Lessons learned from the dynamic identification/qualification tests on the ESC-A upper stage model

Abstract The dynamic qualification of the new cryogenic upper stage ESC-A of the ARIANE 5 is supported by several tests in order to verify the assumptions and the modeling approach made at the beginning of the development. The stage contains a large amount of equipment such as propellant lines, acceleration rockets, batteries, fluid control equipment etc. For the low frequency domain the verification of the equipment responses in the integrated state was done by a sine vibration test, excited to levels representing the predicted flight loads including a qualification factor. Acoustic tests with the upper stage were performed to verify the random vibration responses in the frequency range up to 2000 Hz. To verify the shock response level induced by stage separation (pyro-shock) a stage separation test was performed. The paper concentrates on the experience made with the modal identification and sine vibration test of the stage. For the sine vibration test an electro-dynamic multi-shaker table was used. It was able to produce the required input precisely up to 100 ÷ 150 Hz as specified, not an easy task for a test set-up of 20 tons weight. The paper presents the approach of how the dynamic qualification was reached successfully and highlights the experience accomplished.