TEOA Program Management PDR · Integrated Optical Systems L-3 Communications - Brashear Proprietary TEOA Program Management PDR Craig Peton February 21, 2012 L-3 COMMUNICATIONS –

Integrated Optical Systems

L-3 Communications - Brashear Proprietary

TEOA Program Management PDR

Craig Peton

February 21, 2012

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Integrated Optical Systems L-3 Communications - Brashear Proprietary

The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012

Program Management

• Program Overview

– ATST TEOA Product Breakdown Structure

• Program Health

– Technical

– Schedule

– Contractual

• Project Plan and Milestones

• Risk Analysis and Mitigation

• Quality Assurance Plan

– Summary and Status

• Current Action Item List

• PDR Exit Criteria

2



PROGRAM SUMMARY/SCOPE

Program Name: Top End Optical Assembly (TEOA) for Advanced Technology Solar Telescope (ATST) Customer: Association of Universities for Research in Astronomy, Inc. (AURA)

Program Lead: Craig Peton

Project Engineer: Steve Mix

Contracts Manager: Devi Clarkson

Business Manager: Rachel Belli-Little

Type: FFP

Contract Value: $6,568,000

PoP: 5/11 – 8/14

Description / Deliverables: • Design, Procure, Fabricate and Install the TEOA

3

Program Description



10

1. TEOA

Top Assy

M2 Top Assy

Heat Stop

Assembly

M2 Optic Support

Assembly

M2 Lyot Stop

Assembly

2. Program Office

Program

Management

Quality Systems

Engineering

Support Frame

Assembly

Electronics Enclosure

Product Breakdown Structure



Program Health

5

Status Trend Action Plan / Comments

Overall Program Y

Contract G • No open contractual issues.

Schedule G • Slight schedule delay with PDR date

Technical Y • Maturity of reference design lower than expected

• ECP needed for Hexapod / Fast Tip-Tilt positioning feedback

• Open spec issues that require further discussion

Supply Chain G • No issues presently identified

Program Risk Y • Risk is moderate due to open technical challenges remaining

with preliminary design.

All Yellow issues center primarily on open spec items that require further discussion.



Technical

Requirements compliance quite high, but some

additional work still needed for 100%

Requirements shortfalls will be addressed in detail

during the presentation

Some simply require input from AURA to proceed

Others require discussion due to requirement conflicts

Some may require waivers to fully comply

Schedule

Some setbacks realized during Phase 2 due to

unanticipated design changes required to

reference design

Heat Stop obstruction to science beam

Lyot Stop interference with Heat Stop

Scattered light issue with Heat Stop

Safety Factor of 4 for Hexapod and FTT

CDR efforts have been restructured to help make

up delay in conducting PDR

Contractual

No open contractual issues with AURA

ECP submittal to incorporate autocollimator for

hexapod position feedback expected in March

Major Subcontract/Vendors

Thermacore – Under contract

Pacing item for critical path

Kickoff held 9Feb at L3

L3/SSG – M2 Mirror work underway

Pacing item for secondary critical path

Plan to conduct early CDR in June 2012

Physik Instrumente – letter subcontract issued

Need to resolve safety factor issue

6

Staffing

All technical resources needed for program

execution are on the project

Utilized outside contractor for CFD analysis

Assisted with modeling of airflow on backside of

M2 mirror

Final report received

Program Status



Rebaselined Program Plan/Schedule

7



8

Rebaselined Program Plan/Schedule


The information contained in this document is subject to the restrictions found on the title page. ATST TEOA PDR 02/21/2012 9

Program Milestones

May

2011

Program

Completion

Aug

2014

Program

Start

Jul

2011

Kickoff

Mtg

Phase 2

Initiation

PDR

Phase 3

Initiation

FDR

Phase 4

Initiation

SRR MRR System

Delivery

June

2011

Aug

2011

Oct 2011

Dec

2011

Feb

2012

Mar

2013

Jan

2013 Feb

2014

TRR

Mar

2014

Jul

2014

FAT

Jun

2014

● Overall – L3/SSG proceeding forward with M2 mirror design

• CDR for mirror will have to take place early due to long lead time

• Anticipated CDR date: June 2012

– Thermacore placed under contract in early Feb. Kickoff meeting held 9 Feb at L3. • Initial efforts will focus on revisiting 2007 analysis with new software modeling capability

• Conduct early risk mitigation activities to verify performance

– PI provided letter subcontract to initiate design efforts • Safety factor requirements for this subsystem are a concern (potentially impacts cost and schedule)

● Critical Path(s) Drivers – Primary: Heat Stop Assembly – Design and Fabricate

– Secondary: M2 Assembly – Design and Fabricate

● Key Actions to Meet Upcoming Milestones – Conduct successful PDR and start of Phase 3 CDR efforts immediately

– Proceed with accelerated efforts on M2 Mirror final design

– Obtain direction on safety factor issue

Program Milestones



Top TEOA Risks

10

Risk Title

Probability of

Occurance (=) Mitigation Date Action and Plan

1

If the Heat Stop absorber coating material is

inappropriate for this application, then additional time

will be needed to identify another material.

25% Jan-13 ~ Conduct further trade analysis and possbily make a

sample test article with various materials.

4

If vibration of Heat Stop due to high fluid flow rate is

broad-spectrum and not easily isolated, then the

encircled energy requirement due to excessive jitter may

not be met.

35% Jan-13

~ Provide additional isolation to mitigate affects of

vibration.

~ Conduct early testing with Thermacore to determine

actual impact

5

If vibration of M2 Assembly due to impinging air cooling

jets is broad-spectrum and not easily isolated, then the

encircled energy requirement due to excessive jitter may

not be met.

35% Jan-13

~ Conduct additional analysis and possible mock-up

test.

~ Reallocate encircled energy budget

7

If the encircled energy budget cannot be met, then either

a spec waiver must be issued or significant redesign

could be required for the M2 mirror and its mount.

20% Feb-12

~ Request spec waiver

~ Consider a graduated specification based on mirror

position.

~ Optimize polishing of the mirror while in a specific

position.

~ Conduct redesign of mirror/mount to stiffen the

assembly.

8 If the scattered light from the heat stop exceeds 100W,

the spec will not be met. 25% Mar-12

~ AURA is allowing up to 300W, however trade

analysis is continuing to better define the actual value.

9 If Factor of Safety issue on Hexapod/FTT is not

resolved, cost increase and schedule delays will result. 50% Apr-12

~ AURA looking at changing Seismic Spec from

component level to system level.

~ AURA conducting mitigation study to obtain actual

values.

10 If Long Lead Subcontractor deliveries are late, the

overall schedule will slip day for day. 35% Jul-14

~ Manage subcontractors by holding subassembly

design reviews, weekly IPT calls, and onsite visits.

~ Pull in low risks efforts where possible to create

schedule slack.

11

If strict environmental requirements on electrical

components aren't relaxed, design changes will be

required with cost and schedule impacts.

15% Mar-12

~ Discussed with customer. Tech Note provided by

customer but does not address entire problem. Need

to follow up.



TEOA Technical Directives

11

TD # Title Description

001 Response to SSR Questions dated Aug 15,2011

Apec 008 takes precidence over SPEC-0063 for connectors, male and female connector definition, alignment target locations, M2 coating to bevel edge, ambiamt weather temperature from weather station, discrete input from the GIS through the TEOA LIC.

002 TEOA Spec Rev B Updates Add PSD Plot of Fitted Velociyt for Vr and Close-loop0 Error Transfer Function

003 Response to SRR Question dated Aug 15, 2011 and Copy of SPEC-086

Spec 008 requirements govern for wind speed and design lifetime, Definition of optical surface is entire front surface

004 M2 Mirror Initial Coating FSS90-500 (protective Silver) is the initial coating, the coating may change to bare aluminum for future re-coating.

005 TEOA Document Revisions DWG-0026, TMS to TEOA Interface RevF; DWG-00113, OSS Electronic Rack Sub-Assy Space Allocation RevB

006 ICD 1.3-4.4 TEOA to TCS Sent copy of ICD 1.3/4.4

007 Jib Crane Coverage Drawing Sent Jib Crane Coverage Drawing

008 Clarification on Piston vs Focus Removal of Piston shall include focus.

009 Operating Humidity

L3 shall make best effort to use components that are rated over the specified Humidity Range of 0 to 70 percent. In cases of deviation, L3 shall report to AURA, in writing, of all of the components that are not rated for the specified Humidity Range. AURA shall then grant L3 deviations for the reported components.

010 TN-0094 Environmnetal Conditions at Site Sent copy of TN-0094

011 Heat Stop Scattered Energy An additional 300 watts of scattered energy scattered onto the M1 Mirror is allowed.

012 TEOA Document Revisions SPEC-0029 ATST Optical Prescription, Rev. F

013 AURA Provided Computer AURA provided one computer with CSF. CSF will be updated every 6 months.

014 Clarification on Seismic Acceleration Given the orientation of the TEOA extends from 0 degree to 90 degrees, this effectively is equivalent to a 3 g seismic acceleration.



12

1. TEOA

Top Assy

1.3 M2 Assy

1.3.5 M2

Positioning

System Assy

1.2 Heat Stop Assy

1.3.2 M2

Thermal

Control Assy

1.3.3 M2 Mirror

Assy

1.3.4 M2 Fast

Tip/Tilt Assy

1.3.6 M2 Lyot

Stop Assy

1.4 Control System Assy

1.5 Ancillary Equipment

1.5.1 M2 Assy

Tooling

1.5.2 TEOA

Assy Tooling

1.5.3 M2 Optic

Tooling

2. Program Office

2.1 Program

Mgmt

2.2 Quality 2.3 System

Engineering

Hexapod Incoming

Inspection Point

M2 Mirror Incoming

Inspection Point

M2 Assembly Inspection Point

Heat Stop Assembly

Incoming Inspection Point

TEOA Assembly Inspection Point (Factory Acceptance Testing)

•Compare ICD to vendor

measurements*

•Compare performance to

requirements*


measurements*

•Review polish, coating performance

to requirements*

•Compare ICD to vendor measurements*


measurements*


requirements*


measurements*


requirements

Tooling Incoming Inspection Point


measurements*

•Load testing of lifting components

* Review of C of C and associated data

Quality Assurance Plan Updates



Current Open Action Items

13

Number Description Responsible Interface Date AssignedDate Closed Comments/ Resolution

30Can the safety factor of 4.0 be relaxed for PI? PI's design uses

a safety factor of 3.0. The SF of 4.0 requires a redesign effort.Chen Liang AURA 1/10/2011 Pending AURA Seismic Analysis and Report due in April 2012.

31 Aura will provide a contract mod to eliminate the lyot stop. Chen Liang AURA 1/25/2012

32Aura will provide a contract mod to eliminate the lyot stop.

Brashear to provide a mechanical ICD for future addition.Heller/Mix AURA 1/25/2012

33Update ICD 1.3/2.1 & 1.3/4.4. Include control block diagrams

and signal interfaces. PIO or ethernet. Etc.Balister/Bret GoodrichAURA 1/25/2012

34Update the SDD based on the software training. Incorporate

items in AURA SDD formatBalister AURA 1/25/2012

35

Brashear to provide 2 ECPs for the tip/tilt resolution of 0.2

arcsec requirement. One for a design study, and one for the

downselect from the design study after study is complete.

Mix AURA 1/25/2012

36AURA to approve the electronics Equipment that doesn't

meet the Environmental and EMC Testing Req.Bader AURA 1/25/2012



PDR Exit Criteria

14

Item Status Reference

A. Updated Project Plan

B. Updated Quality Assurance Plan

C. Updated Risk Analysis Chart

D. Specifications Compliance Matrix in Customer Format

E. Preliminary Hardware Design

- 3D models and/or 2D drawings of all major components/subsystems

- PL's & processes for all major components/subsystems

- Summary of major purchased components/subsystems specifications

- Description of major component manufacturability

- Preliminary analyses: Gravity-induced static and dynamic deflections and resulting figure error;

Wind-induced deflections and dynamic figure error; Temperature-induced deflections and

resulting figure error; Quantifying internal vibration sources and resulting jitter; Seismic response

& stresses; Structural resonances

- Preliminary estimate of weight, center of gravity and mass moment of inertia

- Preliminary electronics and cabling designs and layouts

- Preliminary electrical power and grounding designs and layouts

- Preliminary mechanical and packaging design of electronic equipment including consoles, racks,

drawers, printed circuit boards, connectors, cabling and thermal management systems

- Preliminary servo control system designs and summary of analyses

- Summary of built-in tests designed to support required preventative maintenance, fault

localization and fault detection

-Summary of component and subsystem specifications for purchasing of commercial parts

- Summary of design considerations regarding reliability and maintainability of components,

subsystems and systems

Description



PDR Exit Criteria

15

F. Preliminary Software Design

- Description of typical interactions

- Sequence diagrams illustrating the behavior of the system for each typical interaction

- class diagram down to the Component/Controller level and a description of the role and behavior

of each class in the diagram

- Deployment diagram showing the physical relationships among the hardware and software

components

- Integration with the ATST Common Services Framework infrastructure model, per SPEC-0013,

including the use of the Command-Action-Response model and reliance upon the Connection,

Event, Log, and Header, and Property Services

G. Preliminary Software Rapid Prototyping plan

H. Preliminary designs for all mechanical, electronic, and software interfaces WRT ICD's

I. Preliminary design of primary M2 optical surface metrology setup with tolerance analysis/alignment plans

J. Preliminary design of redundant M2 optical surface metrology setup with tolerance analysis/alignment plans

K. Drawings and specifications for all components with particularly long lead items

L. List of likely suppliers for commercial off-the-shelf type components and systems

M. Discussion and outline for the Factory Acceptance Test Plan (F-ATP) including Error Analysis

N. Description of the packaging and transportation plan

O. Draft tables of contents for the Operations and Maintenance Manuals

TEOA Program Management PDR · Integrated Optical Systems L-3 Communications - Brashear Proprietary TEOA Program Management PDR Craig Peton February 21, 2012 L-3 COMMUNICATIONS –

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