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T-ReCSISE Graduate SeminarSeptember 2, 1999
Managing the Design and Fabrication of a
World-class Astronomical Instrument
Thomas Kisko, M.S., P.E.Associate in Industrial Engineering
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T-ReCSISE Graduate SeminarSeptember 2, 1999
AbstractThe 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?
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T-ReCSISE Graduate SeminarSeptember 2, 1999
T-ReCS
Gemini Thermal Region Camera & Spectrograph
Key Personnel:Charles Telesco PI, Optical/Mechanical, ScienceTom Kisko Project Manager, SoftwareRobert Piña Software, ScienceKevin Hanna ElectronicsJeff Julian Mechanical/ThermalDavid Hon SoftwareUCF (CREOL/FSI) Optics
Glenn Boreman Jim Harvey Jongwook Kye Glenn Sellar
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Gemini South on Cerro Pachon, Chile
Photo Courtesy of Gemini Observatory
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T-ReCSISE Graduate SeminarSeptember 2, 1999
The Gemini Telescope Structure
Courtesy of Gemini Observatory
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T-ReCSISE Graduate SeminarSeptember 2, 1999
3D Cold Plate Layout
Split Cold Plate
Window Turret
Top View
Aperture Wheel (i0) withwindow imaging lens.
Sector Wheel
F1 TurningFlat
Filter/LyotWheels (p1)
M1 TransferMirror
Grating/ImagingTurret (p2)
F4 Turning Flat
Array (i2)
Pupil ImagingWheel
M2 Collimator Mirror
Slit Wheel (i1)
F2 Turning Flat
M3 CameraMirror
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Window Changer
•Provides 5 window positions that can be selectedduring 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 actionwhen wheel is turned. No additional motor driverequired.
•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.
Element X Y Z Tip Tilt Rotation(mm) (mm) (mm) Degrees Degrees Degrees
Window 2.0 1 1
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Cryo-Motor Drives
•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 atcryogenic temperatures.
•Stainless steel tubing truss provides rigid mountingand thermal isolation.
•Gearbox connected to mechanisms forheight and gear ratio tuning.
•Electrical connections via heatsunk‘D’ connector helps cool motorwindings.
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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.
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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.
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
collimatormirror
slit wheel
cameramirror
grating/imaging turret
focal plane array
entrance windowwheel
aperture-stopwheelpupil lens
wheel
T-ReCS Optical Layout
transfer mirror
Filter & Lyot-stop wheels
window-imaging lenses
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T-ReCSISE Graduate SeminarSeptember 2, 1999
T-ReCS Unfolded Optical Layout
Collimator Mirror (M2)
Camera Mirror (M3)
Transfer Mirror (M1)
Telescope Focus (i0)
1st Pupil (p1)IntermediateImage (i1)
2nd Pupil (p2)
Final Image(i2, Detector)
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Overall Electronics Block Diagram
MotionControl
TemperatureControl
Array
DewarBias Module
Preamp
ASP Rack
AnalogPower Supplies
Main Readout Electronics
ICS Rack
Main EPICSVME
Components
Motion & Temperature
Control Components
Clocks
Analog
DHS LAN
EPICS CannelAccess LAN
Gemini OCS
ChopperEvent Bus
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T-ReCSISE Graduate SeminarSeptember 2, 1999
2. Overall Architecture
0.2C om ponents
C ontro lle r
O C S
TC S
D H S
S A D
G IS T-R eC SC om ponents
S ta tus &C ontro l S igna ls
In terlockS igna l
0 .3D etector
C ontro lle r
C & R(in form ationa l)
Logging requests &O bservation in fo .
T -R eC SA rray S equencer &P reprocessor (A S P )Im age
D ata
C & RC & R
C & R
C & R
C & R - C om m and & R esponse
0.1Instrum entS equencer
0 .4E ngineering
In terface
S etupIn form ation
S tore
Tester
C & R
S etupS equencerIn form ation
E ngineeringS etup
In form ation
C & R
S C S
C & R(event bus)
D isp lay
C & R
C & R
Level 0 Data Flow:
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T-ReCSISE Graduate SeminarSeptember 2, 1999
OCS TCS & SCS
Sequencer Tasks
Channel Server
Scan &Monitor
Tasks
DHSClient
ImageServer
ASP Interface Fibre/DMA &Serial (RS232)Motor, Serial Port, etc.
EPICS DBGenSub
CAD/CAR
EPICS DBSAD
ICS/IOC (VxWorks/EPICS)
DetectorAgent
LAN(s)
DHS Server
Level 0 Protocol:
ImagePipeline
EPICS Channel Access
DRAMA/IMP
UFLib Protocol
Gemini Event Bus
Eng. Consoles
2. Overall Architecture
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T-ReCSISE Graduate SeminarSeptember 2, 1999
2. Overall Architecture
Level 1 ICS Runtime:
ReplicatedTCS Environment& WCS & SCSRecords
CAD
Apply
CAR
Environment RecordsMotor Records
OCS
TCS &SCS
ComponentsSeq
Detector Records
EnvironmentSeq
Detector Agent(TCP Server)
SystemSeq
MotorSeq
libUFGem (C)
(Epics & VxWorks)
ASP
Interm.CAD/GenSub Records Interm.CAD/GenSub Records
Interm.CAD/GenSub Records
DetectorSeq
libUF (C++)
Image Pipeline&
Server (TCP)EPICS Database I/O
UF Protocol Gemini Event Bus
UFLib Runtime Entry
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T-ReCSISE Graduate SeminarSeptember 2, 1999
2. Overall Architecture
Level 1 Image Pipeline Runtime:
Data LAN
Pixel Sort &Local Archive
Image Preprocessor
libUF (C++)(No Epics Bindings)
libUFGem (C)(Epics Bindings)
NFSPMC/DMAFrameGrabber
Queue of
Frameson
Heap
FrameRing buffer
(SharedMemory)
ASP ImageRing buffer
(SharedMemory)
ImageRing buffers
(diffs & accums) Epics SAD
Image Server(TCP/IP)
DHS Client
(Zbuff Socket)
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T-ReCSISE Graduate SeminarSeptember 2, 1999
7. EPICS Commanding
MESS
ccSysCad.sch
(A)
(B)
(C)
The "apply" record sequences the other
"apply" records contained in the lower level
ccSysCad schematics in the order A, B, C, D
NOTE: ccSysCad3.sch contains commands which are all optional.
They are not required and are therefore left out.
It is important that this fact is reflected in the
Instrument Sequencer, so it does not attempt to forward these commands.
Apply
PV:$(top)$(mech)
DESC:CICS CC system APPLY record
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
NPP
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
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
NMS
apply
OUTG
OCLG
OUTH
OCLH
OCLF
OUTF
OCLE
OUTE
OUTC
OCLC
OUTD
OCLD
INMH
INPH
INMG
INPG
INMF
INPF
INME
INPE
INMD
INPD
INMC
INPC
SLNK FLNK
VAL
MESS
OUTA
OCLA
OUTB
OCLB
DIR
CLID
INPA
INMA
INPB
INMB
System Command Action Directive Records
Core Instrument Control System
112 Aug 97checked:B.Goodrich
Cauthor:S.M.Beard
1 2 3 4
A
B
C
D
4321
D
C
B
A
OFSHEET
DIR
CLID
ccSysCad1
MESS
VAL
CLID
DIR
ccSysCad2
MESS
VAL
CLID
DIR
MESS
VAL
ccSysCad4
DIR
CLID
VAL
MESS
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
=====
ICD14
.
.
.
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Project Management Objectives
• Quality instrument• On time• Under budget• Minimize risk• Contingencies
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Project Schedule
Let’s look at it in detail.
I’ll open it with MS Project.
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T-ReCSISE Graduate SeminarSeptember 2, 1999
The Monthly Management Report Also Includes:
• A summary of:Activities for the monthAccomplishmentsProblems
• 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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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 macrosBudgets
Monthly proration
Sheet for each monthly management report
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Bill of Materials for T-ReCS
• Items are specified in a hierarchy of items, subitems, and terminal items.1 Car1.1 Engine1.1.1 Alternator1.1.1.1 Alternator pulley - $4.231.1.1.2 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.
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
The New “Plan”
• A cost estimating/tracking system• Plans every expenditure:
BOM items
Payroll
Travel
Miscellaneous costs• Based on a planned expenditure list
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T-ReCSISE Graduate SeminarSeptember 2, 1999
Managing ...
• Fabrication of T-ReCS• Expenditures and Staffing• Day-to-day activities• Contingencies
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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)
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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T-ReCSISE Graduate SeminarSeptember 2, 1999
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
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