Patent Description:
The present disclosure relates to an automated testing apparatus and components associated with a testing facility and simulation chamber for a satellite-based on-board propulsion (OBP) system.

Typically, OBP systems are tested in a ground testing facility to determine performance parameters before being delivered to customers for integration with a satellite. This testing produces a deliverable of test data to prove the OBP system's performance and is generally a labor-intensive and time consuming process. Lifetime ground test equipment for an ion thruster is described in <CIT>. The lifetime ground test equipment for the ion thruster comprises a main cabin vacuum container, a gate valve, an auxiliary cabin vacuum container, a vacuum pumping system, an ion beam target, an anti-sputtering screen, a thruster mobile mechanism, a quartz crystal microbalance QCM, a thruster divergence angle measuring system, a grid corrosion on-line monitoring system, a ground test power supply system, an equipment control system, a xenon supply system, a repressing system, a cooling water system, a pneumatic element air supply system, a liquid nitrogen storage and supply system, and a shooting illumination system. A vacuum arc thruster is described in <CIT>. The vacuum arc thruster includes an anode arrangement, a cathode, an insulator which is located between the anode arrangement and the cathode, and a control arrangement. The anode arrangement includes at least two anode elements which are spaced from each other around the cathode. The control arrangement is operatively connected to the cathode and each of the anode elements and is configured to switch each anode element between an active state and an inactive state. When an anode element is in its active state, the control arrangement utilises the anode element in order to generate a vacuum arc pulse between the said anode element and the cathode. When an anode element is however in its inactive state, the particular anode element is not used for vacuum arc generation. A test campaign for qualifying a commercial off-the-shelf cold gas micro-propulsion system is described in <NPL>. An ion test device is described in <CIT>. The ion engine test device jets an ion beam from an ion engine toward a beam target installed in a vacuum tank, in which a shroud kept in an ultralow temperature is provided, to conduct a test of the ion engine. The ion engine test device includes: a cylindrical cryopanel which is provided along an inner peripheral surface of the vacuum tank in a space between the ion engine and the beam target; and a direct attachment type refrigerator which cools the cryopanel. A vacuum chamber to be used for testing an engine is described in <CIT>. The vacuum chamber is adapted to accommodate the ion engine. A vacuum container is disposed to face the ion engine in the vacuum container and receiv ions emitted from the ion engine to generate energy. A beam dump absorbs the ions emitted from the ion engine. An insulating member has an opening through which ions emitted from the ion engine are incident. A heat insulating material covers the beam dump and the inner surface of the vacuum container. A baffle shields a heat ray having a protrusion on the side of the beam dump and a cryopanel for evacuation provided in an area shadowing a heat ray incident from the outer wall of the vacuum container through the opening.

The matter for which protection is sought is defined by the appended claims.

The disclosure provides an interface assembly for connecting an on-board propulsion system to a testing facility. The interface assembly includes a support member configured for coupling to a manipulation system and a mounting member configured for coupling to the on-board propulsion system. A plurality of channels extends between and couples the mounting member to the support member.

The disclosure provides, in another aspect, a testing system for testing an on-board propulsion system. The testing system includes a vessel, a vacuum pump in operative communication with the vessel, and a plurality of sensors positioned within the vessel. The testing system further includes a manipulation system, a portion of which is automatically movable toward and away from the vessel. The testing system further includes an interface assembly having a support member configured for coupling to the manipulation system and a mounting member configured for coupling to the on-board propulsion system. A plurality of channels extends between and couples the mounting member to the support member.

The disclosure provides, in yet another aspect, a method for testing an on-board propulsion system within a testing facility. The method includes coupling the on-board propulsion system to an interface assembly and coupling the interface assembly to a manipulation system. The method also includes moving, via the manipulation system, the interface assembly toward a chamber of the testing facility such that at least a portion of the interface assembly is within the chamber. The method further includes connecting the interface assembly to the testing facility such that the interface assembly is configured to receive a fluid from the testing facility. The method additionally includes de-coupling the manipulation system from the interface assembly, operating the on-board propulsion system, and measuring and recording an output thrust force of the on-board propulsion system.

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of the formation and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of supporting other embodiments and of being practiced or of being carried out in various ways.

<FIG> illustrates a testing assembly <NUM> for testing a satellite-based OBP system. The testing assembly <NUM> includes an interface assembly <NUM> configured for connection with the OBP system and for connection with a portion of a testing facility <NUM>. The testing assembly <NUM> also includes a manipulation system <NUM>. The illustrated manipulation system <NUM> is a robotic arm <NUM> supported by a base <NUM>. The robotic arm <NUM> is configured for movement, i.e., rotating and translating, of the interface assembly <NUM> relative to the testing facility <NUM>. As shown in <FIG>, the illustrated robotic arm <NUM> includes a plurality of segments <NUM> connected by joints <NUM> for moving the interface assembly <NUM>. In other embodiments, the manipulation system may instead take other forms, such as that of a mobile cart, e.g., on wheels or rails, to move the interface assembly <NUM> relative to the testing facility <NUM>.

<FIG> illustrate the interface assembly <NUM> including an interface member or body <NUM>. The body <NUM> includes a mounting member <NUM> (i.e., in the form of a plate or flange) and a support member <NUM> (i.e., in the form of a plate or disc) spaced from and connected by legs <NUM> to the mounting member <NUM>. In the illustrated embodiment, the interface assembly includes three spacers or legs <NUM>, in which each leg <NUM> is positioned at and extends from a corner of the mounting member <NUM>. The mounting member <NUM> is shaped to accommodate the legs <NUM>, which may be more or fewer than three in number in some embodiments. In some embodiments, the mounting member <NUM> may be adjacent the support member <NUM>, either abutting or minimally spaced therefrom. Alternatively, in other embodiments, the body <NUM> may include only one of the mounting member <NUM> and the support member <NUM>. Further, in other embodiments, the body <NUM> may be generally cuboid in shape and accordingly presents a plurality of sides or faces. Still further, in other embodiments the body <NUM> may be one of many shapes that presents a plurality of surfaces, as will be further explained below.

A surface of the mounting member <NUM> facing away from the support member <NUM> is a first surface or side <NUM> of the interface assembly <NUM>. A bracket <NUM> is secured (by fasteners) to the first side <NUM> (i.e., the mounting member <NUM>). The bracket <NUM> is configured for coupling to an OBP system <NUM> such that the OBP system <NUM> extends from and is supported by the mounting member <NUM>. Alternatively, the mounting member <NUM> may serve as the aforementioned bracket or otherwise be in the form of a bracket, brace, arm, truss, etc., and may closely couple the OBP system <NUM> to the body <NUM> or couple the OBP system <NUM> at a spaced distance from the body <NUM>, as alternatively described herein. In other embodiments, the mounting member <NUM> itself may form any one of the sides of the body <NUM> and/or the bracket <NUM> may be positioned on any one of the sides of the body <NUM>.

The support member <NUM> is generally planar and has a generally circular shape. More specifically, the support member <NUM> is cylindrically shaped and defines a longitudinal axis A therethrough. The mounting member <NUM> is spaced from the support member <NUM> along the longitudinal axis A. In addition, the support member <NUM> is sized relatively larger than the mounting member <NUM>, as will be further explained. A surface of the support member <NUM> facing away from the mounting member <NUM> is a second side <NUM> (<FIG>) of the interface assembly <NUM>. A mount <NUM> is secured to the second side <NUM> (such as by fasteners). The illustrated mount <NUM> is itself a plate having a generally circular shape and is sized relatively smaller than the support member <NUM>. In some embodiments, the mount <NUM> is integrally formed as one piece with the support member <NUM>. The interface assembly <NUM> is removably couplable to an end of the robotic arm <NUM> (<FIG>) via the mount <NUM>.

The illustrated first side <NUM> and the second side <NUM> are generally planar and provide attachment surfaces for the coupling of each of the OBP system <NUM> and the end of the robotic arm <NUM> to the interface assembly <NUM>. The second side <NUM> is preferably opposite the first side <NUM> such that the mount <NUM> is on the other side of the body <NUM> from the bracket <NUM>, but that need not be the case in all embodiments.

Referring again to <FIG>, the interface assembly <NUM> includes a plurality of channels <NUM>. The channels <NUM> are supported by the body <NUM>. The illustrated channels extend between the mounting member <NUM> and the support member <NUM>. Furthermore, in the illustrated embodiment, the interface assembly <NUM> includes three channels <NUM>. In other embodiments, the interface assembly <NUM> may include two or fewer or four or more channels <NUM>.

A portion of each of the channels <NUM> is positioned at least partially internally within the mounting member <NUM> and partially internally within the support member <NUM>. The channels <NUM> are routed to transmit electrical signals, liquids, gases, or other materials from an entry point at a body surface to an exit point. The channels <NUM> may therefore be lined or unlined, and may themselves contain wire, hose, pipe, or other forms of conduit to promote the passage of the signals or materials. For example, the first and second channels <NUM> may be routed to transmit electrical signal, and the third channel <NUM> may be routed to transmit fluid such as propellant.

Specifically, in one embodiment, the channels <NUM> are formed by conduit (e.g., pipe) extending between connectors or ports positioned on the first side <NUM> (not shown; axially behind the bracket <NUM> from the frame of reference of <FIG>) of the mounting member <NUM> and connectors or ports <NUM> of the support member <NUM>. The illustrated channels <NUM> extend from the ports on the first side <NUM> as passageways through an edge <NUM> of the mounting member <NUM> to an intermediate side <NUM> of the interface assembly <NUM>. The channels <NUM> then extend as passageways through the support member <NUM> from the intermediate side <NUM> to at or near a top edge <NUM> of the support member <NUM>. In particular, the channels <NUM> enter and exit the support member <NUM> at the intermediate side <NUM>. More specifically, the mounting member <NUM> and the support member <NUM> define passages or passageways and the channels <NUM> are formed by conduit (e.g., flexible hose) portions that extend from the ports on the first side <NUM> through the passages of the mounting member <NUM> and the passages of the support member <NUM> to the ports <NUM> of the support member <NUM>. The passages may be formed during manufacture of the mounting member <NUM> and the support member <NUM> (e.g., by casting) and/or may be formed by boring out the passages in the mounting member <NUM> and the support member <NUM> after manufacture.

In other embodiments, the "channels" are instead wire, hose, pipe, or other conduit routed wholly or partially along an outside surface of the body <NUM> and/or the outside surfaces of the support member <NUM> and the mounting member <NUM>. In some embodiments, the body <NUM> is one piece and the channels are alternatively formed by the passages such that the channels are completely embedded within the body <NUM>. In yet other embodiments, the channels are a mix of internal, partially embedded, or external wires, hoses, pipes, or other conduits extending from an entry point on or in the body <NUM> to an exit point on or in the body <NUM>. In yet still other embodiments, the passages are lined with suitable material for forming the channels such that the channels are formed in part by the passages and the conduit extends from the passages to the ports. Furthermore, in some embodiments, all of the ports (i.e., the ports on the first side <NUM> and the ports <NUM>) may be located on the same or different sides, or in any combination thereof, of the body <NUM>. In yet other embodiments, only a single channel is provided, or a single channel is configured to contain or permit passage of multiple fluids, or a combination of electrical signals, liquids, gases, or other materials in a manner as described herein.

Connectors <NUM> (<FIG>), e.g., "quick connect" or similar connectors for coupling provide coupling points configured to removably join the ports of the mounting member <NUM> and the ports <NUM> of the support member <NUM> with external connections in the form of wire, hose, pipe, and other conduit, which will be further described below. The connectors <NUM> may be integrally formed with the ports <NUM> or connected to the ports of the first side <NUM> and/or the ports <NUM> such that the connectors <NUM> extend from the respective ports <NUM>.

The ports of the mounting member <NUM> are in communication with the OBP system <NUM> (such as by similar connectors <NUM> as described above) such that the channels <NUM> are connected between the OBP system <NUM> and the ports <NUM>. In one embodiment, the bracket <NUM> includes mating connectors such that when the OBP system <NUM> is secured by the bracket <NUM> to the first side <NUM>, the bracket <NUM> also fluidly connects the OBP system <NUM> with the channels <NUM> of the interface assembly <NUM>. In other words, the OBP system <NUM> is fluidly connected with the channels <NUM> through the bracket <NUM>. More specifically, the bracket <NUM> includes ports and channels extending therebetween similar to the channels <NUM> of the body <NUM> which are routed to transmit electrical signals, liquids, gases, or other materials. For example, the bracket <NUM> includes ports for fluidly connecting between the ports on the first side <NUM> of the body <NUM> and connection points of the OBP system <NUM>. The wire, hose, pipe, or other conduit extends between the ports and/or the bracket <NUM> itself may define passages extending between the ports for forming the channels of the bracket <NUM>.

On the other, second side <NUM> of the interface assembly <NUM>, the ports <NUM> of the support member <NUM> are fluidly connected to the testing facility <NUM>, as further discussed below. Therefore, the OBP system <NUM> may be fluidly connected to the testing facility <NUM> via the channels <NUM>.

<FIG> illustrates one embodiment of the testing facility <NUM> including a vessel or chamber <NUM>. The chamber <NUM> includes a plurality of lateral chambers <NUM> and a main test chamber <NUM>. In the illustrated embodiment, the chamber <NUM> includes two lateral chambers <NUM>. In other embodiments, the chamber <NUM> may include one or three or more chambers <NUM> or sub chambers (i.e., test chamber <NUM>, lateral chambers <NUM>). The two illustrated lateral chambers <NUM> are positioned at opposite ends of the test chamber <NUM>. Furthermore, the two lateral chambers <NUM> may be termed as the OBP system engagement chambers.

With reference to <FIG>, the testing facility <NUM> further includes a plurality of connection points <NUM> for connection to vacuum pumps <NUM>. As such, the vacuum pump <NUM> may be in operative communication with the chamber <NUM>. In the illustrated embodiment, the test chamber <NUM> includes four openings <NUM>, and each lateral chamber <NUM> includes one opening <NUM>. In other embodiments, the testing facility <NUM> may include one or more openings <NUM> for connection to a vacuum pump <NUM>. The illustrated openings 1090A of the test chamber <NUM> are configured for connection with a cryopump or cryogenic pump 1096A. Each opening 1090B of the lateral chamber <NUM> is configured for connection with a turbomolecular pump 1096B, an example of which is a stand-in Pfeiffer vacuum turbopump sold by Pfeiffer Vacuum. Other pumps suitable therewith include ion pumps, cryopumps, or diffusion pumps. In other embodiments, the chamber <NUM> may comprise one or three or more vacuum pumps <NUM> for each chamber <NUM> or sub chamber <NUM>, <NUM>, or with only one vacuum pump <NUM> serving all chambers <NUM> or sub chambers <NUM>, <NUM>.

With continued reference to <FIG>, each of the lateral chambers <NUM> is separated from the test chamber <NUM> by a partition or divider <NUM>. In the illustrated embodiment, the divider is a valve <NUM>. The valve <NUM> is movable from a first open position in which the associated lateral chamber <NUM> and the test chamber <NUM> are in fluid communication, to a second closed position in which the associated lateral chamber <NUM> and the test chamber <NUM> are not in fluid communication. In alternative embodiments, no valve or other partition exists between the lateral chamber(s) <NUM> and the test chamber <NUM>.

With reference to <FIG> and <FIG>, an end <NUM> of each lateral chamber <NUM> includes a rim <NUM> forming an opening <NUM> fluidly connecting an internal volume <NUM> of the lateral chamber with the external environment (i.e., of a laboratory or testing room). As shown in <FIG>, one of the lateral chambers <NUM> (i.e., the one to the right from the frame of reference of <FIG>) includes a cover <NUM> secured to the rim <NUM> for enclosing the opening <NUM>, and the other of the lateral chambers <NUM> (i.e., the one to the left from the frame of reference of <FIG>) is open to the external environment. An outer circumferential portion <NUM> (<FIG>) of the support member <NUM> of the interface assembly <NUM> cooperates with the rim <NUM>. In other words, the support member <NUM> is sized corresponding to a circumference of the rim <NUM> such that the support member <NUM> is engageable with the entire circumference of the rim <NUM>. Furthermore, an internal surface <NUM> (e.g., "chamber wall") of the lateral chamber <NUM> is generally cylindrical in view of conditions during testing, as will be further explained. The rim <NUM> may also form a portion of and be termed as the chamber wall.

With reference to <FIG> and <FIG>, the lateral chamber <NUM> includes a supply assembly <NUM>. The illustrated supply assembly <NUM> is positioned at a top <NUM> of the mount chamber <NUM> adjacent the rim <NUM>, as illustrated, but in other embodiments could be positioned about the respective lateral chamber <NUM> at other locations. The supply assembly <NUM> is connected (by connectors not shown) to external supplies (e.g., a propellant supply, a power supply, water, etc.) for supplying the respective material through ports <NUM> to the ports <NUM> of the interface assembly <NUM>. In the illustrated embodiment, the ports <NUM> form the male connection and the ports <NUM> form the female connection. However, in other embodiments, the ports <NUM> may include connectors <NUM> extending from the ports <NUM> for connecting to the ports <NUM> of the interface assembly <NUM>.

The interface assembly <NUM> and/or the testing facility <NUM> may further contain diagnostic equipment such as diagnostic probes, sensors, strain gauges, and other testing components <NUM>. For example, as shown in <FIG>, the testing facility <NUM> includes a plurality of sensors <NUM> positioned within the chamber <NUM> (including the lateral chamber <NUM>). The sensors <NUM> are configured to measure the temperature, emitted exhaust beam, and other testing and environmental parameters that occur during testing within the chamber <NUM>. In addition, the interface assembly <NUM> may include a force measurement system, for instance a strain gauge load cell (not shown) positioned intermediate the OBP system <NUM> and the first side <NUM> (i.e., between the bracket <NUM> and the OBP system <NUM>) or at another suitable location. The strain gauge load cell is configured to measure the output thrust force produced by the OBP system <NUM> during testing.

The testing components <NUM> (e.g., the sensors in the chamber <NUM>, the strain gauge load cell, and others) are in electrical communication with a controller <NUM>. The controller <NUM> may form a part of a test control and data recording system for collecting data indicated by the sensors <NUM>. The controller <NUM> may send the data to a main controller or control system or may itself be the main controller for controlling operation of the testing facility <NUM>. In particular, the controller <NUM> is operable to control and/or initiate testing parameters such as fluid flow, electrical signals, etc., to the OBP system <NUM> and to operate diagnostic equipment and the sensors <NUM> as part of the testing procedure. The controller <NUM> may be further in operable communication with the vacuum pumps <NUM>, the valve <NUM>, and the manipulation system <NUM>. In embodiments with a strain gauge load cell positioned locally to the interface assembly <NUM>, the load cell may be electrically connected to the controller <NUM> via the channels <NUM> routed to transmit electrical signals.

With reference to <FIG> and <FIG>, the robotic arm <NUM> of the manipulation system <NUM> is configured to move the interface assembly <NUM> between a first, disengaged position (<FIG> and <FIG>) and a second, engaged position (<FIG>). When the interface assembly <NUM> is in the disengaged position, the interface assembly <NUM> is not fluidly connected or otherwise coupled to the respective lateral chamber <NUM>. Specifically, the manipulation system <NUM> supports the interface assembly <NUM> in the disengaged position (<FIG>). When the interface assembly <NUM> is in the engaged position, the interface assembly <NUM> (i.e., the support member <NUM>) is secured to the rim <NUM> and the channels <NUM> are fluidly connected to the ports <NUM> of the supply assembly <NUM>. As shown in <FIG>, the manipulation system <NUM> is positioned such that some or all of it may be external to the lateral chamber <NUM> (<FIG>). More specifically, all or a portion of the manipulation system <NUM> may be positionable within a transfer location <NUM> or otherwise configured for access to both the transfer location <NUM> and the lateral chamber <NUM>.

The interface assembly <NUM> is partially insertable (by the manipulation system <NUM>) into a lateral chamber <NUM> and removably couplable to the end <NUM> of the lateral chamber <NUM> (i.e., the OBP system engagement chamber) to seal the internal volume <NUM>. In the illustrated embodiment, the outer circumferential portion <NUM> of the support member <NUM> is coupled to the rim <NUM>, such as by fasteners (e.g., bolts), and the mounting member <NUM> (having the OBP system <NUM>) extends from the support member <NUM> by the legs <NUM> within the lateral chamber <NUM>. In particular, the mounting member <NUM> is sized smaller than the support member <NUM> for fitting within the lateral chamber <NUM>. In addition, the support member <NUM> of the interface assembly <NUM> is configured as a cover for enclosing the opening <NUM>. The OBP system <NUM> is positioned within the lateral chamber <NUM> when the support member <NUM> is secured to the lateral chamber <NUM>.

The coupling of the interface assembly <NUM> to the rim <NUM> may be automatic and/or manually performed. For example, in the illustrated embodiment, the robotic arm <NUM> may position the support member <NUM> adjacent the rim <NUM> and an operator may manually drive fasteners around the outer circumferential portion <NUM> of the support member <NUM>. In other embodiments, the coupling process may be completely automatic (e.g., another robot configured to secure the support member <NUM> to the rim <NUM>, or automated locks or connectors (e.g., pneumatic, electric) to secure the support member <NUM> to the rim <NUM>). The ports <NUM> of the interface assembly <NUM> are fluidly coupled with the ports <NUM> of the supply assembly <NUM> concurrently with or after the interface assembly <NUM> is secured to the rim <NUM> of the respective lateral chamber <NUM>.

As shown in <FIG> and <FIG>, the ports <NUM> of the support member <NUM> are fluidly connected when the interface assembly <NUM> is mounted or otherwise secured to the lateral chamber <NUM>. In particular, in the illustrated embodiment as shown in <FIG>, an end of each of the channels <NUM> having the port <NUM> is received in the respective port <NUM> of the supply assembly <NUM> when the support member <NUM> is mounted flush with the rim <NUM>. In other embodiments, the ports <NUM> may be connected with the ports <NUM> of the supply assembly <NUM> by clamps, pneumatic locks, or other types of connectors/fasteners that fluidly couple the ports <NUM>, <NUM> together. Operational engagement of the interface assembly <NUM> with the vessel <NUM>, to be further described, may therefore be fully automated.

<FIG> illustrates an alternative embodiment of the OBP system engagement chamber <NUM> in which the supply assembly <NUM> is at least partially within the chamber <NUM>. In this embodiment, the outer circumferential portion <NUM> of the support member <NUM> is sized such that the support member <NUM> fits wholly within the lateral chamber <NUM>. The ports <NUM> of the supply assembly <NUM> are also positioned on the portion of the supply assembly <NUM> that is within the lateral chamber <NUM> such that the fluid connection between the interface assembly <NUM> and the supply assembly <NUM> is within the lateral chamber <NUM>. A cover <NUM> is secured to the opening <NUM> after the interface assembly <NUM> is mounted within the lateral chamber <NUM> for sealing the chamber <NUM>. The cover <NUM> may be hinge-mounted or securable in a manner again permitting operational engagement of the interface assembly <NUM> with the vessel <NUM>, to be further described, to be fully automated.

The supply assembly <NUM> of <FIG> may include a performance measurement stand (i.e., a stand including and/or electrically connected to the testing components <NUM>, such as the sensors, within the chamber <NUM>). In one example, the performance measurement stand may include an inverted pendulum stand having non-contact actuators such as electromagnets. Alternative to the strain gauge load cell positioned on the interface assembly <NUM>, the inverted pendulum stand determines the output thrust force produced by the OBP system <NUM> during testing based on how much force the electromagnets generate to maintain the OBP system <NUM>/interface assembly <NUM> in an upright position (relative to the lateral chamber <NUM>). In another embodiment, the performance measurement stand may be a torsional pendulum, which determines output thrust force produced by the OBP system during testing based on an angular displacement of a torsional spring. As such, the testing facility <NUM> may include the sensors and other measurement components suitable to measure the thrust output, as well as the temperature, emitted exhaust beam, and other testing and environmental parameters that occur during testing within the chamber <NUM>.

With reference to <FIG>, the steps of assembly and operation of testing of the OBP <NUM> system is discussed below.

In a first step of assembly and operation, the OBP system <NUM> is coupled to the interface assembly <NUM> via the mounting member <NUM>/bracket <NUM>, step <NUM>. This step may be manual or semi-automated and/or facilitated by additional equipment, and may include coupling the ports of the first side <NUM> with mating ports of the bracket <NUM> and OBP system <NUM> using external connections such as the connectors <NUM> or otherwise in the form of wire, hose, pipe, or other conduit configured to transmit electrical signals, liquids, gases, or other materials as necessary for testing. Step <NUM> occurs in the transfer location <NUM> but may in some instances occur near or in the lateral chamber <NUM>. In other embodiments, the OBP system <NUM> is coupled to the interface assembly <NUM> in a separate procedure and then the OBP system <NUM>/interface assembly <NUM> is positioned within the transfer location <NUM>.

In a second step <NUM>, the interface assembly <NUM> is coupled to the manipulation system <NUM> via the mount <NUM>. The manipulation system <NUM>, which may be controlled by the controller <NUM> or independently controlled, and in particular the robotic arm portion <NUM> thereof, is brought into proximity with the mounting member <NUM> and coupled thereto without manual assistance. In some embodiments, the interface assembly <NUM> may first be coupled to the manipulation system <NUM> and thereafter the OBP system <NUM> is coupled to the mounting member <NUM>/bracket <NUM>.

In a third step <NUM>, the interface assembly <NUM> is connected to or engaged with the testing facility <NUM>. With respect to the testing facility <NUM> of <FIG>, the interface assembly <NUM> is coupled to the end <NUM> of the lateral chamber <NUM> and is operationally connected to the testing facility <NUM> via the supply assembly <NUM>. In particular, step <NUM> may include moving the interface assembly <NUM>/OBP system <NUM> from the transfer location <NUM> toward the lateral chamber <NUM>. Step <NUM> may further include positioning the support member <NUM> adjacent the rim <NUM> of the lateral chamber <NUM> such that the mounting member <NUM> and the OBP system <NUM> is positioned within the lateral chamber <NUM>. Step <NUM> may further include securing the support member <NUM> of the interface assembly <NUM> to the rim <NUM>.

With respect to the testing facility <NUM> of <FIG> and the third step <NUM>, the interface assembly <NUM> is positioned within the lateral chamber <NUM> and is connected to the testing facility <NUM> via the supply assembly <NUM> within the chamber <NUM>. In particular, if mounting of the interface assembly <NUM> to the manipulation system <NUM> occurs in the transfer location <NUM>, step <NUM> includes moving the interface assembly <NUM>/OBP system <NUM> from the transfer location <NUM> into the lateral chamber <NUM>. Step <NUM> further includes positioning the interface assembly <NUM> onto the supply assembly <NUM>. The manipulation system <NUM> may only need to position the interface assembly <NUM> proximate the supply assembly <NUM>, with the weight of the interface assembly <NUM>/OBP system <NUM> wholly or partially supported by the manipulation system <NUM>.

The ports <NUM> (or its connectors <NUM>) are coupled to the ports <NUM> the supply assembly <NUM>. In some embodiments, positioning of the interface assembly <NUM> adjacent the supply assembly <NUM> results in concurrent and automatic coupling of the connectors <NUM> of the ports <NUM> with the supply ports <NUM> (or its connectors). In one example, the channels <NUM> are received in the ports <NUM> when the interface assembly <NUM> is moved into the engaged position for the automatic connection to the supply assembly <NUM>. In other embodiments, the flexible wires/hose/conduit, etc. extend from the supply ports <NUM> to the above-mentioned connectors <NUM>, and may require manual assistance for coupling thereto. Once so connected in either manner, the OBP system <NUM> is in electrical/gas/liquid/fluid communication with the testing facility <NUM> through the interface assembly <NUM> (via the connectors <NUM> and the ports <NUM>, <NUM>). Specifically, electrical signals (power and data), liquids, gases, or other materials can be transferred from the testing facility <NUM> to the OBP system <NUM>.

In a fourth step <NUM>, if the interface assembly <NUM>/OBP system <NUM> is secured to the rim <NUM> or within the chamber <NUM>, the manipulation system <NUM> is subsequently decoupled from the interface assembly <NUM> (the mount <NUM>) and may further be moved (away) from the lateral chamber <NUM>.

In a step <NUM>, the controller <NUM> activates the vacuum pumps <NUM>, 1096A, 1096B to evacuate air in the lateral and test chambers <NUM>, <NUM> to simulate a space environment. The controller <NUM> may be further configured to manipulate the valve <NUM> from a closed position to an open position for introducing the OBP system1082 to the test chamber <NUM>. Specifically, the OBP system <NUM> is no longer isolated from the test chamber <NUM> once the valve <NUM> is opened. Furthermore, the valve <NUM> may only be opened once the controller <NUM> has determined that the OBP system <NUM> is properly connected to the supply assembly <NUM>/performance measurement stand and the chamber <NUM> has been evacuated to appropriately simulate a space environment. At this point, the OBP system <NUM> is ready for testing.

In a sixth step <NUM>, the controller <NUM> enables operation of the OBP system <NUM>. As part of this, the controller <NUM> is configured to activate the supply assembly <NUM> to provide the desired electrical signal(s), fluid (e.g., propellant), gas or other materials from the supply assembly <NUM> to the OBP system <NUM> through the interface assembly <NUM>.

In a seventh step <NUM>, the strain gauge load cell or the inverted pendulum stand or the torsional pendulum stand measures a resultant output thrust force of the OBP system <NUM>. This step <NUM> may further include measuring, using the diagnostic probes or sensors <NUM> (some of which may be located on the stand), and other performance test data such as temperature, pressure, etc., within the lateral and test chambers <NUM>, <NUM>. The controller <NUM> having the test control and data recording system monitors and records the performance data including the resultant output thrust force and associated parameters (e.g., propellant/fluid flow or consumption rate). This step may further include creating a report and/or analytic graphs of the performance test data. Specifically, the test control and data recording system is configured to produce a deliverable of test data to prove the OBP system's performance.

In an eighth step <NUM>, the controller disables the OBP system <NUM>. Specifically, the controller deactivates passage of electrical signals and fluids through the supply assembly <NUM> and to the interface assembly <NUM>.

In a ninth step <NUM>, the OBP system <NUM> is removed from the chamber <NUM> after testing is completed. This step <NUM> may include deactivating the vacuum pumps <NUM> by the controller <NUM> to return the pressure within the chamber <NUM> to atmospheric. Subsequently, the controller <NUM> may control the manipulation system <NUM> to move the robotic arm adjacent the support member <NUM> (i.e., external to or within the lateral chamber <NUM>). This step <NUM> may further include re-coupling the robotic arm <NUM> to the mounting member <NUM> automatically or with manual assistance. The controller <NUM> is then operable to control the manipulation system <NUM> to move the robotic arm <NUM> to return the interface assembly <NUM>/OBP system <NUM> to the transfer location <NUM>, after which the OBP system <NUM> is detached from the interface assembly <NUM>.

In other embodiments, some steps or portions of steps may be completed in a different order than stated above or may not be completed at all.

As such, the testing of the OBP system <NUM> is substantially, if not wholly, automated. Specifically, the controller <NUM> or other control system is operable to control selective connection and movement of the manipulation system <NUM>, establish a testing environment within the chamber <NUM> using the vacuum pumps <NUM> and the valve <NUM>, transfer signals and testing materials such as electrical power and data and liquids, gases, etc. to the OBP system <NUM> from the testing facility <NUM>, and measure and record test data. As such, all testing of the OBP system <NUM>, from coupling to decoupling of the interface assembly <NUM>, may be completed in fewer than <NUM> hours. In other embodiments, the testing may be completed in fewer than <NUM> hours.

The present disclosure provides an automated OBP performance testing apparatus that significantly shortens the time required to conduct a performance test, reduces or eliminates the need for human interaction and assistance in performing the test, reduces the amount of human labor required to collect and report test results, reduces the test-to-test variability that is associated with human manual labor, and provides a unique interface assembly that can accommodate a variety of OBP variants without facility modification. The disclosure is amenable to complete robotic and unassisted operation, although operators may perform one or several assembly or testing functions. The system of the disclosure permits significant reduction in the amount of time and labor required to conduct testing on an OBP system.

Claim 1:
A testing system (<NUM>) for testing an on-board propulsion system (<NUM>), the testing system comprising:
a vessel (<NUM>);
a vacuum pump (<NUM>) in operative communication with the vessel (<NUM>);
a plurality of sensors (<NUM>) positioned within the vessel (<NUM>);
a manipulation system (<NUM>), a portion of which is automatically movable toward and away from the vessel (<NUM>);
an interface assembly (<NUM>) comprising:
a support member (<NUM>) configured for coupling to the manipulation system (<NUM>);
a mounting member (<NUM>) configured for coupling to the on-board propulsion system (<NUM>); and
a plurality of channels (<NUM>) extending between and coupling the mounting member (<NUM>) to the support member (<NUM>); and
a controller (<NUM>) configured to:
couple the interface assembly (<NUM>) to the manipulation system (<NUM>);
move, via the manipulation system (<NUM>), the interface assembly (<NUM>) toward the vessel (<NUM>) such that at least the mounting member (<NUM>) is within the vessel (<NUM>);
connect the moved interface assembly (<NUM>) to the vessel (<NUM>) such that the interface assembly (<NUM>) is configured to receive a fluid from the testing system (<NUM>);
de-couple the manipulation system (<NUM>) from the interface assembly (<NUM>);
operate the on-board propulsion system (<NUM>); and
measure and record an output thrust force of the on-board propulsion system (<NUM>).