GNIRS PROGRESS REPORT

August 25 – September 21, 2001

           Accomplishments / Status

 

  Summary:  80% of the work from the Restart Review to delivery has been completed.

The main focus of this report period has been completing fabrication of mechanisms, mechanical design of remaining assemblies such as radiation shields, and vendor fabrication of the Bulkhead Assembly and Dewar Shells.  Except for the Focus Assembly, all mechanisms have completed fabrication.  The Slit/Decker slide is in rework.  All bench-mechanism fit checks were completed.  The Pre-Slit, Post-Slit and OIWFS benches are being painted.  Mechanism testing is underway.

An update to the Envelope Waiver has been submitted to Gemini.  The new request includes hardware that will extend outside of the allowed envelope in two locations.

Rework of the OIWFS bench is complete.  Work on the WFS has been hampered by missing or late delivery of components and incomplete ICD details, and will continue on a non-interference basis with mechanism assembly and testing.

All optics except two replica mirrors, one flat mirror and the final camera lens have been received.  The final camera lens and flat mirror were each damaged during coating.  The mirror is being recoated and the camera lens is being remade.  The defective camera lens will be used in initial camera set up and replaced when the final lens is received.  The replica mirrors are again delayed due to a procurement/vendor mix up.

Design modifications to the Bulkhead Assembly and Rear Dewar Shell were required to insure the proper location of CG.  In addition, we have contracted the vendor to do vacuum/leak testing of the entire assembly at his site.

To protect the fall 2002 delivery date we have modified the schedule to parallel the following efforts:

• Bulkhead Assembly/Dewar Shell integration and vacuum/leak testing at vendor site
• Assembly integration to Post-Slit Bench
• Includes mechanisms and Collimator Assembly
• Pre-Slit Bench integration and warm testing
• Includes installing the Filter Wheel and Slit/Decker mechanisms and Fore-Optics
• OIWFS integration/alignment/check-out

Following these activities are the assembly of the benches, radiation shields and Bulkhead Assembly, and then the integration testing as already planned.  Flexure testing is now scheduled for mid-April.  The last camera lens should be received in March 2002, and we plan to open the dewar, remove the Post-slit Bench assembly and replace the lens.  This would be a good time to install the IFU and OIWFS prism as well.

A Change Order modification addressing Testing, Training, and Commissioning in Chile is in process.

  Next Milestone: The next major project milestone is the completion of Bulkhead Assembly and Dewar Shell fabrication and leak test, now due in November.

 

  Earned Value:

This table reflects capital and labor charges to the project as of August 31, 2001.  We have spent $1,123K in capital so far, for a total program expenditure of $3,174K to date.

  Project Management: (71% complete)

The project plan may be viewed on the GNIRS web site at: http://www.noao.edu/ets/gnirs/ under Management, Planning. The plan reflects changes due to the slip in delivery of the Bulkhead Assembly and Dewar Shells, and integration of the benches into the top assembly.  The current scheduled delivery date of the GNIRS instrument is September 25, 2002.   There is a total of 3 weeks contingency left in the schedule.

  Systems Engineering: (100% of planned work)

The main focus has been support of design updates, mechanism assembly and warm test, procurement, preparation of the Test Plan for Acceptance Testing, Delivery to Chile, Training and Commissioning, and work on the new Envelope Waiver request.

  Mechanical Design, Fabrication, Assembly and Test: (87% overall)

The major activity in this work package has been design modifications to the Bulkhead and Dewar Shell assemblies, Post-Slit, Pre-Slit and OIWFS Benches, 3D and 2D design of fixed assemblies and fabrication. A new interface plate to collect all input-output connections to and from the wrap-up has been designed.  This is included in the Envelope Waiver request.

Mechanisms: (89% complete overall).  The Focus Mechanism is the only outstanding assembly still in fabrication.  All Design is complete and most mechanisms are essentially ready for test.

 

	Feb	Mar	Apr	May	June	July	Aug	Sept	Status
Camera	69%	77%	78%	88%	90%	91%	91%	91%	Final Fab
Focus	24%	24%	30%	48%	59%	59%	60%	67%	Fab
Environmental Cover	97%	99%	99%	99%	99%	99%	99%	99%	Test (on-hold)
Acquisition Mirror	58%	68%	72%	75%	75%	75%	76%	93%	(waiting for mirror)
Slit/Decker	66%	77%	83%	85%	90%	90%	93%	93%	Rework, Assembly/test
Filter Wheel	71%	70%	73%	78%	83%	83%	95%	95%	Ready for test
Grating Turret	42%	51%	72%	83%	85%	86%	89%	97%	Ready for test
Prism Turret	48%	47%	50%	56%	76%	85%	92%	98%	Ready for test
Motor Drives	90%	90%	100%	-	-	-	-	-	Complete

Benches: (95% complete overall).  All modifications have been completed and the benches sent for final finish coating.  The Collimator has a few parts still in fabrication, and is nearly ready for assembly.

 

	Feb	Mar	Apr	May	June	July	Aug	Sept	Status
Post-Slit	56%	65%	70%	-	77%	88%	94%	99%	Paint
OIWFS	67%	67%	79%	-	86%	87%	89%	99%	Paint
Collimator		29%	29%	46%	62%	64%	77%	95%	Fab
Pre-Slit	44%	62%	70%	81%	83%	87%	91%	99%	Paint

Fixed Assemblies: (62% complete overall).   The Radiation Shields are the pacing items in fixed assemblies.

 

	Feb	Mar	Apr	May	June	July	Aug	Sept	Status
Entrance Window	96%	100%	-	-	-	-	-	-	Complete
Detector Mount	48%	49%	60%	67%	68%	79%	79%	97%	Waiting for wiring
Cryo Cooler	9%	16%	16%	16%	24%	49%	51%	59%	Fab
Thermal Distribution Assembly							12%	26%	3D Design
Bulkhead Rad Shield							1%	5%	3D Design
LN2 Pre-Cool	4%	4%	17%	17%	84%	89%	91%	91%	Fab
Optical Bench Gimbal Mt.	53%	53%	54%	56%	45%	85%	95%	100%	Complete
Bulkhead Assembly	11%	24%	42%	52%	55%	64%	74%	75%	Fab
Front Rad Shield	5%	5%	5%	5%	7%	10%	10%	10%	3D design
Rear Rad Shield							18%	18%	3D design
Front Dewar Shell	26%	34%	37%	37%	37%	38%	66%	70%	Fab
Rear Dewar Shell	6%	8%	21%	21%	26%	-	57%	61%	Fab
Vertical Inst Frame	5%	6%	6%	11%	-	-	14%	77%	Fab
Horizontal Inst Frame	1%	-	-	-	8%	8%	15%	57%	Fab
Dewar Mount Truss	12%	12%	12%	13%	47%	47%	47%	47%	2D drafting
Thermal Enclosure Mount	2%	7%	10%	44%	53 %	53%	58%	70%	Fab
Handling Fixtures	25%	58%	-	68%	68%	68%	100%	100%	Complete
Ballast Weights								75%	Fab

 

Electronics: (86% complete overall)   The Instrument Controller design work is essentially complete and the main activity is fabrication.  The OIWFS electronic components have been received and parts installed in the Thermal Enclosure.  The Leach controller checkout is in process.

 

		Feb	Mar	Apr	May	June	July	Aug	Sept	Status
Component Controller TE		51%	68%	71%	75%	66%	-	90%	86%
	VME Crate	92%	100%	-	-	100%	-	-	-	SW testing
	Motor Drive/Cryo Cooler Crate	62%	94%	100%	-	100%	-	-	-	SW testing
	Internal Cabling and Connectors	12%	16%	16%	18%	90%	98%	98%	98%
	Ancillary Cage Crate	26%	26%	26%	59%	63%	98%	98%	98%	Assembly
	IfA Electronics Box	-	-	-	-	-	-	30%	30%	In check out
	Bench Thermal Controller Crate	-	-	61%	68%	94%	98%	98%	98%	Assembly/wiring
External Cabling (Dewar to TE)		23%	23%	23%	23%	23%	23%	23%	23%
The Dewar Warm-up Controller		37%	37%	37%	37%	37%	37%	37%	37%
Dewar Electronics		-	71%	-	-	95%	-	95%	95%
	Dewar Cold Station PCB’s	60%	60%	50%	60%	80%	80%	80%	80%	Ready for install and fit check
	Dewar Internal Conn/Cabling	-	72%	72%	72%	96%	-	96%	96%	On Hold
Documentation			50%	50%	50%	85%	-	95%	95%

  

Software Development: (85% complete overall).

 

The areas in work include testing software with the electronics crates.  EPICS software is far ahead of schedule.  Resources assigned to the software task are also working on the Gemini Array Controller.

 

	Feb	Mar	Apr	May	June	July	Aug	Sept
Components Controller Software	67%	91%	91%	91%	91%	-	91%	94%
EPICS Software	60%	69%	69%	69%	75%	-	82%	82%
Test & DeBug	-	-	-	-	50%	-	50%	75%

 

  Procurement: (74% complete overall).

 

The major activities in this Work Package included monitoring vendor mechanical and optical component assembly fabrication.

 

	Feb	Mar	Apr	May	June	July	Aug	Sept	Notes
Optics	-	67%	71%	73%	79%	-	89%	86%	Only POM and Acq mirror remain
RMI optics	100%	-	-	-	-	-	-	-	Complete
Flat Mirrors		10%	50%	50%	50%	-	99%	99%	Fab of replica mirrors
Pupil Viewer	100%	-	-	-	-	-	-	-	Complete
BaF2 lenses	8%	50%	93%	75%	75%	-	75%	90%	Final SRC lens failed.  Replacement in Fab
Grating replicas	-	23%	50%	83%	86%	-	100%	100%	Complete
Prisms	-	13%	13%	23%	74%	-	95%	100%	Complete
Wollaston Prisms	-	-	0%	10%	40%	-	95%	100%	Complete

 

 

             Problems / Solutions 

Some schedule time was lost due to required revisions to the Bulkhead and Dewar Shell assemblies.  This caused a 1-month slip in delivery of these items from the vendor.  In order to keep our fall 2002 delivery schedule, we have re-ordered some of the tasks in the initial parts of the instrument Integration sequence.  This is discussed in some detail in the Accomplishments/Status portion of this report.

We have submitted to Gemini an updated Envelope Waiver Request.  This waiver request includes the following items that extend beyond the allowed envelope:

o       Interface plate for connecting Helium, power, signal, air, etc to/from the GNIRS instrument

o       Helium Manifold on side of Bulkhead Assembly

These intrusions are minor and we are proceeding while waiting for Gemini concurrence. 

 

             Key Personnel

 

Ed Hileman, SR. Mechanical Engineer, and Eric Downey, Design Draftsman have been extended on the project through November 1^st.  Dale Circle, Sr. Designer, has been extended until December 31^st.  All were scheduled to leave the project on October 1^st.

 

In view of the design effort winding down and fabrication being nearly complete, it seems appropriate to recognize the technical staff for their hard work and commitment to the GNIRS project.  It should be noted that all the individuals on the project are doing outstanding work, and are considered by the project manager to be “Top People” in their respective fields.  This project has had the benefit of being staffed properly to do the work and enjoyed the work priority at NOAO that enabled work to be done on schedule without interference from other activities.  There are no “average” people working on the project.

 

The instrument design has been based on the optical design done by Ming Liang.  Ming has provided continual input and worked very effectively with the mechanical engineers to ensure that the opto-mechanical hardware and optical design converge.

 

The Opto-Mechanical team (Ed Hileman, John Andrew, David Rosin, Eric Downey and Dale Circle, under the leadership of Gary Muller) has done an outstanding job of getting the work done, and for the most part done right the first time.  Their proficiency in SolidWorks, learned in the midst of the design effort, has been a key item in the success of the design effort.

 

The Instrument Shop team (Ron Harris, Randy Bennett, and Lou Lederer under the guidance of John Stein assisted by Roger Repp) has done an outstanding job of fabrication and assembly of the most difficult parts of the instrument.  Roger has also been an invaluable help in assisting Al Davis by participating in make-buy decisions.

 

Our procurement, handled exclusively by Al Davis, has been done so professionally that we have had little or no anomalies develop due to vendor contract or vendor fabrication.  This includes mechanical, optical and electrical fabrication, development and screening of vendors and parts and inventory control of fabricated parts and components.

 

Optics inspection, done mostly by Al Camacho with some assistance by Heidi Yarborough, has been exceptionally professional and thorough.  Al has been responsive to the needs of the project by being available to travel to do on-site inspections on relatively short notice.

 

Bill Ditsler has handled all parts cleaning and preparation.  His work is in some ways just getting underway, but he has done his usual outstanding job in support of the fabrication and test effort.  Bill will ensure that every component integrated into the instrument is indeed ready to do so.

 

Jerry Penegor and Ron George have built and tested all the electronics used in the instrument, including updating the Array Controller.  Their work has been thorough, complete and professional.

 

Our software effort, under the guidance of Richard Wolff, has been outstanding.  He has ensured that software has not been a problem on GNIRS, and the effort has always been ahead of schedule.  Peter Ruckle, initially handling all EPICS level code and all work with the Array Controller, has now moved into prime responsibility for GNIRS software. 

 

The GNIRS Scientists (Jay Elias, PS, and Dick Joyce, PSS) primarily working systems and hardware issues, have done a great systems engineering job by producing specifications, evaluating performance, controlling interfaces, and testing assemblies.  Both Dick and Jay have done an outstanding job.  Brook Gregory has been a continual assist, working both here in Tucson and from CTIO in Chile.  His contribution has been invaluable.

 

As project manager I have had invaluable assistance from Mark Trueblood, Dan Eklund and my Administrative Assistant Melissa Bowersock.  I could not have performed my function without their assistance and advice.  Melissa has also done an outstanding job managing the GNIRS web site.

 

Our summer intern program has ended, and the three interns of the four assigned to GNIRS have returned to studies at UA.  Each made significant contributions, and our thanks go to Shona Kroto for her work on the opto-mechanical assembly kitting and parts control and organization, Eric Mountford for his work on the OIWFS parts inventory and test set up, and Alex Lowe for his work in designing a bench temperature controller.  John Pina will be remaining on the program to assist with test and integration.

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