Lessons Learned Launch Vehicle Avionics

Fools say that they learn by experience. I prefer to profit by others experience -- Otto Bismark

Lesson 1 Space is unforgiving ; thousands of good

decisions can be undone by a single

engineering flaw or workmanship error, and

these errors and flaws can result in

catastrophe. It is always the simple stuff

that kills you ..

ISRO Launch Failures SLV 3 E1 1 Failure

ASLV
PSLV GSLV

D1 & D2
D1 F02, D3, F06

2 Failures
1 Failure 3 Failures

These failures are caused either by design error or by workmanship errors in fabrication.

World wide Launch Failures in the last decade 2000 -- 2010

Failure Causes Propulsion Percentage 54%

Guidance and Navigation Software and computing systems

Electrical systems Structures Ordnance Pneumatics & Hydraulics All Other Systems

4% 21%
8% 0% 0% 0% 0%

Unknown 13% Avionics systems H/W & S/W - account for 33 % of failures

Lesson 2 Robust Design Essential to Mission Success

All the requirements are designed in All the Avionics parts are properly used Sufficient derating for the parts Design for Testability Very good PCB layout Good grounding scheme Low level Signal adequate protection from noise Good timing design - signal integrity excellent. Thermal design with adequate margins Good mechanical packaging with respect to Shock & Vibration

Lesson 3 Requirements To be adequately captured

Major issue in embedded system design Especially in S/W and H/W design with FPGAs Mars Polar Lander Failure
Processing the Leg sensor data shall not begin untill

12 m above the Ground

This requirement was not included in the systems requirements

Lesson 4 Wrong Application of Avionics Parts

Major cause of failures than a part failure. Interpoint make DC/DC converters Limit on capacitance Value specified in data sheet When exceeded 20 % overshoot in O/P Voltage Power On Reset Circuits for FPGA Use of external Schmidt trigger recommended EEPROM Protection use as directed by Mfr. External to Internal change over Avoid Power interruption Timing capacitors - mount as close to device By pass capacitors always read the data sheet Sneak Path in sequence relay driver ckt inverse hFE is not zero

Lesson 4 Do Not Use FPGA devices in mission critical systems unless the designers are fully aware of the complete characteristics of devices and having good experience in FPGA design

Lesson 5 Test, Test and Test No alternative to testing

Required to validate all the Assumptions Test for all that the system should do Also test for all the system should not do Tests are to be representative of Flight Conditions

Test as you Fly and Fly as you test.

A frequent cause of maiden flight Failures. If not Possible, systematic analysis of differences to be done, to understand the limitations of Ground Tests. Use real flight systems instead of simulations, wherever feasible Assumptions used in Testing and Simulations -- to be fully Understood.

Lesson 6
Early Warning Signals to be considered as very serious

Learn from the Failures and danger Signals from the past
Do not leave any one time observation as insignificant.

Understand the reasons for every minor deviations,

even if it is acceptable. They may be real warnings

Lesson 7
Demonstrate The Design Margins

To be done in the early phase of the projects Design margins to be compliant with interfaces, environments, uncertainties and tolerances

Margins to be proven first by analysis and then demonstrated by partial or Global tests.
Understand the limits of specifications.

Lesson 8
Avoid Changes From a qualified system
Last minute configuration changes, both in h/w and s/w especially made in the heat of countdown is a major cause for failures It is very difficult to verify all the side effects Never perform a test procedure for the 1st time on flight hardware If change is unavoidable there should be a detailed justification and comprehensive review

Lesson 9
Take care of Interfaces
Interfaces between sub systems, systems and of course teams & people. Well defined Interface documents and strict adherence to the documentation is key to mission success.

Not only electrical interfaces, Mechanical aspect of electronic and electromechanical systems are very important.

Lesson 10
Sign errors involving orientation and phasing ( polarity) have resulted in many failures

Examples: PSLV C12 During ACS phase sign reversal Recently in ICU package signal & Return got interchanged

Lesson 11
Strict adherence to Process: an important factor in ensuring reliability. Process deviations have resulted in many system failures .
Examples:

PCB related failures.

Ionic Contamination issues in HMC devices.