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Design, Manufacture, Transport and Integration on-site in Chile of ALMA Antennas

Design, Manufacture, Transport and Integration on-site in Chile of ALMA Antennas Progress Meeting # 3 Alcatel Alenia Space / TORINO DESIGN CONCEPT PHASE Dated April 5 th , 2006. ALMA - Design Phase. 2006.

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Design, Manufacture, Transport and Integration on-site in Chile of ALMA Antennas

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  1. Design, Manufacture, Transport and Integration on-site in Chile of ALMA Antennas • Progress Meeting # 3 • Alcatel Alenia Space / TORINO • DESIGN CONCEPT PHASE • Dated April 5th, 2006

  2. ALMA - Design Phase 2006 DEC JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC JAN PPDR D.P PPDR K.O. Antenna Detailed Concept Design Definition System Analysis & Budgets Antenna Detailed Design

  3. Introduction to the Design Concept • AEM at the KOM presented an operating plan, regarding all the phases of ENGINEERING & DESIGN subdivided in 4 main sections: • T1 - Detailed Conceptual Design Definition • T2 - Freezing of Design & Industrial Processes • T3 - Finalization of all Construction Dwgs & Manufacturing Documentation • T4 - Preparation of all Construction & Workshop Dwgs and all Documentation for Production

  4. ALMA - Design Phase 2006 DEC JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC JAN PPDR Data Pack. PPDR CDR K.O. Antenna Design updating Antenna Detailed Design T1 T2 T3 T4

  5. Detailed schedule and milestones for Design & Engineering activities KOM +3m +3m T1= Detailed Concept Design Definition Main Spec.s General Dwg.s for Pre-Industrialization 3m 6m T2= Freezing of Design & Qualification Results Suppliers & Industrial Processes Definitions +2m T3= CDR AEM Critical Design Review +3m 9m 11m T4= PPDR Data Package Documentation Delivery +1m +1m T5= PPDR Review Meeting 13m 12m T6= Closure of PPDR +AIPC1 31.5m T7= AIPC1 Documentation Delivery +AIPC# T8= Support of Manufacturing & Integration Activities ……..

  6. END of PHASE T1: Detailed Concept Design Definition • OBJECTIVE: • Identify an Antenna Concept able to satisfy the main Requirements of the Specifications (geometrical, functional, etc…), • production of the basic documentation and distribution of the knowledge inside the Consortium • to guarantee the manufacturing and erection process of the antenna

  7. END of PHASE T1: Detailed Concept Design Definition • MODALITY: • Development of drawings activities, modellization, analysis and calculation to support the solutions adopted. • INPUTS: • contract documentation • knowledge of Prototype • OUTPUTS: • main specifications • Assembly and interface drawings

  8. T1 - technical documentation supporting this phase • From KOM (19-20 Dec ‘05) to T1 (13-14 Mar ‘06 ) • General Design Assumption: • Finite Element Analysis: • Error Budget Calculations: • System Engineering Activities: - General Layout& Dimensions - Design Optimisation for Production - Global FEM Model - Preliminary Engineering Calculations Detailed Concept Design Definition - Static & Dynamic Analysis - Survival Conditions Load Cases - Wind & Thermal Analysis - Surface Accuracy - Absolute non reapeatable pointing error - Offset non reapeatable pointing error - Absolute reapeatable pointing error - Offset reapeatable pointing error - Non reapeatable residual delay - Reapeatable residual delay Main Spec.s General Dwg.s for Pre-Industrialization - Mass & Balance Budget - Dynamic Servo Simulation - Lifetime, RAMS Analysis - EMC Plan

  9. T1 - technical documentation supporting this phase Main Spec.s General

  10. T1 - technical documentation supporting this phase Dwg.s for Pre-Industrialization

  11. T1 - technical documentation supporting this phase Dwg.s for Pre-Industrialization

  12. T1 - technical documentation supporting this phase Dwg.s for Pre-Industrialization

  13. T1 - technical documentation supporting this phase Dwg.s for Pre-Industrialization

  14. T2 - Freezing of Design & Industrial Processes • From T1(13-14 Mar ‘06) to T2 (12-13 Jun ‘06 ) • Freezing of Design & • Qualification: • Suppliers & Industrial • Processes Definitions - Detailed cross-check off all Requirements from Spec.s, Manufacturing Processes & Qualification Program - Start of all qualification tests of all major items - Identification of all main suppliers and relative products - Definition of all main manufacturing processes Scope of this phase is to acquire into the design of the main components the informations coming from the manufacturer and partners, for the production and industrialization.

  15. Start and Organization of Phase T2 FROM DEFINED CONCEPT TO CONSOLIDATED DESIGN CROSS-CHECK OF ALL SPECIFICATION REQUIREMENTS CROSS-CHECK WITH MANUFACTURING PROCESSES DATA FROM QUALIFICATION REPORTS TESTS ON COMPONENTS DATA SHEETS OF COMPONENTS SPECIFIC REQUIREMENTS TESTS ON SUB-SYSTEMS SYSTEM REQUIREMENTS CONSTRUCTION REQUIREMENTS ICD REQUIREMENTS ASSEMBLY REQUIREMENTS FROM QUALIFICATION PROGRAM PACKING & TRANSPORT REQUIREMENTS FROM VERIFICATION PLAN FROM SUB-SUPPLIERS AND PARTNERS

  16. T3 - Finalization of all Construction Dwgs & Manufacturing Documentation • From T2(12-13 Jun ‘06) to T3 (14-15 Sep ‘06 ) • CDR • - Verification by compliance matrix of all performancies • Finalization of all construction drawins and manufacturing documentations (critical items) • Freezing af all the interfaces between AEM/Supplier and ALMA The purpose of this part of the design phase is to develop all the activities of calculation, analysis and design, that may guaranty the total overview of the performances specification and meet the entire manufacturing process (from manufacturing to integration on site) A specific internal review (CDR) will be performed at the and of this phase with the ESO presence

  17. Detailed schedule and milestones for Design & Engineering activities • From T3(14-15 Sep ‘06) to T4 (13 Nov ‘06 ) • PPDR Data Package -Finite Element Analysis (DRD-23) - Error Budget Computations (DRD-21) - Mass and Balance Budget (DRD-24) - Dynamic servo simulation analysis for fast switching and other dynamical performances of the antenna. (DRD-23) - HVAC system calculations (DRD-22) - Lifetime, reliability and maintainability analyses (DRD-25) - EMC Control Plan (DRD-32) - Engineering analysis and reports not specifically mentioned here, if necessary (DRD-22) - Preparation of spare parts list. The spare part list shall be the update of the spare part list provided in the Bid phase, and adapted to take into account the results of the reliability requirements and calculations (DRD-35). - Drawings On the Base of the review performed in previous period, during this Design Phase will be made all the construction and workshop drawings and documents to support all the production Phase and all the required documentation of the PPDR.

  18. Detailed schedule and milestones for Design & Engineering activities • From T4(13 Nov ‘06) to T5 (12-13 Dec ‘06 ) • PPDR Review Meeting Complete design review of the antenna This task represents the moment for the verification of the entire design at all levels from antenna system to antenna components

  19. Documentation delivery to ESO: • END of T3 - Critical Design Review (CDR): no contractual ( cfr MoM of ALMA KOM) • END of T4 - Pre-Production Design Review (PPDR): contractual Both phases need specific meetings with ESO for review with prior delivery of documentation on due date • AEM confirms its strong willingness to offer the relevant visibility to ESO along the ALMA Project.

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