STATUS REPORT FOR MAY–JULY 2003

Spartan IR Camera for the SOAR Telescope

Edwin D. Loh Department of Physics & Astronomy Michigan State University, East Lansing, MI 48824 Loh@pa.msu.edu 517 355–9200 ext 2480 26 August 2003

During this reporting period, we (1) finished the metrology of the cryo-optical box, (2) began the cold test of the cryo-optical box, and (3) resumed work on the software. We have completed 80% of the milestones of the project. We have scaled back the instrument to have only J, H, and K filters. The budget is $57 k under the baseline: $44k for filters has been removed, but costs increased by $22 k since 30 April. Delivery of the instrument is delayed for 8 months until February 2004.

-200 0 200 400x @mmD

200

400

600

800

1000y

@mmD

Figure 1 Left: The cryo-optical box suspended above the bathtub of the vacuum enclosure in the semi-clean foyer of the clean room. Center: First cool-down of the instrument without optics. Right: Errors, magnified by 10,000, of the locating pins on the top plate of the cryo-optical box.

2

1 Project Status

1.1 Summary

• Problems with the mirrors, now

expected in early October and 17

months late, will delay completion of

the instrument to the end of February

2004. Axsys uses a computer-

generated hologram (CGH) to

produce a beam that is a spherical

wave upon reflection off of the

aspheric mirror (Figure 3). In addition

the CGH produces two separate

Figure 2 Optical schematic. The red ray is the principal ray for the high-resolution, f/21 channel; the cyan ray, the wide-field, f/12 channel.

Figure 3 The computer-generated hologram (CGH) converts a plane wave entering from the interferometer at the left to a spherical wave if the mirror shape is correct. Picture is from Diffraction International, Minnetonka, MN, www.diffraction.com

3

beams to align itself to the interferometer and to the master plate, which holds the mirror.

Axsys has had problems locating the beam that aligns the master plate. After attempting a

mechanical alignment procedure for 8 months and failing, they have finally located the

missing alignment beam. With metrology secured, they expect to polish one mirror a week.

• The Advanced Technologies and Instrumentation Program of the NSF funded the “Wide-

field Upgrade for the Spartan IR Camera,” for the installation of the third and fourth

detectors. The Fundacao de Apoio a Universidade de São Paulo (FUSP) funded the third

detector with a grant to Beatriz Barbuy of the Instituto de Astronomia, Geofisica e Ciências

Atmosféricas (IAG) da Universidade de São Paulo. The Fundacao de Amparo a Pesquisa

do Estado de São Paulo (FAPESP) funded the fourth detector with a grant to Sueli Viegas

of the IAG. These detectors will be added approximately a year after commissioning.

• We have scaled back the project by eliminating the narrow-band filters; they can be added

after delivery of the instrument if funds become available.

• The labor resources are tight. If any additional open-ended problems arise, additional

resources will be needed. See §1.4.

The project summary is in Table 1, and earned value analysis, percent complete, and work

summaries by WBS are in Table 2. Changes since 30 April 2003, the date covered in the last report,

are also in Table 2. More details are in Tables 3–4.

4

1.2 Earned-value Analysis

The schedule variance (SV) worsened by $12k since the last report1. The schedule variance is due

to delays in the fabrication of the mirrors (WBS 1.3.6.1 and 1.3.8.1) by Axsys Technologies and

delayed installation of the instrument (WBS 1.7.5). The schedule variance in procurements is not

real: inexplicably, some completed tasks show a schedule variance.

The variance at completion (VAC) improved by $24k since the last report, primarily for three

reasons. (1) We removed the narrow-band filters. (2) The bills for work by mechanical fabrication

by vendors and for materials, which were paid in this reporting period, had not been entered

accurately in the project file. (3) We damaged two rotation stages by allowing moisture to condense

on the bearings; repair is costly.

1 Earned value analysis does not apply here to work charged under “Fixed Costs,” WBS 1.1.7, (Biel, Chen, Davis,

Laporte, Lien, and Loh); therefore it cannot show problems in work done by them. It can show problems with purchased

parts and labor that is charged by the hour.

Table 1 Project Summary

Status date 7/31/2003

DatesStart: Tue 9/4/01 Finish: 2/20/2004Baseline Start: Mon 9/3/01 Baseline Finish: Tue 6/10/03Actual Start: Tue 9/4/01 Actual Finish: NAStart Variance: 0 d Finish Variance: 183d

DurationScheduled: 644 d Remaining: 112 dBaseline: 461 d Actual: 532 dVariance: 183 d Percent Complete: 83%

WorkScheduled: 16,550 h Remaining: 1,947 hBaseline: 8,733 h Actual: 14,603 hVariance: 7,817 h Percent Complete: 88%

CostsScheduled: $1,073,549 Remaining: $53,399Baseline: $1,131,372 Actual: $1,020,150Variance: ($57,823)

Task Status Resource StatusTasks not yet started: 129 Work Resources: 0Tasks in progress: 56 Overallocated Work Resources: 7Tasks completed: 519 Material Resources: 0Total Tasks: 704 Total Resources: 7

5

Table 2 Earned value analysis, % complete, and work. A positive “schedule variance,” SV, indicates the project is ahead of schedule. A positive “cost variance,” CV, or “variance at completion,” VAC, indicate the project is less costly than budgeted.

WBS Task BCWP[$] SV [$] CV [$] EAC [$] BAC [$] VAC [$] %WC %C W [hr] RW[hr]1 Spartan IR Camera 1,065,021 (66,352) 44,871 1,073,549 1,131,372 57,824 88% 83% 16,550 1,947

1.1 Project Management 156,619 (5,000) 2,755 176,558 161,619 (14,939) 96% 97% 1,593 67

1.2 System Engineering 780 60 (1,996) 2,776 720 (2,056) 100% 100% 1,177 0

1.3 Mechanical 338,979 (29,081) 43,265 304,690 368,060 63,370 94% 85% 8,157 513

1.4 Electronics 10,105 (2,600) 359 10,426 12,705 2,279 89% 88% 2,347 261

1.5 Software 10,000 (800) 3,860 7,722 10,800 3,078 89% 54% 1,120 119

1.6 Integration 2,200 (1,600) 2,018 2,445 3,800 1,355 36% 40% 1,045 669

1.7 Deliverables 2,600 (18,200) 916 14,956 20,800 5,844 46% 50% 568 309

1.8 Procurement 111,417 (9,131) (6,000) 121,349 120,548 (801) 98% 99% 543 10

1.9 Preplan Spending 432,321 0 (307) 432,628 432,321 (307) 100% 100% 0 0

Change from 04/30/031 Spartan IR Camera 17,924 (11,804) (21,829) (24,168) 0 24,168 6% 1% 1,536 (755)1.1 Project Management 6,364 (6,364) (5,513) (1,932) 0 1,932 5% 0% 182 (60)1.2 System Engineering 0 0 0 0 0 0 1% 1% 47 (11)1.3 Mechanical 8,560 8,560 (15,824) (22,044) 0 22,044 7% 4% 929 (426)1.4 Electronics 0 0 (520) (726) 0 726 7% 1% 303 (107)1.5 Software 0 0 (1,140) (418) 0 418 6% -32% 8 (70)1.6 Integration 0 0 0 672 0 (672) 2% 1% (52) (55)1.7 Deliverables 1,000 (16,000) (552) 0 0 0 19% 22% 33 (82)1.8 Procurement 2,000 2,000 1,720 280 0 (280) 0% 0% 86 11.9 Preplan Spending 0 0 0 0 0 0 0% 0% 0 0

BCWS Budgeted cost of work scheduled BAC Budget at completionBCWP Budgeted cost of work performed VAC Variance at completion; VAC=BAC-EACACWP Actual cost of work performed %WC Work completedSV Schedule variance; SV=BCWP-BCWS %C Percent completed; (duration of the task) / (total duration)CV Cost variance; CV=BCWP-ACWP W WorkEAC Estimate at completion RW Remaining work

6

Table 3 Details on earned value, % completion, and work for WBS 1.1–1.5. The change since 30 April 2003 is in the last three columns.

WBS Task EAC [$] BAC [$] VAC [$] %WC %C W[hr] RW[hr]dW dRW dVAC

1.1 Project Management 176,558 161,619 (14,939) 96% 97% 1,593 67 182 (60) 1,932

1.1.1 Schedule & Budget 5,728 6,611 883 95% 98% 349 16 57 (2) 0

1.1.2 Weekly Meetings 0 0 0 99% 84% 187 1 48 (7) 0

1.1.3 Reviews 0 0 0 0% 0% 10 10 (38) (38) 0

1.1.4 Monthly & Quarterly Reports 0 0 0 87% 94% 318 40 48 (17) 0

1.1.5 Manage 0 0 0 100% 100% 344 0 45 0 0

1.1.6 Consultants 0 10,000 10,000 100% 100% 0 0 0 0 0

1.1.7 Fixed Cost 167,693 140,008 (27,685) 100% 96% 2 0 0 (0) 1,932

1.1.8 Travel 1,000 5,000 4,000 0% 67% 0 0 0 0 0

1.1.9 Move Laboratory 136 0 (136) 100% 100% 126 0 0 0 0

1.1.10 Training 645 0 (645) 100% 100% 54 0 0 0 0

1.1.11 Hire Engineer/Designer 1,356 0 (1,356) 100% 100% 0 0 0 0 0

1.1.12 Maintain Laboratory 0 0 0 100% 100% 203 0 22 0 0

1.2 System Engineering 2,776 720 (2,056) 100% 100% 1,177 0 47 (11) 0

1.2.1 Optics 0 0 0 100% 100% 56 0 0 0 0

1.2.2 Analysis 0 0 0 100% 100% 532 0 32 0 0

1.2.3 Plans 0 0 0 100% 100% 2 0 0 0 0

1.2.4 Requirements/ICDs/Review Designs192 0 (192) 100% 100% 283 0 14 (3) 0

1.2.5 Software Requirements 0 0 0 100% 100% 109 0 0 0 0

1.2.6 Master Layout 2,584 720 (1,864) 100% 100% 196 0 0 0 0

1.3 Mechanical 304,690 368,060 63,370 94% 85% 8,157 513 929 (426) 22,044

1.3.1 Cryo-Optical Box 31,514 41,188 9,674 98% 97% 2,046 51 208 (78) (5,107)

1.3.2 Thermal Reflector 3,518 3,880 362 100% 100% 98 0 0 0 (108)

1.3.3 Vacuum Enclosure 17,373 27,380 10,007 100% 100% 917 0 24 0 (1,721)

1.3.4 Filter Wheel 6,607 12,400 5,793 81% 91% 718 136 4 (43) 132

1.3.5 Rotational Stage 52,496 44,450 (8,046) 97% 89% 430 12 164 12 (10,000)

1.3.6 Mirrors & Mounts 96,188 98,575 2,387 90% 56% 924 91 32 2 (1,206)

1.3.6.1 Mirrors 81,435 95,975 14,540 88% 13% 161 19 6 7 0

1.3.6.2 Mounts for Mechanisms 8,113 1,800 (6,313) 100% 100% 349 0 8 0 (624)

1.3.6.3 Mounts for Mirrors 6,639 800 (5,839) 83% 93% 414 72 18 1 (582)

1.3.7 Filters 6,650 51,000 44,350 100% 100% 15 0 0 0 44,000

1.3.8 Upgrades 82,714 84,186 1,472 93% 75% 1,860 122 61 (94) (813)

1.3.8.1 2nd Channel Mirrors & Mounts [Upgrade]78,816 80,055 1,239 86% 68% 573 78 36 (24) (258)

1.3.8.2 Mask Wheel Upgrade 1,468 4,131 2,663 63% 84% 118 44 (9) (26) 480

1.3.8.3 2-Eyed Focal Plane Assembly 2,430 0 (2,430) 100% 100% 430 0 42 (39) (1,035)

1.3.8.4 4-Eyed Focal Plane Mechanism 0 0 0 100% 100% 739 0 (8) (7) 0

1.3.9 Metrology & Acceptance Tests 2,743 0 (2,743) 96% 97% 768 29 305 (77) (1,511)

1.3.10 Fixtures 4,887 0 (4,887) 81% 85% 382 72 131 (161) (1,623)

1.4 Electronics 10,426 12,705 2,279 89% 88% 2,347 261 303 (107) 726

1.4.1 Detector Assembly 4,200 6,920 2,720 86% 85% 1,844 261 303 (109) 726

1.4.2 Electronic Hardware 6,226 5,785 (441) 100% 100% 503 0 0 0 0

1.5 Software 7,722 10,800 3,078 89% 54% 1,120 119 8 (70) 418

1.5.1 Select Vendor for Software 0 0 0 100% 100% 0 0 0 0 0

1.5.2 Write Minimal Software 5,000 10,000 5,000 100% 100% 464 0 0 0 0

1.5.3 Write Baseline Software 1,140 0 (1,140) 100% 100% 528 0 (13) (92) 720

1.5.4 Write Operating Software 1,582 0 (1,582) 8% 1% 129 119 21 21 (302)

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1.3 Schedule

The remaining tasks are to finish fabrication and to test the mechanical parts (WBS 1.3), to accept

delivery of the mirrors (WBS 1.3.6.1.4.2 & 1.3.8.1.4.2), testing the electronics (WBS 1.4.1), finish

the software (WBS 1.5) and integration (WBS 1.6). The Gantt chart (Figure 4.) shows the tasks on

the critical path, which contains Mirrors and Integration. The critical path means this: delay in any

of these tasks causes a delay in the completion of the project.

Installation of the optics is scheduled to start in late October 11.

Table 4 Details on earned value, % completion, and work for WBS 1.6–1.8. The change since 30 April 2003 is in the last three columns.

WBS Task EAC [$] BAC [$] VAC [$] %WC %C W[hr] RW[hr] dW dRW dVAC

1.6 Integration 2,445 3,800 1,355 36% 40% 1,045 669 (52) (55) (672)

1.6.1 Telescope Simulator 1,773 3,800 2,027 78% 77% 480 104 0 (2) 0

1.6.2 Integration 672 0 (672) 0% 0% 565 565 (52) (52) (672)

1.6.2.1 Install optics 160 0 (160) 0% 0% 28 28 (20) (20) (160)

1.6.2.2 Optical Alignment 512 0 (512) 0% 0% 70 70 0 0 (512)

1.6.2.3 Flexure Test 0 0 0 0% 0% 44 44 0 0 0

1.6.2.4 Cold Tests 0 0 0 0% 0% 343 343 (32) (32) 0

1.6.2.5 Acceptance Tests 0 0 0 0% 0% 79 79 0 0 0

1.6.3 Project Complete 0 0 0 0% 0% 0 0 0 0 0

1.7 Deliverables 14,956 20,800 5,844 46% 50% 568 309 33 (82) 0

1.7.1 Manuals 0 0 0 70% 59% 212 64 30 (39) 0

1.7.2 Acceptance Test 0 0 0 0% 0% 124 124 4 4 0

1.7.3 Pack & Ship 4,476 4,600 124 46% 51% 140 75 0 (45) 0

1.7.4 Documentation 480 1,200 720 50% 48% 92 46 0 (1) 0

1.7.5 Installation 10,000 15,000 5,000 0% 0% 0 0 0 0 0

1.8 Procurement 121,349 120,548 (801) 98% 99% 543 10 86 1 (280)

1.8.1 Procure Computers for Laboratory2,552 2,400 (152) 100% 100% 7 0 0 0 0

1.8.2 Procure Solidworks License 4,643 1,645 (2,998) 100% 100% 0 0 0 0 0

1.8.3 Procure Dust-free Hood 0 3,000 3,000 100% 100% 11 0 0 0 0

1.8.4 Procure Parts for Test Dewar 0 2,000 2,000 100% 100% 2 0 0 0 0

1.8.5 Procure Field-flattening Lens 6,280 2,000 (4,280) 100% 100% 114 0 86 0 (280)

1.8.6 Procure Vacuum Bulkhead 2,605 4,300 1,695 100% 100% 8 0 0 0 0

1.8.7 Procure 4 Additional Rotation Stages [Upgrade]61,968 67,040 5,072 100% 100% 3 0 0 0 0

1.8.8 Procure Parts for Vacuum Enclosure7,949 7,163 (786) 100% 100% 159 0 0 0 0

1.8.9 Procure Parts for Telescope Simulator500 500 0 100% 100% 1 0 0 0 0

1.8.10 Procure Window 6,617 8,000 1,383 100% 100% 176 0 0 0 0

1.8.11 Procure Coordinate Measuring Machine23,212 22,500 (712) 100% 100% 43 0 0 0 0

1.8.12 Procure Mask 0 0 0 50% 67% 20 10 0 0 0

1.8.13 Misc Supplies 3,932 5,000 1,068 0% 0% 0 0 0 0 0

1.8.14 Procure Instrument Computer 1,091 0 (1,091) 100% 100% 0 0 0 0 0

1.9 Preplan Spending 432,628 432,321 (307) 100% 100% 0 0 0 0 0

8

Figure 4 Gantt chart of incomplete summary tasks and incomplete tasks on the critical path. The text to the right of the bar line is the percent of the work completed for summary tasks and the completion date for other tasks.

9

1.4 Work Summary

From 1 May to 31 July, we worked 2,254 hours and the remaining work decreased by 681 hours.

The work efficiency, defined to be the ratio of the change in the remaining work to the change in

the actual work, is 30%, which is about the same as that of the last reporting period.

The project will need more resources in all likelihood. If all of the labor is expended at the end of

the project, then the work efficiency must rise to 70% during the remaining time. Such high

efficiency is not possible if problems arise as they have done in the past. There are several key

milestones where time-consuming problems may arise. (1) Milestone 88: “Detector Tested in Lab,”

(2) Milestone 111: “Cryo-Optical Box Thermal Test Finished,” (3) Milestone 132: “Instrument

Assembled & Aligned at Room Temperature,” (4) Milestone 133: “Flexure Tested,” (5) Milestone

136: “Cold Test #1 [of Entire Instrument] Finished.” The other milestones, which involve

fabrication, writing documentation, and writing software, are not expected to cause open-ended

problems.

1.5 Milestones

The time-phased completion of the milestones is in Figure 6, and a complete list of milestones is in

the Appendix. We have finished 80% of the 147 milestones.

0

2000

4000

6000

8000

10000

12000

14000

16000

18000

20000

Jul-01 Feb-02 Sep-02 Mar-03 Oct-03

Date

Hou

rs

Actual

Remaining

Variance

-60%

-40%

-20%

0%

20%

40%

60%

80%

100%

120%

Jul-01 Feb-02 Sep-02 Mar-03 Oct-03

Date

dR

emai

nin

g /

dA

ctu

al

Figure 5 Work summary (top) and work efficiency (bottom). "Actual" is the number of hours expended. "Remaining" is the estimated hours to complete the project. Variance = Actual + Remaining – Baseline.

10

1.6 Personnel

Jianjun Chen finished his master’s project, “Control Software for the Motors, Spartan IR Camera,”

in May, and left the project.

Nate Verhanovtiz, a graduate student in mechanical engineering, joined the project in May. His

responsibility is software.

2 Task Details

Refer to Table 5.

2.1 Project Management (WBS 1.1)

The cost of labor for the extension in the schedule is included.

2.2 System Engineering (WBS 1.2)

There is nothing to report.

Figure 6 Cumulative number of milestones completed (blue) and not completed (magenta) vs. date.

1018

2533 38

54 60 6471 76 80 81 86 90 92 97 101 102 105 108 110 112 114 117 117

3

9

14

21

32

2327

32

3636

40 4341 39 37

34 32 3537 36 36 35 33 30 30

0

20

40

60

80

100

120

140

160

S-01

O-01

N-01

D-01

J-02

F-02

M-02

A-02

M-02

J-02

J-02

A-02

S-02

O-02

N-02

D-02

J-03

F-03

M-03

A-03

M-03

J-03

J-03

A-03

S-03

Mile

ston

es

11

2.3 Mechanical

2.3.1 Cryogenic Optical Box (WBS 1.3.1.2)

The two major tasks are measuring the cryo-optial box (COB) and the thermal test.

2.3.1.1 Measure Cryo-Optical Box (WBS 1.3.9.1)

Since the cryo-optical box (COB) supports the optics, the positions of the locating pins and the

locating pads must be accurate to 0.1 mm at the tightest, and the relative locations of pairs of pins

that locate mirrors must be accurate to 0.01 mm. The accuracy is beyond the capability of

machining and requires metrology and shims. See the shim assembly for the filter wheels and fold

mirrors (Figure 11). Here we report the metrology of the two large plates, called the top and bottom,

to which the optics mount. Directions are defined in Figure 7.

Table 5 Cost and work by WBS

WBS Task dWork May03EAC Variance Remaining EAC VAC RemainingdEAC dRemaining

1 Spartan IR Camera 16,678 7,945 2,095 1,073,901 57,472 53,751 1664 -6751.1 Project Management 1,593 404 67 176,558 (14,939) 22,694 182 -631.2 System Engineering 1,177 810 0 2,776 (2,056) 0 47 -21.3 Mechanical 8,233 4,039 589 305,202 62,858 9,488 1005 -3661.3.1 Cryo-Optical Box 2,046 499 51 31,514 9,674 0 208 -831.3.1.1 MLI Blanket 60 (11) 0 2,533 1,514 0 0 01.3.1.2 CryoBox 1,650 899 51 21,822 (1,942) 0 208 -831.3.1.3 Mask Plate 59 27 0 1,560 40 0 0 01.3.1.4 A-Frame 52 (220) 0 945 4,655 0 0 01.3.1.5 N2 Can 225 (196) 0 4,654 5,407 0 0 01.3.2 Thermal Reflector 98 35 0 3,518 362 0 0 01.3.3 Vacuum Enclosure 917 430 0 17,373 10,007 0 24 01.3.4 Filter Wheel 718 48 136 6,607 5,793 2,112 4 -401.3.5 Rotational Stage 430 300 12 52,496 (8,046) 5,000 164 121.3.6 Mirrors & Mounts 924 657 91 96,188 2,387 576 32 61.3.6.1 Mirrors 161 114 19 81,435 14,540 0 6 61.3.6.2 Mounts for Mechanisms 349 129 0 8,113 (6,313) 0 8 01.3.6.3 Mounts for Mirrors 414 414 72 6,639 (5,839) 576 18 01.3.7 Filters 15 7 0 6,650 44,350 0 0 01.3.8 Upgrades 1,892 869 154 82,842 1,344 160 93 -681.3.8.1 2nd Channel Mirrors & Mounts [Upgrade]589 (179) 94 78,944 1,111 160 52 -101.3.8.2 Mask Wheel Upgrade 134 (121) 60 1,468 2,663 0 7 -101.3.8.3 2-Eyed Focal Plane Assembly 430 430 0 2,430 (2,430) 0 42 -401.3.8.4 4-Eyed Focal Plane Mechanism 739 739 0 0 0 0 -8 -81.3.9 Metrology & Acceptance Tests 780 780 41 2,839 (2,839) 200 317 -651.3.10 Fixtures 414 414 104 5,175 (5,175) 1,440 163 -1281.4 Electronics 2,347 1,295 280 10,426 2,279 680 303 -901.5 Software 1,120 1,020 119 7,722 3,078 1,582 8 -721.6 Integration 1,097 (161) 721 2,285 1,515 2,103 0 01.7 Deliverables 568 118 309 14,956 5,844 13,272 33 -821.8 Procurement 543 371 10 121,349 (801) 3,932 86 01.9 Preplan Spending 0 0 0 432,628 (307) 0 0 0

Work [hr] Cost [$]

12

The edges of the walls define the vertical position of the

optics; the plates conform to the walls. The measurement

of the bottom edge of the walls deviates by up to 0.12 mm

from a plane. See figure 8. The deviation is mainly a twist:

the right side of the back wall is down by 0.12 mm and the

left side is up by 0.08 mm.

The errors of the locating pins are quite small and well

within the range of adjustment of the shim plates. The

errors left and right halves are different (Figure 9).

Apparently, the machining occurred on two days, and the

temperature was 2.2 C cooler when the right half was

machined.

We have devised a procedure for assembling the COB

reproducibly. With the bolts snug but not tight, we measure

Figure 7 The cryo-optical box.

-200 0 200 400 600-200

0

200

400

600

800back back

inside wall

inside wall

F−Rfrontfront

Figure 8 Deviation, magnified by 2000, of the bottom edge of the walls from a plane. The right edge of the back wall is low (shifted away from the top) by 0.12 mm.

13

and adjust the twist. Then we tighten the bolts. The twist, 0.3 mrad/m, is reproducible to 0.03

mrad/m, which translates to a maximum error of 0.02 mm in height.

2.3.1.2 Cryo-Optical Box Thermal Test (WBS 1.3.1.2.12)

The thermal and vacuum design, though tested with a small dewar, is theoretical; now we test the

design for the first time. With the COB in the vacuum enclosure and cooled, the questions are

• Is the pressure low enough (0.03 mTorr) that heat loss by molecular conduction is lower

than that by radiation?

• Does a test load, here a cradle for a rotation stage, cool at the same rate are the COB? If so,

the thermal conductance of the bolted joints is sufficiently high.

• What is the cooling time of the COB?

• What is the heat load? This is measured by the rate of nitrogen boil-off.

-200 0 200 400

200

400

600

800

1000

dAdA'

fF

fF'

m m'

12Cl12Cl'

21Cm 2121Cl 21Cl'

12Cm 12Cm'

aF

refC

refB

refA

-200 0 200 400

200

400

600

800

1000

dAdA'

fF

fF'

m m'

12Cl12Cl'

21Cm 2121Cl 21Cl'

12Cm 12Cm'

aF

refC

refB

refA

Figure 9 Errors (magnified by 10,000) of the pin holes in the top (left panel) and bottom (right panel) plates. Points with errors less than 0.005mm are shown as dots. The points are shifted so that refA has zero error and rotated so that refB has minimal error. The largest errors are 0.041mm [1.6mil] and 0.047mm [1.9mil] for the top and bottom respectively. The labels are “m” for mask, “fF” for filter-fold mirror assembly, “21Cl” and “12Cl” for f/21 and f/12 collimators, “12Cl” and “21Cm” for f/12 and f/21 collimators, “dA” for detector assembly, and “refA”, “refB”, and “refC” for reference holes.

14

We have assembled the COB

in the vacuum enclosure

(Figure 10).

The results of the first run are

• The e-fold time for

cooling a dummy

load is 3.4 hr. To

cool within 1K of

equilibrium requires

17 hr.

• The heat load is a

factor of 3 higher

than expected,

primarily because the

gas pressure,

0.1 mTorr, is too

high.

We plan to determine the

composition of the residual

gas in order to reduce the

pressure.

2.3.2 2-Eyed Focal-Plane Assembly (WBS 1.3.8.3)

The 2-eyed focal-plane assembly, which holds two detectors, is done. See Figure 11.

2.3.3 Fixtures (WBS 1.3.10)

The Lifting Jig for the COB (WBS 1.3.10.1) is finished. It is in use in Figure 10.

The Test Stand for Flexure Test (WBS 1.3.10.2) is being fabricated.

The Nitrogen Fill & Flush System (WBS 1.3.10.3) has been designed.

Figure 10 The cryo-optical box, which is wrapped in the aluminized mylar blanket, is suspended over the bathtub of the vacuum enclosure in the foyer of the clean room.

15

Figure 11 Left: Filter-fold assembly for the two filter wheels and their rotation stages and the two fold mirrors. Note the hole for one of two pins that locate the assembly accurately in the cryo-optical box. Right: 2-eyed focal-plane assembly without the detector cards and detectors.

Pin

16

The Clean Area for Assembly (WBS 1.3.10.3), which consists of a clean bench, a clean room, and a

clean hood for the coordinate-measuring machine, is finished. The clean room is in use in

Figure 10.

The racks for the computer, motor controller, and electronics (WBS 1.3.10.4) are being designed.

2.4 Electronics (WBS 1.4)

2.4.1 MUX Test at Cold Temperature (WBS 1.4.1.24)

We discovered a problem with the test of the multiplerer. (A multiplexer is a detector without the

HgCdTe sensing layer.) The multiplexer does not accumulate more photoelectrons with a longer

exposure time, even though it can produce an image.2 Since Rockwell has not tried it, we have

abandoned this test.

2.4.2 Cold Lab Test of Engineering-grade Detector (WBS 1.4.1.28)

We have installed the engineering-grade detector. Testing is in progress.

2.5 Software (WBS 1.5)

We have reorganized the software tasks. The engineering software (WBS 1.5.3) is used during

testing, and the operating software is used for observing. The engineering software has all of the

functions for operating the instrument and many diagnostics. It does not have links to the telescope

control system or to the data control system. The operating software (WBS 1.5.4) does have links to

the rest of the observatory. Furthermore, it must be transparent so that a novice such as the PI can

change the operation of the detector as needed.

The engineering software is done. In the process of testing the multiplexer, we discovered timing

problems with the old software, the engineering software was rewritten from scratch. We have used

this software extensively.

The observing software communicates with other parts of the observatory through these packages.

(1) A sequencer controls it and the telescope. (2) A FITS server formats pictures. (3) A data system

2 Loh, 2003, “Status Report for October 2002–April 2003, Spartan IR Camera.”

17

saves data and displays pictures. (4) An event logger saves instrumental events and observing

events. In addition, the observing software has a graphical user interface (GUI) for the astronomer.

We are working on the observing software. We will add links to the packages as they become

available.

2.6 Integration (WBS 1.6)

There is nothing to report.

2.7 Deliverables (WBS 1.7)

2.7.1 Maintenance Manual (WBS 1.7.1.1)

We have sent a draft of the maintenance manual to S. Heathcote for review.

Included is the procedure for installing the mask wheel. That procedure with modifications for each

case will be used for installing all of the optics.

2.7.2 Design and Fabricate Shipping Container (WBS 1.7.3.2)

The design is complete. Shock absorbers will transfer a 3-g acceleration to the instrument if the

shipping container is dropped 15-cm.

2.8 Procurement (WBS 1.8)

2.8.1 Procure Field-flattening Lens (WBS 1.8.5)

The lenses have been delivered.

2.8.2 Procure 4 Additional Rotation Stages [Upgrade] (WBS 1.8.7)

We damaged two rotation stages by allowing moisture to condense on the bearings. For testing, we

now cool the surrounding air to dry it before cooling the rotation stage.

We designed a mechanism with a spring to remove the backlash.

2.9 Preplan Spending (WBS 1.9)

There is nothing to report.

18

3 Appendix

Table 6 Milestones

MilestoneCompleted 117 of 147 (79.6%) Baseline Completed Scheduled Variance

1 Requisition for Flexible Cable Issued 4-Sep-01 1-Oct-01 19 d2 Requisition for Rotation Stage Issued 6-Sep-01 6-Sep-01 0 d3 Optical Design Finished 7-Sep-01 7-Sep-01 0 d4 N2 Can Engineered 7-Sep-01 7-Sep-01 0 d5 A-Frame Strut Engineered 17-Sep-01 13-Nov-01 42 d6 Requisition for Vacuum Blukhead Issued 17-Sep-01 7-Sep-01 -6 d7 Requirements for Optical Alignment Written 17-Sep-01 17-Sep-01 0 d8 Vacuum Enclosure & Cryo Box ICD Written 18-Sep-01 28-Sep-01 9 d9 Controller Card SCA Tested (Existing Computer) 21-Sep-01 12-Dec-01 58 d

10 Detector Physical Dimensions Measured 24-Sep-01 20-Sep-01 -2 d11 Requisition for Mirrors Issued 28-Sep-01 21-Feb-02 104 d12 Requisition for Detector PCB Issued 28-Sep-01 19-Nov-01 36 d13 Software Requirements Written 28-Sep-01 28-Sep-01 0 d14 Method for Optical Alignment Created 1-Oct-01 3-Jan-02 68 d15 Specifications for Telescope Simulator Written 3-Oct-01 3-Oct-01 0 d16 Requisition for Coordinate-Measuring Machine Issued5-Oct-01 27-Nov-01 37 d17 Detector Assembly Concept Developed 8-Oct-01 3-Dec-01 40 d18 Solidworks License Delivered 11-Oct-01 9-Oct-01 -2 d19 Mechanism Mounting Blocks Engineered 12-Oct-01 26-Sep-01 -12 d20 Select SW Vendor 12-Oct-01 16-Oct-01 1 d21 Test-Dewar Concept Sketch Finished 15-Oct-01 19-Oct-01 4 d22 Vacuum Bulkhead Delivered 15-Oct-01 27-Feb-02 97 d23 N2 Can Designed 18-Oct-01 10-Jan-02 60 d24 Requisitions for Computer for Laboratory Issued 19-Oct-01 17-Oct-01 -2 d25 Detector Holder Prototype Designed 25-Oct-01 4-Feb-02 72 d26 Mechanism Mounting Blocks Designed 29-Oct-01 8-Mar-02 95 d27 Rotation Stage Test Fixture Engineered 31-Oct-01 10-Dec-01 28 d28 Coordinate-Measuring Machine Delivered 2-Nov-01 12-Feb-02 73 d29 Rotation Stage Test Fixture Designed 7-Nov-01 7-Jan-02 43 d30 Flex Cable Finished 9-Nov-01 8-Nov-01 -1 d31 Computers for Laboratory Delivered 9-Nov-01 11-Dec-01 22 d32 Project Plan Finished 16-Nov-01 19-Dec-01 24 d33 Cryo-Optical Box Engineering Finished 16-Nov-01 28-Nov-01 8 d34 Detector Holder Prototype Fabricated 19-Nov-01 25-Jun-02 157 d35 Test-Dewar Fabricated 19-Nov-01 24-Apr-02 113 d36 Detector PCB Finished 21-Nov-01 4-Mar-02 73 d37 Master Layout Designed 26-Nov-01 23-Nov-01 -1 d38 Rotation Stage Delivered 29-Nov-01 6-Feb-02 50 d39 A-Frame Strut 3D Designed 30-Nov-01 30-Nov-01 0 d40 Specifications for Vacuum Enclosure Written 6-Dec-01 24-Oct-01 -31 d41 Rotation Stage Test Fixture Fabricated 7-Dec-01 8-Feb-02 45 d42 Requisition for Field-flattening Lenses Issued 7-Dec-01 17-Oct-02 225 d43 Mask Plate Engineering Finished 7-Dec-01 25-Feb-02 56 d

Date

19

44 Requisition for Window Issued 10-Dec-01 8-Feb-02 44 d45 MLI Requisition Issued 10-Dec-01 3-Dec-02 256 d46 Flex Cable/Bulkhead Assembly Finished 11-Dec-01 27-Feb-02 56 d47 Specification for Filter Wheels Written 14-Dec-01 10-Dec-01 -4 d48 Rotation Stage Tested 14-Dec-01 4-Apr-02 79 d49 Mechanism Mounting Blocks Fabricated 14-Dec-01 4-Dec-02 254 d50 Joined Filter Consortium 14-Dec-01 21-May-02 112 d51 Requisitions for Vacuum Parts Initiated 20-Dec-01 19-Apr-02 86 d52 Requisition for Rotation Stage Controller & 2nd Stage Issued25-Dec-01 1-Mar-02 48 d53 Cable for Motors Analyzed 28-Dec-01 8-Feb-02 30 d54 Mask Plate Designed 28-Dec-01 15-May-02 97 d55 Detector Holder Prototype Thermal Test Finished 1-Jan-02 19-Sep-02 187 d56 Vacuum Enclosure Engineered 3-Jan-02 31-Oct-01 -46 d57 MLI Designed 8-Jan-02 12-Feb-02 25 d58 Thermal Reflector Engineered 9-Jan-02 17-May-02 92 d59 Deliver Communications Test Software 14-Jan-02 30-Jan-02 12 d60 Requirements for Window Written 15-Jan-02 18-Jan-02 3 d61 Requirements for Field-Flattening Lens Written 15-Jan-02 8-Feb-02 18 d62 Requirements for Telescope Simulator Modified 15-Jan-02 10-Dec-01 -26 d63 Requirements for Pyramidal MirrorWritten 15-Jan-02 8-Feb-02 18 d64 Motor PCB Designed 18-Jan-02 24-Jun-02 110 d65 Filter Wheel Mounting Block Specified 21-Jan-02 21-Sep-01 -87 d66 MUX Tested at Room Temperature 22-Jan-02 8-May-03 338 d67 Parts for Test Dewar Assembled 25-Jan-02 8-Feb-02 10 d68 Cryo-Optical Box Drawings Finished 30-Jan-02 18-Oct-02 188 d69 Vacuum Parts Delivered 31-Jan-02 15-Jul-02 117 d70 Telescope Simulator Engineered 31-Jan-02 3-Jul-02 109 d71 MUX Tested at Cold Temperature 1-Feb-02 5-Aug-03 393 d72 Requistions for Parts for Telescope Simulator Issued 8-Feb-02 26-Sep-02 164 d73 Motor PCB Fabricated 8-Feb-02 10-Jul-02 108 d74 Communications with NI6533 Card Tested 20-Feb-02 20-Feb-02 0 d75 Vacuum Enclosure Designed 22-Feb-02 13-Nov-02 189 d76 Upgrade Decision for 2nd Channel Made 28-Feb-02 10-Jun-02 72 d77 Web Site Created 28-Feb-02 8-Mar-02 6 d78 MLI Blanket Delivered 7-Mar-02 31-Jan-03 235 d79 Thermal Reflector Concept Analyzed 8-Mar-02 1-Mar-02 -6 d80 Telescope Simulator Designed 11-Mar-02 25-Feb-03 250 d81 Parts for Telescope Simulator Delivered 13-Mar-02 26-Sep-02 141 d82 A-Frame Strut Fabricated 15-Mar-02 14-Dec-01 -65 d83 Software Drives Detector Controller 20-Mar-02 14-Mar-02 -4 d84 Mask Plate Finished 22-Mar-02 5-Jun-02 53 d85 Thermal Reflector Designed 22-Mar-02 30-May-02 49 d86 Vendor for Thermal Reflector Selected 22-Mar-02 29-Oct-02 157 d87 N2 Can Fabricated 28-Mar-02 10-Apr-03 271 d88 Detector Tested in Lab 2-Apr-02 3-Sep-0389 ArcView Drives Detector Controller 3-Apr-02 28-Jun-02 62 d90 Rotation Stage Controller & 2nd Stage Delivered 8-Apr-02 15-Oct-02 137 d91 Cryo-Optical Box Fabricated 9-Apr-02 30-Apr-03 277 d92 Detector Tested with Sky 10-Apr-02 11-Sep-0393 Software Drives Filter Wheels 10-Apr-02 20-Sep-02 116 d94 Filter Wheel Designed 12-Apr-02 26-Apr-02 10 d95 Minimal Software Complete 24-Apr-02 20-Sep-02 106 d

20

96 Detector Assembly Designed 30-Apr-02 17-Mar-03 230 d97 Reworked Electronics Finished 1-May-02 1-Oct-0398 GUI Complete 1-May-02 25-Jul-03 322 d99 Mirrors Delivered 6-May-02 6-Oct-03

100 Window Delivered 9-May-02 2-May-02 -5 d101 Baseline Software Complete 14-May-02 25-Jul-03 313 d102 Thermal Reflector Fabricated 15-May-02 15-Nov-02 132 d103 Telescope Simulator Fabricated 17-May-02 7-Jul-03104 Mirrors Installed in Mounts 20-May-02 20-Oct-03105 Mask Wheel Engineered 21-May-02 25-Feb-02 -61 d106 Vacuum Enclosure Finished 24-May-02 13-Mar-03 209 d107 Mirror Mounts Engineered 31-May-02 15-Jul-02 31 d108 Mirror Mounts Detailed 12-Jun-02 8-Aug-02 41 d109 Collimator and Camera Mirror Mount Designed 14-Jun-02 14-Mar-03 194 d110 Mask Wheel Designed 18-Jun-02 15-May-02 -24 d111 Cryo-Optical Box Thermal Test Finished 21-Jun-02 8-Sep-03112 Operating Software Complete 25-Jun-02 26-Sep-03113 Mirror Mounts Fabricated 10-Jul-02 13-Jan-03 132 d114 Filter Wheels Fabricated 12-Jul-02 4-Dec-02 103 d115 Field-Flattening Lenses Delivered 12-Jul-02 18-Aug-03 287 d116 Test Plan for Filter Wheel Written 12-Jul-02 13-May-02 -45 d117 Detector Assembly Fabricated 15-Jul-02 16-Jun-03118 Detector Assembly Finished 22-Jul-02 15-Oct-03119 Focal-Plane Assembly Designed 23-Jul-02 19-Apr-03 193 d120 Mask Wheel Fabricated 31-Jul-02 21-May-03 210 d121 Filter Wheel #1 Tested Warm 7-Aug-02 10-Dec-02 89 d122 Focal-plane Assembly Fabricated 13-Aug-02 27-Jun-03 228 d123 Filter Wheel #1 Tested Cold 15-Aug-02 15-Aug-02124 Filter Wheel #2 Tested 22-Aug-02 10-Dec-02 79 d125 Mask Wheel Tested 3-Sep-02 24-Jun-03126 F/21 Collimator & Camera Mirrors Delivered [Upgrade]13-Sep-02 6-Oct-03127 2nd Collimator and Mirror Mount Fabricated 13-Sep-02 6-Jun-03 190 d128 Telescope Simulator Finished 7-Oct-02 23-Jul-03129 2nd Collimator and Mirror Mount Tested 17-Oct-02 1-Jul-03130 Basic Filters Delivered 13-Dec-02 3-Jan-03 14 d131 All Filters Delivered 13-Dec-02 3-Jan-03 15 d132 Instrument Assembled & Aligned at Room Temperature21-Jan-03 10-Nov-03133 Flexure Tested 28-Jan-03 17-Nov-03134 Draft Maintenance Manual Written 14-Feb-03 6-Aug-03 123 d135 Draft Software Manual Written 14-Feb-03 9-May-03136 Cold Test #1 Finished 18-Feb-03 8-Dec-03137 As-Built Drawing Package Assembled 28-Feb-03 28-Feb-03138 Draft Operating Manual Written 14-Mar-03 14-Mar-03139 Maintenance Manual Finished 31-Mar-03 18-Sep-03140 Software Manual Finished 31-Mar-03 23-Jun-03141 Draft Acceptance Test Written 31-Mar-03 11-Aug-03142 Shipping Container Finished 31-Mar-03 20-Jun-03143 Cold Tests Finished 11-Apr-03 29-Jan-04144 Operating Manual Finished 30-Apr-03 30-Apr-03145 Acceptance Test Written 7-May-03 17-Sep-03146 Pre-Ship Acceptance Test Finished, Integration Complete14-May-03 5-Feb-04147 Project Complete 10-Jun-03 25-Feb-04