quarterly review june 13, 2001 1 quarterly review june 13, 2001

1

Quarterly ReviewJune 13, 2001

QUARTERLY REVIEW

June 13, 2001

2


This Page Intentionally Left Blank

3


GNIRS Quarterly Review

Table of Contents

• Introduction Pg 4

• Project Summary Pg 7

• Configuration & Integration Pg 23

• Project Management Pg 43

• Appendices Pg 65

4


Introduction• This is the 5th GNIRS Quarterly Review

• GNIRS is in the final design and fabrication phase– Most of our “problems” are the delays in

fabrication which affect our low-level test and integration schedules

5


Outline

• Project summary– Last QR Response– Progress Overview– Cost and Schedule Status

• Problems and Concerns • Integration plans • Project management• Plans for next review • Appendices

6



7


Project Summary

• Response to last QR report

• Progress overview

• Summary schedule

• Budget and expenditures to date

8


Planned Completions by this Quarterly Review

• Complete fabrication of all mechanisms

• Complete design of all fixed assemblies

• Complete lens delivery and acceptance testing

• Complete dewar cold station PCB fabrication

• Complete dewar warm-up controller fabrication

• Complete dewar-to-thermal enclosure cabling

9


Task StatusItem Status Comments

Complete fabrication of all mechanisms

Not Complete – two Camera Barrels, Focus Stage in detail design

Some rework will be required as testing progresses.

Complete design of all fixed assemblies

Not Complete – 10 of 19 fixed assemblies completed design

Should complete the design of the remaining items this quarter

Complete lens delivery and acceptance testing

Not complete - One BaF2 was

broken by the vendor

Delivery of final lens is scheduled for August.

Complete dewar cold station PCB fabrication

Complete

Complete dewar warm-up controller fabrication

Not Complete – start of this activity has been rescheduled

Low priority activity that is not needed until late in the project.

Complete dewar-to-thermal enclosure cabling

Not Complete – design is complete

Actual fabrication waiting for final dimensions/length

10


Exploded View

11


N D J F M A M J J A S O N DCY-2000

Risk Reduction Prototypes

PFR

Structural Analysis

Bench Design/Fab/Assy

OIWFS/Post-Slit/Pre-Slit

Mechanism Design/Fab/Assy/Test

9 Mechanisms

Electronics Design/Fab/Test

Optics Procurement

OIWFS Hardware

Rotary Mechanism Flexure Tests

Systems Engineering

Mirrors/Lenses/Filters/Gratings/Prisms

J F M A M J J A S O N D J F M A M J J A S O N DCY-2001 CY-2002

Fixed Assemblies Design/Fab

Integration/Alignment

WFS Integration/Alignment

Mechanism Design/Fab/Assy/Test

IFU Modules

Software Development/Code/Test

SW Plan/Low-Level/High-Level Code

Electronics Design/Fab/Test

Manuals

ATP

Ship

Training

GNIRS SUMMARY PLAN6/01

MFR

Rotary Mechanism Flexure Tests

Mirrors/Lenses/Filters/Gratings/Prisms WP

Summary Project Plan

12


Project Status - Progress from August ’99

WBS element March Review June Review5.0 Overall project 53% 66%5.1 Management & Reporting 51% 61%5.2 Systems Engineering 100% 100%5.3 Mechanical 52% 70%5.3.1 Mechanisms 66% 84%5.3.2 Benches 55% 70%5.3.3 Fixed Assemblies 16% 36%5.4 Electronics 63% 59%5.5 Software 49% 63%5.6 Integration 0% 0%5.7 Deliverables 0% 0%5.8 Procurement 54% 67%

13


Progress Overview

• The August 2002 delivery date of the instrument has not changed• The project is currently 66% complete overall

– We are in the fabrication phase and in process of completing final design tasks

• We have completed 92 of 224 total project milestones• Our critical path is completing 2D design and fabrication of fixed assemblies• Optics are either complete or in fabrication• Mechanical

– Mechanism fabrication is essentially complete– Bench fabrication is near completion– All cold structure 3D design is complete– 10 fixed assemblies remain to be designed

• Electronics fabrication is 2/3 complete• Software low-level code development is in test

– EPICS code is in work

14


Collimator Passive Compensation

15


Comments on last quarter of work

• Design activity concentrated on– the Bulkhead Assembly design and release to fabrication

– Detector-Focus Assembly design and release to fabrication

– Passive Collimator 3D design

– Start of Fixed Assembly design

• Fabrication – both in-house and vendor contracted– Mechanical and electrical

• Detail planning for mechanism test and integration• Interface issues and the envelope waiver

16



17


Progress and Schedule Comments – The bottom line

• There are no known technical issues left to address• We will enter the integration phase of the project about 6 weeks late

– Delaying integration has not impacted our fall-2002 delivery– The first 3 months of integration schedule is flexible with respect to

integrating different mechanisms and assemblies– We still have contingency built into the integration schedule

• The mechanical design effort is going extremely well but is taking longer than planned– 3D design is nearly complete – <10 fixed assemblies remain– 2D detailing is the critical effort - should complete by mid-July

• Fabrication is running late on several key assemblies– Primarily due to vendor delays– This has impacted mechanism assembly/test– Fabrication will continue through September - October

• Mechanism assembly/test has slipped to summer

18



19


Budget and Expenditures• Baseline Estimate (Jan 99 to completion)

• Labor $3,391,232• Capital $ 836,462• Total $4,227,694

• Current Forecast March Review June Review

Labor $2,866,775 $3,002,938Capital $1,074,798 $1,181,900Total $3,941,573 $4,184,838

• Performance ratios March Review June Review

BCWS $ 1,754,979 $ 2,863,855 BCWP $ 1,611,542 $ 2,011,383ACWP $ 1,742,651 $ 2,113,212CPI 0.92 0.95 SPI 0.92 0.70

20



21


Problems and Concerns

• Fabrication delays• Vendor schedule performance issues are threatening to delay mechanism

testing and integration schedules

• Amount of rework is yet unknown w/respect to schedule allowance

• OIWFS component late delivery• Will cause resources to be diverted from other activities to work on

OIWFS integration and test

• Scheduled delivery continues to slip

• IFU delivery will not occur as planned• We will use mass models instead of the real units

• Integration at a late date will be complicated

• Flexure test rig on line by date needed (mid-February, 2002)

22



23


Configuration Overview

• Envelope• Weight and C.G. estimate• Movement range of electronics boxes

24


25


Configuration - Overview

•Dewar and trusses fully defined–Check/deal with envelope violations–Weight and c.g. uncertainty reduced

26


(envelope image)

27


Configuration - Envelope

•Envelope waiver negotiated with Gemini

–Intrusion into rear dealt with by removable installation truss (normally removed)

–Intrusion into “underside” dealt with by removable installation truss (normally installed)

–Intrusion into service area near ISS dealt with by waiver

28


Configuration - Weight

•Weight is under control–Weight requirement (budget): 4413 lb–Weight estimate 3/01: 4115 lb–Weight estimate 6/01: 3930 lb–Estimated ~100 lb uncertainty through integration

29


Configuration - C. G.

•C. G. under control–Requirement z=100 cm, x,y=0–March/01 z=105 cm, x=4 cm, y=5 cm (4100 lb: error ~630 ft-lb = 860 N-m)–June/01 z=104 cm, x=0, y=-3 cm (3930 lb: error about the same)–Electronics enclosures can be shifted in z, increment ~40 ft-lb

30



31


Configuration - Ballast

•Ballast will be needed–Weight estimate implies need; include ballast points in design–C. G. correction will use <300 lb–Additional ballast will be used to “trim” instrument as required

32


Integration Overview

• Subsystem testing qualifies individual mechanisms and optical assemblies

• Integration into bench permits check of warm optics and mechanisms

• Integration of cold structure into dewar for vacuum, cryo testing

• Final tests

33


Integration Overview

• Subsystem testing

• Bench integration/test

• Dewar integration

34


Subsystem Testing

• Qualifies sub-assemblies for integration– Performance can be checked prior to final integration

– Problems are isolated

– Maximum time for problem fixes

35


Subsystem Testing

• Testing of mechanisms as outlined in previous reviews– Warm functionality

– Warm flexure

– Cold functionality

– Tests (esp. cold tests) without optics

36


Subsystem Testing

• Optics testing of “powered” sub-assemblies– Four cameras

– Offner relay

– Verifies performance, not required for alignment

– Camera tests require calculation of thermal, wavelength shifts

37


Bench Integration

• Add subsystems to bench after qualification – Main bench completes in late July; clean and paint after fit checks– Integrate prism turret, acquisition mirror immediately– Pre-slit assembly (Offner, filter wheels, slit/decker) integration and

test complete early August– Remaining mechanisms test and integration complete late August

(short red camera may slip?)– OIWFS assembly and alignment must be done by August

38


Bench Integration

• Integration into bench permits warm optics and mechanical check (uses warm MUX)– Check (re-check) fit, alignment, repeatability

– Check image quality (“warm” predictions)

– Check flexure compensation calibration & performance (but not flexure calculations)

39


Dewar Integration

• Integration of cold structure into vacuum vessel – prior test of vacuum integrity– should be here at next QR

• Re-test with MUX– possible limited flexure test

• Install engineering array

40



41


Dewar Integration

• Initial cool-down followed by tests outlined in August ‘99 test plan– start October

• Opportunities for IFU installation during testing; schedule penalty varies

42



43


Project Management

• Project Status

• Schedule & Planning

• Milestones

• Budget and Expenditures

• Organization

• Plans for Next Review

44



45


Project Status – WBS 5.2 Systems Engineering

• Systems Engineering activities over this quarter included– Oversight of the top level design and interfaces– Completion of flexure testing/evaluation of rotary

mechanism design approach– Oversight of the passive collimator design– Optical element evaluation

• Included prisms/gratings/mirrors/lenses

– Re-planning the initial phase of instrument integration• In reaction to design and fabrication delays

– Envelope waiver submission

46


Project Status – WBS 5.3 MechanicalMechanism %Camera 89Detector Focus 46Environ Cover 99Acquisition Mirror 75Slit Decker 85Filter Wheel 83Grating Turret 85

Gratings 86Prism Turret 74

Prisms 74Motor Drives 98

Bench %Post-Slit 69OIWFS 86Collimator 45POM/Offner 81

Fixed Assembly %Entrance Window 100Cryo-cooler 18Thermal Dist. 0Bulkhead Rad Shield 0LN2 Pre-Cool 84Opt Bench Mount 43Environ Cover Filter 0Bulkhead 57Front Rad Shield 3Rear Rad Shield 0Front Dewar Shell 37Rear dewar Shell 26Vert Inst Frame 17Horiz Inst Frame 5Dewar Mount Truss 23TE Mount Truss 53Shipping Container 0Handling Fixture 68

47


Project Status – WBS 5.3 Mechanical

• All mechanisms are in fabrication except two camera barrels and the focus stage.

• All optical benches are in fabrication• Fixed assembly 3D design remaining

– Front/rear dewar shells– Radiation shields (4)– Thermal distribution assembly– Cryo-cooler and manifold– LN2 Pre-cool assembly

• Fixed assembly 2D detailing in-work– Detector mount assembly– Vertical and Horizontal installation frames– Dewar mount truss assembly– Thermal enclosure mount assembly

48


Project Status – WBS 5.4 Electrical

• Design activities are completed– schematic and parts list updates occur as needed

• Fabrication in progress– Ancillary Crate is being assembled and harnessed,

will be completed and tested in June 2001– final Component Controller crate (WFS Phytrons) to be delivered– 1/3 of Component Controller internal harnessing is done

• Work Remaining– assemble and clean the Coldstation PCBs– finish the Thermal Enclosure internal harnessing– fab the TE to Dewar cables (are all simple 1:1 cables)– harness the Cold Mechanisms and Cold Bench as they become available

49


Project Status – WBS 5.5 Software

• Component Controller code 90% complete• Code has been tested as far as possible• Waiting for

• Completion of the electronics thermal enclosure

• Actual mechanisms

• High level (EPICS) code 70% complete

• Gemini DHS received, being evaluated

50


Project Status – WBS 5.8 Procurement

ASSEMBLYIN

HOUSE LANDMARK CHALLENGERVENTURA OPTICAL RGI

OPTIICS FOR RESEARCH

OHYO KOGYO BECHDON

TO BE BID

LONG RED CAMERA 1LONG BLUE CAMERA 1CAMERA HUB ASSY 1 2ACQUISTON MIRROR 1SLIT DECKER HOUSING 3SLIT SLIDE 1FILTER WHEEL 1GRATING TURRET 1 1 2PRISM TURRET 1 2 2POST SLIT BENCH 1LONG CAMERA HOUSING 3TOP CAMERA COVER 1BOTTOM CAMERA COVER 1OIWFS BENCH ASSY 1COLLIMATOR TUBE 1PICK OFF MIRROR ASSY 2 1OPTICAL GIMBAL MOUNT 2FOR BULKHEAD WELDMENT 1 BIDAFT BULKHEAD WELDMENT 1 BID

FIXED ASSEMBLIES 9

51


Project Status –Optics• Lenses and Windows

• Only one BaF2 lens for short red camera remains• Vendor remaking the last lens

• Mirrors• All mirrors received except for POM and Acq Mirror

• POM and Acq Mirror are replicas, due in 4 weeks• Flats are due in 3 weeks

• Gratings• 2 Gratings in fabrication, due the end of June; 3rd received

• Filters• 7 filters ordered through UH consortium; 2 failed spec and vendor is

expected to replace

• Prisms• Wollaston prism due in 2nd half of August• Cross-dispersion prisms due late July

52



53


Project Milestones by Quarter

As of 6/8/01

Calendar Year Quarter

Number of Milestones

DueRunning

Total

Number of Milestones

CompRunning

Total1999 4th 1 1 1 12000 1st 15 16 15 162000 2nd 13 29 13 292000 3rd 8 37 8 372000 4th 18 55 18 552001 1st 23 78 20 752001 2nd 45 123 17 922001 3rd 70 193 0 922001 4th 15 208 0 922002 1st 8 216 0 922002 2nd 3 219 0 922002 3rd 5 224 0 92

TOTAL 224 92

54


Work Package Status 8/99 thru 5/01WBS TITLE DESCRIPTION AMOUNT WBS TITLE DESCRIPTION AMOUNT

5 GNIRS LABOR BUDGET $1,812,398 5.3.3 Fixed Assys LABOR BUDGET $280,216LABOR ACTUAL $1,431,863 LABOR ACTUAL $68,136Over/Under $380,535 Over/Under $212,080

CAP BUDGET $718,054 CAP BUDGET $173,099CAP ACTUAL $681,349 CAP ACTUAL $1,494Over/Under $36,705 Over/Under $171,605

5.1 Mgt & Reporting LABOR BUDGET $596,080 5.4 Electronics LABOR BUDGET $79,121LABOR ACTUAL $561,025 LABOR ACTUAL $70,300Over/Under $35,055 Over/Under $8,821

5.2 Systems Eng LABOR BUDGET $174,814 CAP BUDGET $12,050LABOR ACTUAL $223,383 CAP ACTUAL $7,645Over/Under ($48,569) Over/Under $4,405

CAP BUDGET $38,658 5.5 Software LABOR BUDGET $56,371

CAP ACTUAL $55,568 LABOR ACTUAL $54,038Over/Under ($16,910) Over/Under $2,333

5.3 Mechanical LABOR BUDGET $572,969 CAP BUDGET $32LABOR ACTUAL $511,531 CAP ACTUAL $32Over/Under $61,438 Over/Under $0

CAP BUDGET $330,852 5.8 Procurement LABOR BUDGET $4,019CAP ACTUAL $308,707 LABOR ACTUAL $11,585Over/Under $22,145 Over/Under ($7,566)

5.3.2 Benches LABOR BUDGET $192,969 CAP BUDGET $126,931LABOR ACTUAL $172,957 CAP ACTUAL $299,924Over/Under $20,012 Over/Under ($172,993)

CAP BUDGET $107,628CAP ACTUAL $55,801Over/Under $51,827

55


WBS - Total Project

56


GNIRS Staffing FTE by Month

0.0

5.0

10.0

15.0

20.0

25.0

30.0

35.0

40.0

Month

FTE

Plan FTE Actual FTE

57


GNIRS Work by Month

0

1000

2000

3000

4000

5000

6000

Month

Ho

urs

Actual Baseline Jun'01 Plan

58


GNIRS Cumulative Work

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

Month

Hour

s


76,719h[79,615h w /sci.]

79,725h

43,605h

59


GNIRS Capital Spend Plan

$0

$200,000

$400,000

$600,000

$800,000

$1,000,000

$1,200,000

$1,400,000

M onth

Dol

lars


$759,192

$1,181,900

$715,967

60



61


Gemini ProjectsProject Manager

N. Gaughan

Director, NOAOJ. Mould

Project AssistantD. Eklund (.5)

Administrative AssistantM. Bowersock

Project Scientist,Systems

EngineeringJ. Elias

J. EliasMechanical Engineers E. Hileman G. Muller

Electrical Engineer

J. Penegor

J. EliasOptical EngineerM. Liang

Procurement & Vendor Liaison

A. Davis

SoftwareR. Wolff

Support ScientistsD. Joyce

B. Gregory

Mechanical DesignersJ. AndrewD. Rosin

E. DowneyD. Circle

Electrical TechniciansR. George

InternA. Lowe

Staff Added: R. Bennett, L. Lederer, R. Davis, Interns S. Kroto, E. Mountford, A. LoweStaff Transferred: R. Robles

Updated 6/01

General Technician

J. Pina

InternS. Kroto

ProgrammerP. Ruckle

Instrument MakerJ. Stein

R. BennettL. LedererR. Davis

InternE. Mountford

M & PB. Ditsler

62


Plans for Next Review• The Next Quarterly Review will be held in the September timeframe

• We will make significant progress in mechanism and optical subassembly testing

• All optics to be received• Flats/Prisms/Grating replicas

• Final mechanical assemblies to have completed fabrication• Bulkhead assembly (to be undergoing testing at vendor)

• Dewar components (rad shields, shells, etc.)

• Mounting trusses

• Cryo hardware

• Electronics enclosure fabrication and checkout completed

• Final Component Controller Software testing will be in process

• OIWFS components integration/test should be completed

63


Conclusions

• The current project status shows us to be 66% complete

• We will complete the design phase over the next quarter

• We are firmly into the fabrication phase of the plan

• We are about 6 weeks behind baseline schedule

• We are on track to deliver in fall 2002

• The estimated cost of GNIRS is not significantly changed from the August ’99 baseline– Estimated total cost: $4,184,838 - January ’99 to delivery

64



65


Appendix A – ImagesAppendix B – MilestonesAppendix C – Envelope Waiver

66


Appendix A

Configuration and Fabrication

Images

67


Top Assembly

68


Top Assembly

69


Exploded View

70


Top Camera Cover

71


Tangent Support Bar Bracket

72


Slit Decker Housing

73


Pickoff Mirror Housing

74


Pre-Slit Bench Aft Housing

75


Lower Slit Slide Rail

76


Slit Slide Assembly

77


Prism Turret Drive Assembly

78


Grating Turret Drive Assembly

79


Offner Assembly

80



81


Appendix B

Milestones

82



83


Milestones since MFR (3/01)WBS TASK Baseline Plan Est. Plan Act. Finish

5.8.1.1.1 RMI Optics Acceptance 6/16/00 3/1/01 3/1/015.1.4.2.2 Review 11/20/00 3/7/01 3/8/015.2.5.5 Design Axis 2 Wiring Diagram NA 3/12/01 3/12/015.2.5.6 Fab/Test Axis 2 Wiring Harness NA 3/12/01 3/12/015.2.5.8 Mechanism Test Set Complete 9/29/00 3/12/01 3/12/015.3.3.1.3.5 Entrance Window Assembly Fabrication Complete 6/8/01 3/12/01 3/12/015.3.3.16.1.4 Dewar Mount Truss Assembly Design Complete 1/5/01 3/13/01 3/13/015.3.1.4.4.2 Environmental Cover Assembly Testing Complete 8/7/00 3/13/01 NA5.4.1.2.5 Motor Drive / Cryohead Control Chassis Complete 8/29/00 4/9/01 4/9/015.3.1.8.2.6 Grating Turret Drafting Complete 6/7/00 4/10/01 4/10/015.3.3.9.1.5 Bulkhead Assembly Design Complete 9/26/00 4/10/01 4/10/015.3.1.2.2.2.4 Long Red Camera Drafting Complete 10/4/00 4/13/01 4/13/015.3.1.104.5 Motor Drive Assembly Complete 8/2/00 4/16/01 4/16/015.3.1.2.3.1.3 Long Blue Camera Design Complete 5/31/00 4/17/01 4/17/015.3.2.4.2.3.3 Offner Assembly Fabrication Complete 9/11/00 4/24/01 4/24/015.3.3.14.1.4 Vertical Installation Frame Assembly Design Complete 12/4/00 4/27/01 4/27/015.3.3.15.1.5 Horizontal Installation Frame Assembly Design Complete 12/5/00 4/27/01 4/27/015.3.3.17.1.5 Thermal Enclosure Mount Assembly Design Complete 1/23/01 4/30/01 4/30/015.3.3.19.4 Handling Fixtures Complete NA 5/18/01 NA5.3.2.3.3.2.4 Collimator Compensating Mount Design Complete NA 5/23/01 5/23/015.3.2.1.8.3.2 Bottom Camera Cover Fabrication Complete 7/21/00 5/30/01 NA5.3.2.3.2.1.5 Collimator Cover Box Design Complete 5/5/00 5/30/01 5/30/015.3.3.13.1.5 Rear Dewar Shell Design Complete 3/29/01 5/31/01 5/31/015.3.3.9.2.6 Bulkhead AssemblyDrafting Complete 2/21/01 6/1/01 6/1/015.3.1.8.6.4 Grating Fabrication Complete 11/28/00 6/1/01 NA5.3.3.12.1.5 Front Dewar Shell Design Complete 2/26/01 6/1/01 6/1/015.3.2.1.8.4.4 Bottom Camera Cover Complete 7/26/00 6/4/01 NA5.3.3.6.1.3 LN2 Pre-Cool Assemby Design Complete 11/16/00 6/6/01 6/6/015.3.1.6.3.3.6 Decker Slit Slide Fabrication Complete 12/5/00 6/6/01 NA5.3.1.2.3.2.4 Long Blue Camera Drafting Complete 11/27/00 6/6/01 6/6/015.3.1.2.4.3.6 Short Red Camera Barrel Complete 8/2/00 6/7/01 NA5.3.3.17.2.6 Thermal Enclosure Mount Assembly Drafting Complete 3/14/01 6/8/01 NA5.3.2.3.2.2.4 Collimator Cover Box Drafting Complete 8/7/00 6/11/01 NA5.3.1.7.3.2 Filter Wheel Assembly Fabrication Complete 1/10/01 6/11/01 NA5.3.3.11.1.4 Rear Radiation Shield Assembly Design Complete 3/19/01 6/12/01 NA5.3.1.6.2.3.5 Decker Slide Complete 9/11/00 6/12/01 NA5.3.3.3.1.4 Cryo Cooler Design Complete 9/26/00 6/12/01 NA5.3.2.1.6.3.2 LCFMH Fabrication Complete 8/1/00 6/12/01 NA

84



85


Appendix C

Envelope Waiver

quarterly review june 13, 2001 1 quarterly review june 13, 2001

Documents

complete actual fabrication

complete start

mechanisms complete

review appendices

date slide

blank slide

quarter complete lens

summary project plan