This document is separated into two sections: the test specification and the test procedure.
The purpose of this document is to define and validate the integration of cameras within the aerocover assembly for the 2024 launch vehicle.
To confirm that the aerocover is mechanically and geometrically compatible with the payload-mounted cameras, and that the system allows proper placement and unobstructed field of view at both extremities of the aerocover, as per system requirements.
This document specifically addresses the camera integration within the aerocover structure, in compliance with requirement 2024_C_SE_ST_AEROCOVER_REQ_06.
It does not cover camera functional testing, electrical connection verification, or data acquisition performance.
The purpose of this test is to verify the mechanical and geometrical integration of cameras at both extremities of the aerocover structure, as required by 2024_C_SE_ST_AEROCOVER_REQ_06.
The goal is to ensure that the cameras can be mounted without interference, with the correct orientation and unobstructed field of view.
The test is a fit check and visual inspection, without instrumentation or power-up of the cameras. The following characteristics will be assessed:
The test is planned to occur in June 2024, and will be performed by members of the Structures and Payload sub-teams, in collaboration with the Avionics team.
This procedure describes the steps required to verify camera integration into the aerocover.
Required equipment:
Location and conditions:
The test will be carried out in the EPFL Rocket Team assembly area, under standard room conditions.
Step-by-step procedure:
The test is successful if both cameras can be mounted securely, without obstruction or interference, and with verified clear fields of view.
| Term | Definition |
|---|---|
| PL | Payload – The equipment or experimental system carried by the rocket. |
| LV | Launch Vehicle – The rocket structure designed to transport the payload. |
| TSP | Test Specification and Procedure – This document defining the test plan. |
| INF MAP | Infusion Manufacturing Procedure – Describes how the aerocover was made. |
Open Issues:
Assumptions:
Constraints:
The main objective of this test is to confirm the mechanical integration of cameras into both ends of the aerocover structure. This integration includes verifying attachment compatibility, alignment, clearance, and unobstructed camera field of view (FOV).
The test will consist of a visual and mechanical fit check performed in the Rocket Team’s assembly area under ambient conditions. The test items include the final flight hardware aerocover structure and camera mock-ups or engineering models.
Main tools needed:
No instrumentation or electronic testing will be performed during this integration check.
No constraints on the testing activities sequence were identified.
The test is passed if all the criteria above are met; otherwise, it is marked as failed.
The test will be conducted by members of the Structures, Payload, and Avionics sub-teams of the EPFL Rocket Team. No external companies are involved.
Testing is scheduled to occur soon, contingent upon the completion and availability of the aerocover and camera mock-ups. The schedule may be adjusted based on manufacturing timelines.
| Sub-System | Part Name/ID | Type of Part | Version ID |
|---|---|---|---|
| Structure | Aerocover | Flight hardware | - |
| PayLoad | Camera | Model | - |
| Packed ? | Equipment | Packed in | Packed by |
|---|---|---|---|
| ☐ | Aerocover structure | Crate | TBA |
| ☐ | Camera mock-ups | - | TBA |
No instrumentation is required for this visual and mechanical integration test. All assessments will be performed through visual inspection and manual fit checks.
The test will be conducted in the EPFL Rocket Team assembly area under standard indoor ambient conditions (~20 °C, dry, no significant temperature variations expected).
| Responsible for: | Name |
|---|---|
| Equipment Checklist, Data Gathering | TBA |
| Safety | TBA |
| Documenting/Reporting | TBA |
| Preparing the test on-site | TBA |
| Safety Concern | Probability | Impact | Severity | Mitigation | Post-Mitigation Probability | Post-Mitigation Impact | Post-Mitigation Severity |
|---|---|---|---|---|---|---|---|
| Camera does not fit mounting points | Medium | Schedule delay | Medium | Pre-test validation of dimensions | Low | Low | Low |
| Damage to aerocover internal surface | Medium | Rework required | Medium | Use soft supports and careful handling procedures | Low | Low | Low |
| Missing fasteners or tools | Low | Incomplete test | Low | Use checklist and pre-test verification | Very Low | Low | Very Low |
| Safety Concern | Probability | Impact | Severity | Mitigation | Post-Mitigation Probability | Post-Mitigation Impact | Post-Mitigation Severity |
|---|---|---|---|---|---|---|---|
| Hand/finger injury during camera installation | Medium | Minor injury | Medium | Wear protective gloves, careful handling instructions | Low | Low | Low |
| Dropping aerocover or cameras | Low | Equipment damage | Medium | Two-person handling required | Very Low | Low | Very Low |
| Aerocover slipping from supports | Low | Injury or damage | Medium | Securely position aerocover on stable foam supports | Very Low | Low | Very Low |
| Done ? | Task | Time | Operator |
|---|---|---|---|
| ☐ | Transport aerocover to test area | 10m | TBA |
| ☐ | Transport camera mock-ups | 5m | TBA |
| ☐ | Prepare and inspect mounting tools | 10m | TBA |
| ☐ | Set up inspection lighting | 5m | TBA |
| Done ? | Step | Tool |
|---|---|---|
| ☐ | Position aerocover horizontally on foam supports | Foam supports |
| ☐ | Visually inspect mounting points | Flashlight |
| ☐ | Prepare camera mock-ups and fasteners | Toolbox |
| Done ? | Task | Time | Operator |
|---|---|---|---|
| ☐ | Install front-end camera mock-up | 5m | TBA |
| ☐ | Verify front-end camera alignment | 5m | TBA |
| ☐ | Install rear-end camera mock-up | 5m | TBA |
| ☐ | Verify rear-end camera alignment | 5m | TBA |
| ☐ | Document the fit with photos/notes | 5m | TBA |
| Done ? | Step | Tool |
|---|---|---|
| ☐ | Place camera mock-up gently into mounting bracket | Hands |
| ☐ | Align camera holes with bracket holes | Visual/Hands |
| ☐ | Secure camera mock-up using provided fasteners | Allen key |
| ☐ | Inspect visually for clearance and field of view | Mirror, Flashlight |
| ☐ | Photograph camera mounted condition | Camera |
| Done ? | Task | Time | Operator |
|---|---|---|---|
| ☐ | Remove camera mock-ups | 5m | TBA |
| ☐ | Inspect aerocover for damage | 5m | TBA |
| ☐ | Pack components carefully | 10m | TBA |
| ☐ | Document and upload test report | 15m | TBA |
| Done ? | Step | Tool |
|---|---|---|
| ☐ | Gently remove cameras from aerocover mounts | Hands |
| ☐ | Inspect all interfaces for scratches or deformation | Flashlight |
| ☐ | Place aerocover and camera mock-ups into storage | Protective cases |
| ☐ | Complete test report, upload photos and notes | Laptop |