SmallSats to Spaceplanes: The ARS Neutron™ Building Block Approach

ARS’s Neutron™ System is a purpose-built Direct Field Acoustic Test (DFAN) system that enables the same quality of acoustic field and effectiveness of acoustic tests to be applied to a wide range of spaceflight hardware, from smallsats to spaceplanes. 

In the ever-evolving landscape of Direct Field Acoustic Testing (DFAN), efficiency and consistency are paramount. To meet these needs, ARS developed an innovative strategy based on the idea of creating acoustical building blocks. The concept behind this is both simple and profound: Each Neutron™ acoustic device is designed to produce the entire frequency bandwidth to full test levels on its own. Accordingly, we created a modular system that can be scaled seamlessly by ensuring the functionality of the Neutron™. 

The building block approach is based on the principles of modularity and repeatability. By designing Neutrons as standalone units, we can expand systems by simply adding more Neutrons™ as needed to surround the Units Under Test (UUT). This technique ensures consistent test conditions regarding functionality and performance while simplifying the setup process. Whether a project demands a small setup or a large-scale operation, the core components remain the same, reducing complexity and increasing reliability. 

                                                                                                         

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The figure above shows examples from prior ARS tests of how different custom-tailored configurations of Neutron™ devices can be created, each utilizing the same building block methodology to ensure a robust and accurate test regardless of test article size or system configuration. The modularity and full-range design of the Neutron™ device enable significant scalability while maintaining the quality of the test and simplicity of setup, regardless of deployment size. 

This uniformity extends to the control strategies and operational protocols. We streamline the process of scaling up operations by standardizing these elements. The uniformity between the sources—each generating the same acoustic field—ensures that the quality and consistency of the tests are maintained regardless of the scale. This is a significant advantage, as it means that any insights or data obtained from a smaller setup are transferable to larger setups, either in pre-test simulations or post-test data analysis. 

The Building Block Approach guarantees consistent output and quality across varying system sizes, allowing for tailored setups that meet specific project needs. Smaller setups, ideal for testing smaller UUTs, are cost-effective due to reduced equipment needs and fewer personnel, leading to lower operational costs and increased testing time. These efficiencies are scalable to larger setups, maintaining streamlined processes and reliability across all project sizes. 

We increase the number of already tested and proven components when we scale up. This consistency leads to several operational benefits. For one, it simplifies inventory management and procurement since the same types of equipment are used across different setups. Additionally, it facilitates easier maintenance and troubleshooting, as technicians are already familiar with the standardized components and their configurations. Despite the uniformity and standardization, some differences arise with scaling up, particularly in terms of rigging and power requirements. These differences, however, are predictable and manageable. For example, the method of rigging the equipment changes based on the setup size. For small setups, workers can manually handle the equipment, while large-scale setups necessitate a crane for efficient and safe construction. Furthermore, power requirements vary with the setup size. Smaller setups can often operate on a typical installed power system, while larger configurations might need a generator to supply adequate power. Despite these variations, the overall predictability of these needs means they can be planned for and managed effectively. This predictability ensures that scaling up operations does not introduce significant complexities or uncertainties. 

The Building Block Approach innovates acoustic testing with its modularity, standardization, and scalability. Ensuring consistent quality and efficiency across various setups simplifies operations and enhances the reliability of results. This advanced strategy meets diverse testing needs effectively, making it a game-changer in acoustic testing by revolutionizing strategy, enhancing operational efficiency, and resulting in transformative advancements in acoustic testing.