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Abstract

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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Abstract

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  1. 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

  2. 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

  3. 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

  4. http://www.gemini.edu/public/ T-ReCS ISE Graduate Seminar September 2, 1999

  5. Gemini South on Cerro Pachon, Chile Photo Courtesy of Gemini Observatory T-ReCS ISE Graduate Seminar September 2, 1999

  6. The Gemini Telescope Structure T-ReCS ISE Graduate Seminar September 2, 1999 Courtesy of Gemini Observatory

  7. Overview of System Layout3D Boundary Layout T-ReCS ISE Graduate Seminar September 2, 1999

  8. T-ReCS 2D Dewar Layout T-ReCS ISE Graduate Seminar September 2, 1999

  9. 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

  10. 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

  11. 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

  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. T-ReCS ISE Graduate Seminar September 2, 1999

  13. Vacuum Pressure Effects on Dewar Case Lids T-ReCS ISE Graduate Seminar September 2, 1999

  14. Optics Mount Temperature Gradients T-ReCS ISE Graduate Seminar September 2, 1999

  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. T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  17. 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

  18. 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

  19. Mon R2 Star Forming Region T-ReCS ISE Graduate Seminar September 2, 1999

  20. 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

  21. Level 0 Data Flow: 2. Overall Architecture T-ReCS ISE Graduate Seminar September 2, 1999

  22. 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

  23. 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

  24. 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

  25. 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

  26. Project Management T-ReCS ISE Graduate Seminar September 2, 1999

  27. Project Management Objectives • Quality instrument • On time • Under budget • Minimize risk • Contingencies T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  30. Project Schedule T-ReCS ISE Graduate Seminar September 2, 1999

  31. Project Schedule • Let’s look at it in detail. • I’ll open it with MS Project. T-ReCS ISE Graduate Seminar September 2, 1999

  32. Monthly Management Report T-ReCS ISE Graduate Seminar September 2, 1999

  33. 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

  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 macros Budgets Monthly proration Sheet for each monthly management report T-ReCS ISE Graduate Seminar September 2, 1999

  35. UF Accounting Mainframe Data T-ReCS ISE Graduate Seminar September 2, 1999

  36. MS Access Transaction Database T-ReCS ISE Graduate Seminar September 2, 1999

  37. 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

  38. Bill of Materials Sheet T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  40. Bill of Materials Help Sheet T-ReCS ISE Graduate Seminar September 2, 1999

  41. BOM • Let’s do a demo. • I’ll open it with Excel. T-ReCS ISE Graduate Seminar September 2, 1999

  42. 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

  43. Managing ... • Fabrication of T-ReCS • Expenditures and Staffing • Day-to-day activities • Contingencies T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  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) T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  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 T-ReCS ISE Graduate Seminar September 2, 1999

  50. 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

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