TReCS

1
Managing the Design and Fabrication of a
World-class Astronomical InstrumentThomas
Kisko, M.S., P.E.Associate in Industrial
Engineering
2
Abstract

• The 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?

3
T-ReCS Gemini Thermal Region Camera Spectrograph
Key Personnel Charles Telesco PI,
Optical/Mechanical, Science Tom Kisko Project
Manager, Software Robert Piña Software,
Science Kevin Hanna Electronics Jeff
Julian Mechanical/Thermal David
Hon Software UCF (CREOL/FSI) Optics Glenn
Boreman Jim Harvey Jongwook Kye
Glenn Sellar
4
http//www.gemini.edu/public/

5
Gemini South on Cerro Pachon, Chile

Photo Courtesy of Gemini Observatory
6
The Gemini Telescope Structure

Courtesy of Gemini Observatory
7
Overview of System Layout3D Boundary Layout
8
T-ReCS 2D Dewar Layout
9
3D Cold Plate Layout
Window Turret
Sector Wheel
Grating/Imaging Turret (p2)
Aperture Wheel (i0) with window imaging lens.
F4 Turning Flat
Pupil Imaging Wheel
F1 Turning Flat
Array (i2)
M3 Camera Mirror
Filter/Lyot Wheels (p1)
F2 Turning Flat
Slit Wheel (i1)
M1 Transfer Mirror
M2 Collimator Mirror
Split Cold Plate
Top View
10
Window Changer

• Provides 5 window positions that can be selected
• during 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
  action
• when wheel is turned. No additional motor drive
• required.
• 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.

11
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 at
• cryogenic temperatures.
• Stainless steel tubing truss provides rigid
  mounting
• and thermal isolation.
• Gearbox connected to mechanisms for
• height and gear ratio tuning.
• Electrical connections via heatsunk
• D connector helps cool motor
• windings.

12
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.

13
Vacuum Pressure Effects on Dewar Case Lids
14
Optics Mount Temperature Gradients
15
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.

16
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 _at_ 8 ?m
• Image Quality 50 EE-diameter (geo spot) 0.094
  arcsec _at_ 10 ?m 50 EE-diameter (geo spot)
  0.189 arcsec _at_ 20 ?m
• ?1 pixel distortion
• Instrument Background ?1 effective
  emissivity
• (in low ? atmospheric windows)
• Filters 20-30 cold 1-inch filters

17
T-ReCS Optical Layout

Filter Lyot-stop wheels
transfer mirror
camera mirror
focal plane array
grating/imaging turret
collimator mirror
slit wheel
window-imaging lenses
aperture-stop wheel
pupil lens wheel
entrance window wheel
18
Transfer Mirror (M1)
Telescope Focus (i0)
Intermediate Image (i1)
1st Pupil (p1)
2nd Pupil (p2)
Collimator Mirror (M2)
Camera Mirror (M3)
Final Image (i2, Detector)
19
Mon R2 Star Forming Region

20
Overall Electronics Block Diagram
EPICS CannelAccess LAN
DHS LAN
ChopperEvent Bus
21
2. Overall Architecture
Level 0 Data Flow
22
Level 0 Protocol
2. Overall Architecture
OCS
TCS SCS
DHS Server
Eng. Consoles
LAN(s)
ICS/IOC (VxWorks/EPICS)
DHS Client
Sequencer Tasks
Channel Server
Detector Agent
Image Server
EPICS DB GenSub CAD/CAR
Scan Monitor Tasks
EPICS DB SAD
ASP Interface Fibre/DMA Serial (RS232)
Motor, Serial Port, etc.
UFLib Protocol
23
Level 1 ICS Runtime
2. Overall Architecture
CAD
Replicated TCS Environment WCS SCS Records
TCS SCS
Apply
SystemSeq
OCS
CAR
Interm.CAD/GenSub Records
Interm.CAD/GenSub Records
Detector Records
ComponentsSeq
libUFGem (C) (Epics VxWorks)
DetectorSeq
Detector Agent (TCP Server)
Interm.CAD/GenSub Records
EnvironmentSeq
MotorSeq
ASP
libUF (C)
Motor Records
Environment Records
EPICS Database I/O
UF Protocol
24
Level 1 Image Pipeline Runtime
2. Overall Architecture
NFS
PMC/DMA FrameGrabber
Frame Ring buffer (Shared Memory)
ASP
Image Ring buffer (Shared Memory)
Pixel Sort Local Archive
Queue of Frames on Heap
Image Preprocessor
libUF (C) (No Epics Bindings)
libUFGem (C) (Epics Bindings)
Image Server (TCP/IP)
(Zbuff Socket)
Epics SAD
DHS Client
Data LAN
25
7. EPICS Commanding
26
Project Management

27
Project Management Objectives

• Quality instrument
• On time
• Under budget
• Minimize risk
• Contingencies

28
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

29
Phases of a _______ Project

• Concept study
• Requirements development
• Request for proposal (RFP)
• Preliminary design (PDR)
• Critical design (CDR)
• Fabrication
• Integration and test (IT)
• Commissioning

30
Project Schedule
31
Project Schedule

• Lets look at it in detail.
• Ill open it with MS Project.

32
Monthly Management Report
33
The Monthly Management Report Also Includes

• A summary of Activities for the
  month Accomplishments Problems
• 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

34
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 macros
• Budgets
• Monthly proration
• Sheet for each monthly management report

35
UF Accounting Mainframe Data
36
MS Access Transaction Database
37
Bill of Materials for T-ReCS

• Items are specified in a hierarchy of items,
  subitems, and terminal items. 1 Car 1.1
  Engine 1.1.1 Alternator 1.1.1.1 Alternator
  pulley - 4.23 1.1.1.2 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.

38
Bill of Materials Sheet
39
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

40
Bill of Materials Help Sheet
41
BOM

• Lets do a demo.
• Ill open it with Excel.

42
The New Plan

• A cost estimating/tracking system
• Plans every expenditure
• BOM items
• Payroll
• Travel
• Miscellaneous costs
• Based on a planned expenditure list

43
Managing ...

• Fabrication of T-ReCS
• Expenditures and Staffing
• Day-to-day activities
• Contingencies

44
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

45
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)

46
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

47
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

48
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

49
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

50
Web Sites

• Kiskos Web Site (has these PowerPoint
  slides) http//www.ise.ufl.edu/kisko
• T-ReCS Web Site http//t-recs.astro.ufl.edu/
• Gemini Web Site http//www.gemini.edu/