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Integrated Optical Systems
L-3 Communications - Brashear Proprietary
TEOA Program Management PDR
Craig Peton
February 21, 2012
L-3 COMMUNICATIONS – BRASHEAR PROPRIETARY L3 Communications, Brashear Division, reserves all rights in connection with this document and in the subject matter represented herein. The recipient hereby acknowledges these rights and
shall not, without permission in writing, disclose or divulge this document in whole or in part to third parties or use it for any purpose other than that for which it was delivered to recipient.
This technical data is controlled under the Export Administration Regulations (EAR) and may not be exported to a Foreign Person, either in the U.S. or abroad, without proper authorization by
the U.S. Department of Commerce.
DESTRUCTION NOTICE: Destroy by any method that will prevent disclosure of contents or reconstruction.
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
Program Management
• Program Overview
– ATST TEOA Product Breakdown Structure
• Program Health
– Technical
– Schedule
– Contractual
• Project Plan and Milestones
• Risk Analysis and Mitigation
• Quality Assurance Plan
– Summary and Status
• Current Action Item List
• PDR Exit Criteria
2
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
PROGRAM SUMMARY/SCOPE
Program Name: Top End Optical Assembly (TEOA) for Advanced Technology Solar Telescope (ATST) Customer: Association of Universities for Research in Astronomy, Inc. (AURA)
Program Lead: Craig Peton
Project Engineer: Steve Mix
Contracts Manager: Devi Clarkson
Business Manager: Rachel Belli-Little
Type: FFP
Contract Value: $6,568,000
PoP: 5/11 – 8/14
Description / Deliverables: • Design, Procure, Fabricate and Install the TEOA
3
Program Description
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
10
1. TEOA
Top Assy
M2 Top Assy
Heat Stop
Assembly
M2 Optic Support
Assembly
M2 Lyot Stop
Assembly
2. Program Office
Program
Management
Quality Systems
Engineering
Support Frame
Assembly
Electronics Enclosure
Product Breakdown Structure
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
Program Health
5
Status Trend Action Plan / Comments
Overall Program Y
Contract G • No open contractual issues.
Schedule G • Slight schedule delay with PDR date
Technical Y • Maturity of reference design lower than expected
• ECP needed for Hexapod / Fast Tip-Tilt positioning feedback
• Open spec issues that require further discussion
Supply Chain G • No issues presently identified
Program Risk Y • Risk is moderate due to open technical challenges remaining
with preliminary design.
All Yellow issues center primarily on open spec items that require further discussion.
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
Technical
Requirements compliance quite high, but some
additional work still needed for 100%
Requirements shortfalls will be addressed in detail
during the presentation
Some simply require input from AURA to proceed
Others require discussion due to requirement conflicts
Some may require waivers to fully comply
Schedule
Some setbacks realized during Phase 2 due to
unanticipated design changes required to
reference design
Heat Stop obstruction to science beam
Lyot Stop interference with Heat Stop
Scattered light issue with Heat Stop
Safety Factor of 4 for Hexapod and FTT
CDR efforts have been restructured to help make
up delay in conducting PDR
Contractual
No open contractual issues with AURA
ECP submittal to incorporate autocollimator for
hexapod position feedback expected in March
Major Subcontract/Vendors
Thermacore – Under contract
Pacing item for critical path
Kickoff held 9Feb at L3
L3/SSG – M2 Mirror work underway
Pacing item for secondary critical path
Plan to conduct early CDR in June 2012
Physik Instrumente – letter subcontract issued
Need to resolve safety factor issue
6
Staffing
All technical resources needed for program
execution are on the project
Utilized outside contractor for CFD analysis
Assisted with modeling of airflow on backside of
M2 mirror
Final report received
Program Status
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
Rebaselined Program Plan/Schedule
7
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
8
Rebaselined Program Plan/Schedule
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012 9
Program Milestones
May
2011
Program
Completion
Aug
2014
Program
Start
Jul
2011
Kickoff
Mtg
Phase 2
Initiation
PDR
Phase 3
Initiation
FDR
Phase 4
Initiation
SRR MRR System
Delivery
June
2011
Aug
2011
Oct 2011
Dec
2011
Feb
2012
Mar
2013
Jan
2013 Feb
2014
TRR
Mar
2014
Jul
2014
FAT
Jun
2014
● Overall – L3/SSG proceeding forward with M2 mirror design
• CDR for mirror will have to take place early due to long lead time
• Anticipated CDR date: June 2012
– Thermacore placed under contract in early Feb. Kickoff meeting held 9 Feb at L3. • Initial efforts will focus on revisiting 2007 analysis with new software modeling capability
• Conduct early risk mitigation activities to verify performance
– PI provided letter subcontract to initiate design efforts • Safety factor requirements for this subsystem are a concern (potentially impacts cost and schedule)
● Critical Path(s) Drivers – Primary: Heat Stop Assembly – Design and Fabricate
– Secondary: M2 Assembly – Design and Fabricate
● Key Actions to Meet Upcoming Milestones – Conduct successful PDR and start of Phase 3 CDR efforts immediately
– Proceed with accelerated efforts on M2 Mirror final design
– Obtain direction on safety factor issue
Program Milestones
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
Top TEOA Risks
10
Risk Title
Probability of
Occurance (=) Mitigation Date Action and Plan
1
If the Heat Stop absorber coating material is
inappropriate for this application, then additional time
will be needed to identify another material.
25% Jan-13 ~ Conduct further trade analysis and possbily make a
sample test article with various materials.
4
If vibration of Heat Stop due to high fluid flow rate is
broad-spectrum and not easily isolated, then the
encircled energy requirement due to excessive jitter may
not be met.
35% Jan-13
~ Provide additional isolation to mitigate affects of
vibration.
~ Conduct early testing with Thermacore to determine
actual impact
5
If vibration of M2 Assembly due to impinging air cooling
jets is broad-spectrum and not easily isolated, then the
encircled energy requirement due to excessive jitter may
not be met.
35% Jan-13
~ Conduct additional analysis and possible mock-up
test.
~ Reallocate encircled energy budget
7
If the encircled energy budget cannot be met, then either
a spec waiver must be issued or significant redesign
could be required for the M2 mirror and its mount.
20% Feb-12
~ Request spec waiver
~ Consider a graduated specification based on mirror
position.
~ Optimize polishing of the mirror while in a specific
position.
~ Conduct redesign of mirror/mount to stiffen the
assembly.
8 If the scattered light from the heat stop exceeds 100W,
the spec will not be met. 25% Mar-12
~ AURA is allowing up to 300W, however trade
analysis is continuing to better define the actual value.
9 If Factor of Safety issue on Hexapod/FTT is not
resolved, cost increase and schedule delays will result. 50% Apr-12
~ AURA looking at changing Seismic Spec from
component level to system level.
~ AURA conducting mitigation study to obtain actual
values.
10 If Long Lead Subcontractor deliveries are late, the
overall schedule will slip day for day. 35% Jul-14
~ Manage subcontractors by holding subassembly
design reviews, weekly IPT calls, and onsite visits.
~ Pull in low risks efforts where possible to create
schedule slack.
11
If strict environmental requirements on electrical
components aren't relaxed, design changes will be
required with cost and schedule impacts.
15% Mar-12
~ Discussed with customer. Tech Note provided by
customer but does not address entire problem. Need
to follow up.
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
TEOA Technical Directives
11
TD # Title Description
001 Response to SSR Questions dated Aug 15,2011
Apec 008 takes precidence over SPEC-0063 for connectors, male and female connector definition, alignment target locations, M2 coating to bevel edge, ambiamt weather temperature from weather station, discrete input from the GIS through the TEOA LIC.
002 TEOA Spec Rev B Updates Add PSD Plot of Fitted Velociyt for Vr and Close-loop0 Error Transfer Function
003 Response to SRR Question dated Aug 15, 2011 and Copy of SPEC-086
Spec 008 requirements govern for wind speed and design lifetime, Definition of optical surface is entire front surface
004 M2 Mirror Initial Coating FSS90-500 (protective Silver) is the initial coating, the coating may change to bare aluminum for future re-coating.
005 TEOA Document Revisions DWG-0026, TMS to TEOA Interface RevF; DWG-00113, OSS Electronic Rack Sub-Assy Space Allocation RevB
006 ICD 1.3-4.4 TEOA to TCS Sent copy of ICD 1.3/4.4
007 Jib Crane Coverage Drawing Sent Jib Crane Coverage Drawing
008 Clarification on Piston vs Focus Removal of Piston shall include focus.
009 Operating Humidity
L3 shall make best effort to use components that are rated over the specified Humidity Range of 0 to 70 percent. In cases of deviation, L3 shall report to AURA, in writing, of all of the components that are not rated for the specified Humidity Range. AURA shall then grant L3 deviations for the reported components.
010 TN-0094 Environmnetal Conditions at Site Sent copy of TN-0094
011 Heat Stop Scattered Energy An additional 300 watts of scattered energy scattered onto the M1 Mirror is allowed.
012 TEOA Document Revisions SPEC-0029 ATST Optical Prescription, Rev. F
013 AURA Provided Computer AURA provided one computer with CSF. CSF will be updated every 6 months.
014 Clarification on Seismic Acceleration Given the orientation of the TEOA extends from 0 degree to 90 degrees, this effectively is equivalent to a 3 g seismic acceleration.
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
12
1. TEOA
Top Assy
1.3 M2 Assy
1.3.5 M2
Positioning
System Assy
1.2 Heat Stop Assy
1.3.2 M2
Thermal
Control Assy
1.3.3 M2 Mirror
Assy
1.3.4 M2 Fast
Tip/Tilt Assy
1.3.6 M2 Lyot
Stop Assy
1.4 Control System Assy
1.5 Ancillary Equipment
1.5.1 M2 Assy
Tooling
1.5.2 TEOA
Assy Tooling
1.5.3 M2 Optic
Tooling
2. Program Office
2.1 Program
Mgmt
2.2 Quality 2.3 System
Engineering
Hexapod Incoming
Inspection Point
M2 Mirror Incoming
Inspection Point
M2 Assembly Inspection Point
Heat Stop Assembly
Incoming Inspection Point
TEOA Assembly Inspection Point (Factory Acceptance Testing)
•Compare ICD to vendor
measurements*
•Compare performance to
requirements*
•Compare ICD to vendor
measurements*
•Review polish, coating performance
to requirements*
•Compare ICD to vendor measurements*
•Compare ICD to vendor
measurements*
•Compare performance to
requirements*
•Compare ICD to vendor
measurements*
•Compare performance to
requirements
Tooling Incoming Inspection Point
•Compare ICD to vendor
measurements*
•Load testing of lifting components
* Review of C of C and associated data
Quality Assurance Plan Updates
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
Current Open Action Items
13
Number Description Responsible Interface Date AssignedDate Closed Comments/ Resolution
30Can the safety factor of 4.0 be relaxed for PI? PI's design uses
a safety factor of 3.0. The SF of 4.0 requires a redesign effort.Chen Liang AURA 1/10/2011 Pending AURA Seismic Analysis and Report due in April 2012.
31 Aura will provide a contract mod to eliminate the lyot stop. Chen Liang AURA 1/25/2012
32Aura will provide a contract mod to eliminate the lyot stop.
Brashear to provide a mechanical ICD for future addition.Heller/Mix AURA 1/25/2012
33Update ICD 1.3/2.1 & 1.3/4.4. Include control block diagrams
and signal interfaces. PIO or ethernet. Etc.Balister/Bret GoodrichAURA 1/25/2012
34Update the SDD based on the software training. Incorporate
items in AURA SDD formatBalister AURA 1/25/2012
35
Brashear to provide 2 ECPs for the tip/tilt resolution of 0.2
arcsec requirement. One for a design study, and one for the
downselect from the design study after study is complete.
Mix AURA 1/25/2012
36AURA to approve the electronics Equipment that doesn't
meet the Environmental and EMC Testing Req.Bader AURA 1/25/2012
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
PDR Exit Criteria
14
Item Status Reference
A. Updated Project Plan
B. Updated Quality Assurance Plan
C. Updated Risk Analysis Chart
D. Specifications Compliance Matrix in Customer Format
E. Preliminary Hardware Design
- 3D models and/or 2D drawings of all major components/subsystems
- PL's & processes for all major components/subsystems
- Summary of major purchased components/subsystems specifications
- Description of major component manufacturability
- Preliminary analyses: Gravity-induced static and dynamic deflections and resulting figure error;
Wind-induced deflections and dynamic figure error; Temperature-induced deflections and
resulting figure error; Quantifying internal vibration sources and resulting jitter; Seismic response
& stresses; Structural resonances
- Preliminary estimate of weight, center of gravity and mass moment of inertia
- Preliminary electronics and cabling designs and layouts
- Preliminary electrical power and grounding designs and layouts
- Preliminary mechanical and packaging design of electronic equipment including consoles, racks,
drawers, printed circuit boards, connectors, cabling and thermal management systems
- Preliminary servo control system designs and summary of analyses
- Summary of built-in tests designed to support required preventative maintenance, fault
localization and fault detection
-Summary of component and subsystem specifications for purchasing of commercial parts
- Summary of design considerations regarding reliability and maintainability of components,
subsystems and systems
Description
Integrated Optical Systems L-3 Communications - Brashear Proprietary
The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012
PDR Exit Criteria
15
F. Preliminary Software Design
- Description of typical interactions
- Sequence diagrams illustrating the behavior of the system for each typical interaction
- class diagram down to the Component/Controller level and a description of the role and behavior
of each class in the diagram
- Deployment diagram showing the physical relationships among the hardware and software
components
- Integration with the ATST Common Services Framework infrastructure model, per SPEC-0013,
including the use of the Command-Action-Response model and reliance upon the Connection,
Event, Log, and Header, and Property Services
G. Preliminary Software Rapid Prototyping plan
H. Preliminary designs for all mechanical, electronic, and software interfaces WRT ICD's
I. Preliminary design of primary M2 optical surface metrology setup with tolerance analysis/alignment plans
J. Preliminary design of redundant M2 optical surface metrology setup with tolerance analysis/alignment plans
K. Drawings and specifications for all components with particularly long lead items
L. List of likely suppliers for commercial off-the-shelf type components and systems
M. Discussion and outline for the Factory Acceptance Test Plan (F-ATP) including Error Analysis
N. Description of the packaging and transportation plan
O. Draft tables of contents for the Operations and Maintenance Manuals