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This quarterly status review provides updates on the progress of the Particles and Fields Package (PFP) in the fields of power converter layouts, mechanical engineering, and software development. It also highlights the accomplishments and ongoing work of the team.
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Particles and Fields Package Quarterly Status Review (QSR) October 19, 2010 Dave Curtis, PFP PM
SSL Contracting Status Phase B/C/D Contract in place.
Schedule Status No improvement in pre-CDR schedule Power Converter Layouts started, but still lagging SWIA/STATIC mechanical still behind but making progress Due to personnel conflicts with RBSP FM1 through environments, FM2 in environmental tests, so end in in sight See next chart Also the ICDR date has been set, ~3 weeks earlier than previously planned Result is the EM system testing completes right about the time of the ICDR. No impact to CDR to Delivery margin (19w margin) Flight build is currently gated by completion of MCDR Delivery to ATLO moved up 1 week in latest REC-DEL list MAG currently on critical path
Manpower • Concern with competition with RBSP-EFW for some key people • Power converter design team • Reorganized team to streamline priority tasks • SWIA/STATIC/LPW boom mechanical engineers • SWIA/STATIC EM mechanical parts behind • not yet on critical path to EM I&T • FSW lead • keeping ahead of MAVEN schedule • Additional parts engineer to be added to QA team • New hire: Job listed, advertized, should be filled soon.
Accomplishments LPW ‘hingelss whip’ test model built, vibration tested Passed using latest Atlas 5 loads and new aft deck levels 11.9grms random, 1 min.wmv Also ran case with additional margin and also a sine vibe, all OK can eliminate caging system All EM and some FM EEE active parts on order, 87% delivered to GSFC Remaining parts delivery dates meet schedule Part qualification testing has just started, which adds some schedule risk in case parts fail screening PWBs are in layout Most EM Mechanical parts are in fab Some part-level design work still in progress on SWIA/STATIC PFP FSW Boot code 93% coded; operational code started More in instrument sections…
Ongoing Work Supporting Project planning process Supporting EMC, Payload, SDT working groups Getting the last of the EM parts on order (passives) Working parts issues with the PCB, getting qualification tests started. Completing EM layouts and getting EM mechanical parts ordered Preparing for STATIC TOF system acoustic test next month
EM Status Summary SSL EM & GSE Layouts (23) 11 complete 9 in progress 3 awaiting final schematic release LM Interface Test preparations (3/25/2011): DCB board layout complete, PWB in fab, parts being kitted at GSFC GSE & FSW ready to start testing Current schedule shows ready by 1/5/2011 for the LM test EM EEE Parts All active parts ordered, 87 of 94 types delivered to GSFC Connectors on order Passives being ordered EM detectors on order (MCP, SSD, foils, magnets) SWIA MCP, STATIC foils, SEP magnets delivered EM Mechanical parts: SWEA, SEP, LPW Boom (not sensor), STATIC TOF in fab Remaining SWIA, STATIC parts into fab soon
Trades Considering changing LPW boom whip caging Nick Jedrich Mechanical Peer Review recommendation Change from caged to fixed whip Deletes caging mechanism mass & resources Deletes whip hinge Deletes an actuation Simplifies qualification Concerns being investigated Enhanced vibration on whip, preamp Built a demonstration model and completed vibration test to predicted levels plus margin, no problems. Potential damage to exposed whips during I&T Possibly remove whip for some of ATLO PFP team believes we should go with the fixed whip Need to submit a CCR & ECR for this change Whip fundamental is below 100Hz (~25Hz). LM tells us they don’t need a Structural Math Model (CDRL SE-05).
Issues [1] Magnetics New solar array configuration selected U-strings, small increase in ‘diving board’ length Analysis indicates new configuration meets requirements for most conditions Assumes outer-most strings don’t switch Will see a transient going in and out of shadow Acceptable MAG Team and EMEWG will continue to watch magentics
Issues [2] SWEA Surface Treatment Need to modify thermal characteristics of surfaces in SWEA aperture to avoid excessive heating - candidate solutions in work Candidate solutions need to be evaluated for Atomic Oxygen effects, charging effects, thermal properties, and robustness AO test in complete, waiting on test report, post-test surface resistivity measurements Current candidates: DAG213, Ebanol-C, Black Nickel, Black Chrome, Z307 SWIA and STATIC also interested SEP detector Atomic Oxygen effects Heritage instruments survives AO, but we would like to test a MAVEN detector if possible. Included in the test
Issues [3] Amptek HV801 failures Solved immediate problem for EM – NGIMS providing parts Still pursuing three options for flight New lot of Amptek parts In queue behind MMS Micropak parts Some concern at GSFC about internal spacing of HV parts May be OK for us as we do not exceed 5kV VMI parts Larger, would require repackaging of SWIA, STATIC
Issues [4] SWEA Planetary Protection CESR part of SWEA FM build in progress A memo has been developed by Project defining Planetary Protection implementation at CESR which CESR has agreed to. Issue Closed.
Issues [5] Launch Loads Selection of Atlas 5 Launch loads have been reduced significantly ERD update pending based on acoustics SWEA heritage design may be OK with new loads Depends on how you interpret factors of safety Discussions ongoing with LM & GSFC Remaining instruments are OK with new loads
PFP Mass Added extra radiation shield mass to SWEA Increases electronics box walls from heritage ~60 mils to 100mils Not required to meet radiation requirements, but a better use of mass than ballast Submitted CCR0228 to add 400g to SWEA NTE (not included above) Harness masses increased due to latest lengths provided by LM LPW mass may decrease ~330g if we eliminate caging mechanism (CCR pending)
PFP Power Liens: Expect to need operational heat during eclipse None allocated for most instruments; amount needed pending thermal analysis Preliminary estimates included for MAG and EUV IPDR numbers for the remaining instruments are up to 13.3W (worst case cold) Does not look like LM-provided sinks change this much Can decrease operational power requirement by ~3W by coupling SWEA to its ballast mass
PFP Data Rate Per 2009-6-9 allocations from Bruce
Requirements Verification Status Vibration test of LPW boom model verified hingeless whip will survive launch vibration.
MAVEN Magnetometer Status Oct 12, 2010 Connerney, Sheppard, Schnurr, Oliversen, Espley, etc.
GSFC/MAG - Accomplishments Last Month(s) All MAG-related RFA’s have been closed (IPDR, Mission PDR). Obtained agreement on MAG budget (w/PI, Project, Code 600, 690). Received circuit boards for MAG a/c heater circuit; proto heater controller assembly in fabrication. Procurement status of long-lead and limited availability items: Mil spec CMOS quad bilateral switches (4066’s). Received flight LTC1604 ADCs (availability). Received /PROTO PWM 5032 parts from Aeroflex (for new heater design). Fabrication of EM sensor assembly parts nears completion (delivery due Nov 1). EM electronics board layout in process, completion by end of month. Magnetics piece parts (transformers, inductors) wound & in testing.
Near Term Plans & Open Issues Complete EM board layout (Goddard PCB designer and SSL Mechanical Lead are finalizing the PCB MICD, expecting sign-off copy soon). Release EM PCB for fabrication (pending MICD w/UCB). Revise MAG schedule to re-align with UCB schedule. Finalize the baseline instrument command list and telemetry packet contents. Continued specification of the magnetometer as documented in the Specification and User's Manual. Complete FPGA functional blocks and interface definition. Begin winding EM sensor ring cores, feedback/sense bobbins, fabricate sensor terminal boards.
MAVEN PFP SWIA Status October 2010 Jasper Halekas, SWIA Lead
SWIA Progress • Layout Progress • Anode board layout complete, out for quote for fabrication • Preamp/MCP board layout in progress, now top priority • Digital board placed but not routed, likely headed to subcontractor • LVPS layout done, out for quote soon • SWP in progress, settled on shared layout for SWIA/STATIC • Mechanical Design Progress • First priority: Support layout • Most mechanical design now done for boards • Settled connector issues on boards shared with STATIC • Some work to be done on HV connectors, but settled on scheme • Second priority: Flesh out attenuator and Anode/MCP housing • Anode/MCP housing and clamp stack design complete • Mechanical drawings complete and in review, out for fab soon • Attenuator design next to receive major effort • Third priority: Detail analyzer design • Settled issues in interface region between analyzer and electronics box by splitting SWIA/STATIC analyzer designs slightly • Microchannel plates arrived, testing starting soon
SWIA Issues • Staffing • ME staffing continues to be an issue • Dalton and Johnson splitting time with RBSP • Situation should ease greatly in ~November • Layout queue is still tight • Layout Complications • First anode layout had some potential issues • Revised layout now complete, but queue set back somewhat • Sweep board required coordination between SWIA and STATIC • Settled on scheme that works for both (with slightly different schemes for HV connection to inner hemisphere) • Next hurdle: Working on selecting chamber for MCP testing
SWIA Anode Board Layout Anodes/MCP Contact (Analyzer / Top Side) Components/Traces (Component / Bottom Side) Keep-Outs (Component Side)
MAVEN PFP SWEA Status October 2010 Dave Mitchell, SWEA Lead
SWEA Status - CESR • Mechanical • New mechanical sensor parts to upgrade Stereo EM delivered. Stereo EM MAVEN EM • EM sensor disassembled and given to mechanical subcontractor to verify/refine hemisphere concentricity and obturator parallelism. • EM sensor parts returned EM assembly and test in progress (expect to be finished by Oct 22) • Front-end Electronics (MCP, HVPS) • Transformers fab & test – done. • Planetary Protection/AIV procedures in place – clean room testing underway – Amp and HV coupling board fab is next EM sensor in vacuum chamber
SWEA Status - SSL • Pedestal Mechanical • Purge redesigned to point in the right direction • change to CESR mechanical design is very minor • Wall thickness increased to 0.100” for better margin in Mars radiation environment. • Drawings complete, fab out for quote. If all goes well, expect delivery in November. • Design of solar absorber awaiting thermal analysis, but this will not hold up the EM design/fab. • LVPC • Layout based on STEREO SWEA, with modifications because MAVEN SWEA does not have a STE component. • Parts selection done, layout in progress. • Digital • Design complete, layout engineer selected, PO in process.
Surface Coating for Deflectors and Toroidal Grids Candidates are: black chrome, black nickel, DAG213, Z307, and Ebanol-C. Laboratory tests at Glen were recently completed to measure electrical properties before and after exposure to atomic oxygen. Expect report within a few days. FM parts coating can proceed once material is selected. Mechanical Design of Aperture Estimates of launch loads have come down significantly with selection of Atlas V and addition of ballast mass to the SWEA boom. Previous load tests on STEREO SWEA show that current design may be adequate for MAVEN. Currently working to confirm. FM Front-End Electronics CESR procedures, with minor modifications, are compatible with MAVEN Planetary Protection Plan. FM board assembly can proceed. Several Key SWEA Issues Nearly Resolved
MAVEN PFP STATIC Status October 2010 Jim McFadden, STATIC Lead
STATIC Accomplishments EM thick foils attached to frames returned by Luxel, inspected. First batch of carbon foil carrier frames with grids returned from fabrication, inspected, engraved with serial numbers Second batch carbon foil carrier frames inspected for flatness, engraved and sent out for grid attachment EM 15kV-MCP HV board fabricated and ready for inspection EM Low Voltage Power Supply is laid out, ready for fab Mechanical design between TOF housing and analyzer assemblies was detailed by ME Concept to HV sweep custom connectors worked out, awaiting detailed design. Anode, Preamp and TDC board signal routing nearly complete RFQ sent out for bids on calibration chamber Calibration chamber design complete, mounting stand design in process
STATIC Open Issues Ken Hatch optimization of EM Anode, Preamp and TDC boards undergoing review with McFadden. Layouts will require some of Bruce Dalen’s time for final layout completion. Still not getting much ME time on STATIC details due to RBSP, STATIC analyzer and mechanical attenuator still in development STATIC HV Sweep layout needs modifications to accommodate external and internal HV connectors – new EE assigned to complete the design. STATIC FPGA still in development Carbon foils received but are tearing when floated - vendor to send new foils if needed – awaiting new floating tests Clean room refurbishment (320D) still waiting on campus. Ion gun for calibration chamber may not allow for automated computer control – which is desired but not required.
MAVEN PFP SEP Status October, 2010 Davin Larson, SEP Lead
SEP Accomplishments DFE board has gone out for quote – (quote recv’d too) DAP board currently in layout Competing with STATIC for engineer time FPGA design contract in place Awaiting return of Jianxen Chen from vacation Preliminary magnet selection has begun – (all magnetometer equipment has been recovered / software tested)
SEP Open issues DAP / FPGA pinout subject to change pending layout architecture/ FPGA designer input. Cable connector pinout changed due to layout issues Changes can be expected pending DAP layout. Magnet selection to continue following meeting next week.
MAVEN PFP PFDPU, Power Converter & GSE Status October 2010 Dorothy Gordon Tim Quinn Peter Berg
DCB Status PFDPU Processor Data Controller Board Layout complete Board Fabrication in process (expected delivery is 25 October) Quote for Board Population requested from Digicom Awaiting parts shipment from GSFC FPGA Daughter Cards FLASH Daughter Board Layout is complete Board Fabrication in process (expected delivery is 25 October) Quote for Board Population requested from Digicom ETU (FLASH) FPGAs are in-house FLIGHT Daughter Board Layout is pending
GSE Hardware/Firmware Status MISG FPGA Development The MISG FPGA modules supporting PFDPU Mode have been completed and verified via simulation and test Interface to Ethernet controller operational in both directions MISG is receiving directives from the Host and sending status and instrument messages back to the Host Hardware Level Integration proceeding with STATIC prototype Both Command and Message Interface have been verified between the Host – MISG - Instrument Integration with GSE Software (GSEOS) is proceeding MISG Production Status Two fully populated MISG boards in house Quote requested for population of 10 additional boards Chassis and cabling in development
GSE Software Status (1) Tested limit checking function with STATIC housekeeping successfully - out of limit conditions are echoed to log file. All commanding echoed to log file New python module for issuing commands from command line or procedure. Just prefix "cmd." before mnemonic command. Example: >>> cmd.isg_arm_act() Integrated new plotting function into GSEOS. The new plotting function uses the Python plotting library matplotlib. Selected telemetry values are routed to time-value ordered files, which are plotted by running the function plot_prep(value). The resulting plot screen has zoom and panning capabilities.
GSE Software Status (2) Added display log to SSG interface: RTS and DTR events echoes to log Data and svn server maven hooked up to UPS and configured for graceful shutdown GSEOS configured and tested to control 2 power supplies. Additional power supplies will be added to reflect max case for instrument testing. Voltage and current values for each supply are saved to files for display with new plotting feature. GSEOS successfully connected and commanding MISG
Power Converter Status Low Voltage Supplies Both the SWIA Low Voltage Power Converter and STATIC Low Voltage Power Converter ETU have been laid out, quoted, and a supplier recommended. SWEA LVPS layout in process (expected completion is 18 Oct) STATIC Accelerator Board The STATIC Accelerator and MCP board laid out and fabricated Board are in-house REG Board Layout is in process IIB Schematics in process The IIB prototype circuits undergoing test/verification Schematic completion expected by the end of next week (22 Oct)
MAVEN PFP Flight Software Status October 5 2010 Peter Harvey
Schedule Tracker Progress Points=Telecons with GSFC. 1 pt for each telecon, 0 if the telecon did not happen. Management Effort. Expected 10% or less, but has required phase A requirements and plans to be written in phase B.
Technical Status • Technical Developments (Boot) • HSK module : Analog Mux #4 added • IV&V : Provided comments on the L4 and L5 requirements • Supported Fault Protection Telecons • Reviewed another DCB specification (revF) • Technical Developments (Operational) • Reviewed another DFB specification (10/09/27) : Issues involved • Telecon to discuss DFB/DCB Interface 10/11/2010 • PWR module: LVPS control logic (specification needed) • PWR module: HVPS control logic inc/ ramping, enables. (FPGA CDIs needed) • Software tests being performed using Code Warrior simulator, breakpoints, etc.
