Session
Technical Session XI: Better, Cheaper, Faster
Abstract
Constructing a constellation of thirty-six ORBCOMM LEO digital communications satellites mandates an approach to manufacturing and testing significantly different from other small satellite programs. Schedule constraints forced overlap of development, qualification, and early production phases, and a production rate of four spacecraft per month. To avoid problems that could affect a large number of spacecraft, the program included a carefully designed flow of functional and environmental testing on development units and spacecraft, in addition to classical unit and system qualification programs. Although ORBCOMM's complex communications payload was particularly vulnerable to system problems, few emerged because of the thorough unit development effort. In addition, the first four spacecraft served as pre-production models to solidify processes, facilities, GSE, test tools, and documentation to a level far beyond that required for conventional programs. The production process moves the spacecraft through a number of specialty integration and test areas, while the functional test teams retain overall responsibility for individual spacecraft. Early difficulties with unit deliveries and test processes have been overcome, and production is proceeding smoothly. Twelve spacecraft are currently in systems integration and test, with eighteen planned for delivery to the launch site this year.
Manufacturing the ORBCOMM Constellation Satellites
Constructing a constellation of thirty-six ORBCOMM LEO digital communications satellites mandates an approach to manufacturing and testing significantly different from other small satellite programs. Schedule constraints forced overlap of development, qualification, and early production phases, and a production rate of four spacecraft per month. To avoid problems that could affect a large number of spacecraft, the program included a carefully designed flow of functional and environmental testing on development units and spacecraft, in addition to classical unit and system qualification programs. Although ORBCOMM's complex communications payload was particularly vulnerable to system problems, few emerged because of the thorough unit development effort. In addition, the first four spacecraft served as pre-production models to solidify processes, facilities, GSE, test tools, and documentation to a level far beyond that required for conventional programs. The production process moves the spacecraft through a number of specialty integration and test areas, while the functional test teams retain overall responsibility for individual spacecraft. Early difficulties with unit deliveries and test processes have been overcome, and production is proceeding smoothly. Twelve spacecraft are currently in systems integration and test, with eighteen planned for delivery to the launch site this year.
