ECSS-E-30 Part 3A

25 April 2000

EUROPEAN COOPERATION

ECSS
FOR SPACE STANDARDIZATION

Space engineering

Mechanical — Part 3: Mechanisms

ECSS Secretariat
ESA-ESTEC
Requirements & Standards Division
Noordwijk, The Netherlands
ECSS--E--30 Part 3A
25 April 2000 ECSS

Published by: ESA Publications Division

ESTEC, P.O. Box 299,
2200 AG Noordwijk,
The Netherlands
ISSN: 1028-396X
Price: € 20
Printed in The Netherlands
Copyright 2000 E by the European Space Agency for the members of ECSS

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ECSS
ECSS--E--30 Part 3A
25 April 2000

Foreword

This Standard is one of the series of ECSS Standards intended to be applied to-
gether 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 de-
veloping 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 al-
lows existing organizational structures and methods to be applied where they are
effective, and for the structures and methods to evolve as necessary without re-
writing the standards.
This Standard has been prepared by the ECSS Mechanical Engineering Standard
Working Group, reviewed by the ECSS Technical Panel and approved by the ECSS
Steering Board.

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Contents

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2 Normative references . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

3 Terms, definitions, symbols and abbreviated terms. . . . . . . . . . . . . . 13

3.1 Terms and definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

3.2 Symbols and abbreviated terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

4 Space mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

4.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2 General mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.2 Product assurance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.2.3 Reliability and redundancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2.4 Flushing and purging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3 Mission and environments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.2 Mission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.3.3 Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4 Functional requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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4.4.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.2 System performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.4.3 Mechanism function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5 Constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5.2 Physical constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.5.3 Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.5.4 Operational constraints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6 Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.2 Structural interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.3 Thermal interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.4 Thermo-mechanical interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.5 Electrical interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.6 Data interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.7 Physical interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.6.8 Other interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.7 Design requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7.2 Tribology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.7.3 Thermal control requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7.4 Mechanical design and sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.7.5 Pyrotechnics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7.6 Electrical and electronic requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.7.7 Control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.8 Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.8.2 Verification by analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.8.3 Verification by test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.9 Production and manufacturing requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.9.1 Manufacturing process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.9.2 Manufacturing drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.9.3 Marking and labelling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.10 In-service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.11 Deliverables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.12 Use of this Standard to define project requirements . . . . . . . . . . . . . . . . . . . . 46

Annex A (normative) Tailoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

A.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A.2 Applicability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

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A.3 Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A.4 How to use the tailoring table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
A.5 No tailoring allowed (mandatory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
A.6 Type applicable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
A.7 Customer related . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
A.8 Cost reduction and risk increase: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
A.9 Tailoring table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Annex B (informative) Summary of normative documents contents . . . . 59

B.1 ISO 6336 Calculation of the load capacity of spur and helical gears . . . . . 59
B.2 ISO 677, 678 Calculation of the load capacity of straight cut bevel gears 59

Annex C (informative) Model definition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

C.1 Bread board model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

C.2 Engineering (development) model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
C.3 Qualification models (QM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
C.4 Life test model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
C.5 Flight models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
C.6 Protoflight model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Figures

Figure 1: Requirements for space mechanisms engineering . . . . . . . . . . . . . . . . . . . . . . . . 18

Tables

Table 1: Outgassing limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Table 2: Minimum uncertainty factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Table 3: Life test duration factors ............................................... 42
Table 4: Document requirements for mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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Structure of the ECSS- Engineering standards system
25 April 2000

ECSS--E--00
Space engineering: Policy and principles
ECSS--E--30 Part 3A

ECSS--E--10 ECSS--E--20 ECSS--E--30 ECSS--E--40 ECSS--E--50 ECSS--E--60 ECSS--E--70

System Electrical and Mechanical Software Communications Control Ground systems
engineering electronic and operations

Part 1 Ground Rendezvous

System engineering Electrical power Requirements Mission operations
Thermal control communications and docking
process requirements
Part 2
Requirement def. Electromagnetics Design
Structures
and analysis Altitude and
Part 3 Space links Ground systems
orbit control
System Optics Mechanisms Production
verification
Part 4
Spacecraft Avionics Verification and Spacecraft data Pre-flight
ECLS Robotics
launcher interface validation interfaces operations
Part 5
Environments Propulsion Transfer, operations
and maintenance
Part 6 Mission control
Human factors
Pyrotechnics
and ergonomics
Part 7
Configuration In-orbit operations
Mechanical parts
definition
Part 8
Materials
Mission data

Post-flight
operations
ECSS

Engineering
aspects of ILS
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Scope

Part 3 of ECSS--E--30 in the engineering branch of the ECSS Standards defines

mechanical engineering requirements for mechanisms.
This Standard defines the requirements and statements applicable to the concept
definition, design, analysis, development, production, test verification and in-
orbit operation of space mechanisms on spacecraft, payloads and launcher el-
ements in order to meet the mission performance requirements.
This Standard contains the list of mandatory requirements to achieve reliable
operation of space mechanisms in orbit. It should also prevent anomalies during
the development phase influencing schedule and cost efficiency of space pro-
grammes.
When viewed from the perspective of a specific project context, the requirements
defined in this Standard should be tailored to match the genuine requirements of
a particular profile and circumstances of a project.
NOTE Tailoring is a process by which individual requirements of
specifications, standards and related documents are evalu-
ated, and made applicable to a specific project by selection,
and in some exceptional cases, modification of existing or
addition of new requirements.

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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 publi-
cation referred to applies.
ECSS--P--001 Glossary of terms
ECSS--E--10 Space engineering — System engineering
ECSS--E--20 Space engineering — Electrical and electronic
ECSS--E--30 Part 1 Space engineering — Mechanical — Part 1: Thermal con-
trol
ECSS--E--30 Part 2 Space engineering — Mechanical — Part 2: Structural
ECSS--E--30 Part 6 Space engineering — Mechanical — Part 6: Pyrotechnics
ECSS--E--30 Part 7 Space engineering — Mechanical — Part 7: Mechanical
parts
ECSS--E--30 Part 8 Space engineering — Mechanical — Part 8: Materials
ECSS--Q--20 Space product assurance — Quality assurance
ECSS--Q--30 Space product assurance — Dependability
ECSS--Q--40 Space product assurance — Safety
ECSS--Q--60 Space product assurance — EEE Components
ECSS--Q--70 Space product assurance — Materials, mechanical parts
and processes
ISO 76:1987 Rolling bearings — Static load ratings
ISO 128 Technical drawings
ISO 6336--1 Calculation of the load capacity of spur and helical gears —
Part 1: Basic principles, introduction and general influence
factors
ISO 6336--2 Calculation of the load capacity of spur and helical gears —
Part 2: Calculation of surface durability (pitting)
ISO 6336--3 Calculation of the load capacity of spur and helical gears —
Part 3: Calculation of tooth bending strength

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ISO 677:1976 Straight bevel gears for general engineering and for heavy
engineering — Basic rack
ISO 678:1976 Straight bevel gears for general engineering and for heavy
engineering — Modules and diametral pitches
ISO 1341:1976 Straight bevel gears -- Information to be given to the manu-
facturer by the purchaser in order to obtain the gear re-
quired

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Terms, definitions, symbols and abbreviated

terms

3.1 Terms and definitions

For the purpose of this ECSS--E--30 Part 3 Standard, the definitions as given in
ECSS--P--001, together with the following terms and definitions specific to this
Standard shall apply.

3.1.1
acceptance test
test to determine that a system, sub-system, component, or functional part is ca-
pable of meeting performance requirements prescribed in purchase specifications
or other documents specifying what constitutes the adequate performance capa-
bility for the item and to demonstrate the item is free from manufacturing defects

3.1.2
actuator
component that performs the moving function of a mechanism
NOTE An actuator can be either an electric motor, or any other
mechanical (e.g. spring) or electric component or part provid-
ing the torque or force for the motion of the mechanism.

3.1.3
cleanliness
level in both particulate contamination and molecular contamination that con-
taminates the part or assembly

3.1.4
component
assembly or any combination of parts, sub-assemblies and assemblies, and assem-
blies mounted together and normally capable of independent operation in a var-
iety of situations

3.1.5
control system
system (open or closed loop) which controls the relative motion of the mechanism

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3.1.6
deliverable output torque (TL )or force(FL)
torque or force at the mechanism or actuator output required by the customer for
an unspecified purpose and not affecting the actual performance of the mechanism
except in applying the external torque or force
EXAMPLE A theoretical torque or force of a robotic mechanism (service
tool) for which no specific function except torque or force
provision can be specified at an early stage in the project de-
velopment.

3.1.7
drawings
graphic data, including drawings as defined in the ISO/DIS 128 series.

3.1.8
dynamic output force (FD)
force required to accelerate a mass

3.1.9
dynamic output torque (TD)
torque required to accelerate an inertia

3.1.10
electronics
current carrying or voltage operated devices

3.1.11
fasteners
part utilized to provide attachment of two or more separate parts, components or
assemblies
EXAMPLE Fasteners have the function of locking the parts together and
thus providing the structural load path between the parts or,
if used as securing part, to ensure proper locating of the parts
to be secured (e.g. bolt, nut, joint axis shaft securing).

3.1.12
flushing or purging
control of the mechanism environment by enclosing the mechanism in specific gas-
eous or fluid media which are either surrounding the mechanism or passing over
or through the mechanism

3.1.13
integration
combination of activities and processes to assemble payload or spacecraft compo-
nents, subsystems, and systems elements into a desired configuration ensuring
compatibility

3.1.14
interface
mechanical, thermal, electrical, and operational common boundary between two
elements of a system

3.1.15
item
any level of hardware assembly (system, subsystem, equipment, component, or
part)

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3.1.16
latching or locking
intentional constraining of one or more previously unconstrained degrees of free-
dom of a mechanism which then requires action to release

3.1.17
lubrication
use of specific material surface properties or of applied material between two sur-
faces in contact in order to reduce friction, wear or adhesion between contacting
or moving surfaces

3.1.18
mechanism
assembly of components that are linked together allowing relative motion

3.1.19
mission
performance of coherent investigations or operations in space to achieve program
goals
NOTE A single mission might require more than one flight, or more
than one mission might be accomplished on a single flight.

3.1.20
off-loading
complete or partial unloading of a part or assembly from an initial pre-load typi-
cally employed not to expose a mechanisms part or assembly to launch loads or
other induced loads

3.1.21
payload
total complement of specific instruments, space equipment, support hardware,
and consumables carried in the spacecraft to accomplish a discrete activity in
space

3.1.22
phase margin
indicator for the stability of dynamic control systems

3.1.23
programme
activity involving manpower, material, funding, and scheduling which is necess-
ary to achieve desired goals (e.g. space mission)

3.1.24
positively locked
form-locking of a part or assembly into a defined position from which release can
only be obtained by application of a specific actuation force

3.1.25
qualification tests
tests to determine that the design of a system, subsystem, component or functional
part is capable of meeting it’s specified performance requirements in it’s oper-
ational environment with the margins specified

3.1.26
screw
fastener without a shank, being threaded over the full length of the shaft

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3.1.27
shank
unthreaded portion of the bolt or fastener shaft between the underside of the head
and start of the thread

3.1.28
stowing
process of placing a payload or spacecraft component, subsystem, and systems el-
ement in a retained position

3.1.29
stud
externally threaded headless fastener with shank separating the threaded por-
tions

3.1.30
threaded fastener
fastener with a head at one end and threaded portion at the other
NOTE The threaded portion is intended to mate with a matching in-
ternally threaded part, usually a nut.
A fastener is not threaded over the full length having a
shank.
A threaded fasteners is often referred to as a bolt.

3.1.31
tribology
study that deals with the design, friction, wear and lubrication of interacting sur-
faces in relative motion to each other

3.1.32
venting
compensation of the internal mechanism pressure environment with its surround-
ing pressure environment (e.g. by use of dedicated venting holes or passages)

3.1.33
wire
definition of wire covers both electrical and mechanical wires, when electrical is-
sues are addressed, the wire definition covers both flat harness wires and single
or bundle harness wires

3.2 Symbols and abbreviated terms

The following abbreviated terms and symbols are used within this Standard.
Abbreviation Meaning
AC alternating current
CVCM collected volatile contaminant material
DC direct current
EMC electromagnetic compatibility
ESD electrostatic discharge
FD dynamic force
FL deliverable output force
FMECA failure mode effects and criticality analysis
Fmin minimum actuator force required
FR friction torque/force
HA harness and other torque/force resistances
HD adhesion torque/force

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HY hysteresis torque/force
HV hardness Vickers
IF inertia resistance (linear)
IT inertia resistance (angular)
LEO low Earth orbit
M mass
MLI multi-layer insulation
MS strength safety margin
n.a. not applicable
RML recovered mass loss
S spring force
S/C spacecraft
TBD to be determined
TBS to be specified
TD dynamic torque
TL deliverable output torque
Tmin minimum actuator torque required
TML total mass loss
V volt

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4.2.1
General
4.8.2.2
4.2 Worst cases
General mechanisms identification
engineering 4.2.2
Product assurance

4.3 4.8.2.3
Mission and environmental 4.2.3 Thermal analysis
Reliability and
redundancy

4.4 4.8.2.4
Functional 4.5.2 Structural analysis
Physical constraints 4.2.4
Other requirements

4.5 4.5.3 4.8.2.5

Constraints Materials Pre-load and tolerance
4.7.2.1 budget analysis
General tribology
4.5.4
4.6
Operational
Inter face 4.8.2.6
constraints 4.8.2.2
Functional performance
Dry lubrication
analysis

4.7
Design 4.7.2.3
Fluid lubrication 4.8.2.7
Hertzian contact
analysis
4.7.2 4.7.2.4
Tribology Tribological
components
4.8.2.8
4.7.3.2 Torque/force ratio
Thermal engineering analysis

4.7.3 4.7.3.3
Thermal control Mechanisms thermal 4.8.2.9
design and sizing Reliability analysis
FMECA

4.7.3.4
Multi-layer insulation
4.7.4 4.8.2.10
Mechanical design and 4.7.4.1 Gear analysis
sizing General

4.7.4.2 4.8.2.11
4.7.5 Structural Shock generation and
Pyrotechnics dimensioning susceptibility

4.7.4.3
4.7.6 4.8.2.12
Functional
Electrical and electronic Disturbance generation
dimensioning
(emission) and
susceptibility
4.7.7 4.7.4.4
Control system Other requirements
4.8.2.13
Analysis of control
systems
Requirements for space
mechanisms engineering
4.8.2.14
Lubrication analysis
4.8.2
Verification by analysis

4.8.2.15
4.8.3.1
Life time analysis
General
4.8
Verification

4.8.3.2 4.8.2.16
4.8.3 Characterization Magnetic and
Verification by test /development testing electromagnetic
4.9
Production and analysis
manufacturing
4.8.3.3
Qualifiication testing 4.8.2.17
Radiation analysis
4.10
In service
4.8.3.4
Acceptance testing 4.8.2.18
Electrical analysis

Figure 1: Requirements for space mechanisms engineering

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ECSS--E--30 Part 3A
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Space mechanisms

4.1 Overview
This Standard addresses the detailed aspects of the mechanical engineering steps
for the various engineering disciplines involved in the achievement of the required
space mechanisms performance. The disciplines cover where applicable thermal
control, structures, pyrotechnics, mechanical parts, materials, processes, electri-
cal/electronic engineering, and control systems engineering.
The following requirements are identified considering the typical interfaces and
interactions of mechanisms with thermal control, structures, functional oper-
ations, materials and parts, pyrotechnics, electrical and electronics, and servo-
control interactions. Where interactions with other ECSS Engineering Standards
are identified, reference is made to the corresponding documentation of the related
standards.

4.2 General mechanism

4.2.1 General
This group of requirements covers the interaction of mechanisms engineering
with project management, processes, parts and components, product assurance,
and the related requirements affecting the conceptual definition, design, sizing,
analysis, development, and hardware production of mechanisms. Figure 1 pro-
vides an overview of the subjects covered by this Standard.

4.2.2 Product assurance

4.2.2.1 Marking and labelling
a. Marking and labelling of mechanisms components, sub-assemblies, assem-
blies of the mechanism shall carry an identification.
b. The marking and labelling related requirements in subclause 4.2.2.2 are spe-
cific to mechanisms and shall be applied taking precedence over other stan-
dards.

4.2.2.2 Specific identification

Any delivered piece of hardware, part, component, sub-assembly, assembly shall
carry identification (removable if appropriate) on non functional surfaces consist-
ing of at least the following information:

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ECSS--E--30 Part 3A
25 April 2000 ECSS
1. identification number;
2. equipment title;
3. serial number (where appropriate).
Items 1. and 2. may be defined by the contracting authority.

4.2.2.3 Parts and components

a. Existing (commercially available or off-the-shelf) parts and components used
in mechanisms shall be fully qualified for the intended application according
to a qualification procedure approved by the customer.
b. The use of flight proven parts and components shall be preferred, or shall be
selected according to the procedures defined in ECSS--E--30 Part 7.

4.2.2.4 Marking of bearings

Bearings shall not be marked by the use of vibro-etch marks on the lateral faces
of the bearing races.
NOTE Etched marks on the lateral faces of the bearing races affect
the mounting tolerances of the bearing in the housing and
the bearing’s tribological performance characteristics.

4.2.2.5 Interchangeability
All components, sub-assemblies and assemblies having the same identification
number shall be functionally and dimensionally interchangeable.

4.2.2.6 Maintainability
a. The mechanism shall be designed to require no maintenance during storage
and ground life.
b. If ground maintenance during storage or ground operation cannot be avoided,
the maintenance requirements including
1. number of operations,
2. frequency of operations,
3. special tooling and test equipment,
4. calibration and adjustments, and
5. fault identification and repair,
shall be documented, justified and agreed with the customer.

4.2.3 Reliability and redundancy

4.2.3.1 General
In view of the criticality of space mechanisms which are often potential mission
critical single point failures, the reliability and redundancy of mechanisms engin-
eering shall require particular attention.

4.2.3.2 Reliability
a. All mechanisms which are critical to mission success shall demonstrate con-
formance to the required reliability figure according to the following methods:
1. electronic components: by parts count as a minimum or other methods to
be agreed by the customer;
2. mechanical parts: by stress analysis or other methods to be agreed by the
customer;
3. mechanical limited-life parts: reliability and confidence to be demon-
strated by life test to be agreed by the customer.

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ECSS
ECSS--E--30 Part 3A
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b. Other (non-critical) mechanisms shall identify conformance to the reliability

figure by simplified methods (parts count or other methods accepted by the
customer).
c. The method to achieve by design, derive by analysis, and demonstrate the re-
quired reliability figure can be found in ECSS--Q--30.
d. Failure of one part or element shall not result in consequential damage to the
equipment or other spacecraft components.

4.2.3.3 Structural reliability

a. Structural reliability, subclause 4.2.13 of ECSS--E--30 Part 2A shall apply.
b. Where structural failure of a mechanisms can cause a catastrophic or critical
hazardous event (see ECSS--Q--40), fasteners and load bearing paths within
mechanisms shall be designed in accordance with fracture control principles.

4.2.3.4 Redundancy
a. High-reliability of a mechanism may be incorporated in a design by including
component redundancy or high design margins. The aim shall be to deliver a
design which is single failure tolerant.
b. During the design of the mechanism all single point failure modes shall be
identified.
c. All single points of failure shall be eliminated by redundant components
where practicable.
d. Redundancy concepts shall be selected to minimize the number of single
points of failure and to satisfy the reliability requirements.
e. Where a single point failure mode is identified and redundancy cannot be
provided, the required reliability shall be demonstrated.
f. Unless redundancy is achieved by the provision of a complete redundant
mechanism, active elements of mechanisms such as sensors, motor windings
(and brushes where applicable), actuators, switches and electronics shall be
redundant.
g. Failure of one element or part shall not prevent the other redundant element
or part from performing its intended function, nor the equipment from
meeting its performance requirements.

4.2.4 Flushing and purging

a. Parts of mechanisms that are sensitive to operation in air due to the presence
of moisture or other deleterious contamination shall be provided with a means
for flushing with an inert clean dry gas.
b. The cleanliness of the gas shall conform to the mechanism specification.
c. The residual humidity of the dry gas shall be compatible with the specific lu-
bricant performance concerned.

4.3 Mission and environments

4.3.1 General
This group of requirements covers the interaction of mechanisms engineering
with mission requirements and environments.

4.3.2 Mission
a. The mission phase shall commence with on-ground life of the mechanisms
until end of operational life of the spacecraft.

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ECSS--E--30 Part 3A
25 April 2000 ECSS
b. The mechanism engineering shall consider every mission phase identified for
the specific space programme and conform to the related mission require-
ments and environmental constraints.
c. Based on the mission phases, a mechanism specification shall be established.
d. The mechanism specification shall define the functional requirements and
environments applicable to each phase of the mission.
e. The mechanism specification shall conform to the spacecraft system specifica-
tion.

4.3.3 Environment
The mechanism shall conform to its environmental specification.

4.4 Functional requirements

4.4.1 General
This group of requirements covers the overall function of mechanisms on space-
craft and payload.

4.4.2 System performance

The mechanism functional performance shall conform to the system performance
requirements.

4.4.3 Mechanism function

a. The mechanism shall provide structural support to an equipment or payload
unit of the spacecraft and shall change its relative position with respect to the
spacecraft.
b. The kinematic requirements applicable to each position change shall be sub-
stantiated; mechanical interface, position accuracy or velocity tolerances
shall be specified and demonstrated to conform to the functional needs.
c. The envelopes within which each moving part is allowed to move shall be de-
fined. The movement shall be without risk of mechanical interference with
any other part of the mechanism, the spacecraft or the payload.

4.5 Constraints
4.5.1 General
This group of requirements covers the constraints to which mechanisms shall con-
form and to which the mechanisms have to be designed, manufactured and oper-
ated.

4.5.2 Physical constraints

4.5.2.1 Climatic protection and specific environment constraints
Specific climatic protection requirements shall be defined. Parts, components,
sub-assemblies and assembly shall conform to the specific climatic protection re-
quirements.

4.5.2.2 Sterilization
Sterilization requirements and sterilization test procedure requirements shall be
defined. The mechanism shall conform to its sterilization requirements and steril-
ization test procedures requirements.

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4.5.3 Materials
4.5.3.1 Mechanical and physical properties of materials
The materials used for space mechanisms shall conform to the materials require-
ments defined in the ECSS--E--30 Part 8.
The following material requirements are however specific to this Standard and
shall be applied taking precedence over ECSS--E--30 Part 8.

4.5.3.2 Material selection

Materials shall be selected from the preferred materials list or shall be demon-
strated to conform to approved requirements. (See ECSS--Q--70--71,
ECSS--Q--70--04, and where applicable ECSS--Q--70--36 and ECSS--Q--70--37).
For additional requirements relating to tribology, see 4.7.2

4.5.3.3 Corrosion
All metals shall be either corrosion resistant, or shall be suitably treated using a
process, approved by the customer which resists corrosion caused by conditions
arising during storage, test and all phases of the mission. This shall include stress
corrosion where applicable
NOTE Corrosion resistance is demonstrated when no corrosion is
identified on the surface after exposure to the worst case
conditions and mission phases durations, and if the material
is a Class 1 material (see ECSS--Q--70--37) and has
demonstrated not to show surface corrosion after exposure to
the related test environment.

4.5.3.4 Dissimilar metals

Where possible, dissimilar metals shall not be used in contact with each other un-
less they have been treated by a customer approved process which resists galvanic
and electrolytic corrosion.

4.5.3.5 Stress corrosion cracking

Metals used and not demonstrated to conform to approved selection criteria, shall
be tested according to approved methods and shall demonstrate conformance to
respect to stress corrosion cracking (see ECSS--Q--70--36 and ECSS--Q--70--37).

4.5.3.6 Material allowables

The requirements identified in subclause 4.7.4.2 are applicable.

4.5.3.7 Fungus protection

Materials that are nutrients for fungi shall not be used where their use can be
avoided. Where they are used and not hermetically sealed, they shall be treated
with an approved fungicidal agent.

4.5.3.8 Flammable, toxic and unstable materials

The use of flammable, toxic and unstable materials shall be avoided as far as poss-
ible. In manned space systems, the use of flammable, toxic and unstable materials
is not allowed.

4.5.3.9 Induced emissions (stray-light protection)

Stray light protection and emission requirements shall be determined. Materials
and their coatings shall be selected such that their surface properties reduce their
induced emissions (stray light and others) below the permitted levels of stray light.

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ECSS--E--30 Part 3A
25 April 2000 ECSS
4.5.3.10 Radiation
The degradation of material properties due to the effects of exposure to radiation
shall not degrade the functional performance of the mechanism below require-
ment over the complete mission.

4.5.3.11 Atomic oxygen

The material properties due to exposure to atomic oxygen present in LEO shall not
degrade below the functional performance requirements of the mechanism
throughout the mission

4.5.4 Operational constraints

a. The mechanism shall not impose additional operational constraints on the
mission.
b. If operational constraints cannot be avoided, they shall be identified, justified
and approved by the customer.

4.6 Interfaces
4.6.1 General
This group of requirements covers the interfaces of mechanisms on spacecraft and
payload.

4.6.2 Structural interfaces

The mechanism shall conform to the structural interface definitions and require-
ments identified in the mechanism specification.

4.6.3 Thermal interfaces

The mechanism shall conform to the thermal interface definitions and require-
ments identified in the mechanism specification.

4.6.4 Thermo-mechanical interfaces

Thermo-mechanical interfaces shall be designed to account for the induced stress.

4.6.5 Electrical interfaces

The mechanism shall conform to the electrical interface definitions and require-
ments identified in the mechanism specification.

4.6.6 Data interfaces

The mechanism shall conform to the data interface definitions and requirements
identified in the spacecraft mechanism specification.

4.6.7 Physical interfaces

The mass of the mechanism shall conform to the requirements specified by the cus-
tomer.

4.6.8 Other interfaces

The mechanism shall conform to optical, alignment, access, stay-out zones and
GSE interfaces identified in the mechanism specification.

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ECSS--E--30 Part 3A
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4.7 Design requirements

4.7.1 General
The design requirements have been further split into tribology, thermal control,
mechanical design and sizing, pyrotechnic, electrical and electronic, and control
system requirements.

4.7.2 Tribology
4.7.2.1 General tribology requirements
a. This group of requirements covers the requirements related to tribological is-
sues of mechanisms on spacecraft and payload. The tribology of surfaces that
separates or moves relative to one another play a key function in the concept-
ual definition, design, analysis, test verification, launch, and in-orbit non-op-
erational or operational performance of the mechanisms. The following re-
quirements shall be applied.
b. Mechanisms shall be designed to provide adequate lubrication function be-
tween surfaces in relative motion in order to ensure it conforms to the mech-
anism performance requirements throughout the required lifetime and to
minimize wear.
c. Mechanisms shall employ lubricants or lubricating surfaces that are space ap-
proved (see ECSS--Q--70).
If non-approved lubricants are used, they shall be validated in advance to en-
sure space compatibility of the lubricant material (see ECSS--Q--70)
NOTE The lubrication function is not covered in ECSS--Q--70.

d. Degradation of the lubricant in the on-ground and in-orbit environments shall

be verified not to occur or shall be verified not to lead to unacceptable mechan-
ism performance degradation (adhesion friction, wear, lubricant performance
variability).
e. The use of sliding surfaces shall be avoided as far as possible, but where such
use cannot be avoided, one of the surfaces shall be hard and the other shall
be lubricated or shall be composed of a self--lubricating material (e.g. polyimi-
de resins). Metal to metal contacts shall be composed of dissimilar materials.
f. The cleaning of surfaces prior to the application of lubricant shall facilitate
adequate adhesion or wetting of lubricant on the substrate surface. The clean-
ing of the surfaces prior to lubricant application shall not degrade the lubri-
cating action.
g. The lubricant shall conform to the molecular and particulate contamination
requirements specified for the entire mission.

4.7.2.2 Dry lubrication

a. Dry lubricants shall be selected in accordance with space tribology require-
ments (see ECSS--E--30--09).
b. At the same time as the mechanism tribological surfaces are being lubricated,
samples of representative material, surface roughness, surface cleanliness
and surface orientation shall be co-deposited in each process run with the
flight components. The thickness and adhesion of the lubricant on the
samples shall be verified.
c. The process validation of the dry lubricant application shall be demonstrated
with respect to achieved lubricant performance and repeatability.
d. Handling, storage and all operational requirements of all dry lubricated com-
ponents shall be defined and documented.

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ECSS--E--30 Part 3A
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4.7.2.3 Fluid lubrication
a. Amount of fluid lubricant
The quantity of lubricant provided shall be determined to leave an adequate
surplus of lubricant at the end of the total lifetime of the mechanism and shall
take into account outgassing, creep and other sources of absorption or degra-
dation. The exposure to on-ground storage and related gravity effects, and
other ground or in-orbit accelerations on lubricant distribution shall be vali-
dated.
b. Containment or sealing requirements
Liquid lubricated systems shall be appropriately designed to prevent outgas-
sing, creeping and possible sources of contamination and shall demonstrate
conformance to the contamination requirements.
c. Outgassing rate
The outgassing rate of liquid lubricants shall be measured by an approved
screening test (see ECSS--Q--70--02). The limits of acceptance for material out-
gassing shall be according to Table 1.
Table 1: Outgassing limits
Application TML [%] RML [%] CVCM [%]
General applications < 0,1 n.a. < 0,1
Optical device applications n.a. < 0,1 < 0,01

These limits can be more stringent if the materials concerned are later used
in critical areas. The use of materials that are deemed acceptable according
to the limits stated above does not necessarily ensure that the spacecraft sys-
tem or component remains uncontaminated.
d. Sensitive applications
For sensitive applications, specific outgassing requirements shall be defined.
e. Anti-creep barriers
Anti-creep barriers shall be used to avoid migration of liquid lubricants to
sensitive equipment within the mechanism or when migration of liquid lu-
bricants causes a change of the lubricant amount on the essential parts to be
lubricated.
f. Integrity of the anti-creep barrier
The integrity of the anti-creep barrier shall be verifiable by using suitable
indicators (e.g. UV-detectable).

4.7.2.4 Tribological components requirements

4.7.2.4.1 Materials for tribological surfaces

a. The mating surfaces used in end stops shall be < Ra 0,4 µm.
b. When metallic material mating or separating surfaces subject to relative mo-
tion are used, they shall have a minimum hardness of 500 HV (unless one sur-
face is a self-lubricating material e.g. bronze) and shall be composed of dis-
similar material or at least one of the two surfaces shall have a dissimilar
coating (e.g. nitride, carbide or oxide). The use of bonded or sputtered MoS2
or polymeric materials is not excluded.
c. The life of tribological components shall be demonstrated to suit the applica-
tion under representative conditions.

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ECSS--E--30 Part 3A
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4.7.2.4.2 Bearing pre-loading

a. Ball bearings shall be pre-loaded. Pre-loading should be applied by solid pre-
load or produced by compliant loading techniques which do not require sliding
at the bearing mounting interfaces.
b. If sliding at the bearing mounting interfaces cannot be prevented, sliding
shall be facilitated by a dedicated lubricated sliding sleeve/bush or dedicated
tribological coating.
c. If bearing gapping occurs during vibration, adequacy of lubricant and poten-
tial consequential mechanisms damage or degradation due to bearing compo-
nents or shaft motion shall be demonstrated to conform with the required
functional performance and lifetime.
d. Any set pre-load at component level shall be measured.
e. Where the functional performance of the mechanism or spacecraft is sensitive
to the pre-load, the pre-load shall be measured after assembly.
f. Where the pre-load can be affected by the running-in process, the pre-load
shall be confirmed after running-in. If possible, the pre-load shall be checked
without dismantling the mechanism.

4.7.2.4.3 Mechanical cables

Mechanical cables used on moving parts or assemblies shall be adequately lubri-
cated.

4.7.3 Thermal control requirements

4.7.3.1 General
This group of requirements covers the interaction of mechanisms engineering
with thermal control and its related requirements affecting mechanisms engineer-
ing.

4.7.3.2 Thermal engineering

a. The mechanism engineering shall conform to the thermal engineering re-
quirements identified in the ECSS--E--30 Part 1.
b. If no specific thermal control provisions are applied on the mechanism, the ap-
plicability of ECSS--E--30 Part 1 shall be limited to the overall thermal sizing,
analysis and verification requirements.
c. The following requirements of subclause 4.7.3.3 are specific to this Standard
and shall be applied taking precedence over ECSS--E--30 Part 1.

4.7.3.3 Mechanisms thermal design and sizing requirements

a. The thermal design of the mechanism shall ensure that all components are
maintained within their qualification temperature range under all specified
ground, test, launch and in-orbit conditions throughout the lifetime of the
mechanism.
b. The mechanism shall be compatible with on-ground thermal vacuum testing
which is representative of in-orbit thermal conditions.
c. Temperature control shall be passive to the maximum extent practicable.
d. The mechanism design shall consider the extremes of operational and sur-
vival steady-state and transient temperatures that can be encountered and
also the temperature gradients across the mechanism.
NOTE Failure to consider the effects of differential expansion can
lead to a catastrophic failure. Further details of the thermal
analysis required and margins to be used on predicted tem-
peratures are given under the Verification requirements
group 4.8.

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ECSS--E--30 Part 3A
25 April 2000 ECSS
4.7.3.4 Multi-layer insulation (MLI) requirements
a. When using MLI, supported at discrete positions (supports: maximum of
100 mm apart), on moving parts of mechanisms or on spacecraft structure
close to its moving paths, the following clearances shall be provided:
1. between structural components and MLI hardware a minimum clearance
of 20 mm (in out-of-plane direction to the MLI)
2. between MLI protected moving parts and other MLI hardware a minimum
clearance of 35 mm (in out-of-plane direction to the MLI).
b. Other specific design solutions (e.g. MLI not supported at discrete positions)
shall demonstrate that clearances with adequate margin, agreed by the cus-
tomer, are maintained throughout the mission.
c. The MLI design shall be such that the dynamic envelopes of the MLI during
vibration exposure and venting or purging do not exceed the required clear-
ances.

4.7.4 Mechanical design and sizing

4.7.4.1 General
a. This group of requirements covers the overall conceptual design, the mechan-
ical sizing of parts, components and assemblies, and the detailed design de-
finition of mechanisms.
b. Mechanisms shall be designed to meet the mechanical performance require-
ments and to withstand the specified environment during handling, trans-
portation, testing, storage, launch and operation in orbit for the specified life-
time without damage or degradation.

4.7.4.2 Structural dimensioning

4.7.4.2.1 Structural engineering requirements

The structural dimensioning of mechanisms shall conform to the Structural En-
gineering requirements identified in the ECSS--E--30 Part 2.
The following requirements of subclause 4.7.4.2 are specific to this Standard and
shall be applied taking precedence over ECSS--E--30 Part 2.

4.7.4.2.2 General
Mechanisms shall conform to the specified stiffness, strength and safety require-
ments derived from the launcher and the spacecraft structural requirements.

4.7.4.2.3 Loads
The requirements of subclause 4.2.10 of ECSS--E--30 Part 2A shall apply with the
following additions for in-orbit loads:
a. The operational loads shall be added to the in-orbit loads.
b. The operational loads of the mechanisms shall be derived according to the
functional dimensioning requirements based on dynamic performance analy-
ses or test measurements in worst case conditions.
c. For the derivation of the operational loads, the related induced reaction of the
spacecraft shall be considered.

4.7.4.2.4 Limit loads

The requirements of subclause 4.2.11 of ECSS--E--30 Part 2A shall apply with the
following modifications for the worst case condition:
For cases where a statistical distribution of the loads cannot be demonstrated
(typically for mechanisms operating loads), the limit loads shall be defined based
on the worst case conditions.

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ECSS--E--30 Part 3A
25 April 2000

4.7.4.2.5 Design loads

The requirements of subclause 4.2.12 of ECSS--E--30 Part 2A shall apply.

4.7.4.2.6 Material allowables

The requirements of subclauses 4.6.9 through 4.6.13 inclusive of ECSS--E--30
Part 2A shall apply to structural sizing, with the following addition for the “A” va-
lues:
Metallic material “A” allowable value as specified in ref. MIL--HDBK--5F or equiv-
alent definition shall be used for structural sizing.

4.7.4.2.7 Margin of safety (MOS)

The requirements of subclause 4.6.14 of ECSS--E--30 Part 2A on structural margin
of safety shall apply with the following modifications:
a. Mechanisms shall be designed with a positive margin of safety against yield-
ing and against ultimate under all environmental and operational load condi-
tions.
b. The margin of safety (MOS) shall be derived from stresses and shall employ
the factors of safety (FOS) identified below. It is defined as follows and shall
be demonstrated to be positive:
MOS = (allowable stress limit / (actual stress x factor of safety)) - 1 > 0.

4.7.4.2.8 Factors of safety (FOS)

The requirements of subclause 4.6.15 of ECSS--E--30 Part 2A on structural factors
of safety definition shall apply with the following modifications:
a. In the computation of safety margins the following minimum factors of safety
shall be used for standard metallic materials:
S yield stress factor of safety 1,25
S ultimate stress factor of safety 1,5
S minimum fatigue factor (cycles) 4
b. Other materials shall require customer approval of required factors of safety
on a case by case basis.
c. The following specific factors of safety shall apply on the components identi-
fied below:
S cables, stress factor of safety against rupture 3
S stops, shaft shoulders and recesses, against yield 2

4.7.4.3 Functional dimensioning (motorization)

4.7.4.3.1 General
The mechanisms engineering shall conform to the motorization factor require-
ments on quasi-static torque (or force) ratio and where applicable on dynamic
torque (or force) ratio as defined in the following subclauses.

4.7.4.3.2 Quasi-static torque applicability

The quasi-static torque (or force) ratio is applicable to mechanisms where the mov-
ing function is performed without imposing design driving requirements on the
functional performance due to time constraints. (e.g. deployment systems, unfold-
ing devices).
NOTE The quasi-static torque (or force) ratio is defined as the
actuation torque (or force) divided by the sum of the factored
worst case resistive components opposing the movement of
the mechanism plus any required deliverable output torque
or force.

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25 April 2000 ECSS
4.7.4.3.3 Dynamic torque applicability
The dynamic torque (or force) ratio requirement is applicable to mechanisms
which have to fulfil a specified acceleration requirement or for which an indirect
acceleration requirement can be deduced from speed/time or other (dynamic) re-
quirements.
NOTE The ratio is defined as the dynamic actuation torques (or
forces) divided by the sum of the factored dynamic worst case
resistive components and the additional factored inertial
torque (or force) induced by the acceleration of the mechan-
ism moving assembly plus any required deliverable output
torque or force.

4.7.4.3.4 Motorization factor - “quasi-static” torque (or force) ratio

a. Actuators (electrical, mechanical, thermal and others) shall be sized to pro-
vide throughout the operational lifetime and over the full range of travel
actuation torques (or forces) which exceed at least two times the combined fac-
tored worst case resistive torque or forces in addition to any required deliver-
able output torque or force. The following minimum uncertainty factors shall
be applied to the resistance components when deriving the worst case
resistive torques (or forces):
In order to derive the factored worst case quasi-static resistive torques (or
forces), the components of resistance, considering worst case conditions, shall
be multiplied by the following minimum uncertainty factors (see Table 2).
Table 2: Minimum uncertainty factors
Component of resistance Symbol Factor
Inertia IT (or IF ) 1,1
Spring S 1,2
Friction FR 3 # (1,5)
Hysteresis HY 3 # (1,5)
Others (harness) HA 3 # (1,5)
Adhesion HD 3

b. The minimum required actuation torque (or force) is defined by the equations:
Minimum required actuation torque (Tmin)
Tmin = 2,0 × ( 1,1 I T + 1,2 S + 3 FR + 3 HY + 3 HA + 3 HD ) + TL
c. Minimum required actuation force (Fmin)
Fmin = 2,0 × ( 1,1 IF + 1,2 S + 3 FR + 3 HY + 3 HA + 3 HD ) + FL
The deliverable output torque or force is only applicable if specified by the cus-
tomer.
d. When a function of the mechanism is to deliver an output torques or forces
TL /FL , for further actuation, the output torque or force shall be derived ac-
cording to the above torque or force requirements considering the specified
uncertainty factors on the individual components of resistance as appropriate
and the motorization factor of two shall also be applied to TL / FL .
e. The inertia resistance term (IT or IF ) in the required minimum actuation
torque (or force) equation is applicable to mechanisms being mounted in an
accelerating frame of reference (e.g. spinning spacecraft, payload or other)
and shall be derived considering the imposed inertial resistance load.
f. The specified uncertainty factors marked by # in Table 2 may be reduced to
1,5 providing that the worst case measured torque or force resistive compo-
nents to which they refer are determined by measurement according to a test

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procedure approved by the customer and demonstrate the adequacy of the un-
certainty factor with respect to the dispersions of the resistive component
functional performances.
g. The kinetic energy of the moving components shall not be considered in the
provision of actuation torques (or forces).
h. Environmental effects shall be accounted for separately in addition to the use
of the above uncertainty factors when deriving the worst case resistive
torques (or forces).

4.7.4.3.5 Motorization factor - dynamic torque (or force) ratio

a. Actuators (electrical, mechanical, thermal and others) shall be sized to pro-
vide throughout the operational lifetime and over the full range of travel
actuation torques (or forces) which exceed the sum of at least two times the
combined worst case dynamic resistive torque (or forces) and 1,25 times the
inertial resistance torque (or force) caused by the required worst case acceler-
ation function. The minimum uncertainty factors (see Table 2) shall be ap-
plied to the resistance components when deriving the worst case resistive dy-
namic torques (or forces).
In order to derive the worst case dynamic resistive torques (or forces), the com-
ponents of resistance considering the worst case conditions shall be multiplied
by the minimum uncertainty factors (see Table 2).
b. The minimum required actuation torque (Tmin) to meet the dynamic torque
ratio requirements is given by the formula:
Tmin = 2,0 × ( 1,1 I T + 1,2 S + 3 FR + 3 HY + 3 HA + 3 HD ) + 1,25 TD
where
TD is the dynamic torque.
c. The minimum required actuation force (Fmin) to meet the dynamic force ratio
requirements is given by the formula:
Fmin = 2,0 × ( 1,1 IF + 1,2 S + 3 FR + 3 HY + 3 HA + 3 HD ) + 1,25 FD
where
FD is the dynamic force.
d. The inertia resistance term (IT or IF ) in the required minimum actuation
torque (or force) equation is applicable to mechanisms being mounted in an
accelerating frame of reference (e.g. spinning spacecraft, payload or other)
and shall be derived considering the imposed inertial resistance load.
e. The specified uncertainty factors marked by # in table 2 may be reduced to 1,5
providing that the worst case measured torque or force resistive components
to which they refer are determined by measurement according to a test pro-
cedure approved by the customer and demonstrating adequacy of the uncer-
tainty factor with respect to the dispersions of the resistive component func-
tional performances.
f. The kinetic energy of the moving components shall not be considered in the
provision of actuation torques (or forces).
g. Environmental effects shall be accounted for separately in addition to the use
of the above uncertainty factors when deriving the worst case resistive
torques (or forces).

4.7.4.3.6 Actuation torque (or force) dimensioning

a. When the actuation torque (or force) is supplied by a spring actuator, the worst
case actuation torque required in the equations in subclause 4.7.4.3, shall be
derived considering worst case conditions and shall be multiplied by the maxi-
mum uncertainty factor of 0,8.
b. Spring actuators shall be redundant unless agreed by the customer, and un-
less it is demonstrated by analysis and test that appropriately conservative
spring sizing and functional performance characteristics guarantee the re-

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25 April 2000 ECSS
quired reliability of the mission. The appropriate spring sizing shall demon-
strate that a spring failure can be excluded as potential failure mode.
c. Actuating torques or forces based on hysteresis, harness generated, or any
item whose primary function is not to provide torques or forces, shall not be
used as a motorization source.
d. If torques (or forces) from harness or other above excluded actuator sources
are relied upon to meet the motorization requirements in subclause 4.8.3.3.
their use shall be justified, agreed with the customer and the adequacy of the
uncertainly factor with respect to the dispersion of the component actuation
functional performances shall be demonstrated.

4.7.4.4 Other requirements

4.7.4.4.1 Replaceable elements

a. All parts or components which are intended to be replaced or re-installed shall
be designed to ensure they can only be installed in the correct orientation.
b. Designs of mechanisms using deformable elements (e.g. crush dampers.) shall
only allow correct assembly orientation or orientations.
c. The design of replaceable items shall inhibit the reuse in the mechanism or
spacecraft in the un-refurbished state.

4.7.4.4.2 Status monitoring

Unless monitored at spacecraft system level, the design of mechanisms shall in-
clude appropriate means to monitor the execution of its main functions. Mission
critical mechanisms shall be designed in such way that monitoring information of
its critical function(s) is accessible to the spacecraft telemetry.

4.7.4.4.3 Latching or locking

a. Latching mechanisms used to assure positive locking shall be designed to
avoid inadvertent opening by vibration or shock occurring during the mission.
b. Locking or latching mechanisms shall provide a clear indication of whether
the latch or lock is open or closed.
c. Electrically actuated deployable items require positive latching or locking.
d. The latch capture range shall be sufficient to ensure capture of the mechanism
over the complete range of temperatures or temperature gradients and manu-
facturing and assembly tolerances.
e. Where latching is not achieved on initial completion of motion, the design
shall not prevent subsequent successful latching.
f. Latches shall be self-locking and shall be easily resettable for ground testing.
g. Off--load mechanisms shall be capable of being operated manually.
h. Latches and locks shall conform to the shock load requirements.

4.7.4.4.4 End stops

a. Mechanisms with restricted travel or rotation shall be provided with regular
or emergency mechanical end stops which limit their motion and travel ex-
tremes to the maximum position for proper functioning of the actuated item
and to prevent interference with interfacing equipment.
b. The mechanical end stops and arresting mechanisms shall be designed to
withstand without damage the maximum shock loads possible.
c. The shock loads shall conform to the sizing requirements on adhesion forces
for end stops stated in subclause 4.7.4.4.5a.
d. Contact with a stop shall not result in a non-recoverable situation.
e. Electrical deployment indicators (e.g. micro switches) shall not be used as
mechanical end stops.

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4.7.4.4.5 Separable contact surfaces (not applicable to gears and ball or

journal bearings)
a. Separable contact surfaces shall be designed to minimize the adhesion forces.
The contact between the mating surfaces shall be well-characterized and re-
producible, including for the area of contact, alignment and load conditions.
b. The peak Hertzian contact pressure shall be demonstrated to be below 93%
of the yield limit of the weakest material.
c. Sliding at the separable contact surfaces shall be prevented to avoid potential
contact surface property changes.
d. The torque or force ratio of the actuator which separates the contact surfaces
shall be sized according to subclause 4.7.4.3.4 and shall be demonstrated to
overcome two times the worst possible adhesion force in representative envi-
ronmental condition.
e. The minimum hardness of metal to metal couples in contact shall be 500 HV.

4.7.4.4.6 Ball bearings - sizing for static loads

Ball bearings “manufactured from good quality hardened steel” (ISO 76) shall be
sized concerning the static load rating in accordance with ISO 76 with respect to
the maximum allowable Hertz contact stress.

4.7.4.4.7 Gears
The dimensioning and sizing of gears shall be performed according to the ISO 6336
standard and its reference documents.

4.7.4.4.8 Mechanical clearances

When designing and locating movable, actuating, or similar mechanisms, ad-
equate clearance shall be provided to prevent:
S interference (collision) with the structure;
S contact with electrical wiring and components, thermal insulation, or
other subsystem components;
S puncture of fluid lines, valves and tanks if applicable;
S blocking of optical paths if applicable.

4.7.4.4.9 MLI clearance

For clearance requirements to MLI see subclause 4.7.3.4.

4.7.4.4.10 Threaded parts or locating devices

a. All threaded parts (e.g. fasteners and others) and locating devices require sec-
ondary, redundant locking, i.e. shall be positively locked.
b. All threaded fasteners, screws and studs shall be manufactured in accordance
with general requirements for threaded fasteners (see ECSS--Q--70--46).
c. All threaded fasteners, screws and studs shall be made from materials which
are not susceptible to stress corrosion cracking, (see ECSS--Q--70--37).
d. All threaded fasteners, screws and studs shall be designed to be fail-safe.

4.7.4.4.11 Venting
a. Unless the mechanism is hermetically sealed or sized in all its functions and
performances for internal pressure build-up, adequate means of venting dur-
ing launch and in-orbit shall be provided.
b. The method and design of venting shall minimize the contamination of bear-
ings, optics and other sensitive components.
c. If venting to the outside of a lubricated enclosure is implemented, compatibil-
ity of the lubricant with the other spacecraft materials used and with conta-
mination requirements shall be demonstrated.

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25 April 2000 ECSS
4.7.4.4.12 Release and locking devices with pyrotechnics or other
actuators
a. All pyrotechnic and other release and locking devices actuators (e.g. thermal
knives, memory metal and paraffin actuators) shall be redundant unless
agreed by the customer. Redundancy shall be provided by duplication up to
and including the level of the initiators, heating element or equivalent for
non-pyrotechnic devices and its power supply.
b. The design, material and manufacture of bolts, rods and cables (and other el-
ements to be cut) used in release and locking devices shall be demonstrated
to conform to the reliability requirements to be fulfilled in the cutting func-
tion.
c. The operation of release devices shall be compatible with the cleanliness re-
quirements. Suitable means of debris containment shall be included. If criti-
cal, contamination shall be measured.
d. Release and locking devices shall conform to the shock load requirements.

4.7.5 Pyrotechnics
For pyrotechnic actuators see ECSS--E--30 Part 6.

4.7.6 Electrical and electronic requirements

4.7.6.1 General
a. This group of requirements covers the interaction of mechanisms engineering
with electrical and electronic engineering and its related requirements affec-
ting mechanisms engineering.
b. For electrical and electronic engineering requirements see ECSS--E--20. If no
electrical or electronic provisions are applied on the mechanism, the applic-
ability of the Standard shall be limited to the potential compatibility require-
ments of mechanical systems with electrical and electronic systems.
c. The following electrical and electronic requirements are specific to this
Standard and shall be applied taking precedence over ECSS--E--20.

4.7.6.2 Electrical design

a. Mechanisms shall be designed to meet all the requirements regarding electri-
cal interfaces and performances, and shall exhibit stable electrical character-
istics and electromechanical transfer functions throughout their specified
period of life.
b. Electrical power consumption, generated electrical disturbances and propen-
sity for fault propagation shall be minimized by design.
c. The design of electric motors shall conform with the design requirement for
space electric motors.

4.7.6.3 Insulation
a. Electrical wires shall be insulated from the structure and from each other by
not less than 10 MΩ measured with a DC voltage of 500 V applied.
b. Electric motor windings shall be insulated from the structure and from each
other by not less than 100 MΩ measured with a DC voltage of either 100, 250
or 500 V DC applied. The voltage applied shall be about five times the worst
case flight operating voltage.

4.7.6.4 Dielectric
a. Electrical wires shall be designed to withstand a high voltage of 500 V AC
(50 Hz) applied between each other or between wires and the structure with-
out causing disruptive discharges.

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ECSS--E--30 Part 3A
25 April 2000

b. Electric motor windings shall be designed to withstand a high voltage of:

D 250 V AC (worst flight operating motor current up to 50 V)
D 500 V AC (worst flight operating motor current up to 100 V)
applied between each other or between windings and the structure without
causing disruptive discharge.

4.7.6.5 Grounding
a. Each mechanism shall be electrically bonded to the satellite structure or its
carrying equipment.
b. If electronic or electrical components are mounted internally to or externally
on the mechanism, an earth bonding strap shall be used.
c. The length-to-width ratio of the bonding strap shall be smaller than four (4).
d. The DC resistance, between the mechanism and the spacecraft ground plane
or carrying equipment ground plane in both polarities, shall be less than 10
mΩ if an earth bonding strap is used.
e. The DC resistance, between any point on a metallic external surface of the
mechanism and the bonding point reference of the mechanism, shall be less
than 5 mΩ if an earth bonding strap is used.
f. Where the grounding is to provide protection against electrostatic discharge
only and the mechanism contains no electronics, the DC resistance shall be
less than 1 Ω .

4.7.6.6 Electrical connectors

a. With the exception of the bonding strap for grounding, all electrical connec-
tions to the mechanism shall be made through electrical connectors of an ap-
proved type mounted on the mechanism where practicable.
b. Flying leads shall be avoided where practicable.
c. Connector types and configurations (e.g. number of pins) shall be selected to
preclude damage or inadvertent operation resulting from mis-mating.
d. Electrical connectors shall be redundant.

4.7.6.7 Over current protection

a. Mechanisms containing electrical parts and circuitry shall incorporate ad-
equate means of protection against excessive currents due to abnormal im-
pressed voltages or internal conditions (e.g. faults). The current protection
can be provided externally.
b. The mechanism shall provide adequate means to protect against the gener-
ation of over voltages.

4.7.6.8 Strain on wires

Moving cable harness shall have reproducible resistive torques or forces. The lay
up of cables shall not change during motion.

4.7.6.9 Magnetic cleanliness and ESD or EMC protection

Mechanisms shall conform to the spacecraft system requirements on magnetic
cleanliness, and conductivity of external surfaces for electrostatic discharge (ESD)
protection.

4.7.7 Control system

4.7.7.1
The following requirements are mandatory where applicable for mechanisms that
utilize a control system (open or closed loop) to achieve the specified performance.

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ECSS--E--30 Part 3A
25 April 2000 ECSS
4.7.7.2
The gain margin shall not be less than a factor of four (4) throughout the oper-
ational lifetime for linear or quasi-linear control systems. Non-linear control sys-
tems may use a lower gain margin that shall be agreed with the customer.

4.7.7.3
The phase margin shall not be less than 30 degrees throughout the operational
lifetime of the equipment and under worst case combination of parameters (drift,
temperature effects).

4.7.7.4
The bandwidth of the control system shall be designed to achieve the commanded
action within the required response time.

4.7.7.5
The damping ratio of the control system shall be greater than 0,05 (equivalent Q
value (amplification factor) of 10).

4.7.7.6
The control system shall not excite mechanism and where applicable shall not ex-
cite structural resonances of the spacecraft as agreed by with the customer.

4.7.7.7
The control system shall, as far as practical, be decoupled between different direc-
tions of movement.

4.7.7.8
The control system shall be compatible with the maximum angular rates and ac-
celerations of the spacecraft.

4.7.7.9
The control system shall respect the torque or force ratio requirements identified
in subclause 4.7.4.3.

4.7.7.10
Transfer functions of the controller shall not contain pure derivative terms (to pre-
vent excessive amplification of the noise). The ratio between the derivative time
constant and the time constant limiting the high frequency gain shall not exceed
20.

4.7.7.11
Harnesses and cables to moving parts shall be characterized in terms of hysteresis
and stiffness, and shall be taken into account in the control system design. The
characterization shall take place in representative configuration over the full
range of displacement and over the specified qualification temperature range and
shall also include lifetime, speed effects.

4.7.7.12
If the sampling frequency is not sufficiently high to prevent aliasing of the sampled
data, an anti-aliasing filter to reduce the bandwidth of the analogue signal (to be
sampled) shall be used.

4.7.7.13
The resolution of sensors used in the control system to feedback information shall
be at least a factor of five (5) better than the required resolution of the complete
system.

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ECSS--E--30 Part 3A
25 April 2000

4.8 Verification
4.8.1 General
a. The verification process shall be a mandatory step in the development of a
space mechanism and shall comprise verification of both analytical and test.
Accordingly, the mechanisms verification requirements are subdivided into
analytical and test verification requirements.
b. A verification matrix shall be established and agreed with the customer.

4.8.2 Verification by analysis

4.8.2.1 General
a. The mechanisms parts, components and assembly analytical verification
shall include, where applicable:
1. Worst operational and non-operational sizing cases identification thermal
analysis;
2. Structural analysis (stiffness, stress or strength, thermo-elastic effects,
fatigue, fracture control (if relevant) to demonstrate adequate sizing of the
components and the overall assembly for all sizing cases. For the struc-
tural analyses, the requirements of subclause 4.9 of ECSS--E--30A Part 2
Structural are applicable;
3. Pre-load and tolerance budgets considering manufacturing tolerances,
thermo-elastic effects, external or induced loads;
4. Functional performance analyses in all applicable environments under all
operational conditions (based on worst case identification) to derive sizing
loads, time, shocks, speed, dimensional stability and positional accuracy;
5. Hertzian contact analysis for separable contacts, sliding contacts or for
bearings;
6. Torque or force ratio;
7. Reliability (parts count reliability as a minimum), FMECA;
8. Gear analysis;
9. Shock generation and susceptibility;
10. Disturbance generation and susceptibility (micro-vibration);
11. Analysis of control systems (performance, stability margin);
12. Lubrication analysis;
13. Lifetime analysis;
14. Hygroscopic effects analysis;
15. Magnetic or electromagnetic analysis;
16. Radiation analysis;
17. Electrical analysis.
b. If any of the analysis above is considered not relevant, adequate justification
shall be provided.
c. The analyses shall cover the combinations of range of extreme conditions ap-
plicable to the flight system and which do not necessarily all occur during
qualification testing (e.g. worst case friction levels). Analysis shall always
cover the worst or extreme case conditions.

4.8.2.2 Worst cases identification

The worst case operational and non-operational sizing of a mechanism shall be
identified according to the environmental, load and functional performance char-
acteristics applicable to the particular spacecraft and mechanism concerned.

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25 April 2000 ECSS
4.8.2.3 Thermal analysis
Thermal analysis of a mechanism shall conform to the requirements identified in
ECSS--E--30 Part 1.

4.8.2.4 Structural analysis

Mechanisms structural analysis shall conform to the requirements identified in
ECSS--E--30 Part 2, however, for the derivation of margins of safety subclause
4.7.4.2 of this Standard shall apply.

4.8.2.5 Pre-load and tolerance budget analysis

Mechanisms pre-load and tolerance budget analysis shall consider the relevant
combination of the worst cases environmental, functional, residual loads, manu-
facturing tolerances and demonstrate adequacy of the moving joint play for incor-
poration of worst case conditions in the functional analysis.

4.8.2.6 Functional performance analysis

a. Functional model requirements
1. The analysis shall be based on an analytical or numerical model, which
shall represent the flight hardware mechanisms and its components, in-
cluding interface conditions and overall spacecraft characteristics, with
respect to mass, inertia, location of the centre of mass, structural stiffness,
actuation forces or torques, resistances for conditions specified in
subclause 4.7.4.3.
2. The model shall be sufficiently accurate to allow an adequate assessment
of the behaviour of the mechanism to be made.
3. The model shall allow a parametric study of all the mechanical variables
to be made and allow an update of input parameters during the design and
test phase.
b. Analysis requirements
1. The analysis shall demonstrate that the mechanism conforms to the mech-
anism requirement specification and the mechanical design and sizing re-
quirements (subclause 4.7.4) under worst case parameter combinations.
2. Failure cases shall be analysed and, where identified, contingency scen-
arios shall be validated by analysis.
3. An integrity check of the results shall be performed (e.g. energy or momen-
tum balance).
4. A sensitivity analysis (parameter variation) covering the uncertainty of
parameters shall be carried out.
5. The results of the analysis shall be verified by comparison with relevant
test results.

4.8.2.7 Hertzian contact and contact stress

a. An analysis shall be provided of the predicted Hertzian contact or yield or
bending stresses of moving surfaces in contact under worst case conditions.
The analysis shall demonstrate adequacy with the material allowables of the
chosen material couple, lubricant and other coating used.
b. An analysis shall be provided demonstrating appropriate sizing of ball bear-
ings in accordance with ISO 76 or equivalent norm.

4.8.2.8 Torque or force ratio analysis

Conformance of mechanisms to specified requirements on torque or force ratio
shall be demonstrated by analysis.

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ECSS--E--30 Part 3A
25 April 2000

4.8.2.9 Reliability analysis, FMECA

The reliability of a mechanism shall be determined (see ECSS--Q--30).

4.8.2.10 Gear analysis

An analytical verification of the adequacy of dimensioning and sizing of gears shall
be performed according to ISO 6336.

4.8.2.11 Shock generation and susceptibility

The conformance of the mechanism with the requirements identified in the mech-
anism requirement specification concerning shock generation and susceptibility
shall be verified by analysis. Adequate dimensioning and sizing shall be demon-
strated.

4.8.2.12 Disturbance generation (emission) and susceptibility

a. The conformance of the mechanism operation with the requirements identi-
fied in the mechanism requirement specification concerning vibration (micro-
vibration) shall be characterized by analysis. Adequate dimensioning and siz-
ing shall be demonstrated.
b. The moving parts of the mechanism shall be balanced to meet the specified
requirements on disturbances.

4.8.2.13 Analysis of control systems

a. A mathematical model or computer simulation describing the dynamic behav-
iour of the mechanism and its associated control system shall be established
to perform verification by analysis.
b. the functional performance of the control system shall be analysed for
1. stability,
2. bandwidth,
3. dynamic and static accuracy,
4. resolution, and
5. generation of and susceptibility to disturbances at the interfaces of the
mechanism,
and shall demonstrate conformance to the mechanism requirement specifica-
tion.
c. Non-linearities such as backlash, dead-zones, friction, saturation of drive
electronics shall be characterized and taken into account in the control system
analysis. Characterization shall take place over the full range of displace-
ments and over the full specified qualification temperature range. The worst
case combinations of parameters occurring during the operational lifetime of
the equipment shall be considered.
d. Non-linearities, if any, shall be analysed
e. The robustness of the control against variations in the environment and over
the operational lifetime shall be demonstrated by analysis.

4.8.2.14 Lubrication analysis

a. An assessment of the choice of lubrication system and its adequate dimension-
ing for the proposed application and lifetime shall be provided.
b. The adequacy of the quantity of lubricant shall be assessed by analysis.

4.8.2.15 Lifetime analysis

a. Limited-life components shall be identified.
b. Conformance of limited-life components to the lifetime requirements shall be
demonstrated by analysis, using as a minimum the lifetime factors specified

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ECSS--E--30 Part 3A
25 April 2000 ECSS
in subclause 4.8.3.3.9 in addition to the fatigue factor specified in subclause
4.7.4.2

4.8.2.16 Magnetic and electromagnetic

The sizing of magnetic or electromagnetic components shall be substantiated by
analysis.

4.8.2.17 Radiation analysis

Components susceptible to radiation shall be analysed with respect to the accumu-
lated radiation dose and to demonstrate the (lifetime) performance requirements
are met.

4.8.2.18 Electrical analysis

Electrical parts stress analysis shall be performed to demonstrate the electrical
parts conform to the derating requirements (see ECSS--Q--30--06).

4.8.3 Verification by test

4.8.3.1 General
a. Verification by test shall be a mandatory step in the demonstration that the
mechanisms fulfil the requirements for use as space hardware. The aim of
testing can be either characterization, development, qualification or accept-
ance.
b. The mechanism design shall be compatible with operation on ground in ambi-
ent and thermal vacuum conditions. The permissible operations and the con-
straints for the operations in ambient shall be defined.
c. The mechanisms verification test programme shall ensure that the hardware
conforms to the design, construction and performance requirements.
d. The test verification shall demonstrate that the mechanism conforms to the
torque (or force) ratio requirements specified in subclause 4.7.4.3.
e. Tests shall be performed to check mechanism performance in both launch and
operational configurations.
f. Mechanisms shall be considered as structures as far as strength and stiffness
tests are concerned, and their design shall be verified against the same re-
quirements as other structural components as defined in subclause 4.7
ECSS--E--30 Part 2A.
g. When relevant, fracture control shall be verified according to subclause 4.7.29
of ECSS--E--30 Part 2A.
h. Hysteresis, backlash and other non-linearities shall be measured in order to
characterize the dynamic behaviour of the mechanism.

4.8.3.2 Characterization or development testing

4.8.3.2.1 Model requirements

Developments tests shall be carried out on bread-board models of varying levels
of sophistication to test specific aspects or assumptions of a design on which the
outcome of the design depends.

4.8.3.2.2 Test
Unless the heritage is clearly demonstrated by test data from previous space ap-
plications the following verification tests on development model mechanisms shall
be performed at an early stage of the project:
1. functional performance tests in ground ambient environment;
2. vibration tests;
3. tribological lifetime test on life critical components.

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4.8.3.3 Qualification testing

4.8.3.3.1 General
a. All mechanisms shall be qualified by test for the application concerned.
b. The qualification tests shall be performed in a representative sequence and
in a representative environment, agreed with the customer.

4.8.3.3.2 Structural qualification testing

The mechanisms structure shall be qualified according to the requirements for
structural qualification identified in ECSS--E--30 Part 2.

4.8.3.3.3 Thermal vacuum qualification testing

a. The thermal qualification of the mechanism shall be performed according to
the requirements identified in ECSS--E--30 Part 1.
b. Adequate operation in representative environment of the mechanism under
worst case temperature gradients shall be demonstrated by test at a level
agreed with the customer.

4.8.3.3.4 Functional qualification testing

a. When relevant, micro-setting and thermal stabilization shall be performed
prior to functional performance testing.
b. The conformance of the mechanism to the performance requirements
following exposure to environmental conditions (loads, thermal) at qualifica-
tion level and mechanism qualification duration shall be demonstrated by
test.

4.8.3.3.5 Energy or shock

a. Adequacy of mechanisms to withstand release and end shocks caused by the
motion of the mechanism shall be demonstrated by test.
b. Latching shock emissions shall be measured.

4.8.3.3.6 Solid lubricated ball bearing verification

a. The adequacy of solid lubricated ball bearing material, design and perform-
ance (including the cage) shall be demonstrated by testing.
b. The appropriate environment for the lubricant life test demonstration shall
be agreed with the customer.

4.8.3.3.7 Liquid lubricated ball bearing verification

a. The adequacy of ball bearing cage material, design, impregnation procedures
for cages and reservoirs, and performance shall be demonstrated by testing.
b. The adequacy of the lubricant quantity shall be demonstrated by confidence
tests.
c. The compatibility of the liquid lubricant with the mechanism materials and
if applicable other lubricants used within the mechanism, shall be demon-
strated.

4.8.3.3.8 Lifetime qualification

The adequacy of the mechanism design, lubricant lifetime and performance shall
be demonstrated by test on a flight representative life test model in the appropri-
ate environment after exposure to flight representative environmental tests
(worst case loads and accumulated vibration durations). Exposure of lifetime
model to vibrations prior to life test shall include:
1. One time exposure to qualification load level and duration of vibration;
2. Exposure to accumulated durations of acceptance tests at acceptance load
level and accumulated durations corresponding to the number of vibra-
tions tests to be seen by the flight hardware.

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ECSS--E--30 Part 3A
25 April 2000 ECSS
The environment in which the lifetime of a lubricant is to be demonstrated shall
be agreed with the customer.

4.8.3.3.9 Life test model requirements

The model and lifetime testing shall be valid with respect to the representation of
the following lifetime influencing parameters:
1. Thermal conditions, loading conditions, contact stress, motion profile and
speed during testing appropriately representative of the operational
conditions;
2. Lubrication regime representative of worst cases anticipated operational
conditions, and for durations factored as a minimum according to
subclause 4.8.3.3.6. Where relevant, extended life durations to be agreed
by the customer shall be implemented to satisfy the simulation of realistic
conditions during accelerated tests.

4.8.3.3.10 Life test profile

The profile and sequence of a life test shall be justified.

4.8.3.3.11 Life test duration

The lifetime qualification shall be demonstrated using the factored sum of the pre-
dicted nominal ground test cycles and the in-orbit operation cycles. For the test
demonstration, the number of predicted cycles shall be multiplied by the following
factors in Table 3:

Table 3: Life test duration factors

Type Number of predicted cycles Factor
Ground testing Number of on-ground test cycles 4
(minimum 10)
In-orbit 1 to 10 cycles 10
11 to 1000 cycles 4
1001 to 100000 cycles 2
> 100000 cycles 1,25

The cycle definition is subject to agreement with the customer and shall consider
as a minimum, the number of motions over the same location, motion amplitude
and number of reversals. In order to determine the lifetime to be demonstrated by
test, an accumulation of cycles multiplied by their individual factors shall be used.
EXAMPLE Predicted ground test cycles: 15 15 × 4 = 60
Predicted in-orbit cycles: 100
10 cycles (first 10 cycles) 10 × 10 = 100
90 cycles (remaining 90 cycles) 90 × 4 = 360
Total life test number = 520

Any element in a chain of actuation (e.g. motor, bearing, gear) shall conform with
the maximum number of cycles applicable to any of the remaining elements in the
chain.

4.8.3.3.12 Lifetime testing success criteria

Lifetime testing of critical mechanisms components or assemblies shall be con-
sidered successful when the following criteria are demonstrated at the end of the
test:
a. No metal to metal contact identified in the interface of solid lubricated contact
surfaces;
b. Surface properties of contact surfaces unmodified in its essential performance
properties;

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c. No detrimental chemical deterioration of liquid lubricants is found;

d. The amount and size of wear products conforms to contamination require-
ments and overall mechanism performance requirements;
e. Worst case variation or degradation peak torque or force overall throughout
life testing is compatible with the required torque (or force) ratio require-
ments (subclause 4.7.4.3) and deterioration torque or force performance is
less than or equal 50%. Other degradation factors shall be agreed, case by
case, with the customer.

4.8.3.3.13 Accelarated lifetime testing

If accelerated lifetime testing is employed to verify the lifetime performance of the
mechanism, the model used for accelerated lifetime testing shall be representative
of the worst case environmental conditions with respect to degradation.

4.8.3.3.14 Post-test inspection

After completion of the life test, the mechanisms shall be disassembled into its tri-
bological components. The status of the components shall be verified with respect
to the life test success criteria identified in subclause 4.8.3.3.12.

4.8.3.3.15 EMC or ESD qualification testing

a. EMC tests
The EMC performance (susceptibility and emissivity) of mechanisms shall be
verified by testing when components are used on the mechanism which are
sensitive to EMC or when spacecraft specific EMC requirements are imposed
on the mechanism.
b. ESD tests
Testing shall be performed on a complete mechanism including all electrical
components and thermal hardware.

4.8.3.3.16 Electrical qualification testing

a. Electrical wire -- insulation test
Electrical wires shall be demonstrated to provide insulation from the struc-
ture and from each other by not less than 10 MΩ with a DC voltage of 500 V
applied for a duration of 2 minutes or until a steady state resistance value is
measured.
b. Electric motors -- insulation test
Motor windings shall be demonstrated to provide insulation from the struc-
ture and from each other by not less than 100 MΩ with a DC voltage of at least
five times the worst case flight operating voltage applied for a duration of 2
minutes or until a steady state resistance value is measured.
c. Electrical wires -- dielectric test
Electrical wires shall be demonstrated to withstand a voltage of 500 V AC
(50 Hz) applied between each other or between wires and the structure for a
duration of 1 minute without causing disruptive discharges (flash-over,
spark-over, breakdown).
d. Electric motors -- dielectric test
Motor windings shall be demonstrated to withstand a voltage of:
S 250 V AC (worst flight operating motor voltage up to 50 V);
S 500 V AC (worst flight operating motor voltage up to 100 V).
(50 Hz) applied between each other or between windings and the structure for
a duration of 1 minute without causing disruptive discharges (flash-over,
spark-over, breakdown).

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4.8.3.3.17 Control system qualification testing
a. The mathematical model used to analyse the dynamic behaviour of the control
system shall be correlated with measurements performed on representative
hardware.
b. The verification of control system performance by test shall preferably be
demonstrated using independent measurement devices of sufficient band-
width and resolution. Use of the control system transducer as a reference dur-
ing the tests shall only be admissible if the transducer has been calibrated
previously in a representative environment.

4.8.3.4 Acceptance testing

4.8.3.4.1 Mechanical micro-setting and thermal stabilization

If relevant, mechanical micro-setting and thermal stabilization shall be performed
prior to acceptance testing.

4.8.3.4.2 Acceptance tests

New builds of qualified designs shall be acceptance tested to verify that the actual
manufactured hardware is free from manufacturing defects. The acceptance level
testing shall be carried out at levels which are higher than expected in flight but
less than the qualification levels. After acceptance testing, refurbishment should
not be required as the test levels experienced should be at a level which is not detri-
mental to the health of the hardware.

4.8.3.4.3 Dielectric test

Electrical wires shall be demonstrated to withstand a voltage of:
D 250 V AC (worst flight operating motor voltage up to 50 V);
D 500 V AC (worst flight operating motor voltage up to 100 V).
(50 Hz) applied between each other or between windings and the structure for a
duration of 10 seconds without causing disruptive discharges (flash-over, spark-
over, breakdown).

4.9 Production and manufacturing requirements

4.9.1 Manufacturing process
a. In order to achieve the required levels of safety and reliability, proven and re-
peatable procedures shall be used to manufacture mechanisms hardware.
b. All processes used in the manufacture of space mechanisms hardware require
customer approval and shall be part of the overall product assurance system.

4.9.2 Manufacturing drawings

Manufacturing drawings shall conform to ISO 128.

4.9.3 Marking and labelling

The requirements of subclauses 4.2.2.1, 4.2.2.2 and 4.2.2.4 are applicable.

4.9.4 Assembly
The assembly of mechanisms shall be performed in an appropriate clean environ-
ment.

4.10 In-service
a. The design of a mechanism shall not impose operational constraints on the
spacecraft.
b. If the above requirement (4.10 a.) cannot be met, all the operational con-
straints shall be identified, agreed with the customer and documented in the
mechanism operational manual.

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c. When the in-service operation of a mechanism results in limited oscillatory

motion of a ball (rolling element) bearing, the bearing shall be exercised over
a complete revolution where possible at regular intervals.
d. An operations (user) manual for the mechanism shall be established, by the
supplier of the mechanism.

4.11 Deliverables
a. To demonstrate the viability of the design of a space mechanism, the following
technical subjects (Table 4) shall, as a minimum, be included in documents to
be provided by the supplier.
b. Where the subject is not specified as part of the content of an existing docu-
ment requirement definition (DRD), the customer and supplier shall agree
the most suitable document or format in which to report the subject.

Table 4: Document requirements for mechanisms

Document title Controlling DRD reference

AIT plan ECSS--E--10--02
Assembly fault analysis ECSS--Q--40--12
Assembly safety analysis ECSS--Q--40
Calibration data --
CFL (critical functions list) --
Critical items list ECSS--Q--20--04
Configuration item data list ECSS--M--40
Declared components list ECSS--Q--60
Design description ECSS--E--10
Design verification ECSS--E--10--02
Design load summary --
Design, development and --
verification plan
Declared materials list ECSS--Q--70
Declared parts list ECSS--Q--70
FEM description and condensed
FEM model -- in a format to be
agreed
FMECA ECSS--Q--30
Fracture control plan and where --
necessary analysis
Hazard analysis ECSS--Q--40
Interface control documentation ECSS--E--10
Manufacturing plan ECSS--E--10
Manufacturing file or drawings --
Mechanism end item data package ECSS--Q--20
Mechanisms user manual ECSS--E--10
Mechanisms specification ECSS--E--10
Parts procurement plan --
Qualification status list --

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Table 4: Document requirements for mechanisms
(continued)
Document title Controlling DRD reference
Resource budget, including pointing --
alignment budget
Structural analysis --
Test procedures ECSS--E--10--02
Test prediction analysis --
Test results and correlation --
analysis

4.12 Use of this Standard to define project requirements

The mechanism requirements in this document may be tailored to suit specific pro-
grams subject to the tailoring implementation described in annex A.

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Annex A (normative)

Tailoring

A.1 General
This section of the standard for space mechanisms defines the rules, principles,
methods, approach and process to be followed in applying tailoring to the require-
ments for the use in specific space projects.

A.2 Applicability
Tailoring is the process by which the relevant requirements for a particular ap-
plication are selected from the “complete” set given. The higher level customer or
contractor is primarily responsible for tailoring the requirements and passing on
a specific subset to the contractor or supplier.

A.3 Objectives
The requirements of the mechanisms engineering standard are generically appli-
cable considering the full range of space mechanism designs for all projects. How-
ever, some of these requirements may not be applicable to every type of mechanism
or mission. As a result, the total number of requirements identified in this Stan-
dard may be reduced for particular projects.
The objective of this section is to provide guidelines to the customer to consciously
select the applicable requirements for the particular mission application. As a re-
sult of the tailoring process, the requirements shall be classified as mandatory re-
quirements and other requirements of a lesser importance. The latter can enable
the use of more cost efficient company proprietary approaches and processes for
the benefit of achieving substantial cost savings within the project. The relaxation
of the requirements, however, can lead to a related risk increase with respect to
the mechanisms function, the overall spacecraft development costs and total
mission success.

A.4 How to use the tailoring table

The columns are used to indicate if a requirement is not suitable for tailoring (i.e.
mandatory), type applicable, customer related or specified and finally whether
waiving the requirements can result in a cost saving but with some associated in-
crease in risk of experiencing anomalies in flight or during development. Anoma-
lies in flight can only be worked around while anomalies discovered in the develop-
ment of a mechanism have inherent rectification costs.

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In each column against each requirement a ‘X’ has been entered depending on the
requirement category. It is reasonable for there to be more than one ‘X’ against an
individual requirement. This most commonly occurs where mandatory require-
ments are not applicable to all types of mechanism. For example, the mandatory
electric motor requirements are obviously not applicable if the mechanism does
not include an electric motor.

A.5 No tailoring allowed (mandatory)

Where an ‘X’ has been placed against a requirement in this column, the require-
ment shall not be subject to tailoring and the requirement shall be considered
mandatory. Most of the requirements are listed as mandatory . However, some are
related to specific types of mechanism or design, development or qualification
phases. Where this is the case, an ‘X’ has also been added to the type applicable
column.

A.6 Type applicable

The “Type applicable” column has been used to highlight if the requirement is ap-
plicable only to a specific type of mechanism. In addition this column has also been
used to indicate if the requirement is only applicable during certain phases of the
mechanisms development. This identifies for the user (in this case customer or
supplier) which mandatory requirements can be tailored out.

A.7 Customer related

Many of the requirements are subject to an agreement between the customer and
the supplier which is explicitly stated in the requirement. In some cases, customer
involvement is implicit. In both cases, this has been indicated by using the “Cus-
tomer--related” column. This shall enable the person responsible to identify the re-
quirements in which the level of detail shall be agreed between the customer and
supplier.

A.8 Cost reduction and risk increase:

Not all of requirements are mandatory and can with the agreement of the cus-
tomer be waived. In which case, the supplier and customer should ensure alterna-
tive in-house requirements are in place which are known to be satisfactory. The
customer shall be made aware of the risk or cost benefit that waiving the require-
ment entails.

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A.9 Tailoring table

No tailoring Cost reduction

allowed Type Customer and risk
Subclause (mandatory) applicable related increase
4.2 General mechanisms
4.2.2 Product assurance
4.2.2.1 X
4.2.2.2 X
4.2.2.3 X
4.2.2.4 X
4.2.2.5 X X
4.2.2.6.a X X
4.2.2.6.b X
4.2.3 Reliability and redundancy
Reliability
4.2.3.2.a X X X
4.2.3.2.b X X
4.2.3.2.c X
4.2.3.2.d X
Structural reliability
4.2.3.3.a X
4.2.3.3.b X
Redundancy
4.2.3.4.a X
4.2.3.4.b X X
4.2.3.4.c X X
4.2.3.4.d X X
4.2.3.4.e X X
4.2.3.4.f X
Flushing or purging
4.2.4.a X X
4.2.4.b X
4.2.4.c X
4.3 Mission and environments
Mission
4.3.2.b X
4.3.2.c X
4.3.2.d X
4.3.2.e X
Environment
4.3.3 X
4.4 Functional requirements

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No tailoring Cost reduction
allowed Type Customer and risk
Subclause (mandatory) applicable related increase
System performance
4.4.2 X
Mechanism function
4.4.3.a X
4.4.3.b X
4.4.3.c X
4.5 Constraints
Physical constraints
4.5.2.1 X X
4.5.2.2 X X
Materials
4.5.3.1 X X
4.5.3.2 X X
4.5.3.3 X X
4.5.3.4 X
4.5.3.5 X
4.5.3.6 X
4.5.3.7 X
4.5.3.8 X
4.5.3.9 X X
4.5.3.10 X X
4.5.3.11 X X
Operational constraints
4.5.4.a X
4.5.4.b X X
4.6 Interfaces
4.6.2 X
4.6.3 X
4.6.4 X
4.6.5 X
4.6.6 X
4.6.7 X X
4.6.8 X
4.7 Design requirements (continued)
Tribology (continued)
Tribology requirements (continued)
4.7.2.1.b X X
4.7.2.1.c X X
4.7.2.1.d X X
4.7.2.1.e X X

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No tailoring Cost reduction

allowed Type Customer and risk
Subclause (mandatory) applicable related increase
4.7.2.1.f X
4.7.2.1.g X
Dry lubrication
4.7.2.2.a X X
4.7.2.2.b X X
4.7.2.2.c X X
4.7.2.2.d X X
Fluid lubrication
4.7.2.3.a X X
4.7.2.3.b X X
4.7.2.3.c X X
4.7.2.3.d X X
4.7.2.3.e X X
4.7.2.3.f X X
4.7.2.4 Tribological components requirements
4.7.2.4.1.a X
4.7.2.4.1.b X X X
4.7.2.4.1.c X X
4.7.2.4.2.a X
4.7.2.4.2.b X X
4.7.2.4.2.c X X
4.7.2.4.2.d X X
4.7.2.4.2.e X X
4.7.2.4.2.f X X
4.7.2.4.3 X X
4.7.3 Thermal control requirements
Thermal engineering
4.7.3.2.a X X
4.7.3.2.b X X
4.7.3.2.c X X
Mechanisms thermal design and sizing requirements
4.7.3.3.a X
4.7.3.3.b X
4.7.3.3.c X
4.7.3.3.d X
Multi-layer insulation requirements
4.7.3.4.a X X
4.7.3.4.b X X X
4.7.3.4.c X X
--

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No tailoring Cost reduction
allowed Type Customer and risk
Subclause (mandatory) applicable related increase
4.7.4 Mechanical design and sizing
General
4.7.4.1 X
Structural dimensioning
4.7.4.2.1 X
4.7.4.2.2 X
4.7.4.2.3 X
4.7.4.2.4 X
4.7.4.2.5 X
4.7.4.2.6 X
4.7.4.2.7 X
4.7.4.2.8 X
4.7.4.2.8.a X
4.7.4.2.8.b X X X
4.7.4.2.8.c X X
Functional dimensioning (motorization)
4.7.4.3.1 X
4.7.4.3.2 X
4.7.4.3.3 X
4.7.4.3.4.a X
4.7.4.3.4.b X
4.7.4.3.4.c X
4.7.4.3.4.d X
4.7.4.3.4.e X
4.7.4.3.4.f X X
4.7.4.3.4.g X X
4.7.4.3.4.h X
4.7.4.3.5.a X X
4.7.4.3.5.b X X
4.7.4.3.5.c X X
4.7.4.3.5.d X X
4.7.4.3.5.e X X
4.7.4.3.5.f X
4.7.4.3.5.g X X
4.7.4.3.6.a X X
4.7.4.3.6.b X X
4.7.4.3.6.c X X
4.7.4.3.6.d X X
Other requirements
4.7.4.4.1.a X X

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No tailoring Cost reduction

allowed Type Customer and risk
Subclause (mandatory) applicable related increase
4.7.4.4.1.b X X
4.7.4.4.1.c X X X
4.7.4.4.2 X
4.7.4.4.3.a X X
4.7.4.4.3.b X X
4.7.4.4.3.c X X
4.7.4.4.3.d X X
4.7.4.4.3.e X X
4.7.4.4.3.f X X
4.7.4.4.3.g X X
4.7.4.4.3.h X X
4.7.4.4.4.a X X
4.7.4.4.4.b X X
4.7.4.4.4.c X X
4.7.4.4.4.d X X
4.7.4.4.4.e X X
4.7.4.4.5.a X X
4.7.4.4.5.b X X
4.7.4.4.5.c X X
4.7.4.4.5.d X X
4.7.4.4.5.e X X
4.7.4.4.6 X X
4.7.4.4.7 X X
4.7.4.4.8 X
4.7.4.4.10.a X
4.7.4.4.10.b X
4.7.4.4.10.c X
4.7.4.4.10.e X
4.7.4.4.11.a X X
4.7.4.4.11.b X X
4.7.4.4.11.c X X
4.7.4.4.12.a X X
4.7.4.4.12.b X X
4.7.4.4.12.c X X
4.7.4.4.12.d X X
4.7.5 Pyrotechnics
4.7.5 X X
4.7.6 Electrical and electronic requirements
General
4.7.6.1 X X

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No tailoring Cost reduction
allowed Type Customer and risk
Subclause (mandatory) applicable related increase
Electrical design
4.7.6.2.a X X
4.7.6.2.b X X
4.7.6.2.c X X
Insulation
4.7.6.3.a X
4.7.6.3.b X X
Dielectric
4.7.6.4.a X X
4.7.6.4.b X X
Grounding
4.7.6.5.a X
4.7.6.5.b X X
4.7.6.5.c X X
4.7.6.5.d X X
4.7.6.5.e X X
4.7.6.5.f X
Electrical connectors
4.7.6.6.a X X
4.7.6.6.b X X
4.7.6.6.c X X X
4.7.6.6.d X X
Over current protection
4.7.6.7.a X X X X
4.7.6.7.b X X X
Strain on wire
4.7.6.8 X X
Magnetic cleanliness and ESD or EMC protection
4.7.6.9 X X
4.7.7 Control system
4.7.7.2 X X X
4.7.7.3 X X X
4.7.7.4 X X
4.7.7.5 X X
4.7.7.6 X X X
4.7.7.7 X X
4.7.7.8 X X
4.7.7.9 X X
4.7.7.10 X X
4.7.7.11 X X

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No tailoring Cost reduction

allowed Type Customer and risk
Subclause (mandatory) applicable related increase
4.7.7.12 X X
4.7.7.13 X X
4.8 Verification
General
4.8.1 X
Verification by analysis
4.8.2.1.a X
4.8.2.1.b X
4.8.2.1.c X
Worst cases identification
4.8.2.2 X
Thermal analysis
4.8.2.3 X
Structural analysis
4.8.2.4 X
Pre-load and tolerance budget analysis
4.8.2.5 X X
Functional performance analysis
4.8.2.6.a.1 X X X X
4.8.2.6.a.2 X X X X
4.8.2.6.a.3 X X X X
4.8.2.6.b.1 X
4.8.2.6.b.2 X X X
4.8.2.6.b.3 X X X
4.8.2.6.b.4 X X X
4.8.2.6.b.5 X X X
Hertzian contact analysis
4.8.2.7.a X X
4.8.2.7.b X X
Torque or force ratio analysis
4.8.2.8 X
Reliability analysis FMECA
4.8.2.9 X X
Gear analysis
4.8.2.10 X X
Shock generation and susceptibility
4.8.2.11 X X X
Disturbance generation (emission) and susceptibility
4.8.2.12.a X X
4.8.2.12.b X

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No tailoring Cost reduction
allowed Type Customer and risk
Subclause (mandatory) applicable related increase
Analysis of control systems
4.8.2.13.a X X
4.8.2.13.b X X
4.8.2.13.c X X
4.8.2.13.d X X
4.8.2.13.e X X
Lubrication analysis
4.8.2.14.a X
4.8.2.14.b X X X
Life time analysis
4.8.2.15.a X
4.8.2.15.b X X
Magnetic and electromagnetic
4.8.2.16 X X
Radiation analysis
4.8.2.17 X X
Electrical analysis
4.8.2.18 X X
4.8.3 Verification by test
General
4.8.3.1.b X
4.8.3.1.c X
4.8.3.1.d X
4.8.3.1.e X
4.8.3.1.f X
4.8.3.1.g X X X
4.8.3.1.h X X X
Characterization or development testing
4.8.3.2.1 X X X X
4.8.3.2.2 X X X
Qualification testing
General
4.8.3.3.1.a X
4.8.3.3.1.b X X
Structural qualification testing
4.8.3.3.2 X
Thermal vacuum qualification testing
4.8.3.3.3.a X
4.8.3.3.3.b X X
Functional qualification testing

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No tailoring Cost reduction

allowed Type Customer and risk
Subclause (mandatory) applicable related increase
4.8.3.3.4.a X X
4.8.3.3.4.b X
Energy or shock
4.8.3.3.5.a X
4.8.3.3.5.b X X X
Solid lubricated ball bearing verification
4.8.3.3.6.a X X X
4.8.3.3.6.b X X
Liquid lubricated ball bearing verification
4.8.3.3.7.a X X
4.8.3.3.7.b X X
4.8.3.3.7.c X X
Lifetime qualification
4.8.3.3.8 X X
Life test model
4.8.3.3.9 X X
4.8.3.3.10 X
4.8.3.3.11 X
4.8.3.3.12 X X
4.8.3.3.13 X X
4.8.3.3.14 X X
EMC or ESD qualification testing
4.8.3.3.15.a X X
4.8.3.3.15.b X X
Electrical qualification testing
4.8.3.3.16.a X X
4.8.3.3.16.b X X
4.8.3.3.16.c X X
4.8.3.3.16.d X X
Control system qualification testing
4.8.3.3.17.a X X
4.8.3.3.17.b X X
Acceptance testing
4.8.3.4.1 X X
4.8.3.4.2 X
4.8.3.4.3 X X
4.9 Production and manufacturing requirements
4.9.1.a X
4.9.1.b
4.9.1.c X X X

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No tailoring Cost reduction
allowed Type Customer and risk
Subclause (mandatory) applicable related increase
4.9.2 X X X
4.9.3 X
4.9.4 X
4.10 In service
4.10.a X X
4.10.b X X X
4.10.c X X X
4.10.d X

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Annex B (informative)

Summary of normative documents contents

B.1 ISO 6336 Calculation of the load capacity of spur and helical
gears
ISO 6336 provide the principles for a coherent system of procedures for the calcula-
tion of the cylindrical involute gears with external and internal teeth. It addresses
the gear principles and general influence factors and demonstrates how to calcu-
late the surface durability and tooth strength and hence leads to a correctly sized
design.

B.2 ISO 677, 678 Calculation of the load capacity of straight cut
bevel gears
The information in these standards aids the engineer with the design of straight
cut bevel gears and allows the correct information to be given to the manufacturer
in order to obtain the required gear.

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Annex C (informative)

Model definition

C.1 Bread board model

Bread board models are used to demonstrate key aspects of a design are feasible
and understood. They should be manufactured during the early stages of a project
such that maximum benefit can be derived. They need not be flight representative
in respect of the materials used but are functionally representative of the key as-
pects to be proven.

C.2 Engineering (development) model

The engineering model is representative of the intended flight design in all func-
tional aspects and materials. Some relaxation in the level of redundancy implem-
ented or the quality of the electronic components is permissible. Tests on this
model give confidence that the qualification programme using the QM is ready to
proceed.

C.3 Qualification models (QM)

The intention of the qualification model is that it should be identical to the pro-
posed flight design and be subjected to testing at levels in excess of those that the
flight unit will experience. In this manner any incipient flaws in the design or any
aspects of the design for which there is insufficient margin should be identified.
A unit which has been subjected to qualification testing is not fit for flight.

C.4 Life test model

The purpose of the life test model is to prove by testing that the mechanism can
perform the required quantity of cycles under extreme conditions, taking into ac-
count the applicable margins. For development schedule or development risk re-
duction, this model can be a specific model.

C.5 Flight models

The flight model is the realized design delivered for flight. The flight model is sub-
jected to acceptance testing to demonstrate the actual build performs as required
and is free from manufacturing defects.

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C.6 Protoflight model
As yet there is no accepted or satisfactory route by which a mechanism can be
tested to reach a qualified status and be accepted for flight. The duration or levels
of vibration seen during qualification by a purpose built qualification model are
required to exceed the duration or levels that the flight unit will accumulate dur-
ing acceptance testing and flight. Clearly this is not possible with a protoflight
unit. Each protoflight approach shall be justified on a case by case basis.

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Bibliography

Informative references to the extent specified in the text are cited at appropriate
places and listed hereafter. They contain non-mandatory mechanisms design
practices and validation information, however, which is strongly recommended for
use in order to achieve anomaly-free operation of space mechanisms. Summary in-
formation on the listed documents is attached as Annex C.

ECSS--Q--20--07 1) Space product assurance — Quality assurance of test faci-

lities
ECSS--Q--30--06 1) Space product assurance — Derating
ECSS--Q--70--04 Space product assurance — Thermal cycling test for the
screening of space materials and processes
ECSS--Q--70--36 Space product assurance — Material selection for control-
ling stress-corrosion cracking
ECSS--Q--70--37 Space product assurance — Determination of susceptibility
of metals to stress-corrosion cracking
ECSS--Q--70--46 1) Space product assurance — General requirements for
threaded fasteners
ECSS--Q--70--71 1) Space product assurance — Data for the selection of space
materials
ECSS--E--30--01 Space engineering — Fracture control
ECSS--E--30--09 1) Space engineering — Space tribology handbook
MIL--HDBK--5F Military handbook, metallic materials and elements for
aerospace vehicle structures
MIL--A--83577B(USAF) Assemblies, moving mechanical, for space and launch ve-
hicles, general specification for.
MSFC--STD--1299 Design criteria for flight experiment latches

1) To be published.

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ECSS Document Improvement Proposal

1. Document I.D. 2. Document date 3. Document title
ECSS--E--30 Part 3A 25 April 2000 Mechanical — Part 3:
Mechanisms
4. Recommended improvement (identify clauses, subclauses and include modified text or
graphic, attach pages as necessary)

5. Reason for recommendation

6. Originator of recommendation
Name: Organization:
Address: Phone: 7. Date of submission:
Fax:
e-mail:

8. Send to ECSS Secretariat

Name: Address: Phone: +31--71--565--3952
W. Kriedte ESTEC, P.O. Box 299 Fax: +31--71--565--6839
ESA--TOS/QR 2200 AG Noordwijk e-mail: [email protected]
The Netherlands
Note: The originator of the submission should complete items 4, 5, 6 and 7.
This form is available as a Word and Wordperfect--Template on internet under
http://www.estec.esa.nl/ecss/improve/

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