The following is an insight into the status of the Cupola Programme at regular intervals since August 1998.
Within an ‘Agreement in Principle’ with NASA, ESA initially agree to produce two Cupolas for the ISS in exchange for the up/down transportation of five European external payloads. Technical specifications are agreed with NASA and the Invitation to tender is released to Industry.
Negotiations between ESA and NASA are successfully concluded in October 1998. Under the subsequent agreement, which is amended the following year, ESA will carry out some enhancements to the European Columbus Laboratory in addition to providing the two Cupolas. In return NASA agree to transport five external European payloads to the ISS as well as providing an additional launch mass allocation of 70kg on the Columbus Laboratory, which is also due to be launched by NASA.
Following the approval of the contract proposal by ESA’s Industrial Policy Committee, Alenia Spazio is chosen as the prime contractor for develop-ment of the Cupola. A ‘Kick-off’ meeting is held in Turin on 9, 10 and 11 December 1998 with representatives of ESA and representatives of Alenia Spazio.
Following successful completion of negotiations, the 20 million euro Cupola contract is signed in Turin on 8 February 1999 between ESA and Alenia Spazio.
Alenia Spazio has finalised and signed all subcontracts for the development of the Cupola and begins coordinating an industrial team of six other European companies.
A full-scale mock-up is completed and is used to conduct a crew review with the participation of ESA and NASA astronauts. Following a request from NASA, production of the second flight-model Cupola is cancelled. The project is realigned into a one-Cupola project. The impact this will have is identified and negotiated with industry and NASA. The upper dome part of the Cupola Structural Test Article, a Cupola structural replica used for testing purposes, is successfully forged.
The Design Consolidation Review is successfully completed. Forgings of the primary structure of the Structural Test Article are delivered and are being machined to final dimensions. Manufacturing-tool design activities are completed and procurement of the window frames is initiated for the Structural Test Article and the flight unit: the Cupola that will actually be attached to the ISS.
The upper dome and lower ring sections of the Structural Test Article are now in final machining and will be delivered to Alenia Spazio during the summer. Following the Design Consolidation Review concerns relating to the Cupola’s thermal robustness from launch to arrival at the ISS and during transfer of the Cupola from one location to another while in orbit are satisfactorily resolved. The design concept of the internal layout known as the secondary structure is established and detailed design has begun.
The machining of the dome and ring for the Structural Test Article is finished, and the sub-elements have been delivered to Alenia Spazio, ready for welding. The window glass is delivered and inspected. Shutters are being manufactured for the Structural Test Article.
The dome and ring of the Cupola Structural Test Article are successfully welded together.
Pressure testing on the Cupola Structural Test Article is completed without problems. Manufacturing of the flight-unit dome and ring has started. Design changes to the window shutters, driven by the need for improved protection against space debris, are being negotiated with NASA.
The modal-survey test is successfully completed. This demonstrates that the Cupola complies with the dynamic requirements imposed by the shuttle during launch. A second 1-g mock-up campaign is performed, verifying that the internal changes previously recommended by the crew have been properly incorporated. The thermal-vacuum test is completed on the shutter mechanism. This exposes the shutter mechanism to extreme temperatures in a vacuum, as it would experience in space. Associated life-cycle tests are also completed.
The Neutral Buoyancy Test in the NASA/Johnson Space Center pool in Houston is successfully conducted with a few minor changes recommended. Manufacture of the flight-unit ring and dome sections is underway, as is that of the window frames.
The Cupola Critical Design Review and Safety Review-I/II are successfully completed.
The new flight-unit dome is forged and delivered for final machining, and the manufacture of the flight-unit shutters, harness and window frames is in progress.
The Cupola Structural Test Article is shipped to the test site for vibro-acoustic testing. This subjects the Cupola to acoustic levels equivalent to its future launch conditions. The shutters, harness and window frames are now manufactured.
Vibro-acoustic testing of the Structural Test Article is successfully completed. It is delivered to Johnson Space Center in Houston for use in crew training. Manufacture of the flight-unit dome is progressing.
Machining of the Cupola’s flight unit dome and welding of the dome and ring is completed. Acceptance testing of the shutter mechanism and flight-unit harness is completed, as well as all Structural Test Article activities.
Deliveries of the flight-unit harness and Micrometeoroid and Debris Protection System have been made for the Cupola.
Integration of the Cupola flight unit is continuing. The acceptance test campaign for the flight unit is on hold pending completion of technical investigations involving the titanium springs for the windows.
The flight-unit proof pressure test for the Cupola is performed successfully and integration of the windows has started. Window assembly, installation and leak testing is started.
Window integration and leak testing on the Cupola is successfully completed and the Element Leak Test has started.
Checks are performed with NASA to control and fine tune all the details of the Cupola construction from the human factor point of view.
Eurobot Ground Prototype (EGP)
PMM
Cygnus
