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Blanco TCS Upgrade Project

Blanco TCS Upgrade Project. Status & path forward September 29, 2011. Review of Project . Review Panel Rolando Rogers Esteban Parkes Gale Brehmer Steve Heathcote Ricardo Schmidt Brainstorming meeting Sept. 26, 2011 Review, as part of ACTR Sept. 29, 2011.

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Blanco TCS Upgrade Project

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  1. Blanco TCS Upgrade Project Status & path forward September 29, 2011

  2. Review of Project Review Panel • Rolando Rogers • Esteban Parkes • Gale Brehmer • Steve Heathcote • Ricardo Schmidt • Brainstorming meeting Sept. 26, 2011 • Review, as part of ACTR Sept. 29, 2011

  3. Blanco 4M TCS Upgrade Project Reasons Why! • Off-sets of 2.5 degree in 27s • Requirement for DECAM • Replace HW that is or will be obsolete • Architecture for new system based on LSST architecture

  4. Outline Presentation • Overview New System • Status • Rotator Upgrade (new requirement!) • Results with New System • Hybrid System • To allow testing of upper level SW to proceed • (with requirements of old TCS) • NOTE: Increased weight of DECam imposes a new requirement! • Results September run • Strategy • Proposed solutions / Brainstorming meeting • w/ Review panel • Conclusion – solution chosen • Budget & plan forward

  5. Chosen solution presented first • To allow the entire review panel to be present and comment on solution • So directly to slides with solution 3a & 3b • To come back to rest of presentation afterward

  6. TCS Brainstorming meeting • 3a. Buy different “Off the shelf” programmable driver • Might close all three loops • Pros: • Possible to choose a proved solution • Cons: • Might not have the required flexibility (programmable?) • Might require time to find a suitable unit • Conclusions • Wednesday 28 September • After extensive search we did not found any "off the shelf" • programmable driver, which satisfy all the following requirements • at the same time. • 1.- Permit close the current loop. • 2.- Adequate reading and signal filtering for tachometer, • to close the velocity loop. • 3.- Include the possibility to close both velocity and current loop. • 4.- DC motor control to 20V and current to 20A. • 5.- Low internal DC bus voltage. • 6.- Enough signal inputs and ADC converters to read external signals. • 7.- Enough flexibility to add feedback signals on each loop.

  7. TCS Brainstorming meeting • Because no off-the-shelf solution was found, option 3b is the only option left. • 3b. cRIO based implementation • This solution considers closing • current loop with an amplifier, • velocity loop using the cRIO and • position loop using the PMAC board • Pros: • Maximum flexibility • Good telemetry • Cons: • Requires time/man-power to produce new software for the cRIO • Chosen solution is based on SOAR M3 Tip-Tilt System. • Proven, working system, • with which we already have lots of experience; • Extensive telemetry will permit adaptation of drive control • to new dynamics of the telescope, after DECam is installed.

  8. Console Manual Slew(1) Console Velocity Demand(2) Console Current Current Drivers (4) Motor CRIO FPGA 8-Slot Controller PMAC Velocity Demand (2) 16 Ch ADC 4Ch-DAC Motor Voltages(4) Motor Currents(4) 32 Ch Dig I/O 16Ch ADC PMAC Status Relay Tach Safety Enable Power Supply Blanco Motor Driver Chassis

  9. End intermezzo Back to rest of presentation

  10. Blanco 4M TCS Upgrade Diagram Instruments IMAN Ethernet Operator GUI PC-Guider DECAM ISPI HYDRA MOSAIC NEWFIRM Motor Controllers (SMC) Remote Ops added added NEW To Dome PLC 4MAP PF4M IMAN ROT4M CFADC F8SEC old F8SEC UDP, TCP/IP Dome Interface RS-485 Dome Encoders F.O RS-485 Serial/ Fiber Op. To Ra/Dec Motors Dome/ Utility TCS App HandPaddle Mount Control Comparison Lamps Interlocks Lamps Interface Facility Database Mount Interface / Kernel cRIO Tape Encoders To Guider Motors NEW IRIG-B NEW Guider Interface Guider Encoders Time Weather, MASS DIMM, Sky Cam.

  11. Current Rotator Motion Control L1,L2 Heurikon TCS Old Comparison Lamps Guider: Axis X Axis Y Axis Z 3 stepper motors Rot4M SMC has the following functions: Control of Rotator Control of Rotator Mirror Reading of the Guide Probe Encoders Control of Iman RS232 to RS485 M4 Control 1 Old Quick Silver motors Lens flip Lens focus Camera focus Slit flat Rot4M SMC Mux 4 dc motors IMAN 4MAP CFADC F8SEC PF4M IMAN On/Off Pellicle Flat mirror Aperture wheel Led 4 dc motors 2 digital outputs Rotator Power Supply Driver Rotator Motor Hand Paddle

  12. Guider Upgrade Guider Motor Drive Abs. Encoder Reader NEW! Dome/Utility Computer F8SEC F.O./RS485 Guider: Axis X Axis Y Axis Z IMAN 4MAP CFADC F8SEC old PF4M RS485 3 stepper motors 3 abs. encoder 4 M4 Control 1 Old Quick Silver motors Lens flip Lens focus Camera focus Slit flat Rot4M SMC Mux 4 dc motors IMAN On/Off Pellicle Flat mirror Aperture wheel Led 4 dc motors 2 digital outputs Rotator Power Supply Driver Rotator Motor Hand Paddle

  13. Present Servo Racks & Mount Control Loop TCS on VME Chassis Mount Encoders VME 9100 RA Manual Slew Tach1 M1 RA Servo Rack Abs. RA Inc. RA Slew/Track Select. Tach 2 M2 RA Speed Ref. VME PMAC DEC Speed Ref. Tach 3 M3 DEC Servo Rack Slew/TrackSelect. Abs. DEC Inc. DEC Heurikon Processor Tach 4 M4 DEC Manual Slew VME 9100

  14. NEWMount Control Loop

  15. Some History • Closed position loop w/ velocity feedback • position & velocity fromtape encoders ! • => tracking & off-setting not as fast as required • Closed position loop w/ velocity feedback • now position & velocity from incremental encoders • => performance improved a lot • but still not up to specs! • Not possible to add separated velocity loop using tacho-generators • because of high noise & un-stability on their reading. • In addition, PMAC did not permit a direct velocity feedback • (velocities are derived from position readings) • Not possible to close current loop on PMAC • because of un-stability of current loop for high current demand • worked well at low current demand

  16. Results with new systemAugust 2011 • Tuned new system w/ incremental encoders • Does not fulfill TCS demand, because • Small offsets: excessive delay • Tracking commands: • excessive oscillation • Tracking error: • 0.057 arcsecrms • No more tuning improvement • could be done • w/ control parameters provided • by PMAC board • => different approach needed

  17. Hybrid System Telescope Mount ACC65M I/O Peripheral Macro Ring (Fiber Optic) DEC (South) GEOMacro Driver Mount PC DEC Absolute Encoder. DEC Servo Rack Tach1 M1 DEC (North) GEOMacro Driver Tach2 DEC Tape Encoder M2 PCI-PMAC Ultralite Board Controller Compact RIO Tape Encoder Preprocessor RA (East) GEOMacro Driver RA Tape Encoder M3 Tach3 RA Servo Rack RA (West) GEOMacro Driver Tach4 M4 RA Absolute Encoder. ACC65M I/O Pheripheral

  18. Hybrid System – Resultsas tested in September 2011 • Behavior similar to old system but using new PMAC board on an industrial PC • Tracking Error = 0.128” rms • Requirement of 27s for 2.5 degree • currently: 2.4 degree in 27s, see graph. Acceleration was 6x slower then what can be achieved • 2.5d in 27s – TBC (Oct. 1, 2011) • Permits complete development of rest of SW & interfaces. • Hybrid system can be totally functional, but unclear if capable of handling additional weight incorporated by DECAM (new requirement!)

  19. Strategy Short term to be able to proceeding with testing of upper level SW Fine-tune hybrid system Implement dynamic change of loop parameters Long term to Replace obsolete servo’s Prepare for new weight requirement Need to control 3 loops (to reproduce current system): i) Current; ii) Velocity; iii)Position

  20. Proposed solutionsinput for brainstorming meeting • To obtain a system similar to the old one, we will: • Close velocity loop, using separated PMAC control loop, • in cascade with position loop • Close current loop on PMAC –– hasn’t worked so far! • NOTE: Depends on functionality of Geo-macro –– to be analyzed! • Preprocess tacho-generator signal with cRIO, before reading by PMAC • Alternative solutions • Use upgraded analog version of present (old) servos • Buy different drivers commanded by voltages generated by turbo PMAC board • Other improvements needed (independent of solution chosen) • Preprocess tape encoder signals, using cRIO, before reading by PMAC. • Dynamic adjustment of loop parameters depending on velocity (as mentioned before)

  21. TCS Brainstorming meeting • Monday 26 September 2011 • Present: RS, SH, MW, EM, RR, EP, OE, MM, GS, RC, GB, NvdB • Four paths forward were proposed: • Continue with present solution • Analog version of present hardware • Replace certain elements of present solution • Buy different “Off the shelve” programmable driver. Might close all three loops. • cRIO based implementation. This solution considers closing • current loop with an amplifier; • velocity loop using the cRIO; • positon loop using the PMAC board • Replace motors • The pros & cons of the four solutions were discussed in great length, and it was decided not to follow-up on solution 1, 2 and 4. Only options 3a and 3b were explored in more detail.

  22. TCS Brainstorming meeting • 3a. Buy different “Off the shelf” programmable driver • Might close all three loops • Pros: • Possible to choose a proved solution • Cons: • Might not have the required flexibility (programmable?) • Might require time to find a suitable unit • Conclusions • Wednesday 28 September • After extensive search we did not found any "off the shelf" • programmable driver, which satisfy all the following requirements • at the same time. • 1.- Permit close the current loop. • 2.- Adequate reading and signal filtering for tachometer, • to close the velocity loop. • 3.- Include the possibility to close both velocity and current loop. • 4.- DC motor control to 20V and current to 20A. • 5.- Low internal DC bus voltage. • 6.- Enough signal inputs and ADC converters to read external signals. • 7.- Enough flexibility to add feedback signals on each loop.

  23. “Off-the-shelf” solutions

  24. TCS Brainstorming meeting • Because no off-the-shelf solution was found, option 3b is the only option left. • 3b. cRIO based implementation • This solution considers closing • current loop with an amplifier, • velocity loop using the cRIO and • position loop using the PMAC board • Pros: • Maximum flexibility • Good telemetry • Cons: • Requires time/man-power to produce new software for the cRIO • Chosen solution is based on SOAR M3 Tip-Tilt System. • Proven, working system, • with which we already have lots of experience; • Extensive telemetry will permit adaptation of drive control • to new dynamics of the telescope, after DECam is installed.

  25. Console Manual Slew(1) Console Velocity Demand(2) Console Current Current Drivers (4) Motor CRIO FPGA 8-Slot Controller PMAC Velocity Demand (2) 16 Ch ADC 4Ch-DAC Motor Voltages(4) Motor Currents(4) 32 Ch Dig I/O 16Ch ADC PMAC Status Relay Tach Safety Enable Power Supply Blanco Motor Driver Chassis

  26. Budget • Guider Probe Control & Electronics Box 4k • Telemetry 3k • Integration & testing 8k • Servo/Driver 20k • Servo System Control 17k • Contingency (20%) • Total 62k

  27. Schedule / Path forward Hybrid system • October • Before Engineering run: • prepare Hybrid system: • Purchase elements for telemetry • Test & analyze Hybrid system • During Engineering run: • Fine tune system • Deliverable: System that performs as well as old system, • but with new PMAC & PMAC SW • November • Between October & November Engineering run: • Integrate SW & HW • During Engineering run: • Use Hybrid system to integrate & test new upper level SW • Observe with Hybrid system, new SW and an instrument which has it’s own guider (MOSAIC) • December • During December Engineering run: • Continue testing upper level SW

  28. Schedule / Path forward Upgraded system • October • Telemetry • Install telemetry components • Start detailed characterization of old system • Upgrade Servo HW • Detailed selection of components for Servo replacement • Internal review of components (before mid-Oct) • Deliverable: Purchase list (Delivery times ~ 4-8 weeks (?)) • November/December • Components arrive • Integrate HW & Serial SW (1 month) • Integrate HW of new servo @telescope (1 week) • January (?) • Test new HW (preferably 2 engineering runs) • Contingency ? • Final fine-tuning of system • To be done with dummy DECam weight (and counterweight) present)

  29. Schedule / Path forward continued • Final fine-tuning of system • To be done with dummy DECam weight (and counterweight) present) • Contingency ? • Rotator upgrade – in parallel • Before December Engineering run: • Guider control • Electronics box • At a later stage: • IMAN • Rotator function • M4 control

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