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GLAST Large Area Telescope: Integration and Test Two Tower Integration Readiness Review Integration, Facilities, Configu

Gamma-ray Large Area Space Telescope. GLAST Large Area Telescope: Integration and Test Two Tower Integration Readiness Review Integration, Facilities, Configuration and Test (IFCT) Department Ken Fouts / Brian Grist. IFCT Outline. Operations Readiness EGSE Integration Facility.

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GLAST Large Area Telescope: Integration and Test Two Tower Integration Readiness Review Integration, Facilities, Configu

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  1. Gamma-ray Large Area Space Telescope GLAST Large Area Telescope: Integration and Test Two Tower Integration Readiness Review Integration, Facilities, Configuration and Test (IFCT) Department Ken Fouts / Brian Grist

  2. IFCT Outline • Operations Readiness • EGSE • Integration Facility

  3. IFCT Part I. Operations Readiness • Summary of 2 tower I&T Operations and AIDS • Mapping of AIDS to schedule / PMCS • AIDS and Time Estimates Overview • Grid Installation and Survey • Calorimeter Receiving and Post-Ship Test • TEM/TPS Receiving • Tracker Receiving and Post-Ship Test • Calorimeter and TEM/TPS I&T • Test Bay I&T • Grid Bay I&T • Bays 8 + 9 I&T

  4. Two Tower I&T Operations Receive Calorimeter, TEM/TEM PS Flight Units B Receive and assemble Grid Receive Calorimeter, TEM/TEM PS Flight Units A Receive Tracker Flight Unit B Receive Tracker Flight Unit A Integrate Grid onto Rotation Stand Install in Metrology Bay for Shimming & Assembly Install in Metrology Bay for Shimming & Assembly Install tower in Test Bay Test CAL B & TEM/TEM PS B Install tower in Test Bay Test CAL A & TEM/TEM PS A Grid Optical Survey Test Single Bay Tower Test Single Bay Tower De-Install Tower from test bay De-Install Tower from test bay Integrate Tracker A into Grid Integrate CAL/TEM/TPS A into Grid Single Tower Test in Grid Optical Survey Integrate Tracker B into Grid Integrate Cal/TEM/TEM-PS B into Grid Single Tower Test in Grid Two Tower I&T

  5. Assembly and Inspection Data Sheet

  6. Assembly and Inspection Data Sheet

  7. Assembly and Inspection Data Sheet

  8. Mapping of AIDS to schedule / PMCS • Strategy • AIDS line items tracked in MS Project • Line items are groups of work which take >1hr • Status • AIDS drafts delivered to scheduler; data input in process; ECD Dec. 18

  9. AIDS and Time Estimates Overview

  10. Key Two Tower Risk Minimal Risk Grid Installation and Survey Notes • Mechanical Systems (Martin Nordby) is working with SLAC metrology to define the Grid survey requirements. Risk Mitigation • Plan for completing a Grid to Grid Perimeter Ring fit check in work ECD 12/1.

  11. Calorimeter Receiving and Post-Ship Test Notes • Calorimeter post-ship test performed by Calorimeter Subsystem using subsystem GSE and staff. • Calorimeter TEM/TPS safe-to-mate performed by I&T for TEM-GASU and TPS-PDU connectors only • Calorimeter I&T receiving test performed by I&T Risk Mitigation • ELX will complete acceptance testing on EGSE Test Stand

  12. TEM/TPS Receiving Notes • TEM/TPS manufacturing is completed in Room 103 • Safe-to-mate is performed on all TEM/TPS connectors (14)

  13. Tracker Receiving and Post-Ship Test Notes • Tracker receiving inspection yet to be defined • Tracker post-ship test performed by tracker subsystem Risk Mitigation • I&T working closely with TKR subsystem to develop processes. • Plan is to use the TKR Mock Up with Flight-like Cables delivered in December to dry run receiving procedures. • ELX will complete acceptance testing on EGSE Test Stand

  14. Calorimeter and TEM/TPS I&T Notes • I&T is considering requirements for relocating this process from room 104 (current baseline) to room 103 to relieve floor space usage in room 104 Risk Mitigation • ELX will complete acceptance testing on EGSE Test Stand

  15. Test Bay I&T Notes • Tracker installation procedures not finalized at this time • Tower survey is managed by Martin Nordby and staffed from SLAC Metrology • Tower trigger test procedures and software not finalized at this time • E2E test software not finalized at this time • SVAC test software not finalized at this time Risk Mitigation • Plan is to use the TKR Mock Up with Flight-like Cables delivered in December to dry run receiving procedures • ELX will complete acceptance testing on EGSE Test Stand

  16. Tracker Installation • Basic Procedure complete • New inputs from Tracker Group to be incorporated • Cone assembly process (done) • Cable bonding process (still in work) • Some Project decisions pending • Adjustment of Tower lean • Measurement of Tower location • Procedures and documentation for Lifting need approval after procedure release

  17. I&T Test Definitions • Single Bay Test (in EM single bay) 54 hrs total (40 hrs w/o E2E/SVAC/VDG) • Aliveness Test (15 min) • Calorimeter: CPT (2 hrs) • Tracker: Pass/fail tests (2hrs) • Trigger: Module internal timing, GEM timing alignment, subsystem TACK delays (36 hours) • End-to-end Test, 6 hrs • SVAC Data Collection (Bay 9 only, includes VDG) 8 hrs • Single Bay Test (in flight grid) 44 hrs total (4 hrs w/o SVAC) • Aliveness Test (15 min) • Calorimeter: CPT (2 hrs) • Tracker: Pass/fail tests (2hrs) • SVAC Data Collection (Bay 9 only, no VDG) Day 1=16 hrs, Day 2 = 24 hrs • Two Bay Test (in flight grid) 104 hrs total • Aliveness Test (15 min) • Calorimeter: CPT (4 hours) • Tracker: Pass/fail tests (4hrs) • End-to-end Test, 40 hrs • SVAC Data Collection (includes VDG) Day 1=16 hrs, Day 2 = 24 hrs, VDG=16 hrs

  18. Grid Bay I&T Notes • Same as for test bay I&T, except no trigger nor E2E tests Risk Mitigation • Plan is to use the TKR Mock Up with Flight-like Cables delivered in December to dry run receiving procedures • ELX will complete acceptance testing on EGSE Test Stand

  19. Bays 8+9 I&T Notes • Flight mates are performed on DAQ cables to bays 8 & 9 • Subsystem tests are executed module by module • E2E test software not finalized at this time • SVAC test software not finalized at this time Risk Mitigation • ELX will complete acceptance testing on EGSE Test Stand • Test definition in process with Systems Engineering

  20. IFCT Part II. EGSE Preparation • Acceptance and validation process • COTS • BOBs • Connector savers • PDU • GASU • TEM/TPS • BPU • Test Stands • Test Procedures

  21. EGSE Process; Design to Use Integration and Test (I&T) Subsystem Electrical Ground Support Equipment (EGSE) Plan LAT-MD-01533 Just released for review.

  22. Break Out Boxes are Ready • Breakout boxes facilitate interface verification without significant risk to flight hardware. Note that the LAT electronics design does not easily permit measurements of LVDS signaling characteristics at data rate. Four boxes are required: • 26 pin interface • 44 pin interface • 78 pin interface • 104 pin interface • Adapter cables adapt between different pin outs, connector styles and sizes. Examples of breakout boxes are shown in the following picture:

  23. Configuration Block Diagram, Tracker Test EGSE TKR

  24. Equipment List, Tracker Test

  25. Configuration Block Diagram, Two Tower Test

  26. Equipment List, Two Tower Test

  27. EGSE IN SINGLE TOWER ASSY FLOW

  28. EGSE IN TWO TOWER ASSY

  29. EGSE TEST REQUIREMENTS: MD-00408 • Configuration of EGSE shall be controlled via released documentation • EGSE shall be acceptance tested • EGSE shall be validated before use if it has been moved, reconfigured, or repaired • Validation shows that equipment is both ready for use and safe to use • High degree of confidence that equipment in that configuration has full operating capabilities • NASA guidance • Perform an EICIT and an SVT to ensure electrical safety • Trip points on circuit breakers, current limits in power supplies, shall be verified • While everything is validated, the scope of validation is tailored for each piece equipment type

  30. STATUS OF EGSE– COTS • Digital Multimeters (I&T responsible for these) • Calibrated Instrument • Validation Tests • Embedded within test procedure that calls them • STATUS: Meter purchased exceed maximum voltage for parts in some equipment, so we are re-procuring • Borrowing “Safe” DMM’s in the meantime • Hand Tools • Procured, cleaned, and placed in toolbox within cleanroom • Automated Test Equipment for Safe to Mate • All parts received - calibrated • Interconnection harness designed –in assembly • Rack tray’s sent out for machining – affected by safety stand down at SLAC

  31. SCOPE OF EGSE TESTS – BOB’s ETC. • Cables and break out boxes (I&T is responsible for these) • Design documentation complete and released • Acceptance Tests include • Configuration inspection to assembly drawing • Interface integrity and cleanliness, inspection • Electrical continuity & isolation tests per LAT-TD-04325 • Labeling with test due date, operator, QA • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical continuity tests, manual • Connector Savers • Tests: Interface integrity and cleanliness, inspection

  32. STATUS OF BOB’s ETC • All BOB’s designed, built, and tested • Inspection remains to be completed • Associated cables designed, built to shortage, and tested • The backshells for the 100 pin cables were back ordered and just arrived. Estimate assembly complete 12/1 • Inspection remains to be completed • Long versions of the Two Tower test cables for EGSE interconnections are awaiting the floor layout to determine lengths. Design, build, and test complete 12/31. • Acceptance and Validation Test Procedures in sign off cycle

  33. STATUS OF CONNECTOR SAVERS • Determining connector saver needs • Coordinating with subsystems • All ELX boxes arrive with connector savers on each connector • CAL delivers mated to an EM TEM, so they are not needed • TKR towers arrive with connector savers that will be turned over to I&T • Determining who buys connector savers for the flight cables – submitted lien to program office to fund procurement • Complete determination by 11/24

  34. SCOPE OF EGSE TESTS - PDU • EM PDU • Acceptance Tests include • Configuration inspection to LAT-DS-01696 • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD-02544-01 • Labeling with test due date, operator, QA • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Further validation tests performed within the test stand using load box

  35. SCOPE OF EGSE TESTS – PDU LOAD • EM PDU LOAD BOX • Acceptance Tests include • Configuration inspection to LAT-DS-03400 • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD-04095-01 • Labeling with test due date, operator, QA • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Further validation tests performed within the test stand

  36. STATUS OF PDU & LOAD BOX • Documentation • PDU Assy, LAT-DS-01696, released • PDU Test Procedure, LAT-TD-02544-01, released • PDU Load Box Assy, LAT-DS-03400, released • PDU Load Test Procedure, LAT-TD-04095-01, released • EICIT Procedure, PDU, LAT-TD-04332, released • SVT Procedure, PDU, LAT-TD-04332, in work (12/1) • Delivered to I&T • Inspection, acceptance test, validation pending development of flight documentation

  37. SCOPE OF EGSE TESTS - GASU • EM GASU • Acceptance Tests include • Configuration inspection to LAT-DS-01611-09 • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD-04267-02 • Labeling with test due date, operator, QA • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Further validation tests performed within the test stand

  38. STATUS OF GASU • Documentation • GASU Assy, LAT-DS-01611-09, released • GASU/Test Stand Test Procedure, LAT-TD-04267-02, released • EICIT Procedure, GASU, LAT-TD-04260, released • SVT Procedure, GASU, LAT-TD-04382, in work (12/1) • Delivered to I&T • Inspection, acceptance test, validation pending development of flight documentation

  39. SCOPE OF EGSE TESTS – TEM/TPS • EM TEM/TPS • Acceptance Tests include • Configuration inspection to LAT-DS-01643 • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD-4085-01 • Labeling with test due date, operator, QA • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Further validation tests performed within the test stand

  40. STATUS OF TEM/TPS • Documentation • TEM/TPS Assy, LAT-DS-01643, released • TEM/TPS Test Procedure, LAT-TD-4085-01, released • EICIT Procedure, TEM, LAT-TD-03875-02, released • SVT Procedure, TEM, LAT-TD-04097-02, released • EICIT Procedure, TPS, LAT-TD-03875-02, released • SVT Procedure, TPS, LAT-TD-04098-01, released • Two delivered to I&T • Inspection, acceptance test, validation pending development of flight documentation

  41. SCOPE OF EGSE TESTS – BUS PROTECTOR • Acceptance Tests include • Configuration inspection to LAT-DS- • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD- • Labeling with test due date, operator, QA • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Validation tests performed in accordance with LAT-TD-

  42. STATUS OF BUS PROTECTOR • Requirements identified in EGSE Plan • Design assigned within ELX • Documentation needs be created • Developing schedule with ELX to support Two Tower Test

  43. TEM TEST STAND - CAL AND TKR TESTS • Acceptance Tests include • Configuration inspection • LAT-DS-02861 CAL • LAT-DS-03605 TKR • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD-4085-01 • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Perform tests described in LAT-TD-4085-01, Para. 5.5.4, Basic Test

  44. STATUS OF TEM TEST STAND • Documentation • CAL Test Stand set up procedure, LAT-DS-02861, released • TKR Test Stand set up procedure, LAT-DS-03605, released • TEM/TPS Test Procedure, LAT-TD-4085-01, released • EICIT Procedure, TEM, LAT-TD-03875-02, released • SVT Procedure, TEM, LAT-TD-04097-02, released • EICIT Procedure, TPS, LAT-TD-03875-02, released • SVT Procedure, TPS, LAT-TD-04098-01, released • Two Test Stands delivered to I&T • Inspection, acceptance test, validation pending development of flight documentation

  45. GASU TEST STAND – TESTS IN 1X1 • Acceptance Tests include • Configuration inspection LAT-TD-04267-02 • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD-04267-02 • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Perform tests described in LAT-TD-4085-01, Para. 5.5.4, Basic Test

  46. STATUS OF GASU TEST STAND • Documentation • Assembly and test procedure, LAT-TD-04267-02, released • Validation test, run LAT-TD-4085-01, released • EICIT Procedure, GASU, LAT-TD-04260, released • SVT Procedure, GASU, LAT-TD-04382, in work (12/1) • Delivered to I&T • Inspection, acceptance test, validation pending development of flight documentation

  47. GASU/PDU TEST STAND – TWO TOWER • Acceptance Tests include • Configuration inspection LAT-TD-04267-02 • Interface integrity and cleanliness, inspection • EICIT and SVT tests • Functional Tests in accordance with LAT-TD-04267-02 • Validation Tests include • Verify Acceptance Testing has been performed and is not due for re-test • Configuration inspection • Interface integrity and cleanliness, inspection • Electrical STM tests • Perform tests described in • LAT-TD-02544-01, Para. 5.3.6, PDU-GASU Interface and electrical load tests • LAT-TD-4085-01, Para. 5.5.4, Basic Test

  48. STATUS OF GASU/PDU TEST STAND • Documentation • Assembly and test procedure, LAT-TD-04267-02, released • PDU Validation LAT-TD-02544, released • Validation test, run LAT-TD-4085-01, released • EICIT Procedure, PDU, LAT-TD-04332, released • SVT Procedure, PDU, LAT-TD-04332, in work (12/1) • EICIT Procedure, GASU, LAT-TD-04260, released • SVT Procedure, GASU, LAT-TD-04382, in work (12/1) • Delivered to I&T • Inspection, acceptance test, validation pending development of flight documentation

  49. TEST PROCEDURE STATUS • I&T Test procedures are being written prior to completion of test plan. • CAL Test Procedure • Draft complete and in review • Draft must be updated with new input from CAL subsystem (received after procedure completed) • Complete one week after CAL final update • TKR Test Procedure • Draft was complete and in review three weeks ago • Draft was updated with new input from TKR subsystem (received after procedure completed) • Complete one week after TKR final update

  50. TEST PROCEDURE STATUS (cont) • Single Tower Test • Draft in review in I&T • Affected by change to subordinate documents • References to be updated and test descriptions re-written • Complete 12/15 • Two Tower Test • Draft begun • Complete 12/31 • VG and CR Data Runs for LAT Integration

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