Transcript Document

Quarterly Review
August 15, 2000
GNIRS Quarterly Review
August 15, 2000
1
Quarterly Review
August 15, 2000
Overview
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Project management
Systems engineering
Optics design and fabrication
Mechanical design and fabrication
Electronics design and fabrication
Software
Procurement
Images
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Quarterly Review
August 15, 2000
Project Management
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Quarterly Review
August 15, 2000
Project Management
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Project Summary
Review Committee Concerns and Responses
Status and Plans
Problems and Concerns
Planning
Milestones, Cost and Manpower
Budget and Expenditures to date
Organizational Changes
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Quarterly Review
August 15, 2000
Project Summary
• Current activities
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Prototyping
Bench design and analysis
Mechanism design
Mechanism fabrication
Electronics design
Software coding
• Prototyping
– Optical, Rotary and Linear Prototyping effort is complete
– Enough data collected to justify proceeding with mechanism design
• Bench design and analysis
– Bench deflection analysis is complete
• The manufactured bench should meet deflection requirements
– Bench drawings will go to vendors this week for fabrication bids
• Bench fabrication is scheduled to start with the OIWFS bench on 9/5/00
• All benches scheduled for release for fabrication by 9/29/00
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Quarterly Review
August 15, 2000
Project Summary
• Mechanism designs in process
– Filter wheel assembly
• Starting 2D detailing
– Camera turret assembly
• Two of 4 camera barrels through 3D solid model design
– This work is currently on hold
• Camera drive and hub in 3D design
– Key design element requiring some development testing
– Results will be propagated to the Grating and Prism Turrets
– Acquisition mirror assembly
• 2D design, currently on hold
– Focus mechanism assembly
• 3D design starts on August 15
– Slit/Decker assembly
• 2D detailing in process
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Quarterly Review
August 15, 2000
Project Summary
• Mechanism fabrication
– Environmental cover assembly
– Motor drive assemblies
– Camera turret assembly
• Some parts in fabrication
• Electronics design
– Mechanism and dewar functional simulator
• For software debug and checkout
– Dewar and mechanism wiring definition
– Array interface wiring definition
– TE wiring design
• Software coding activity
– Components controller
– System software (thin EPICS layer)
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Quarterly Review
August 15, 2000
Review Committee Concerns and Responses
•
It is premature to assume that the aggressive 0.1 pixel flexure per 15º attitude
change specification will be met by this design.
– The bench analysis presented here predicts low image degradation due to flexure of
the pre and post slit bench structures.
•
Further develop the fall back plan of active flexure compensation. Identify an
optimal compensator in the system. Determine if adequate space/mass budget
is available to retrofit a mechanism.
– A fall back plan has been adopted, namely correction at the collimator (as
suggested by Tom O'Brien). We are not pursuing the implementation unless and
until evidence shows it is needed.
•
Consider running ultimate lifetime tests using the prototypes.
– We have decided not to run the lifetime tests on the prototypes, on the ground that
the prototypes are not representative enough of the real mechanisms for the tests to
be helpful. We have carried out inspections on the mechanisms (disassembly) and
have seen no wear problems for use that represents >10% of a "lifetime".
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Quarterly Review
August 15, 2000
Review Committee Concerns and Responses
•
Go straight to rotary prototype #2.
– We are working on the camera turret design, with the idea that it is not a prototype. We
are accelerating fabrication and test of the camera hub to ensure we have time to detect
and remedy and deficiencies.
•
There is no need for additional prototype testing of the lens mount. We
recommend contacting Klaus Hodapp to understand what difficulties he has had
with this design.
– We have finished these tests and are proceeding. Klaus's design is somewhat different.
•
If NOAO wants to pursue the idea of IfA installing elements in this module and
testing it as a unit, that should be explored quickly.
– We are pursuing this. Klaus wants to see how NIRI does at the telescope before
proceeding much further.
•
Consider the use of invar bushings on the bolts that “permanently” connect parts
of the main bench.
– We are following this suggestion. We are incorporating partially compensating collars
in the bench design.
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Quarterly Review
August 15, 2000
Review Committee Concerns and Responses
•
We expect that the (software) architecture described will meet existing ICDs and
support all key functionality. (The software) must conform to all principal
system interfaces.
– We acknowledge these comments and are proceeding accordingly.
•
Clarify what will be delivered in the (software) engineering system.
– At this time, we do not envision delivering a system which would require any special
software licenses. It may be desirable to use an improved version of the EPICS
display manager, or to incorporate some new TCL code. However, we will neither
deliver nor require any software that is not a part of the standard Gemini environment
without approval from Gemini.
•
Thoroughly document the S/W that operates below the proposed “thin EPICS
layer” to permit long-term support.
– The software maintenance manual manual will contain a thorough documentation of
the software.
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Quarterly Review
August 15, 2000
Review Committee Concerns and Responses
•
Rectify the discrepancy between CAS and Neil’s costs, by reporting in real
dollar values. Specifically, reconcile the difference between accounting for
scientists’ time between the cost schedules maintained.
–
•
We are struggling to do this. We have subtracted out all scientist labor charges
from our planning to better reflect what the actual charges represent. We are still
working with CAS on a more permanent solution.
Release some parts for fabrication to (1) test the entire off-site fabrication
process with a vendor and (2) stimulate a change in the psychology of the
team, from one of only designing to actually building the instrument.
– The prototype fabrication was intended to "test the process". We are releasing parts
as ready and have completed the environmental cover.
•
Use an engineer independent of the GNIRS team to double check drawings
that depict key interfaces between the main bench and mechanisms and optical
assemblies.
– We have effectively done this using our “new” mechanical engineer. Also, one of
the points of the 3-D modeling is to avoid the dependence on building up the raytrace from individual drawings.
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Quarterly Review
August 15, 2000
Statement of Work to IFA for OIWFS integration and test
•
Install all OIWFS components onto the provided optical bench.
– This bench is especially designed to receive the Gemini provided components and
to fit into the GNIRS Instrument.
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Perform a mechanical and optical alignment of these components.
Connect and test the OIWFS using the actual electronics and boards that will
be delivered to the GNIRS Project.
Checkout and test the integrated OIWFS as a subsystem
– IFA is uniquely qualified to do this work
– IFA possesses the needed test cables, equipment and software needed to do this
work.
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Conduct an acceptance test which will demonstrate basic operation of the
OIWFS as a subsystem, preferably in a vacuum and at representative cryo
temperatures which will be seen in actual operation.
Pack and ship the completed OIWFS subsystem in a suitable shipping
container to the GNIRS Project at NOAO, Tucson.
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Quarterly Review
August 15, 2000
Plans for Next Review
• The Next Quarterly Review will be held in the November-December
timeframe.
• The project expects to make significant progress in fabrication.
– All benches should be to vendors
– Several mechanisms will be in fabrication
• 3D designs of all remaining mechanisms will be complete
– Focus, prism turret, grating turret, camera assembly, acquisition mirror
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Lens delivery should be complete; all optics on order/delivered
Work will have started on several fixed assemblies
Electronics fabrication will have started
OIWFS components integration will be underway
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Quarterly Review
August 15, 2000
Status and Plans
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The project is 29% complete overall
We have completed 29 of 208 scheduled milestones
The planned Systems Engineering effort is 97% complete
Software low-level code development is 56% complete
Mechanism design is underway for several mechanisms
Procurement of optics, mirrors, filters, gratings, materials,
etc., is proceeding per plan
• Currently qualifying additional vendors for outside
fabrication
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Quarterly Review
August 15, 2000
Status and Plans
Progress from August ’99
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Overall project
Management & Reporting
Systems Engineering
Mechanical
– Benches
– Mechanisms
– Fixed Assemblies
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•
•
Electronics
Software
Integration
Procurement
29%
35%
97%
16%
16%
24%
1%
4%
27%
0%
31%
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Quarterly Review
August 15, 2000
Problems and Concerns
• Bench solid models and details for fabrication
• Contracting for bench fabrication
– Contractor selection
– Work start and schedule/cost
• Aluminum billet cutting & distribution
– Complete by 9/5, start of vendor fabrication
• Electronics technician shortage
– The software effort is outpacing the electronics build
schedule needed to support software checkout.
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Quarterly Review
August 15, 2000
Project Planning
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Quarterly Review
August 15, 2000
Summary Plan
N
D
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CY-2000
J
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J
F
M
A
M
CY-2001
J
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CY-2002
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Risk Reduction Prototypes
MFR
Fixed Assemblies Design/Fab
PFR
Integration/Alignment
Structural Analysis
ATP
IFU Modules
Bench Design/Fab/Assy
Manuals
Ship
OIWFS/Post-Slit/Pre-Slit
Training
WFS Integration/Alignment
OIWFS Hardware
Mechanism Design/Fab/Assy/Test
9 Mechanisms
Software Development/Code/Test
SW Plan/Low-Level/High-Level Code
Electronics Design/Fab/Test
GNIRS SUMMARY PLAN
Optics Procurement
8/15/00
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Quarterly Review
August 15, 2000
Project Plan
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Quarterly Review
August 15, 2000
Critical Path
• There is no one assembly on the critical path
• We review the schedule on a continuing basis
– critical path changes as a function of time
• We periodically adjust priorities and resources
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Quarterly Review
August 15, 2000
Fabrication Schedule
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Quarterly Review
August 15, 2000
Project Milestones
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Quarterly Review
August 15, 2000
Milestones by Quarter
Calendar
Year
1999
2000
2000
2000
2000
2001
2001
2001
2001
2002
2002
2002
Quarter
4th
1st
2nd
3rd
4th
1st
2nd
3rd
4th
1st
2nd
3rd
TOTAL
Number of
Milestones
Due
1
18
35
32
28
32
38
10
5
1
3
5
208
Number of
Milestones
Comp
1
17
11
0
0
0
0
0
0
0
0
0
29
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Quarterly Review
August 15, 2000
Milestones since PFR
WBS
M ile s tone
5.3.1.2.3.1.3
Long Blue Camera Design Complete
Date Due
05/31/00
5.8.1.3.1
Flat Mirrors Acceptance
06/02/00
5.3.1.1.3
Complete Final Revision Mechanism Test Plan
06/06/00
5.3.1.8.2.6
Grating Turret Draf ting Complete
06/07/00
5.3.2.1.7.1.5
Top Camera Cover Design Complete
06/12/00
5.3.2.1.8.1.5
Bottom Camera Cover Design Complete
06/12/00
5.4.1.1.1.4
Temperature monitor board (VME) spare Complete
06/12/00
5.3.2.4.1.1.6
Pick-Of f /Fold Mirror Assembly Complete
06/14/00
5.3.2.4.2.2.6
Of f ner Assembly Draf ting Complete
06/14/00
5.3.2.1.6.1.5
LCFMH Design Complete
06/14/00
5.8.1.1.1
RMI Optics Acceptance
06/16/00
5.3.2.1.7.2.6
Top Camera Cover Draf ting Complete
06/19/00
5.3.1.7.2.6
Filter Wheel Assembly Draf ting Complete
06/21/00
5.3.2.1.8.2.6
Bottom Camera Cover Draf ting Complete
06/21/00
5.4.4.1.5
Dew ar Connector Interf ace Boards Complete
06/28/00
5.3.2.3.1.1.5
Collimator Mount Design Complete
06/29/00
5.3.2.1.6.2.6
LCFMH Draf ting Complete
06/30/00
5.3.2.4.1.2.6
Pick-Of f /Fold Mirror Assembly Draf ting Complete
06/30/00
5.5.2.7
Component Controller Sof tw are Complete
06/30/00
5.4.1.1.6
VME Chassis Wiring & Assy Complete
07/03/00
5.2.8.3
Validate Structural Analysis
07/11/00
5.3.3.2.1.6
Detector Mount Assembly Design Complete
07/17/00
5.3.2.1.7.3.3
Top Camera Cover Fabrication Complete
07/19/00
5.3.2.1.8.3.3
Bottom Camera Cover Fabrication Complete
07/21/00
5.3.2.1.7.4.4
Top Camera Cover Assembly Complete
07/24/00
5.3.3.7.1.4
Optical Bench Mount Assembly Design Complete
07/25/00
5.3.2.1.8.4.4
Bottom Camera Cover Complete
07/26/00
5.3.1.103.2
Motor Drive Assembly Fabrication Complete
07/26/00
5.3.2.1.2.7
Post-Slit Bench Draf ting Complete
07/27/00
5.3.2.3.1.2.6
Collimator Mount Draf ting Complete
07/28/00
5.3.1.6.1.1.6
Slit/Decker Housing Assembly Design Complete
08/01/00
5.3.2.1.6.3.3
LCFMH Fabrication Complete
08/01/00
5.3.1.2.4.3.5
Short Red Camera Barrel Complete
08/02/00
5.3.1.104.5
Motor Drive Assembly Complete
08/02/00
5.3.1.4.3.6
Environmental Cover Assembly Fabrication Complete
08/03/00
5.3.2.1.6.4.4
LCFMH Complete
08/04/00
5.3.1.4.4.2
Environmental Cover Assembly Testing Complete
08/07/00
5.3.2.3.2.2.4
Collimator Cover Box Draf ting Complete
08/07/00
5.3.2.3.2.3.2
Collimator Cover Box Fabrication Complete
08/08/00
5.3.1.2.6.2.6
Camera Hub Draf ting Complete
08/08/00
5.3.2.2.1.2.6
OIWFS Assembly Draf ting Complete
08/11/00
Com p
06/07/00
24
Quarterly Review
August 15, 2000
Project Costs
25
Quarterly Review
August 15, 2000
Project Costs
• Baseline Estimate (Jan 99 to completion)
– Labor
– Capital
– Total
$3,391,232
$ 836,462
$4,227,694
• Current Forecast (revised 7/31/00)
– Labor
– Capital
– Total
$3,309,187
$ 877,842
$4,187,029
• Performance ratios
–
–
–
–
–
BCWS = $ 1,181,581
BCWP = $ 816,464
ACWP = $ 846,211
CPI = 0.96
SPI = 0.69
(budgeted cost of work scheduled)
(budgeted cost of work performed)
(actual cost of work performed) (source: CAS)
(BCWP/ACWP)
(BCWP/BCWS)
26
Quarterly Review
August 15, 2000
Project Costs
Budget
Actual
this Month this Month
Manpower $ 77,368 $
80,531
Capital
$4,141
$10,176
Total $ 81,509 $
90,707
GNIRS Project as of July 2000
Delta
Cum Plan Cum Actual Cum Delta
Total
this Month
to Date
to Date
to Date
Budget
-$3,163 $1,100,647 $ 1,060,084
$40,563 $ 3,127,063
-$6,035 $ 240,126
$262,820
-$22,694 $ 906,513
-$9,198 $ 1,340,772 $ 1,322,904
$17,869 $ 4,033,576
Previous
Cum
to Dec 1998
$ 1,629,705
$ 748,851
$ 2,378,556
This report is given to Gemini monthly.
27
Quarterly Review
August 15, 2000
GNIRS WBS
• WBS Elements shown to 3rd level
28
Quarterly Review
August 15, 2000
Planned vs Actual Expenditures
WBS
5.0
5.1
5.2
5.3.1
5.3.2
5.3.3
5.4
5.5
5.6
5.7
5.8
Title
GNIRS Total
Management
Systems Eng
Mechanisms
Bench Assemblies
Fixed Assemblies
Electronics
Software
Integration
Deliverables
Procurement
Total
Plan
$3,752,409
$1,148,014
$ 225,686
$ 904,104
$ 301,081
$ 501,174
$ 150,014
$ 95,122
$ 201,960
$ 37,164
$ 188,090
Planned
to date
Actual
to date
$928,845
$285,982
$213,472
$238,409
$ 50,915
$ 13,800
$ 4,135
$ 40,291
$
0
$
0
$102,469
$888,283
$281,710
$236,524
$196,130
$ 50,393
$ 9,852
$ 11,586
$ 27,161
$
0
$
0
$ 95,364
29
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FTE
Quarterly Review
August 15, 2000
GNIRS Staffing FTE by Month
30.0
25.0
20.0
15.0
10.0
5.0
0.0
Month
Plan FTE
Actual FTE
30
Quarterly Review
August 15, 2000
GNIRS Cumulative Work
90000
79,725
80000
76,391
70,974
70000
50000
40000
30000
20000
10000
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Actual
Baseline
May00 Plan
Aug00 Plan
31
Quarterly Review
August 15, 2000
GNIRS Capital Spend Plan
$900,000
$800,572
$800,000
$700,000
$759,192
$500,000
$400,000
$300,000
$200,000
$100,000
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Dollars
$600,000
Month
Actual
Baseline
May'00 Plan
Aug'00 Plan
32
Quarterly Review
August 15, 2000
Organization
Director, NOAO
S. Wolff
Gemini Projects
Project Manager
N. Gaughan
Project Assistant
D. Eklund (.5)
Project
Scientist,
Systems
Engineering
J. Elias
Support
Scientists
D. Joyce*
B. Gregory**
Administrative Assistant
M. Bowersock
Mechanical
Engineers
E. Hileman
G. Muller
Electrical
Engineer
J. Penegor
Mechanical
Designers
J. Andrew
D. Rosin
E. Downey
R. Robles
Electrical
Technicians
S. Nguyen
Optical
Engineer
M. Liang
Procurement
& Vendor
Liaison
A. Davis
Software
R. Wolff
Staff Added: No changes
Staff Transferred: No changes
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Quarterly Review
August 15, 2000
Systems Engineering
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Quarterly Review
August 15, 2000
Systems Engineering
• Two Main Areas:
– Analyses
• Thermal analysis (completed 5/00)
• Flexure analysis (completed 8/00)
– Prototyping
• Motor testing (completed 12/99 [report 5/00])
• Lens mount tests (completed 5/00)
• Rotary prototype (completed 7/00, except final report)
• Linear prototype (completed 8/00, except final report)
35
Quarterly Review
August 15, 2000
Analyses
• Thermal Analysis
– Thermal design presented 5/00
– Additional analysis as required in support of design (not systems engineering - e.g.
wire cold-station details)
• Structural Analysis
–
–
–
–
Flexure analysis interacts with bench design
Specific analyses were used to support prototype design
Prototype results confirm mechanism analyses
Additional structural analysis in support of design (e.g, dewar shell)
• Flexure Analysis Results
– Bench appears to perform adequately
– XY control could be implemented at collimator
36
Quarterly Review
August 15, 2000
New Prototype Results
• Rotary Prototype Final Results
– Drive mechanism meets repeatability, torque, wear specifications
– Pre-load redesigned to meet flexure specifications; early testing of most
demanding implementation (camera) to confirm performance
• Linear Prototype Final Results
–
–
–
–
Multiple design changes - either tested or straightforward
Drive mechanism will meet repeatability, torque, wear requirements
Motor isolation mount meets requirements (<10% of heat into structure)
Mechanism will meet flexure requirements
• Design Changes Implemented
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Quarterly Review
August 15, 2000
Optics Design and Fabrication
•
Lenses and Windows
– large lenses & windows in fabrication with RMI; 11 of 18 accepted
– small lenses (2) will be fabricated by RMI
•
Mirrors
– Powered mirrors (3) delivered by II-VI (accepted); Alumiplate surface delivers
required low scattering (<40Å rms, require 50Å)
– Flat mirrors to be ordered as individual mechanism design proceeds; 2 aluminum
substrates & 7 glass substrates
•
Gratings
– Master rulings (3) completed and measured
– Replicas will be done when turret 3-D design nears completion
•
Filters
– 7 filters ordered through UH consortium; 2 fail spec and should be replaced
•
Prisms
– Preliminary quotes on prisms; will initiate procurement once 3-D design of prism
38
turret nears completion (9/00)
Quarterly Review
August 15, 2000
Mechanical
39
Quarterly Review
August 15, 2000
Mechanical
• Overview
– Work in the Mechanical WBS element has primarily
concentrated on the bench structures, mechanisms and
mechanism interfaces to the benches
– Starting August 15th we will finish mechanism 3D
design definition in order to release the benches for
fabrication
• This will include the focus, grating turret, and prism turret
mechanisms
– Bid packages for the three benches will be released to
four vendors and our own Instrument Shop in the week
of August 14th
40
Quarterly Review
August 15, 2000
Mechanical Design and Fabrication
• Mechanical design
– Bench detail design
• Pre-slit, Post-Slit, OIWFS benches
– Mechanisms
•
•
•
•
Filter wheel
Camera barrels
Camera hub assembly
Slit/Decker assembly
• Mechanical fabrication
– Environmental cover assembly
– Motor drive assembly
– Bench assembly bid packages
41
Quarterly Review
August 15, 2000
Problems and Concerns
• Fabrication times are internal estimates
– Actual fabrication times for the benches is an unknown at
this time
• We will use multiple vendors to insure that
mechanical fabrication supports our schedule
commitment.
– Multiple vendors and in-house fabrication may affect the
estimates
42
Quarterly Review
August 15, 2000
Electronics design and fabrication
• Design activities
– Mechanism Motor Simulator for software testing
– Dewar, mechanisms and WFS cabling
• Fabrication
– The software simulation tool is fabricated and ready for
test/checkout.
– Fabrication of the deliverable electrical hardware will
start in September.
43
Quarterly Review
August 15, 2000
Software
• Software is under control
• Not on the critical path.
• The software schedule includes a several month
period, for test and debug using the real
electronics, prior to going into the project
integration phase.
• Status
– Low level (Component Controller) code 56% complete
– High level (EPICS) code 5% complete
44
Quarterly Review
August 15, 2000
Procurement Status
•
Optics Status
–
–
–
•
RMI – 8 Parts left including two pupil viewers
Filters – Received 6 of 7 Filters
3 Master Rulings Have Been Ordered
Benches
–
•
All 3 benches out for bid this week
Future procurement
–
–
–
–
Flat Mirrors
Prisms
CRYO Heads/Lines
Electronics connectors/boards
45
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Images
46
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Full Assembly
47
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Full Assembly
48
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Tangent Rings
49
Quarterly Review
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Tangent Rings
50
Quarterly Review
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Single Bulkhead
51
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Twin Bulkheads
52
Quarterly Review
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Slit-Decker Assembly
53
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Slit-Decker Assembly
54
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Slit-Slide
55
Quarterly Review
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Linear Prototype
56
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Rotary Prototype
57
Quarterly Review
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Lens Mount
58
Quarterly Review
August 15, 2000
Bench Assembly F. E. A. Model
Main Bench (comprised of upper and lower hogouts bolted together)
Long Camera Fold
Mirror Housing
Collimator Mirror
Upper Camera Cover
Collimator Housing
Tangent Bar
Support Bracket
OIWFS Bench
Slid/Decker Fore &
Aft Housings
Offner Housing
Weights:
Model Size:
Solve Time:
All benches & Housings = 696 lbs
Mechanisms & Optics =
273 lbs
Total Weight = 969 lbs
866,000 degrees of freedom Nodes:
5 hours
Elements:
288,503
145.529
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Quarterly Review
August 15, 2000
Instrument Assembly F.E.A. Model
Deformed shape scaled by 7500x loading; gravity in the –y direction scale in inches.
10m
Note: Much of the Offner deflection is due to rigid body motion of the assembly with respect to its
support bulkhead, and will not contribute image decenter.
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