Test Planning

Test Configuration

Test Article Definition

1. Configuration Control

   • Part number and revision
   • Serial number
   • Manufacturing records
   • Deviations from design

2. Pre-Test Condition

   • Dimensional verification
   • Surface condition
   • Prior test history
   • Environmental exposure

Test Setup

1. Boundary Conditions

   Fixture requirements:
   - Simulate actual mounting
   - Minimize artificial constraints
   - Allow access for instrumentation
   - Safe for failure modes
   

2. Load Introduction

   • Point loads vs distributed
   • Static vs dynamic
   • Load path verification
   • Fixture compliance effects

Instrumentation Planning

Strain Measurement

Displacement Measurement

Force/Load Measurement

Load cell selection:
- Capacity: 1.5-2x expected maximum
- Accuracy: Class 0.1 or better for critical
- Type: Tension, compression, universal
- Environmental: Temperature, humidity range

Acceleration Measurement

Data Acquisition

Sampling Requirements

Nyquist criterion: f_sample >= 2 * f_max

Practical guideline: f_sample >= 5-10 * f_max

For transient events:
- Sample at 10x highest frequency content
- Include anti-aliasing filter

Channel Planning

1. Channel List

   • Channel ID
   • Measurement type
   • Sensor type
   • Location
   • Expected range
   • Calibration requirements

2. Data Management

   • File naming convention
   • Storage requirements
   • Backup procedures
   • Archive policy

Test Procedures

Procedure Structure

1. Scope and applicability
2. Reference documents
3. Safety requirements
4. Equipment and materials
5. Pre-test setup
6. Test execution steps
7. Data recording requirements
8. Post-test procedures
9. Acceptance criteria
10. Reporting requirements

Safety Considerations

1. Hazard Analysis

   • Energy sources
   • Failure modes
   • Personnel exposure
   • Environmental impact

2. Risk Mitigation

   • Barriers and shields
   • Emergency stops
   • Warning systems
   • PPE requirements

Data Analysis Plan

Analysis Methods

Uncertainty Analysis

Combined uncertainty:
u_c = sqrt(sum(u_i^2))

Expanded uncertainty (95%):
U = k * u_c (k = 2 for 95%)

Sources:
- Calibration uncertainty
- Resolution
- Environmental effects
- Repeatability

Process Integration

• ME-021: Test Plan Development

Input Schema

{
  "test_article": {
    "part_number": "string",
    "description": "string",
    "quantity": "number"
  },
  "requirements": {
    "specifications": "array of requirement IDs",
    "success_criteria": "array"
  },
  "test_type": "development|qualification|acceptance|certification",
  "test_conditions": {
    "loads": "array of load cases",
    "environments": "array of conditions",
    "duration": "string"
  },
  "resources": {
    "facility": "string",
    "equipment": "array",
    "personnel": "array"
  }
}

Output Schema

{
  "test_plan": {
    "document_number": "string",
    "revision": "string",
    "test_matrix": "array of test cases",
    "instrumentation_list": "array",
    "schedule": "object"
  },
  "test_procedures": "array of procedure references",
  "safety_analysis": {
    "hazards": "array",
    "controls": "array",
    "approval_required": "boolean"
  },
  "data_analysis_plan": {
    "methods": "array",
    "acceptance_criteria": "array"
  },
  "resource_requirements": {
    "cost_estimate": "number",
    "duration": "number (days)",
    "personnel": "array"
  }
}

Best Practices

1. Define success criteria before testing
2. Verify instrumentation calibration
3. Document all deviations from plan
4. Include margin in load capacity
5. Plan for potential failure modes
6. Review procedures with test team

Integration Points

• Connects with Requirements Flowdown for test requirements
• Feeds into Test Correlation for model validation
• Supports Design Review for verification evidence
• Integrates with FAI Inspection for first article