1 - 1 T-ReCS ISE Graduate Seminar September 2, 1999 Managing the Design and Fabrication of a World-class Astronomical Instrument Thomas Kisko, M.S., P.E

1 - 1

T-ReCSISE Graduate SeminarSeptember 2, 1999

Managing the Design and Fabrication of a

World-class Astronomical Instrument

Thomas Kisko, M.S., P.E.Associate in Industrial Engineering

1 - 2


AbstractThe University of Florida is developing a mid-infrared

imager/spectrograph, called T-ReCS, for the Gemini telescope under construction at Cerro Pachon, Chile. There is a sister Gemini telescope that just recently saw first light in Hawaii. The two Gemini telescopes have 8 meter primary mirrors, the largest in the world.

T-ReCS is basically an expensive ($1.8 million) digital camera for the Gemini telescope. The detector in T-ReCS is a chip that is optimized for the mid-IR (8-25 micron) and cost about $100,000.

The seminar will highlight some of the project management and software issues related to the project. Most world class telescope instrument projects end up millions of dollars over budget and years late. T-ReCS is currently on time and under budget. Why?

1 - 3


T-ReCS

Gemini Thermal Region Camera & Spectrograph

Key Personnel:Charles Telesco PI, Optical/Mechanical, ScienceTom Kisko Project Manager, SoftwareRobert Piña Software, ScienceKevin Hanna ElectronicsJeff Julian Mechanical/ThermalDavid Hon SoftwareUCF (CREOL/FSI) Optics

Glenn Boreman Jim Harvey Jongwook Kye Glenn Sellar

1 - 4


http://www.gemini.edu/public/

1 - 5


Gemini South on Cerro Pachon, Chile

Photo Courtesy of Gemini Observatory

1 - 6


The Gemini Telescope Structure

Courtesy of Gemini Observatory

1 - 7


Overview of System Layout3D Boundary Layout

1 - 8


T-ReCS 2D Dewar Layout

1 - 9


3D Cold Plate Layout

Split Cold Plate

Window Turret

Top View

Aperture Wheel (i0) withwindow imaging lens.

Sector Wheel

F1 TurningFlat

Filter/LyotWheels (p1)

M1 TransferMirror

Grating/ImagingTurret (p2)

F4 Turning Flat

Array (i2)

Pupil ImagingWheel

M2 Collimator Mirror

Slit Wheel (i1)

F2 Turning Flat

M3 CameraMirror

1 - 10


Window Changer

•Provides 5 window positions that can be selectedduring an observational run.

•Custom 25 cm dia. ferrofluidic feedthru*.

•Active dry air purging cover with relief valve, pressure regulator, and air filter.

•Purge cover is spring loaded and lifts by cam actionwhen wheel is turned. No additional motor driverequired.

•Window retaining rings have Teflon contact surfaces.

•Stepper-motor shaft can be accessed for manual operation.

*Used in window changer designed by George Rieke of Steward Obs.

Element X Y Z Tip Tilt Rotation(mm) (mm) (mm) Degrees Degrees Degrees

Window 2.0 1 1

1 - 11


Cryo-Motor Drives

•Portescap size 23 motor

•Prepared for cryogenic use by disassembly and de-greasing of the rotor shaft bearings. Bearings re-greased with Molydenum-Disulfide.

•Rotor will not demagnetize when removed from the motor housing.

•Motors have passed numerous tests atcryogenic temperatures.

•Stainless steel tubing truss provides rigid mountingand thermal isolation.

•Gearbox connected to mechanisms forheight and gear ratio tuning.

•Electrical connections via heatsunk‘D’ connector helps cool motorwindings.

1 - 12


I0 Aperture Wheel

•Placed at the telescope focal plane (i0).

•Five (5) position.

•Holds the window imaging lenses.

•Four (4) removable aperture disks.

•Gear reduction of 7.

1 - 13


Vacuum Pressure Effects on Dewar Case Lids

1 - 14


Optics Mount Temperature Gradients

1 - 15


Total Weights and C.G. of System

Total frame weight: 2707lbs (main + 2 TE)

Total dewar weight: 579lbs (dewar + ISS mount)

TE 1: 337lbs

TE 2: 293lbs

Ballast weight: 484lbs (variable)

Total: 4400lbs (2000 kg)

C.G.: Z = -1000mm

Above values were determined using 3D AutoCAD, FEA, or actual weight measurements.

1 - 16


T-ReCS Imaging Requirements

• Wavelength Range: 8-26 m

• Detector Format: 320 256 pixels, 50 m pixels

• High Throughput: 75% (excluding detector & filters); goal of 90%

• Pixel Scale: 0.09 arcsec/pixel, diffraction-limited @ 8 m • Image Quality: 50% EE-diameter (geo spot) 0.094 arcsec @ 10 m

50% EE-diameter (geo spot) 0.189 arcsec @ 20 m 1 pixel distortion

• Instrument Background: 1% effective emissivity (in low atmospheric windows)

• Filters: 20-30 cold 1-inch filters

1 - 17


collimatormirror

slit wheel

cameramirror

grating/imaging turret

focal plane array

entrance windowwheel

aperture-stopwheelpupil lens

wheel

T-ReCS Optical Layout

transfer mirror

Filter & Lyot-stop wheels

window-imaging lenses

1 - 18


T-ReCS Unfolded Optical Layout

Collimator Mirror (M2)

Camera Mirror (M3)

Transfer Mirror (M1)

Telescope Focus (i0)

1st Pupil (p1)IntermediateImage (i1)

2nd Pupil (p2)

Final Image(i2, Detector)

1 - 19


Mon R2 Star Forming Region

1 - 20


Overall Electronics Block Diagram

MotionControl

TemperatureControl

Array

DewarBias Module

Preamp

ASP Rack

AnalogPower Supplies

Main Readout Electronics

ICS Rack

Main EPICSVME

Components

Motion & Temperature

Control Components

Clocks

Analog

DHS LAN

EPICS CannelAccess LAN

Gemini OCS

ChopperEvent Bus

1 - 21


2. Overall Architecture

0.2C om ponents

C ontro lle r

O C S

TC S

D H S

S A D

G IS T-R eC SC om ponents

S ta tus &C ontro l S igna ls

In terlockS igna l

0 .3D etector

C ontro lle r

C & R(in form ationa l)

Logging requests &O bservation in fo .

T -R eC SA rray S equencer &P reprocessor (A S P )Im age

D ata

C & RC & R

C & R

C & R

C & R - C om m and & R esponse

0.1Instrum entS equencer

0 .4E ngineering

In terface

S etupIn form ation

S tore

Tester

C & R

S etupS equencerIn form ation

E ngineeringS etup

In form ation

C & R

S C S

C & R(event bus)

D isp lay

C & R

C & R

Level 0 Data Flow:

1 - 22


OCS TCS & SCS

Sequencer Tasks

Channel Server

Scan &Monitor

Tasks

DHSClient

ImageServer

ASP Interface Fibre/DMA &Serial (RS232)Motor, Serial Port, etc.

EPICS DBGenSub

CAD/CAR

EPICS DBSAD

ICS/IOC (VxWorks/EPICS)

DetectorAgent

LAN(s)

DHS Server

Level 0 Protocol:

ImagePipeline

EPICS Channel Access

DRAMA/IMP

UFLib Protocol

Gemini Event Bus

Eng. Consoles


1 - 23



Level 1 ICS Runtime:

ReplicatedTCS Environment& WCS & SCSRecords

CAD

Apply

CAR

Environment RecordsMotor Records

OCS

TCS &SCS

ComponentsSeq

Detector Records

EnvironmentSeq

Detector Agent(TCP Server)

SystemSeq

MotorSeq

libUFGem (C)

(Epics & VxWorks)

ASP

Interm.CAD/GenSub Records Interm.CAD/GenSub Records

Interm.CAD/GenSub Records

DetectorSeq

libUF (C++)

Image Pipeline&

Server (TCP)EPICS Database I/O

UF Protocol Gemini Event Bus

UFLib Runtime Entry

1 - 24



Level 1 Image Pipeline Runtime:

Data LAN

Pixel Sort &Local Archive

Image Preprocessor

libUF (C++)(No Epics Bindings)

libUFGem (C)(Epics Bindings)

NFSPMC/DMAFrameGrabber

Queue of

Frameson

Heap

FrameRing buffer

(SharedMemory)

ASP ImageRing buffer

(SharedMemory)

ImageRing buffers

(diffs & accums) Epics SAD

Image Server(TCP/IP)

DHS Client

(Zbuff Socket)

1 - 25


7. EPICS Commanding

MESS

ccSysCad.sch

(A)

(B)

(C)

The "apply" record sequences the other

"apply" records contained in the lower level

ccSysCad schematics in the order A, B, C, D

NOTE: ccSysCad3.sch contains commands which are all optional.

They are not required and are therefore left out.

It is important that this fact is reflected in the

Instrument Sequencer, so it does not attempt to forward these commands.

Apply

PV:$(top)$(mech)

DESC:CICS CC system APPLY record

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NPP

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

NMS

apply

OUTG

OCLG

OUTH

OCLH

OCLF

OUTF

OCLE

OUTE

OUTC

OCLC

OUTD

OCLD

INMH

INPH

INMG

INPG

INMF

INPF

INME

INPE

INMD

INPD

INMC

INPC

SLNK FLNK

VAL

MESS

OUTA

OCLA

OUTB

OCLB

DIR

CLID

INPA

INMA

INPB

INMB

System Command Action Directive Records

Core Instrument Control System

112 Aug 97checked:B.Goodrich

Cauthor:S.M.Beard

1 2 3 4

A

B

C

D

4321

D

C

B

A

OFSHEET

DIR

CLID

ccSysCad1

MESS

VAL

CLID

DIR

ccSysCad2

MESS

VAL

CLID

DIR

MESS

VAL

ccSysCad4

DIR

CLID

VAL

MESS

APPLY record.

(e.g. ccSysCad5) and attach it to the

a new lower level schematic to this one

To add a lot of new system commands, add

=====

ICD14

.

.

.

1 - 26


Project Management

1 - 27


Project Management Objectives

• Quality instrument• On time• Under budget• Minimize risk• Contingencies

1 - 28


Major Management Activities Since PDR

• Responded to PDR comments• Submitted detailed spectroscopic justification• Made “dual” schedule - UF and AURA• Submitted spectro & scope change proposal• Developed detailed schedule• Developed cost estimating/tracking system• Worked on amendment 3, the extension

1 - 29


Phases of a _______ Project

• Concept study• Requirements development• Request for proposal (RFP)• Preliminary design (PDR)• Critical design (CDR)• Fabrication• Integration and test (I&T)• Commissioning

1 - 30


Project Schedule

1 - 31


Project Schedule

Let’s look at it in detail.

I’ll open it with MS Project.

1 - 32


Monthly Management Report

1 - 33


The Monthly Management Report Also Includes:

• A summary of:Activities for the monthAccomplishmentsProblems

• A project schedule update with % complete• A detailed cost transactions database• An email stating that the report files are ready

on a password protected part of our web site

1 - 34


Monetary Information Flow

• UF Accounting data extracted from University mainframe application to

• MS Access transaction database and macros provides data to

• MS Excel sheets and macrosBudgets

Monthly proration

Sheet for each monthly management report

1 - 35


UF Accounting Mainframe Data

1 - 36


MS Access Transaction Database

1 - 37


Bill of Materials for T-ReCS

• Items are specified in a hierarchy of items, subitems, and terminal items.1 Car1.1 Engine1.1.1 Alternator1.1.1.1 Alternator pulley - $4.231.1.1.2 Alternator front bearing - $2.55

• Terminal items are items you "buy"; they have no subitems.

• The BOM is implemented in MS Excel with macros to: Recalculate item numbers

Rollup costs

Rollup component status• The T-ReCS BOM sheet has over 700 items.

1 - 38


Bill of Materials Sheet

1 - 39


BOM Codes

Code Definition X No cost estimate W Wild estimate E Estimated cost Q Quoted cost P Purchased R Received I Installed O Operational

T Tested

1 - 40


Bill of Materials Help Sheet

1 - 41


BOM

Let’s do a demo.

I’ll open it with Excel.

1 - 42


The New “Plan”

• A cost estimating/tracking system• Plans every expenditure:

BOM items

Payroll

Travel

Miscellaneous costs• Based on a planned expenditure list

1 - 43


Managing ...

• Fabrication of T-ReCS• Expenditures and Staffing• Day-to-day activities• Contingencies

1 - 44


Managing the Fabrication of T-ReCS

• MS Project - for high-level Gantt Chart scheduling of fabrication

• BOM - enumerates all items & key dates• Drawings - fabrication details• Drawing management sheet - key status

columns• A person dedicated to keeping the above

up-to-date

1 - 45


Managing Expenditures and Staffing

• We have a “plan”• Purchase only items on BOM• Travel has not been a problem, yet• Staff according to contracted FTEs

(significant UF cost sharing)• Use students for technical support (they are a

bargain)

1 - 46


Managing Day-to-Day

Meetings - when necessary, short, to the point

Progress - written status & % complete input for monthly reports, informal progress updates

Deliverables - remind due dates, request drafts,

Productivity - meet the requirements with optimal effort, avoid changing scope

1 - 47


Risk(Possible reasons that may delay delivery)

• Staff unavailability• Software problems• Vendor non-performance• Schedule slip (bad duration estimates)• System performance problems• Money problems• Gemini interface problems• Other unknowns

1 - 48


Contingency Management

• Monetary - we have a “plan”; less than budget; we are doing better than expected

• Timing - we plan to deliver ahead of the 5/01 contracted date, a 2 month contingency

• Staffing - backup for key personnel; currently teaming many activities

1 - 49


Lessons Learned Workshop

• Parksville, BC, Canada, July 1998• Instrument developers for GEMINI and KECK• Candid discussions on problems and solutions• Many instrument projects were millions of dollars

over budget and years late. WHY?- Management inadequacies- Software- Feature creep

1 - 50


Web Sites

• Kisko’s Web Site (has these PowerPoint slides)http://www.ise.ufl.edu/kisko

• T-ReCS Web Sitehttp://t-recs.astro.ufl.edu/

• Gemini Web Sitehttp://www.gemini.edu/

Documents

1 - 1 T-ReCS ISE Graduate Seminar September 2, 1999 Managing the Design and Fabrication of a World-class Astronomical Instrument Thomas Kisko, M.S., P.E