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Managing the Design and Fabrication of a World-class Astronomical Instrument Thomas Kisko, M.S., P.E. Associate in Industrial Engineering. Abstract.

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slide1

Managing the Design and Fabrication of a World-class Astronomical InstrumentThomas Kisko, M.S., P.E.Associate in Industrial Engineering

T-ReCS

ISE Graduate Seminar

September 2, 1999

abstract
Abstract
  • The 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?

T-ReCS

ISE Graduate Seminar

September 2, 1999

slide3

T-ReCS

Gemini Thermal Region Camera & Spectrograph

Key Personnel:

Charles Telesco PI, Optical/Mechanical, Science

Tom Kisko Project Manager, Software

Robert Piña Software, Science

Kevin Hanna Electronics

Jeff Julian Mechanical/Thermal

David Hon Software

UCF (CREOL/FSI) Optics

Glenn Boreman

Jim Harvey

Jongwook Kye

Glenn Sellar

T-ReCS

ISE Graduate Seminar

September 2, 1999

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

T-ReCS

ISE Graduate Seminar

September 2, 1999

gemini south on cerro pachon chile
Gemini South on Cerro Pachon, Chile

Photo Courtesy of Gemini Observatory

T-ReCS

ISE Graduate Seminar

September 2, 1999

the gemini telescope structure
The Gemini Telescope Structure

T-ReCS

ISE Graduate Seminar

September 2, 1999

Courtesy of Gemini Observatory

overview of system layout 3d boundary layout

Overview of System Layout3D Boundary Layout

T-ReCS

ISE Graduate Seminar

September 2, 1999

t recs 2d dewar layout
T-ReCS 2D Dewar Layout

T-ReCS

ISE Graduate Seminar

September 2, 1999

3d cold plate layout
3D Cold Plate Layout

Window Turret

Sector Wheel

Grating/Imaging

Turret (p2)

Aperture Wheel (i0) with

window imaging lens.

F4 Turning

Flat

Pupil Imaging

Wheel

F1 Turning

Flat

Array (i2)

M3 Camera

Mirror

Filter/Lyot

Wheels (p1)

F2 Turning Flat

Slit Wheel (i1)

T-ReCS

ISE Graduate Seminar

September 2, 1999

M1 Transfer

Mirror

M2 Collimator Mirror

Top View

Split Cold Plate

window changer
Window Changer
  • Provides 5 window positions that can be selected
  • during 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 action
  • when wheel is turned. No additional motor drive
  • required.
  • 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.

T-ReCS

ISE Graduate Seminar

September 2, 1999

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 at
  • cryogenic temperatures.
  • Stainless steel tubing truss provides rigid mounting
  • and thermal isolation.
  • Gearbox connected to mechanisms for
  • height and gear ratio tuning.
  • Electrical connections via heatsunk
  • ‘D’ connector helps cool motor
  • windings.
Cryo-Motor Drives

T-ReCS

ISE Graduate Seminar

September 2, 1999

i0 aperture wheel
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.

T-ReCS

ISE Graduate Seminar

September 2, 1999

vacuum pressure effects on dewar case lids
Vacuum Pressure Effects on Dewar Case Lids

T-ReCS

ISE Graduate Seminar

September 2, 1999

optics mount temperature gradients
Optics Mount Temperature Gradients

T-ReCS

ISE Graduate Seminar

September 2, 1999

total weights and c g of system
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.

T-ReCS

ISE Graduate Seminar

September 2, 1999

slide16

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

T-ReCS

ISE Graduate Seminar

September 2, 1999

slide17

T-ReCS Optical Layout

Filter & Lyot-stop wheels

transfer mirror

camera

mirror

focal plane array

grating/imaging turret

collimator

mirror

slit wheel

window-imaging lenses

aperture-stop

wheel

pupil lens

wheel

entrance window

wheel

T-ReCS

ISE Graduate Seminar

September 2, 1999

slide18

T-ReCS Unfolded Optical Layout

Transfer

Mirror

(M1)

Telescope

Focus

(i0)

Intermediate

Image (i1)

1st Pupil (p1)

2nd Pupil (p2)

Collimator

Mirror

(M2)

Camera

Mirror

(M3)

Final Image

(i2, Detector)

T-ReCS

ISE Graduate Seminar

September 2, 1999

mon r2 star forming region
Mon R2 Star Forming Region

T-ReCS

ISE Graduate Seminar

September 2, 1999

overall electronics block diagram
Overall Electronics Block Diagram

ASP Rack

Dewar

ICS Rack

Bias Module

Clocks

Main EPICSVME Components

Main Readout Electronics

Analog

Array

Gemini OCS

Motion & Temperature ControlComponents

AnalogPower Supplies

Preamp

TemperatureControl

MotionControl

EPICS CannelAccess LAN

DHS LAN

ChopperEvent Bus

T-ReCS

ISE Graduate Seminar

September 2, 1999

2 overall architecture

Level 0 Data Flow:

2. Overall Architecture

T-ReCS

ISE Graduate Seminar

September 2, 1999

level 0 protocol

Image

Pipeline

EPICS Channel Access

DRAMA/IMP

Gemini Event Bus

2. Overall Architecture

OCS

DHS Server

Eng. Consoles

TCS & SCS

Level 0 Protocol:

LAN(s)

ICS/IOC (VxWorks/EPICS)

DHS

Client

Sequencer

Tasks

Channel

Server

Detector

Agent

Image

Server

EPICS DB

GenSub

CAD/CAR

Scan &

Monitor

Tasks

EPICS DB

SAD

ASP Interface

Fibre/DMA &

Serial (RS232)

Motor, Serial Port, etc.

T-ReCS

ISE Graduate Seminar

September 2, 1999

UFLib Protocol

level 1 ics runtime

Image Pipeline

&

Server (TCP)

UFLib Runtime Entry

Gemini Event Bus

2. Overall Architecture

CAD

Replicated

TCS Environment

& WCS & SCS

Records

TCS

&

SCS

Level 1 ICS Runtime:

Apply

SystemSeq

OCS

CAR

Interm.CAD/GenSub Records

Interm.CAD/GenSub Records

Detector Records

ComponentsSeq

libUFGem (C)

(Epics & VxWorks)

DetectorSeq

Detector Agent

(TCP Server)

Interm.CAD/GenSub Records

EnvironmentSeq

MotorSeq

ASP

libUF (C++)

Motor Records

Environment Records

T-ReCS

ISE Graduate Seminar

September 2, 1999

EPICS Database I/O

UF Protocol

level 1 image pipeline runtime

Image

Ring buffers

(diffs & accums)

2. Overall Architecture

Level 1 Image Pipeline Runtime:

NFS

PMC/DMA

FrameGrabber

Frame

Ring buffer

(Shared

Memory)

ASP

Image

Ring buffer

(Shared

Memory)

Pixel Sort &

Local Archive

Queue

of

Frames

on

Heap

Image Preprocessor

libUF (C++)

(No Epics Bindings)

libUFGem (C)

(Epics Bindings)

Image Server

(TCP/IP)

(Zbuff Socket)

Epics SAD

DHS Client

T-ReCS

ISE Graduate Seminar

September 2, 1999

Data LAN

slide25

A

B

C

D

1

1

DIR

CLID

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

Apply

INMF

INPF

CLID

DIR

INMH

INPH

INMG

INPG

INME

INPE

INMD

INPD

INMC

INPC

INMB

INPB

INMA

INPA

SLNK

PV:$(top)$(mech)

The "apply" record sequences the other

"apply" records contained in the lower level

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

2

2

apply

DESC:CICS CC system APPLY record

OCLF

OUTF

VAL

FLNK

OCLH

OUTH

OCLG

OUTG

OCLE

OUTE

OCLD

OUTD

OCLC

OUTC

OCLB

OUTB

OCLA

OUTA

MESS

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

MESS

VAL

MESS

It is important that this fact is reflected in the

They are not required and are therefore left out.

DIR

DIR

DIR

CLID

CLID

CLID

ccSysCad4

ccSysCad2

ccSysCad1

3

(C)

(B)

(A)

3

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

ccSysCad.sch

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

MESS

MESS

MESS

VAL

VAL

VAL

.

.

.

=====

ICD14

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

author:S.M.Beard

checked:B.Goodrich

C

4

4

12 Aug 97

Core Instrument Control System

System Command Action Directive Records

SHEET

1

OF

A

B

C

D

7. EPICS Commanding

T-ReCS

ISE Graduate Seminar

September 2, 1999

project management

Project Management

T-ReCS

ISE Graduate Seminar

September 2, 1999

project management objectives
Project Management Objectives
  • Quality instrument
  • On time
  • Under budget
  • Minimize risk
  • Contingencies

T-ReCS

ISE Graduate Seminar

September 2, 1999

major management activities since pdr
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

phases of a project
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

project schedule
Project Schedule

T-ReCS

ISE Graduate Seminar

September 2, 1999

project schedule1
Project Schedule
  • Let’s look at it in detail.
  • I’ll open it with MS Project.

T-ReCS

ISE Graduate Seminar

September 2, 1999

monthly management report
Monthly Management Report

T-ReCS

ISE Graduate Seminar

September 2, 1999

the monthly management report also includes
The Monthly Management Report Also Includes:
  • A summary of: Activities for the month Accomplishments Problems
  • 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

T-ReCS

ISE Graduate Seminar

September 2, 1999

monetary information flow
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 macros

Budgets

Monthly proration

Sheet for each monthly management report

T-ReCS

ISE Graduate Seminar

September 2, 1999

uf accounting mainframe data
UF Accounting Mainframe Data

T-ReCS

ISE Graduate Seminar

September 2, 1999

ms access transaction database
MS Access Transaction Database

T-ReCS

ISE Graduate Seminar

September 2, 1999

bill of materials for t recs
Bill of Materials for T-ReCS
  • Items are specified in a hierarchy of items, subitems, and terminal items. 1 Car 1.1 Engine 1.1.1 Alternator 1.1.1.1 Alternator pulley - $4.23 1.1.1.2 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.

T-ReCS

ISE Graduate Seminar

September 2, 1999

bill of materials sheet
Bill of Materials Sheet

T-ReCS

ISE Graduate Seminar

September 2, 1999

bom codes
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

bill of materials help sheet
Bill of Materials Help Sheet

T-ReCS

ISE Graduate Seminar

September 2, 1999

slide41
BOM
  • Let’s do a demo.
  • I’ll open it with Excel.

T-ReCS

ISE Graduate Seminar

September 2, 1999

the new plan
The New “Plan”
  • A cost estimating/tracking system
  • Plans every expenditure:
  • BOM items
  • Payroll
  • Travel
  • Miscellaneous costs
  • Based on a planned expenditure list

T-ReCS

ISE Graduate Seminar

September 2, 1999

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

T-ReCS

ISE Graduate Seminar

September 2, 1999

managing the fabrication of t recs
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

managing expenditures and staffing
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)

T-ReCS

ISE Graduate Seminar

September 2, 1999

managing day to day
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

risk possible reasons that may delay delivery
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

contingency management
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

lessons learned workshop
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

T-ReCS

ISE Graduate Seminar

September 2, 1999

web sites
Web Sites
  • Kisko’s Web Site (has these PowerPoint slides) http://www.ise.ufl.edu/kisko
  • T-ReCS Web Site http://t-recs.astro.ufl.edu/
  • Gemini Web Site http://www.gemini.edu/

T-ReCS

ISE Graduate Seminar

September 2, 1999