
electrical, 600V, low frequency
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3
Terms, definitions and abbreviated terms
3.1
Terms defined in other standards
a.
For the purpose of this Standard, the terms and definitions from
ECSS-S-ST-00-01 apply, in particular for the following terms:
1.
acceptance
2.
analysis
3.
batch
4.
component
5.
conformance
6.
contaminant
b.
For the purpose of this Standard, the terms and definitions from ECSS-
Q-ST-60-05 apply, in particular for the following terms:
1.
process identification document (PID)
c.
For the purpose of this Standard, the terms and definitions from ECSS-Q-
ST-70-08 apply, in particular for the following terms:
1.
electrical connection
3.2
Terms specific to the present standard
3.2.1
adjustable indenter tool
crimping ratcheting tool which has an adjustable part (setting variable) that
indents or compresses the conductor barrel or ferrule
3.2.2
crimping configuration
combination of crimping tool, crimp item and number and type of wires
defined by the procurement specification
NOTE 1
Example of crimp item include lug, splice and
contact, ferrule.
NOTE 2
Type of wires include material, size, finish and
batch if not ESCC qualified wire.
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NOTE 3
Crimping tool based on the combination of tool
reference, setting and locator (when necessary).
3.2.3
crimping tool
mechanical ratcheting tool used for permanently attaching a wire connection
device to a conductor by pressure deformation or by reshaping the barrel
around the conductor to establish good electrical and mechanical contact
3.2.4
ferrule
short metal tube used to make crimp connections to the outer conductor of
shielded or coaxial cables
3.2.5
intrinsic wire strength
tensile strength of a wire used in a crimped assembly, determined by a specific
pull test
3.2.6
lug
metallic tube with drilled flange projection for fixing to a connection point
3.2.7
splice
metallic tube for joining two or more conductors to each other
3.2.8
terminal
metallic device that is used to make an electrical connection
3.3
Abbreviated terms
For the purpose of this Standard, the abbreviated terms from ECSS-S-ST-00-01
and the following apply:
Abbreviation
Meaning
AWG
American wire gauge
DRD
document requirement definition
IPA
iso-propyl alcohol
KIP
key inspection point
MIP
mandatory inspection point
NCR
nonconformance report
PID
process identification document
QA
quality assurance
RFA
request for approval
RFW
request for waiver
RH
relative humidity
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3.4
Nomenclature
The following nomenclature applies throughout this document:
a.
The word “shall” is used in this Standard to express requirements. All
the requirements are expressed with the word “shall”.
b.
The word “should” is used in this Standard to express recommendations.
All the recommendations are expressed with the word “should”.
NOTE
It
is
expected
that,
during
tailoring,
recommendations in this document are either
converted into requirements or tailored out.
c.
The words “may” and “need not” are used in this Standard to express
positive and negative permissions, respectively. All the positive
permissions are expressed with the word “may”. All the negative
permissions are expressed with the words “need not”.
d.
The word “can” is used in this Standard to express capabilities or
possibilities, and therefore, if not accompanied by one of the previous
words, it implies descriptive text.
NOTE
In ECSS “may” and “can” have completely
different
meanings:
“may”
is
normative
(permission), and “can” is descriptive.
e.
The present and past tenses are used in this Standard to express
statements of fact, and therefore they imply descriptive text.
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4
Principles
This Standard is structured such that the necessary level of quality is achieved,
consistently maintained and high reliability of the end product assured. The
following principles are covered:
•
Preparatory conditions to determine the availability of facilities, tools and
equipment, along with obligatory hazard and health precautions.
•
Specific interconnections, as identified in the Scope above, are then
covered in detail including
Material selection,
Process identification and documentation.
•
New crimp combinations beyond those identified in the Scope.
•
Test methods and acceptance criteria for both specific and generic types
of interconnections are specified.
•
Quality assurance measures for both the operator and the inspector are
prescribed:
Training and certification of personnel,
Calibration of tools and equipment,
Workmanship standards and acceptance criteria,
Inspection criteria and sequence,
Records from material incoming inspection through delivery of the
end product, including KIP, MIP, travellers, follow-up sheets, log
books, traceability samples and the handling of deviations by RFA
or NCR.
It is important to perform the work taking into account health and safety
regulations, and in particular the national standards on this subject.
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5
Requirements
5.1
Preparatory conditions
5.1.1 Facilities
5.1.1.1 Overview
The requirements in this clause can generally be met by using cleanrooms. It is
not, however, mandatory to use a cleanroom.
NOTE
Depending on supplier and customer business
agreement.
5.1.1.2 Facility cleanliness
a.
The supplier shall provide cleaning services for production facilities
where high reliability crimping is performed.
b.
Production facilities where high reliability crimping is performed shall be
maintained in a clean and tidy condition.
c.
Loose material that can cause contamination of the crimped connection
shall be removed.
NOTE
For example: Dirt, dust, oils and cut wire
strands.
d.
Furniture shall be kept to a minimum in the work areas and be arranged
to allow easy and thorough cleaning of the floor.
e.
Working surfaces shall be covered with an easily cleaned hard top,
antistatic mat or have a replaceable surface of clean, non-contaminating
silicone-free paper.
5.1.1.3 Environmental conditions
a.
The crimping area shall have a controlled environment, which limits
entry of contamination.
b.
The area shall be continuously controlled as follows:
1.
room temperature:
(22 ± 3) °C;
2.
relative humidity:
(55 ± 10) %.
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c.
The workstations shall not be exposed to draughts.
d.
Fresh air shall be supplied to the room through a filtering system with
positive pressure difference with regard to adjacent rooms.
e.
The exhaust air shall be suitably restricted.
5.1.1.4 Lighting requirements
a.
The supplier shall ensure adequate illumination conditions of the crimp
workstations.
b.
The minimum light intensity shall be 1 080 lux on the work surface.
c.
A minimum of 90 % of the work area shall be shadow-less and without
severe reflections.
5.1.2 Tools and equipment
5.1.2.1 Crimping tools
a.
The supplier shall provide the tooling necessary for continued high
quality crimping.
NOTE
Examples of crimping tools are shown in Figure
5-1.
b.
Tools used shall employ an integral ratcheting mechanism, which
controls the crimping operation in conformance to SAE-AS-22520.
NOTE
The
mechanism
ensures
that,
once
the
operation is started, the tool cannot be opened
until the crimping cycle is complete.
c.
Tools shall be sealed on one setting value in case of variable settings
tools.
d.
Tool calibration shall be verified in conformance with the clause 5.5.6
requirements.
e.
Proper operation of the integral ratcheting mechanism or the positive
stops on pneumatic tools shall be verified as defined in clause 5.5.6.
f.
Before starting a crimping process on a new terminal size and wire type,
the tool used for crimping of the previous wire type shall be returned to
the tool storage.
g.
If the tool settings seals are found removed or broken, the tool shall be
removed from the work place and returned immediately for
recalibration.
h.
Tools used in the crimping operation shall be clean and excess lubricant
removed before crimping starts.
i.
Tools shall be individually labelled.
NOTE
This
identification
is
recorded
in
the
manufacturing connector follow up sheet.
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Contact crimping tool
Splice-lug crimping tool
Figure 5-1: Example of crimping tools
5.1.2.2 Insulation strippers
a.
The supplier shall provide the tooling necessary to avoid damage to the
conductor.
b.
The selection of thermal or precision cutting devices, manual or
automatic power-driven, shall ensure integrity of the conductor strands.
c.
Wire stretching by use of mechanical strippers shall be avoided.
d.
The conductor shall not be twisted, ringed, nicked, cut or scored by
stripping operation.
e.
Both thermal and mechanical stripping tools shall be calibrated
periodically on sample evaluation during a production run.
f.
For coated wires the exposure of underlined base metal shall be a cause
for rejection.
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5.1.2.3 Cutting pliers
a.
The supplier shall provide the tooling necessary for precision wire
trimming and cutting.
b.
The cutter used for trimming conductor wire shall shear sharply and
consistently to produce a clean, flat, smooth-cut surface along the entire
cut edge.
c.
Twisting action during cutting operation shall be avoided.
d.
<<deleted>>
e.
The cutting edges shall be regularly checked for damage and maintained
in a sharp condition.
5.1.2.4 Test and monitoring equipment
a.
The supplier shall provide the equipment specified in Table 5-1 necessary
for verification activities specified in clause 5.4.3.
Table 5-1: Equipment for verification process
Performance tests activity
Equipment characteristic
<<deleted>>
<<deleted>>
Tensile strength (in conformance
with clause 5.4.3 requirements)
Tensile testing machine conforming to ISO 7500
class 1 or better. Axial load applied at a rate of
(20 – 40) mm/min ±2 mm/min
Visual inspection
Magnification ×7 to ×40
Monitoring requirements of the
process
Temperature
15 °C to 30 °C, accurate to ±1 °C
Relative humidity (RH)
40 % to 70 %, accurate to ±1 %
5.2
Crimping operations for different types of
interconnections
5.2.1 General
a.
The supplier shall visually examine wires, terminals and connector
contacts for cleanliness, absence of oil films and freedom from tarnish or
corrosion before assembly.
b.
The supplier shall perform cleaning of the work pieces using IPA.
c.
Further cleaning or other treatment shall not be carried out except the
case when validation and qualification of a cleaning product was
performed on all used materials.
d.
The supplier shall handle work pieces with clean lint free gloves or finger
cots.
e.
Before a crimping activity, tools at the operator’s station shall be verified
to conform to those selected in accordance with the applicable PID or
procedures.
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f.
All conductor strands shall be inserted cleanly into the barrel without
any buckling.
g.
Strands shall not be left outside or cut back to reduce the conductor
diameter to fit an undersized barrel.
h.
The supplier shall use tools as specified in SAE-AS-22520 for the crimp
contact configuration.
NOTE
Examples of crimping parameters are given in
Table A-1 to Table A-6
i.
The supplier shall take provisions to avoid degradation of the silver
plated wire caused by tarnish during storage.
j.
<<deleted>>
k.
The crimping of single solid wires shall not be used.
5.2.2 Material selection
a.
The supplier shall use silver plated copper multi stranded wire and
braided shield cable procured in conformance with the requirements
from ESCC generic specification 3901.
b.
In cases where other types of wire and wire finishes are used a request
for approval (RFA) in conformance with DRD from Annex D from ECSS-
Q-ST-70 shall be provided to the customer for approval.
NOTE
Examples of wire and wire finishes needing
RFA include nickel- or fused tin-plated wires,
stainless
steel,
phosphor
bronze,
copper,
constantan, and nickel alloys.
c.
The supplier shall use high strength copper alloy wire for 24 AWG,
26 AWG and 28 AWG crimped joints.
NOTE
Soft or annealed copper wire are not acceptable
for crimped joints of 24 AWG, 26 AWG and
28 AWG size.
d.
The supplier shall use space-qualified components having gold plated
finishes in conformance with ECSS-Q-ST-60.
e.
Specific items such as ferrules, splices, contacts and lugs shall be
purchased to SAE-AS-7928 specification.
f.
When gold plating is not available the finish shall be in conformance with
ECSS-Q-ST-70-71.
NOTE
Ferrules, splice, contacts and lugs supporting
an external nickel layer can be used in case
there is no alternative finish, although tool wear
is accelerated.
g.
Cadmium, chromate-coated cadmium, tin-lead and non-fused tin-plating
shall not be used.
NOTE
Tin-lead finish is not acceptable for crimp
connection due to creep.
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5.2.3 Process review and documentation
a.
The supplier shall perform a review of all the materials, tools and
techniques planned to be used to ensure conformance to requirements of
this standard and as a means of identifying potential problems.
NOTE
Type of wire includes base material, number of
strands, plating metal, type and thickness of
insulation.
b.
Dies, setting of controls for the length of strip in automatic stripping
machines and the selection of specific locators or positioners for crimping
tools, shall be selected to meet process requirements.
NOTE
The requirement is valid for power driven and
manual crimping processes as well as for size
and tolerance for crimping tools.
c.
The results of the review shall be documented in a specific internal
procedure.
5.2.4 Contact barrel and single wire crimping
a.
The supplier shall give preference to the selection of single multistranded
wire interconnections.
b.
The supplier shall not use strands of wire doubled backed to increase the
conductor diameter.
c.
The supplier shall use a specific contact to be compatible with the cross-
sectional area of the wire.
NOTE
Examples of a specific contact include reduced,
normal or enlarged barrel.
d.
For 28 AWG up to 16 AWG wire sizes, the insulation clearance shall be
maintained between 0,3 mm and 1,0 mm.
e.
For wire size bigger than 16 AWG the insulation clearance shall be
maintained between 0,3 mm and 2 mm.
f.
On D-sub contacts, a transparent shrink fit insulation sleeve shall be
applied over the rear of the contact and the wire insulation both to cover
the insulation clearance and to prevent any risk of a short circuit.
NOTE
Examples of crimping parameters are given in
Table A-1. An example of a typical contact
barrel and an example of single wire crimping
is shown in Figure 5-2.
g.
Multistranded type of wire shall be used in case the filler wire is used to
increase the conductors diameter.
h.
The use of potting, to ensure insulation at the rear of connectors with
removable contacts, shall not be used except when authorized by the
customer through RFA.
NOTE
The use of potting on these types of connectors
can violate specification from manufacturer and
can invalidate the qualification status of the
connector itself.
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Figure 5-2: Example of a typical connector barrel and single wire crimping
5.2.5 Contact barrel and multiple wire crimping
a.
Requirements of this clause shall be applied when single multistranded
wire crimping cannot be used.
b.
The maximum number of wires in one crimp barrel shall be two.
c.
The sum of the two nominal conductor sections shall be compatible with
the crimp barrel used
d.
Both conductors shall be of the same material and support the same
plating finish.
NOTE 1
For example: both are silver plated and not a
combination of silver and nickel plated, both
are high-strength copper alloy and not a
combination of pure copper and high-strength
copper alloy.
NOTE 2
Strand wires or conductors can be inserted
straight into the barrel or twisted together to
obtain a “single” conductor.
e.
Axial strength measurements shall be performed in compliance with
requirements in clause 5.4.3.2.
NOTE
Examples of crimping parameters are given in
Table A-2 and an example of a typical contact
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barrel and multi-wire crimping is shown in
Figure 5-3.
f.
For separate conductors introduced straight into the barrel the following
shall apply:
1.
the actual strength measurement is performed on one of the wires
(the smaller, if two different sizes are used);
2.
the axial strength requirement is determined as specified in
requirements of clause 5.4.3.2 for the actual size of wire pulled,
assuming a barrel size equal to that wire’s gauge.
NOTE
Examples of crimping parameters are given in
Table A-3 and an example of a typical connector
barrel and multi-wire crimping is shown in
Figure 5-3.
g.
The conductor diameter shall not be increased by the use of individual
strands of wire or double back wire.
h.
Multistranded type of wire shall be used in case the filler wire is used to
increase the conductors diameter.
i.
For 28 AWG up to 16 AWG wire sizes the maximum insulation clearance
shall be maintained between 0,3 mm and 1,0 mm.
Figure 5-3: Example of a typical connector barrel and multi-wire crimping
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5.2.6 Ferrule shield crimping
a.
The shielding on coaxial cables shall be ensured by braided strands.
b.
Axial strength measurements shall be performed in compliance with
requirements from clause 5.4.3.3.
c.
<<deleted, moved to 5.2.6f>>
d.
Only one braided shield shall be crimped in one ferrule connection.
e.
The braid end shall only be located at the ferrule crimp level in order to
prevent any risk of short circuit between central pin and braid strands.
f.
Following crimping, the assembly shall be protected by shrink tubing.
NOTE
Examples of crimping parameters are given in
Table A-6 and an example of a typical ferrule
shield crimping is shown in Figure 5-4.
Figure 5-4: Example of a typical ferrule shield crimping
5.2.7 Lug and splice wire crimping
a.
Only tools specified by the manufacturer of the terminals shall be used.
b.
The maximum number of wires shall be ten on the same assembly.
c.
Seven wires maximum shall be on the same side.
d.
All conductors shall be of the same material and within a size range of 4
wire gauges including odd and even AWG sizes on the same side.
e.
If the number of conductors on the same side is more than two all
conductors shall be positioned parallel in the terminal barrel before
crimping.
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f.
Axial strength measurements shall be performed in compliance with
requirements from clause 5.4.3.3.
g.
<<deleted>>
h.
Figure A-6Following crimping, the assembly shall be protected by shrink
tubing.
NOTE
Examples of typical lug and splice wire
crimpings are shown in Figure 5-5 and Figure
5-6.
i.
In case the number of conductors on the same side is limited to two then
the conductors may be twisted together to form a single conductor.
j.
For 28 AWG up to 16 AWG wire sizes the maximum insulation clearance
shall be maintained between 0,3 mm and 1,0 mm.
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Butt splice crimping
Two sided parallel splice crimping
One side parallel splice crimping
Figure 5-5: Examples of typical lug and splice wire crimping (1 of 2)
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Crimping of lug
Crimping of lug with filler wire
Microgaph of crimping of lug with filler wire
Figure 5-6: Examples of typical lug and splice wire crimping (2 of 2)
5.3
Requirements for crimp configuration qualification
5.3.1 General
a.
All crimp configurations shall be qualified in compliance with
requirements from clause 5.3.2.
b.
The supplier shall document the data of successful process qualification
in a specific internal procedure to ensure continued high quality of
production performance.
c.
<<deleted>>
d.
Any change to an element of the qualified crimp configuration specified
in requirement 5.3.1a shall be qualified.
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e.
The supplier shall ensure that the selected materials are qualified for the
mission environment.
f.
In case the mission environment exceeds the temperature range for
which the materials are qualified, a qualification shall be performed and
agreed with the customer
NOTE
Examples of materials include cables and crimp
items.
g.
In case qualification is needed, the supplier shall issue an RFA.
5.3.2 Qualification process test procedure
a.
The supplier shall perform tensile strength tests on samples prepared at a
number of tool settings, in conformance with the requirements specified
in clause 5.4 and in conformance with the following process:
1.
Ten samples prepared at the point specified by the crimping tool
manufacturer as a starting point for calibrating tools.
2.
For connector contacts the tool indenter opening is then adjusted
in convenient increments above and below this point, and ten
samples pulled at each increment.
3.
For lugs, splices and ferrules, ten samples are prepared at each
setting of the crimping tool and pulled.
4.
A plot is made with increments being close enough together to
obtain a smooth curve.
5.
The maximum in tensile strength is then determined and
evaluated.
6.
The optimum tool setting lies approximately in the middle of the
flat top portion of the tensile-strength plot.
7.
In case of very close average tensile strength values, the
microsectioning of the samples relevant to the concerned settings
is performed to identify the best setting.
NOTE
Typical settings of crimping tool are given in
Annex A.2.
b.
The supplier shall validate satisfactory results achieved from the final
tool setting at the operating point on a minimum of ten samples in
conformance with the methods defined in clause 5.4 and according to the
following process:
1.
Tensile strength tests are performed on five samples corresponding
to the operating point.
2.
<<deleted>>
3.
Metallographic tests are performed on a minimum of three
samples corresponding to the operating point.
4.
Not tested samples are retained for reference.
c.
Test data shall be recorded in a qualification report.
d.
The qualification report shall include the results of the search for the
optimum tool setting specified in requirement 5.3.2a.
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NOTE
Figure 5-7 presents a flow chart of the
Qualification process test procedure of clause
5.3.2.
Wire / braid
under ESCC specification?
Wire / braid
intrinsic tensile strength already
characterized?
Wire / braid
intrinsic tensile strength already
characterized?
YES
NO
Ensure the intrinsic wire / braid tensile strenth characterization
(clause 5.4.3.5)
[Average values on 10 samples]
Wire / braid batch is
the same than the already used
on a previous qualified crimping
configuartion?
YES
NO
NO
NO
Choice of the crimp item: Crimp item barrel section > wire /braid section to be crimped into
Optimum setting search (clause 5.3.2)
Optimum setting research:
For connector contacts:
- Average tensile strength values on 10 samples of the chosen setting
- Average tensile strength values on 10 samples of the just above setting
Optimum setting qualification
Optimum setting research:
- 10 samples with the chosen setting,
- 5 samples for tensile strenght tests
YES
YES
Figure 5-7: Qualification process test procedure flow chart
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5.3.3 Sealing and marking
a.
The supplier shall seal and mark calibrated tools in conformance with
clause 5.5.6.3 requirements.
5.3.4 Batch to batch variation
5.3.4.1 Wires qualified by ESCC
a.
For wires qualified by ESCC the qualified tool set-up may be used
without additional validation when different batches of wires are used.
5.3.4.2 Wires not qualified by ESCC
a.
For wires not qualified by ESCC the qualified optimum set-up shall be
confirmed for each new batch of wire in conformance with the following
qualification process:
1.
tensile strength tests are performed on five samples corresponding
to the operating point,
2.
a further five samples are produced at tool settings above and
below the operating point and tensile tested.
b.
The average tensile strength at the operating point, as per 5.3.4.2a.1, shall
be higher or equal to the result obtained in 5.3.4.2a.2 and in compliance
with 5.4.3.
c.
In case the average result at the operating point is lower than the result
obtained in 5.3.4.2a.2 the qualification process specified in the
requirements from clause 5.3.2 shall be repeated.
5.4
Test methods
5.4.1 General
a.
The supplier shall submit samples to the tests specified in clauses 5.4.3
and 5.4.4.
NOTE
The number of samples is dependent on the
specific process requirement (in conformance
with clauses 5.3.2 ,5.3.4, 5.5.5 and 5.5.6.2
requirements).
b.
Test samples shall meet the requirements of clause 5.5.4.1.
c.
Records of all results shall be tabulated in conformance with 5.5.7.
5.4.2 <<deleted>>
a.
<<deleted>>
b.
<<deleted>>
c.
<<deleted>>
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5.4.3 Tensile strength
5.4.3.1 General
a.
The supplier shall use a tensile testing device with characteristics in
conformance with Table 5-1.
b.
The connections shall be loaded until failure occurs.
c.
The value at failure shall be recorded, together with the information as to
whether the failure was “pull-out”, “break in crimp” or “break in wire”.
d.
The required ultimate axial strengths for compactive and dispersive
crimped joints shall be determined as specified in clauses 5.4.3.2 and
5.4.3.3.
NOTE
A typical test fixture for testing ferrule lug,
splice and contact crimps is shown in Figure A-
6.
e.
The clamping of the free bare ends of wire or metallic braided shield
directly in the clamping fixtures of the tensile machine shall not be used.
5.4.3.2 Contact barrel wire crimping
a.
The required axial strength of the crimped assembly shall be 75 % of the
intrinsic wire strength as specified in clause 5.4.3.5.
NOTE
Examples of typical values of intrinsic wire
strength of ESCC qualified wires and the 75%
requirement are detailed in Table B-1.
b.
<<deleted>>
c.
In case of two crimped wires the axial strength the measurement shall be
performed on one of the two inserted wires and be at least 75 % of the
intrinsic strength of the wire.
d.
If two different wire gauges are used then the test specified in 5.4.3.2c
shall be performed on the smaller of the two.
e.
Only one tensile test per sample is performed and the test shall be
continued until failure occurs.
5.4.3.3 Ferrule
a.
The required axial strength of the crimped assembly shall be 75 % of the
intrinsic wire or braid strength as specified in clause 5.4.3.5.
b.
Axial strength measurements shall be performed only on the shield after
removal of the core dielectric.
5.4.3.4 Lug and splice
a.
The required axial strength of the crimped assembly shall be 75 % of the
intrinsic wire or braid strength as specified in clause 5.4.3.5.
b.
In the case of several equal wire sizes crimped into the same barrel axial
strength measurements shall be performed on only one wire per sample.
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c.
In the case of different wire sizes crimped into the same barrel axial
strength measurements shall be performed on only one wire per sample
from the smallest gauge
d.
In the case where opposed wires are tested a specifically designed test
fixture shall be used.
NOTE
A typical test fixture is shown in Figure A-6
e.
Only one tensile test per sample is performed and the test shall be
continued until failure occurs.
5.4.3.5 Characterisation of intrinsic wire / braid strength
a.
Intrinsic strength of wire or metallic braided shields shall be determined
as follows:
1.
A minimum of ten samples of 200 mm length from the wire batch
to be used for the crimped assembly are prepared for testing by
first stripping the insulation from both ends of the wire,
2.
For metallic braided shield axial strength measurements are
performed only on the shield after removal of the core dielectric,
3.
To avoid wire or metallic braided shield strands damage in the
clamping area, suitable end tabs, such as soldered splice are used,
4.
The samples are tested to failure at a rate of (20 – 50) mm/min,
5.
The maximum load achieved is recorded,
6.
In case of failure in the clamps the result is discarded,
7.
Intrinsic wire strength is calculated by averaging a minimum of
ten valid tests.
b.
The intrinsic wire strength characterization shall be performed once for
each batch of wire.
c.
For ESCC wires, the intrinsic wire strength characterization value
obtained on a batch of wire to other batches of the same type and size of
wire from the same manufacturer, may be applied.
5.4.4 Metallography
a.
The supplier shall employ a certified laboratory to perform the
metallographic tests specified in the requirements 5.4.4c to 5.4.4i.
b.
The customer shall approve the certification status of the laboratory.
c.
The joint to be sectioned shall be mounted in a low exotherm resin
capable of being moulded without the application of external pressure.
d.
The joint shall be oriented that the wire is perpendicular to the polishing
surface.
e.
The specimen shall be ground with the aid of appropriate grades of
silicon carbide papers, in order to expose the mid-section of the joint.
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f.
This section shall then be polished with successively finer grades of
diamond paste down to 1 µm.
g.
To aid microscopic examination, the polished section shall be very lightly
etched with an accepted chemical reagent specific to the composition of
the materials being crimped.
h.
The section shall be examined in both as-polished and etched states using
a metallographic microscope at a magnification up to ×400.
i.
The following acceptance criteria shall be met:
1.
Each micro section is free from contamination;
2.
The crimp barrel is evenly deformed;
3.
Voids occupy less than 10 % of the cross sectioned area of the wire
volume;
4.
The wires and barrel appear as a gas-tight joint and conform to the
workmanship sample prepared during qualification;
5.
All strands are deformed from their circular cross section;
6.
There are no indentations or fracturing of the deformed receptacle
barrel or its plated finish.
NOTE For ferrule shield crimping the requirements of
5.4.4i.3. and 5. are not applicable.
j.
The laboratory for the metallographic tests should be certified with ISO
17025.
5.5
Quality assurance
5.5.1 General
a.
The supplier shall install a Quality Assurance (QA) function in
conformance with the requirements as defined in ECSS-Q-ST-20.
b.
The quality control process shall be as specified in Figure 5-8.
5.5.2 Personnel training and certification
5.5.2.1 Training program
a.
The supplier shall employ trained and certified personnel for all
stripping and crimping operations implementing and maintaining a skill
matrix.
b.
The supplier shall develop, maintain and implement a training
programme, in conformance with ECSS-Q-ST-20.
NOTE
The aim of the training programme is to
provide for excellence of workmanship and
personnel skills, careful and safe operations,
and improvement of the quality of crimped
joints.
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5.5.2.2 Certification
a.
<<deleted>>
b.
The certification of personnel shall be based upon objective evidence of
crimp quality, resulting from test and inspection of the crimped joints.
c.
Operators or inspectors shall be re-certified in cases of repeatedly
unacceptable quality levels and changes in crimping techniques,
parameters or required skills.
d.
The supplier shall perform training and certification at a school
authorized by the customer.
e.
Certification shall be valid for a period of two years.
5.5.2.3 Documentation
a.
The supplier shall maintain records of the training and certification status
of crimping operators and inspection personnel.
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Figure 5-8: Quality control during crimping operation
Personnel trained and certified
(in conformance with clause 5.5.2)
Control of compatibility of parts,
crimping and stripping tools
(in conformance with clauses 5.1.2.1
and 5.1.2.2)
Crimp configuration qualified
(in conformance with clause 5.3.1
Crimping tool calibrated using go/no-go
gauges and sample crimps
(in conformance with subclause 5.5.6.2
Definition of tool setting parameters
(in conformance with clauses 5.5.6.2b)
Pre-crimp production inspection of
wires and barrels
(in conformance with clause 5.5.4.1)
Remove stripping tool from the area and
repair/recalibrate or reject as necessary
nonconformance
Performance inspection and test of
crimping operations
(in conformance with subclause 5.5.5
or 5.5.9)
All crimping production performed
with the crimp tool concerned since its
last acceptable sampling shall be
rejected
nonconformance
Crimping operation
Post-crimp production inspection
(in conformance with clause 5.5.4.2
REJECT
ACCEPT
nonconformance
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5.5.3 Workmanship
a.
The supplier shall prepare standards consisting of satisfactory work
samples (in conformance with the Figure 5-9 and Figure 5-10)
b.
The supplier shall have readily available visual aids, which clearly
illustrate the quality characteristics of all crimped connections utilized.
c.
Defects such as those listed in clause 5.5.4.2 and shown in Figure 5-9 shall
be included as examples.
d.
The operator shall discard production crimps which are defective.
e.
Defective test samples shall not be discarded.
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Figure 5-9: Visible workmanship standards
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Unacceptable: undercrimp
Limit of acceptability: void 10 %
Acceptable: preferred
Not acceptable: overcrimp
A
Figure 5-10: Workmanship examples and crimp micro-sections
5.5.4 Visual inspection
5.5.4.1 Pre-crimp inspection (performed by the operator)
a.
The wire shall be examined for no evidence of nicks, rings, broken
strands, untwisted lay or not-removed insulation in the area of the crimp
before the stripped wire is inserted into the crimped item barrel.
b.
Damaged wires where the base material is exposed shall not be used.
c.
Contacts and terminal barrels that show evidence of the presence of
tarnish, corrosion or physical damage, including bent contacts, shall not
be used.
d.
Inspection shall check that the combination of wire size and type and
crimp item are in accordance with the drawing or control document.
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5.5.4.2 Post-crimp inspection (performed by quality
assurance)
a.
The QA inspector shall carry out inspection with the use of a binocular
microscope having a minimum linear magnification of ×7.
NOTE
Further examination of surface characteristics
can be performed at higher magnifications.
b.
The inspector shall not physically disturb parts and conductor leads to
help inspection.
c.
The following acceptance criteria shall be met;
1.
Wire insulation is not damaged by the crimping operation;
2.
The conductor is visible in the inspection hole when an inspection
hole is provided; in the case of lugs and splices the free end of the
conductor is visible at the exit point;
3.
The crimp barrel has no unintentional sharp edges, peeled metal,
burrs, cracked platings or cuts after crimping;
4.
All functional parts, including all retention clips or locking devices,
are operational after the crimp has been made;
5.
No tarnished or corroded crimped item are present;
6.
No misplaced crimps, as determined by marks found on areas not
designed to take crimping, are present
7.
No undercrimps or overcrimps are present;
8.
The detection of an under crimp or over crimp shall cause the stop
of manufacturing as follows:
(a)
operations at that work place ,
(b)
rejection of all production crimps made since the last
verification or pull test,
(c)
investigation of tools, wire and crimp item to determine the
cause of failure.
9.
No bent contacts are present.
10.
Wire strands are not damaged as a result of the crimping
operation.
11.
The insulation clearance complies with the requirements 5.2.4d
and 5.2.4e.
d.
Failure to meet the acceptance criteria of 5.5.4.2c shall be cause for
rejection.
5.5.4.3 General
a.
100 % visual inspection shall be performed by independent inspector.
b.
The independent inspector should be from Quality Assurance.
c.
Pre-crimp inspection may be performed by an operator who has
successfully followed and passed an internal training scheme which has
been implemented by QA as specified in 5.5.2.
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5.5.5 Shift performance inspection and test for
harness manufacturing
a.
<<deleted>>
b.
<<deleted>>
c.
<<deleted>>
d.
<<deleted>>
e.
<<deleted>>
f.
<<deleted>>
g.
<<deleted>>
h.
<<deleted>>
i.
<<deleted>>
j.
<<deleted>>
k.
Prior to the start of a new harness manufacturing the following shall be
done:
1.
The tool settings are determined for each crimp combinations, wire
and crimp item, that are planned to be used during the project,
2.
Crimping tools are dedicated to one crimping combination, wire
and contact, and have individual identification,
3.
Crimping tools are validated at start of manufacture and
traceability noted in its correspondent log book,
4.
Crimp configuration settings are locked on each contact crimping
tool.
NOTE 1
Ideally, crimping tools are dedicated to one
project.
NOTE 2
Shift performance test for crimping operation
with small number of crimps as integration and
repairs, are detailed in clause 5.5.9.
l.
At the start of harness manufacturing the following shall be done:
1.
Four samples of each of the different configurations are produced
at the optimum setting for connector and ferrules,
2.
Four samples of the configuration with the minimum number of
wires into the barrel and four samples of the configuration with
maximum number of wires for lugs and splices,
3.
Three of the samples of each type from the four samples specified
in the requirements 5.5.5l.1 and 5.5.5l.2 are pull tested,
4.
The fourth sample is retained as traceability witness,
5.
All results are recorded in the dedicated project logbook.
m.
Intermediate tool inspections of a harness manufacturing shall be done as
follows:
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{
"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 39
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
1.
At the start of each new shift cleanliness control of the active part
of the tool and “go/no-go” checks are performed,
2.
Crimping tools which are used for less than 500 crimps per week
shall be revalidated after each 500 crimp operations or 2 months
whichever is earlier in conformance with requirements from the
clause 5.5.6.2
3.
The results are recorded in the dedicated tool logbook in
accordance with 5.5.6.2c.
n.
For manufacturing runs of more than 500 crimps per week with the same
crimping tool the following shall be done:
1.
Cleanliness control of the active part of the tool and “go/no-go”
checks are performed,
2.
Tensile test on not less than four samples each 500 crimp
operations are performed,
3.
Revalidation of the tools is performed each 1500 crimp operations
or 2 months, whichever is earlier in conformance with
requirements from the clause 5.5.6.2,
4.
The results are recorded in the dedicated tool logbook in
accordance with 5.5.6.2c.
o.
At the end of the harness manufacturing the following shall be done:
1.
Four samples of each of the different configurations are produced
at the optimum setting for connector contacts and ferrules,
2.
Four samples of the configuration with the minimum number of
wires into the barrel and four samples of the configuration with
maximum number of wires for lugs and splices,
3.
Three samples from four samples specified in the requirements
5.5.5o.1 and 5.5.5o.2 are pull tested,
4.
The fourth sample is retained as traceability witness,
5.
All results are recorded in the dedicated project logbook.
5.5.6 Calibration of crimping tools
5.5.6.1 General
a.
The QA organization of the supplier shall ensure that each crimping tool
and measuring equipment is calibrated as indicated in the subsequent
sub clauses.
b.
The QA organization of the supplier shall record any suspected and
actual equipment failure as a project nonconformance report
NOTE
Based
on
past
nonconformance
reports
previous results can be examined to ascertain
whether or not re-inspection or retesting is
required.
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
c.
The QA organization of the supplier shall notify the customer of the
nonconformance details.
d.
The supplier’s calibration procedure shall include the requirements
specified in this clause for tool calibration.
5.5.6.2 Validation
a.
The QA organization of the supplier shall ensure that crimping tools,
both manual and powered, are calibrated when initially set up for each
specific wire size, connection size and type prior to first use.
b.
Calibration shall be verified in conformance with the following check-list:
1.
cleanliness control of the active part of the tool (e.g. indenters);
2.
set up with the aid of the “go/no-go” gauge in conformance with
specified conditions;
3.
tests in conformance with the clause 5.4 requirements on not less
than four samples.
c.
After satisfactory verification of calibration the tool status shall be
documented in a “tool calibration sheet” to ensure tool traceability.
d.
This traceability shall be established by periodic analysis of the
corresponding data from the performance inspection and tests (in
conformance with clause 5.5.5 requirements),
e.
A significant drift in test results shall result in tool rejection.
NOTE
Such a tool is generally labelled "out-of-
calibration tool" (in conformance with clause
5.5.6.4 requirements).
5.5.6.3 Sealing and marking
a.
The supplier shall provide sealing for calibrated crimping tools to ensure
against unauthorized alteration of adjustment settings.
b.
A wire and lead seal method shall be used if the tool has provisions for it;
c.
In case requirement 5.5.6.3b cannot be implemented, the tool shall be
sealed by a non-reusable decal seal, which, if the calibrated setting is
altered, is visibly damaged.
d.
Seals shall be placed on all external adjustment points of the tool.
5.5.6.4 Out-of-calibration tools
a.
Tools that are out of calibration shall be returned to the tool facility for
readjustment and calibration.
b.
Tools that are worn or damaged shall be identified as rejected and
removed from the fabrication area.
5.5.7 Records
a.
The supplier shall maintain traceability throughout the process from
incoming inspection to final test, including details of test equipment,
tools and personnel employed in performing the task.
b.
Quality records and logbooks shall be retained for at least ten years
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"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 41
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
c.
Quality records and logbooks shall contain the following information:
1.
the as-built and test configuration list (waiver and deviation
summary);
2.
nonconformance reports and corrective actions;
3.
copy of the visual inspection and performance test results with
reference to the relevant procedure, personnel and tools used;
4.
records of the training, testing and certification status of crimping
operators in conformance with clause 5.5.3 requirements.
5.5.8 Nonconformance
a.
The
QA
organization
of
the
supplier
shall
disposition
any
nonconformance which is observed in respect of the process in
conformance with the quality assurance requirements, in conformance
with ECSS-Q-ST-10-09.
b.
Failure of a crimping tool to pass any requirement specified in clause
5.1.2.1 shall require rejection of all crimps made by that tool since it was
last tested successfully for acceptance.
5.5.9 Special crimping activities at spacecraft level,
modifications and repairs
a.
Crimping tools shall have individual identification.
b.
Crimping tools shall be validated every 12 months or every 1500 crimps
whichever is earlier in compliance with requirements from clause 5.5.6.2.
c.
Results of validation specified in the requirement 5.5.9b shall be recorded
in its dedicated logbook.
d.
The supplier shall keep a logbook for each tool.
e.
The logbook shall show the quantity of parts crimped since each
calibration and since each “go/no-go” operation.
f.
The in-process controls shall be in compliance with requirements 5.5.9g
or 5.5.9h.
g.
After every 250 crimping operations four samples shall be crimped of
which:
1.
three samples are submitted to the tensile strength test as specified
in the requirements from the clause 5.4.3,
2.
the fourth sample is retained for reference and traceability
purposes in conformance with requirements from clause 5.5.6.2,
and
3.
a “go/no-go” check of the tool is performed at the beginning of
each shift and recorded in the logbook.
h.
In case the supplier does not maintain a logbook of the crimping
operation, detailed in 5.5.9g, the following shall be performed by each
operator:
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"page_number": 42
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
1.
prepare four samples at the beginning of a shift or before a series
of crimping operations of which:
(a)
three samples are submitted to the tensile strength test as
specified in the requirements from the clause 5.4.3, and
(b)
the fourth sample is retained for reference and traceability
purposes in conformance with requirements from clause
5.5.6.2.
2.
at the end of the shift or after 250 crimping operations, whichever
is reached first, four samples are crimped of which:
(a)
three samples are submitted to the tensile strength test as
specified in the requirements from the clause 5.4.3, and
(b)
the fourth sample is retained for reference and traceability
purposes in conformance with requirements from clause
5.5.6.2.
i.
A crimping tool shall be changed whenever a wire size or contact size is
changed.
j.
After a change of a crimping tool, as specified in the requirement 5.5.9i,
the operator shall, unless the tool has a current validation, prepare four
samples at the start of the operation, of which:
1.
three samples are submitted to the tensile strength test as specified
in the requirements from the clause 5.4.3, and
2.
the fourth sample is retained for reference and traceability
purposes in conformance with requirements from clause 5.5.6.2.
k.
The supplier shall perform an analysis of shift performance test results, in
comparison with initial tool calibration results, to determine any drift in
tool performance.
NOTE
Figure 5-11 illustrates the shift performance test
flow.
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"page_number": 43
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Tools preparation per 5.5.5k
Preparation and test of 4 samples per tool
in compliance with 5.5.5l at beginning of
the manufacturing of a new harness.
“Go/no-go” check is done at beginning of
each shift per 5.5.5m.1
Are more than 500 crimps
performed with the tool in a
week?
Perform the intermediate checks as per
5.5.5m
“Go/no-go” check is done at beginning of
each shift per 5.5.5m.1
NO
YES
At the end of the harness manufacturing perform the
testing on four samples per tool as per 5.5.5o
Tool preparation as per 5.5.9b and 5.5.9c
Supplier maintains logbook for
crimping tool
Preparation and test of 4 samples per tool
in compliance with 5.5.9g
“Go/no-go” check is done at beginning of
each shift per 5.5.9g.3
Preparation and test of 4 samples per tool
in compliance with 5.5.9g
After 250 crimping operations
At the beginning of the shift Preparation and
test of 4 samples per tool in compliance with
5.5.9h.1
At the end of the shift or after 250 crimping
operation whichever is reached first:
Preparation and test of 4 samples per tool in
compliance with 5.5.9h.2
Every 1500 crimps of 12 months whichever is reached first
the crimp is validated as per 5.5.9b
YES
NO
Harness manufacturing according to clause 5.5.5
Integration activities at PCB / unit / spacecraft level
according to clause 5.5.9
Figure 5-11: Shift performance test flowchart
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{
"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 44
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
5.6
Document requirements
a.
The supplier shall produce documentation for:
1.
Process identification, in a PID or a specific internal procedure and
RFA,
2.
Inspection,
3.
Traceability,
4.
Testing, both procedures and records,
5.
Logbooks, and
6.
Calibration.
b.
The format of the documents shall be in accordance with the deliverables
item list defined in the business agreement.
NOTE
No specific DRD requirements emerge from
this Standard.
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"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 45
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Annex A (informative)
Crimp configurations and tools
A.1
Overview of crimp configurations
Many crimp interconnection technologies are currently available for space
applications. Confined or compactive crimps are made by a tool, which exerts
an even pressure around the receptacle barrel circumference such that even
deformation is applied on all sides; the only means of stress relief is by
elongation of the barrel and wire. Typical settings for the crimping tool are
given in A.2.
Non-confined or dispersive crimps result from compression of the receptacle
barrel with an indenter die having one or two indents or, alternatively, by two
or four radially opposed indenter dies (in conformance with Figure A-4 and
Figure A-5).
The achievement of an acceptable crimped joint is controlled by the tools and
materials used, but workmanship - the manner in which they are employed - is
also important. Items that constitute workmanship are those under the control
of the operator. They include careful butting of the wire against the stop in the
stripping operation to ensure correct insulation gap, loading of a connector pin
in the positioner to the full distance, inserting the stripped wire into the
connector pin barrel or terminal until it shows in the inspection hole or through
the contact in the case of crimp lugs and re-twisting the strands not more than
the natural lay, if disturbed during the stripping operation.
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"page_number": 46
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Figure A-1: Confined irregular-octagon crimp (compactive)
Figure A-2: Dimpled confined octagon crimp (compactive)
Figure A-3: Regular-hexagon crimp (compactive)
Figure A-4: Semicircular one- or two-indent crimp (dispersive)
Figure A-5: Four-indent crimp (dispersive)
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"page_number": 47
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
A.2
Typical settings of crimping tools
For the type of crimping covered in this Standard typical tool selector settings
are applicable. Those are, however, only indicative and require effective
calibration or validation before use for production of high-reliability crimps, in
conformance with clause 5.5.6
Tables for the different types of crimp configuration are shown below. They
include reference to the tooling and selector settings by wire and barrel sizes.
For the specific case of lug and splice configurations where opposed wires are
tested (in conformance with clause 5.4.3 requirements) a typical test fixture is
shown in Figure A-6.
Table A-1: Guideline for selector setting - Four-indent crimp (dispersive) - Single wire
Connector
Wire gauge
(AWG)
Wire barrel
contact size
Crimping tool / Selector setting
M22520/2-01 M22520/1/01
M300-BT
D * SUB 3401-002 connector family
8
8 - 8
-
-
6
10
8 - 10
-
-
5
12
8 - 14/12
-
-
2
16
20 - 18
7
-
18
20 - 18
6
-
-
-
-
20
20 - 20
7
-
-
22
20 - 20
6
-
-
24
20 - 20
5
-
-
26
20 - 26
6
-
-
28
20 - 26
6
-
-
22
22 - 22
4
-
-
24
22 - 22
3
-
-
26
22 – 22
2
-
-
28
22 – 22
1
-
-
MIL-C 38999 3401-044;3401-052 and
3401-056 connector family
12
12 - 12
-
8
-
14
12 - 12
-
-
-
16
12 - 12
-
7
-
16
16 - 16
-
6
-
18
16 - 16
-
5
-
20
16 - 16
-
4
-
20
20 - 20
7
3
-
22
20 - 20
6
2
-
24
20 - 20
5
1
-
22
22 - 22
4
-
-
24
22 - 22
3
-
-
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"page_number": 48
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
26
22 - 22
2
-
-
28
22 - 22
1
-
-
DBAS 3401-008 connector family
12
12 - 12
-
8
-
14
12 - 12
-
7
-
16
16 - 16
-
6
-
18
16 - 16
-
5
-
20
16 - 16
4
-
20
20 - 20
7
-
-
22
20 - 20
6
-
-
24
20 - 20
5
-
-
26
20 - 26
6
-
-
28
20 - 26
5
-
-
HE801
3401-016
connector
family
22
22 - 22
5
24
22 - 22
4
26
22 - 22
4
Table A-2: Guideline for selector setting - Four-indent crimp (dispersive) - Two wires
Connector
Wire gauge
(AWG)
Wire barrel
contact size
Crimping tool / Selector setting
M22520/2-01 M22520/1/01
M300-BT
D*SUB
3401-002 connector family
12 + 12
8 - 8
-
-
6
-
8 - 10
-
-
-
16 + 16
8 - 14/12
-
-
3
20 + 20
20 - 18
7
-
-
22 + 22
20 - 18
6
-
-
24 + 24
20 - 20
6
-
-
26 + 26
20 - 20
5
-
-
28 + 28
20 - 20
4
-
-
DBAS 3401-008
connector family
-
12 - 12
-
-
-
20 + 20
16 - 16
-
6
-
24 + 24
20 -20
6
-
-
26 + 26
20 - 20
5
-
-
28 + 28
20 - 20
4
-
-
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"page_number": 49
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Table A-3: Guideline for selector setting – Four-indent crimp (dispersive) – Two different
wires
Connector
Wire gauge
(AWG)
Wire barrel
contact size
Crimping tool / Selector setting
M22520/2-01 M22520/1/01
M300-BT
D*SUB
3401-002 connector family
-
8 - 8
-
-
-
12 + 16
8 - 10
-
-
5
-
8 – 14/12
-
-
-
20 + 22
20 - 18
6
-
-
22 + 24
20 - 20
8
-
-
22 + 26
20 - 20
7
-
-
24 + 26
20 - 20
6
-
-
26 + 28
20 - 20
4
-
-
26 + 28
22 - 22
4
DBAS
3401-008
connector
family
-
12 - 12
-
-
-
-
16 - 16
-
-
-
26 + 28
20 -20
5
-
-
Table A-4: Guideline for selector setting – Four-indent crimp (dispersive) – Single wire
Connector
Wire gauge
(AWG)
Wire barrel
contact size
Crimping tool / Selector
setting
M22520/2-01
MDMA
3401-077
connector family
24
24 – 24
3
26
24 – 26
2
28
24 - 26
2
Table A-5: Guideline for selector setting – Four-indent crimp (dispersive) – Two identical
wires
Connector
Wire gauge
(AWG)
Wire barrel
contact size
Crimping tool / Selector setting
M22520/2-01
MDMA
3401-077
connector family
28 + 28
24 -24
3
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"page_number": 50
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Table A-6: Guideline for die selection – Regular hexagon (compactive ) – Ferrule coaxial
shield crimp
Coaxial sort
Coaxial
cable
reference
M22520/5-01 Crimping tool
Die / Slot selection
M22520/10-01 Crimping
tool Die / Slot selection
D*SUB
3401-002 connector
family
RG 178 BU
M22520/5-03
B
M22520/10-05
B
RG 196 AU
M22520/5-03
B
M22520/10-05
B
RGL-196 #28
M22520/5-03
B
M22520/10-05
B
50 CIS
M22520/5-03
A
M22520/10-05
A
50 CIS BLG
M22520/5-03
A
M22520/10-05
A
SMA
3402-001
connector
family
50 CIS
M22520/5-03
A
M22520/10-05
A
50 CIS BLG
M22520/5-03
A
M22520/10-05
A
50 CIS DTR
M22520/5-03
A
M22520/10-05
A
A.3
Typical test fixture for pull tests
For the specific case of lug and splice configurations where opposed wires are
tested, see clause 5.4.3, a typical test fixture is shown in Figure A-6.
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Figure A-6: Typical test fixture for testing lug and splice crimps
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"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 52
}
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ECSS-Q-ST-70-26C Rev.1
15 March 2017
Annex B (informative)
Examples of typical ultimate axial strength
Examples of typical values of intrinsic wire strength of ESCC qualified wires and presented in the Table B-1.
Table B-1: Typical ultimate axial strength for compactive and dispersive crimped joints manufactured using qualified ESCC wires
AWG
Number and size of strands (∅ in mm)
Conductor
section in mm2
Minimum tensile resistance for
crimps with the following
composition
Kapton
Tefzel
Teflon/Kapton
Silver-plated
pure copper
Silver-plated
copper alloy
3901/001-002
3901/012
3901/019
28
19 x 0,08
7 x 0,12
7 x 0,127
0,095
-
35 N
26
19 x 0,10
19 x 0,10
19 x 0,10
0,15
-
45 N
24
19 x 0,12
19 x 0,12
19 x 0,12
0,22
-
60 N
22
19 x 0,16
19 x 0,15
19 x 0,15
0,38
65 N
-
20
19 x 0,20
19 x 0,20
19 x 0,20
0,6
110 N
-
18
19 x 0,25
19 x 0,25
-
0,93
170 N
-
16
19 x 0,30
19 x 0,30
19 x 0,30
1,34
250 N
-
14
27 x 0,30
37 x 0,25
-
1,91
330 N
-
12
45 x 0,30
37 x 0,32
37 x 0,32
3,18
550 N
-
53
|
{
"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 53
}
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|
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|
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15 March 2017
AWG
Number and size of strands (∅ in mm)
Conductor
section in mm2
Minimum tensile resistance for
crimps with the following
composition
Kapton
Tefzel
Teflon/Kapton
Silver-plated
Silver-plated
10
-
-
-
5,30
850 N
-
8
-
-
-
8,98
1500 N
-
6
-
-
-
13,4
2300 N
-
4
-
-
-
21,8
3750 N
-
2
-
-
-
33,5
-
-
1
-
-
-
41,8
-
-
0
-
-
-
53
-
-
54
|
{
"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 54
}
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15 March 2017
Bibliography
ECSS-S-ST-00
ECSS system — Description and implementation
and general requirements
55
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"document_id": "ECSS-Q-ST-70-26C-Rev.1(15March2017)+Corrigendum1(1June2017)",
"page_number": 55
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ECSS-E-ST-10-09C(31July2008)
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ECSS-E-ST-10-09C
31 July 2008
Space engineering
Reference coordinate system
ECSS Secretariat
ESA-ESTEC
Requirements & Standards Division
Noordwijk, The Netherlands
|
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ECSS‐E‐ST‐10‐09C
31 July 2008
Foreword
This Standard is one of the series of ECSS Standards intended to be applied together for the
management, engineering and product assurance in space projects and applications. ECSS is a
cooperative effort of the European Space Agency, national space agencies and European industry
associations for the purpose of developing and maintaining common standards. Requirements in this
Standard are defined in terms of what shall be accomplished, rather than in terms of how to organize
and perform the necessary work. This allows existing organizational structures and methods to be
applied where they are effective, and for the structures and methods to evolve as necessary without
rewriting the standards.
This Standard has been prepared by the ECSS‐E‐10‐09C Working Group, reviewed by the ECSS
Executive Secretariat and approved by the ECSS Technical Authority.
Disclaimer
ECSS does not provide any warranty whatsoever, whether expressed, implied, or statutory, including,
but not limited to, any warranty of merchantability or fitness for a particular purpose or any warranty
that the contents of the item are error‐free. In no respect shall ECSS incur any liability for any
damages, including, but not limited to, direct, indirect, special, or consequential damages arising out
of, resulting from, or in any way connected to the use of this Standard, whether or not based upon
warranty, business agreement, tort, or otherwise; whether or not injury was sustained by persons or
property or otherwise; and whether or not loss was sustained from, or arose out of, the results of, the
item, or any services that may be provided by ECSS.
Published by:
ESA Requirements and Standards Division
ESTEC, P.O. Box 299,
2200 AG Noordwijk
The Netherlands
Copyright:
2008 © by the European Space Agency for the members of ECSS
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31 July 2008
Change log
ECSS‐E‐ST‐10‐09A
Never issued
ECSS‐E‐ST‐10‐09B
Never issued
ECSS‐E‐ST‐10‐09C
31 July 2008
First issue
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Table of contents
Change log.................................................................................................................3
Introduction................................................................................................................7
1 Scope.......................................................................................................................8
2 Normative references.............................................................................................9
3 Terms, definitions and abbreviated terms..........................................................10
3.1
Terms from other standards .....................................................................................10
3.2
Terms specific to the present standard ....................................................................10
3.3
Abbreviated terms ....................................................................................................11
4 Objectives, process and principles ....................................................................13
4.1
General.....................................................................................................................13
4.2
Concepts and processes..........................................................................................13
4.2.1
Process.......................................................................................................13
4.2.2
Documentation ...........................................................................................13
4.2.3
Coordinate system chain analysis..............................................................13
4.2.4
Notation ......................................................................................................14
4.3
Technical issues.......................................................................................................14
4.3.1
Frame and coordinate system....................................................................14
4.3.2
Transformation between coordinate systems.............................................14
4.3.3
IERS definition of a transformation.............................................................15
4.3.4
Time............................................................................................................15
5 Requirements........................................................................................................16
5.1
Overview ..................................................................................................................16
5.2
Process requirements ..............................................................................................16
5.2.1
Responsibility .............................................................................................16
5.2.2
Documentation ...........................................................................................16
5.2.3
Analysis ......................................................................................................17
5.3
General requirements...............................................................................................17
5.3.1
Applicability.................................................................................................17
4
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5.3.2
Notation ......................................................................................................18
5.3.3
Figures........................................................................................................18
5.4
Technical requirements ............................................................................................19
5.4.1
Frame .........................................................................................................19
5.4.2
Coordinate system......................................................................................19
5.4.3
Unit .............................................................................................................19
5.4.4
Time............................................................................................................19
5.4.5
Mechanical frames .....................................................................................20
5.4.6
Planet coordinates......................................................................................20
5.4.7
Coordinate system parameterisation..........................................................20
5.4.8
Transformation decomposition and parameterisation ................................20
5.4.9
Transformation definition............................................................................21
Annex A (normative) Coordinate Systems Document (CSD) - DRD....................23
Annex B (informative) Transformation tree analysis ...........................................26
B.1
General.....................................................................................................................26
B.2
Transformation examples.........................................................................................26
B.3
Tree analysis ............................................................................................................26
B.4
Franck diagrams.......................................................................................................26
Annex C (informative) International standards authorities..................................33
C.1 Standards .................................................................................................................33
C.2 Time .........................................................................................................................33
C.2.1
United States Naval Observatory (USNO) .................................................33
C.2.2
Bureau International des Poids et Mesures (BIPM) ...................................33
C.3 Ephemerides ............................................................................................................33
C.3.1
Institut de Mécanique Céleste et de Calcul des Ephémérides
(IMCCE)......................................................................................................33
C.3.2
Jet Propulsion Laboratory (JPL) ephemerides ...........................................34
C.4 Reference systems...................................................................................................34
C.4.1
International Earth Rotation and Reference Systems Service (IERS)........34
C.4.2
International Astronomical Union (IAU) ......................................................34
C.4.3
United States naval observatory (USNO)...................................................34
C.4.4
National Imagery and Mapping Agency (NIMA) .........................................35
C.5 Consultative Committee for Space Data Systems (CCSDS)....................................35
C.5.1
Navigation...................................................................................................35
C.5.2
Orbit............................................................................................................35
C.5.3
Attitude .......................................................................................................35
5
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C.6 IAU/IAG Working Group on Cartographic Coordinates and Rotational
Elements (WGCCRE)...............................................................................................36
References ...............................................................................................................37
Bibliography.............................................................................................................38
Figures
Figure B-1 : General tree structure illustrating a product tree ................................................29
Figure B-2 : Transformation chain decomposition for coordinate systems ............................30
Figure B-3 : Example of Franck diagram for a spacecraft......................................................31
Figure B-4 : Example of Franck diagram for a star tracker ....................................................32
Tables
Table B-1 : Example of mechanical body frame.....................................................................27
Table B-2 : Example of orbital coordinate system..................................................................28
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31 July 2008
Introduction
Clear definition of reference directions, coordinate systems and their inter‐
relationships is part of the System Engineering process. Problems caused by
inadequate early definition, often pass unnoticed during the exchange of
technical information.
This Standard addresses this by separating the technical aspects from the issues
connected with process, maintenance and transfer of such information. Clause 4
provides some explanation and justification, applicable to all types of space
systems, missions and phases. Clause 5 contains the requirements and
recommendations. Helpful and informative material is provided in the
Annexes.
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1
Scope
The objective of the Coordinate Systems Standard is to define the requirements
related to the various coordinate systems, as well as their related mutual inter‐
relationships and transformations, which are used for mission definition,
engineering, verification, operations and output data processing of a space
system and its elements.
This Standard aims at providing a practical, space‐focused implementation of
Coordinate Systems, developing a set of definitions and requirements. These
constitute a common reference or “checklist” of maximum utility for organising
and conducting the system engineering activities of a space system project or
for participating as customer or supplier at any level of system decomposition.
This standard may be tailored for the specific characteristics and constraints of a
space project in conformance with ECSS‐S‐ST‐00.
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2
Normative references
The following normative documents contain provisions which, through
reference in this text, constitute provisions of this ECSS Standard. For dated
references, subsequent amendments to, or revisions of any of these
publications, do not apply. However, parties to agreements based on this ECSS
Standard are encouraged to investigate the possibility of applying the most
recent editions of the normative documents indicated below. For undated
references the latest edition of the publication referred to applies.
ECSS‐S‐ST‐00‐01
ECSS system– Glossary of terms
ECSS‐M‐ST‐10
Space project management – Project planning and
implementation
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3
Terms, definitions and abbreviated terms
3.1
Terms from other standards
For the purpose of this Standard, the terms and definitions from
ECSS‐S‐ST‐00‐01 apply.
NOTE 1
Some terms are taken from other documents,
referenced in square brackets in the References.
NOTE 2
There is no agreed convention for usage of
combinations of the words “reference, coordinate,
frame and system”. These terms are often used
interchangeably in practice. In 1989, Wilkins’ [1]
made a proposal. This Standard adopts a simpler
terminology, which is more in line with everyday
practice.
3.2
Terms specific to the present standard
3.2.1
coordinate system
method of specifying the position of a point or a direction with respect to a
specified frame
NOTE
E.g. Cartesian or rectangular coordinates, spherical
coordinates and geodetic coordinates.
3.2.2
frame
triad of axes, together with an origin
3.2.3
inertial frame
non‐rotating frame
NOTE 1
Inertial reference directions are fixed at an epoch.
NOTE 2
The centre of the Earth can be considered as non‐
accelerating for selecting the origin, in some
applications.
3.2.4
J2000.0
astronomical standard epoch 2000 January 1.5 (TT)
NOTE
equivalent to JD2451545.0 (TT).
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3.3
Abbreviated terms
For the purpose of this Standard, the abbreviated terms from ECSS‐S‐ST‐00‐01
and the following apply:
Abbreviation
Meaning
AIT
assembly integration and test
AIV
assembly integration and verification
BCRS
barycentric celestial reference system
BIPM
Bureau International des Poids et Mesures –
international bureau of weights and measures
CAD
computer aided design
CCSDS
Consultative Committee for Space Data Systems
CoM
centre of mass
CSD
coordinate systems document
DoF
degree of freedom
DRD
document requirements definition
GCRS
geocentric celestial reference system
IAG
International Association of Geodesy
IAU
International Astronomical Union
ICD
interface control document
ICRF
international celestial reference frame
ICRS
international celestial reference system
IERS
international Earth rotation and reference service
IMCCE
Institut de Mécanique Céleste et de Calcul des
Ephémérides
ISO
International Organization for Standardization
ITRF
international terrestrial reference frame
ITRS
international terrestrial reference system
IUGG
International Union of Geodesy and Geophysics
J2000.0
epoch 2000 January 1.5 (TT)
JPL DExxx
Jet Propulsion Laboratory development ephemeris,
number xxx
L/V
launch vehicle
MICD
mechanical interface control document
RCS
reaction control system
SEP
system engineering plan
SI
système international
STR
star tracker
TAI
temps atomique international – international atomic
time
ToD
true of date
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TT
terrestrial time
UTC
coordinated universal time ‐temps universel coordonné
WGCCRE
Working Group on Cartographic Coordinates and
Rotational Elements
w.r.t.
with respect to
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4
Objectives, process and principles
4.1
General
This
Clause
provides
the
background
to
the
requirements
and
recommendations stated in Clause 5, from the conceptual, process and technical
points of view.
4.2
Concepts and processes
4.2.1
Process
The coordinate systems used within a project are identified early in the lifecycle
of a project. These coordinate systems are then related via a chain of
transformations to allow the transformation of coordinates, directions and other
geometric parameters into any coordinate system used within the project at any
time in the project life.
4.2.2
Documentation
Besides the ICDs, CAD drawings and SRD, a specific document for all
coordinate systems and their inter‐relationships, throughout the product tree
and the project life, are created, maintained and configured. The Coordinate
System Document (CSD) takes shape before the end of phase‐A.
4.2.3
Coordinate system chain analysis
A chain of transformations is constructed using chain elements or links. A link
is composed of two coordinate systems together with the transformation
between them. The product tree can be mapped into a set of connected chains.
For any analysis, the appropriate connected chain is used, even if other paths
within the tree are later found to be useful for satellite integration, operations or
processing. For subsystem or unit analysis, any link may be decomposed into a
sub‐chain containing intermediate coordinate systems. The relationship
between two coordinate systems can involve kinematics, dynamics,
measurement or constraints. See Annex B for some examples.
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The main mission chain typically includes inertial, rotating planet‐centred
orbital, spacecraft mechanical, instrument and product (i.e. post‐processing
related) coordinate systems.”
4.2.4
Notation
Experts working together within a project need to have a common
understanding of the parameters and variables. Specific coordinate systems are
used to obtain a convenient formulation of the kinematic and dynamic
equations involved. A shared understanding of all the coordinate systems and
their parameterisations is therefore paramount. This necessitates the definition
of a notational convention for naming variables, coordinate systems and their
inter‐relationships.
4.3
Technical issues
4.3.1
Frame and coordinate system
Transformations between frames, having orthogonal axes, the same handedness
(right or left) and unit vectors along each axis, enjoy the properties of unitary
matrices, which facilitate the calculation of inverse transformations between
these frames.
The method for constructing a triad of orthogonal axes needs to be agreed and
specified. The definition requires at least two non‐parallel directions, which
may be derived from physical elements, theoretical considerations or
mathematical definitions. In general, a set of (physical) directions is not likely to
be orthogonal.
By definition of a coordinate system, the position of a point can be expressed by
a set of coordinates with respect to its frame. The concept of coordinates
requires a unit and an origin in addition to the directions as defined by the
selected frame.
Several mathematical representations exist to describe a position or direction,
each with their own advantages. The Cartesian vector representation, being a
common representation, is selected for this standard. Other parameterisations
(e.g. geodetic coordinates and topocentric direction) can be also used to
describe a position or direction.
Formal parameterisation is specified in vector notation using an explicit
mathematical relationship.
4.3.2
Transformation between coordinate
systems
Accurate verbal, graphical and mathematical description of a transformation
between two coordinate systems is essential for its correct interpretation.
In general, each transformation consists of a translation, a rotation and possibly
a scale factor operation. The specification of the order of operations is
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important, even when the nominal translation is assumed to be the null vector.
A theoretically null translation can later, in the project life or in more precise
calculations, become non‐null.
Quaternions, Euler angles, mechanical and other parameters can be used to
describe transformations between coordinate systems. In this standard, matrix
representation is selected for the mathematical definition of a rotational
transformation.
4.3.3
IERS definition of a transformation
The general transformation of the Cartesian coordinates of a point from frame 1
to frame 2 is given by the following equation, see Reference [2], page 21 from
Bibliography.
→
→
→
×
×
+
=
)
1
(
2
,1
2
,1
2
,1
)
2
(
X
R
T
X
λ
where:
→
2,1
T
is the translation vector,
2,1
λ
is the scale factor, and
2,1
R
is the rotation matrix.
This relates two Cartesian coordinate systems, by defining the coordinates of
the origin and the three unit vectors of one of them in the other one.
4.3.4
Time
Certain coordinate systems are time dependent. A unique specification of the
time standard is necessary. Such a definition includes the mathematical
relationship between each of the time standards used within the project.
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5
Requirements
5.1
Overview
This clause contains process requirements, covering the management and
utilisation of coordinate systems throughout the life cycle of space missions;
general requirements, covering applicability, terminology, notation, figures and
illustrations; and technical requirements, covering the definition of coordinate
systems and their parameterisation, and of the transformations between
coordinate systems.
5.2
Process requirements
5.2.1
Responsibility
a.
The responsibility for the task of system‐level definition of the coordinate
systems and their inter‐relationships, applicable to the whole product
tree and to be used throughout the lifetime a project, shall be identified.
NOTE 1
See ECSS‐M‐ST‐10, subclause 4.3.4 and 5.3 and
Annex B of this document for product tree. See
also ECSS‐S‐ST‐00‐01 for the definition of product
tree.
NOTE 2
The product tree includes the space segment, the
launcher, the ground segment and associated
processors, the user segment, operations, and the
engineering tools and models such as simulators,
emulators and test benches.
5.2.2
Documentation
a.
The Coordinate Systems Document (CSD) shall be produced in
conformance with Annex A.
NOTE
The CSD is intended for reviews.
b.
The CSD shall identify the specified coordinate systems and time scales
used throughout the project, by two or more subsystems or
organisations, together with their inter‐relationships (in a parametric
form).
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NOTE
Subsystems (or organisations) are free to make
specifications within their area of responsibility, so
long as the specific (internal) coordinate system or
time scale is not used by another subsystem (or
organisation).
c.
For a spacecraft project, a preliminary version of the CSD shall be
produced before the end of phase A.
d.
The CSD (and related database) shall be put under configuration control
at the beginning of phase B.
e.
At each phase of the project, the coordinate systems and their inter‐
relationships shall be re‐examined.
f.
The CSD shall include the new coordinate systems and transformations
following the progress of the project development.
NOTE
During the project, new details and elements are
defined (e.g. equipment, methods and algorithms).
5.2.3
Analysis
a.
The elements, which need coordinate systems, shall be identified.
NOTE
This involves iterative analysis of the functional
and product trees as well as the interfaces, at each
phase.
b.
Each identified element of the system shall have its coordinate systems
defined.
c.
A transformation chain structure shall be built to link coordinate systems
used by two or more subsystems
NOTE
See Annex B for guidelines and examples.
d.
The nominal value, in numeric or parametric form, of the transformation
between two coordinate systems shall be specified.
5.3
General requirements
5.3.1
Applicability
a.
Applicable parts of the international standards and conventions listed in
Annex C shall be selected and specified in the CSD.
NOTE
Such
organisations
maintain,
for
example,
definitions of certain reference coordinate systems,
and of time.
b.
Applicable non compliant external conventions shall be converted into
the project’s convention.
c.
The conversion of 5.3.1b shall be specified.
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5.3.2
Notation
a.
A coordinate system shall be identified by a unique descriptive name.
b.
Recognised international names should not be used if the exact definition
is not followed.
NOTE
E.g. the name “Pseudo True of Date” can be used if
the conventional definition of ToD is not strictly
followed.
c.
A unique mnemonic shall be derived from the descriptive name of the
coordinate system.
d.
The transformation from one coordinate system to another shall be
identified by a unique name, which also indicates the direction of the
transformation.
e.
The convention for naming coordinate systems and transformations shall
be specified.
f.
The notation convention shall be specified.
g.
Sign conventions shall be identified and defined.
NOTE
E.g. rotation around an axis.
5.3.3
Figures
a.
A figure shall show the relationship of a coordinate system with
equipment, spacecraft or mission.
b.
The origin and axes of a coordinate frame shall be identified in figures
using the reference mnemonic as indicated in 5.3.2c.
c.
A figure should show the relationship of a coordinate system to at least
one other already defined coordinate system, once the first has been
defined.
d.
If two or more rotations are used in a transformation between coordinate
systems, they should be indicated on the figure with intermediate
rotation axes.
e.
Symbols used within illustrations, figures and supporting diagrams shall
be defined.
f.
In an engineering drawing, the applicable projection system shall be
indicated.
NOTE
The projection system is generally European or
American.
g.
In a 3D figure, the axes above, within and below a plane shall be
differentiated.
NOTE 1
An axis pointing out of the plane of the paper can
be depicted by a circle with a dot in it; an axis
pointing into the paper by a circle with a cross.
NOTE 2
Shadowing and dotted lines can be used in 3D
figures.
18
|
{
"document_id": "ECSS-E-ST-10-09C(31July2008)",
"page_number": 18
}
| null |
ECSS-E-ST-10-09C(31July2008)-page=19
|
ECSS-E-ST-10-09C(31July2008)
|
ECSS‐E‐ST‐10‐09C
31 July 2008
5.4
Technical requirements
5.4.1
Frame
a.
The origin of the frame shall be specified.
b.
The derivation of the origin of a frame from reference points shall be
defined.
c.
The derivation of the axes of a frame from reference directions shall be
defined.
d.
The axes of a frame shall be orthogonal.
e.
The orientation of the axes of a frame shall be defined according to the
right hand rule.
NOTE 1
Sometimes left handed frames cannot be avoided,
because of imported off‐the‐shelf equipment.
NOTE 2
E.g. raw measurements or actuator commands
may be given in a left handed frame.
f.
Any imported left handed frame shall be specified.
g.
Any left handed frame shall be associated with a system reference right
handed frame with the related transformation, for project development
use.
NOTE
This avoids a “change of sign” in the software
without a change of variable.
h.
The epoch of an inertial frame shall be defined.
5.4.2
Coordinate system
a.
If a coordinate system is time dependent, then its time scale shall be
defined.
b.
The position of a point shall be definable by a set of coordinates with
respect to a selected frame.
5.4.3
Unit
a.
Dimensionless quantities shall be explicitly denoted as such.
b.
The units or physical dimensions of all non‐dimensionless parameters,
including angles, shall be defined.
NOTE
E.g. Units for angles include radians and degrees.
5.4.4
Time
a.
The unit of time shall be defined.
b.
The relationship between all time scales used shall be defined.
NOTE
E.g. The relationship between local clocks on a
group of spacecraft and UTC on Earth.
19
|
{
"document_id": "ECSS-E-ST-10-09C(31July2008)",
"page_number": 19
}
| null |
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