GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Integration, Test, and Calibration
Martin Nordby
Stanford Linear Accelerator Center
Stanford University
Integration and Test Manager
nordby@slac.stanford.edu
Martin Nordby
1
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Integration, Test, and Calibration
Outline
 I & T Work Breakdown and organization
 I & T activity flow
 Qualification & Verification testing
 Calibration planning
 Integration planning
 I & T scheduling and milestones
 I & T budget summary
 Issues
Martin Nordby
2
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Integration and Test Subsystem Work Breakdown
•
4.1.9.1 I & T Management
– Coordinate I & T planning
– Develop LAT I & T plan, to ensure flow of verification test activities
•
4.1.9.2 Reliability and Quality Assurance
– Collect subsystem verification test results
– Manage LAT verification test assurance activities
•
4.1.9.3 I & T Preparation
– Prepare LAT I & T facilities
– Develop calibration equipment
•
4.1.9.4 Calibration Unit I & T
– Prepare for and integrate Calibration flight modules
– Prepare for and test Cal. Unit in electron, photon, and hadron beams
•
4.1.9.6 Flight LAT I&T
– Prepare for integration of flight LAT; fabricate and test all mechanical GSE
– Mechanically integrate flight LAT
– Plan for and execute environmental verification testing
•
4.1.9.7 Mission I&T Support
– Support planning and execution of Observatory I&T
Martin Nordby
3
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Integration, Test, and Calibration Organization
LAT IPO
WBS 4.1
LAT Project Manager
IPM: Bill Althouse
LAT Integration & Test
WBS 4.1.9.1/.2
I&T
I&T Mgr: Martin Nordby
I&T Preparation
WBS 4.1.9.3
I&T
Martin Nordby
Calibration Unit I&T
WBS 4.1.9.4
I&T
TBD
I&T Planning
I&T
Cal. Unit Integration
I&T
Calibration Development
I&T
Cal. Elec. GSE
Elec.
Facility Preparation
I&T
Calibration Operations
IOC
Calibration Planning
I.S., I.T.M.
Calibration Analysis
Analysis Software
I&T Integration and Test
I.S. Instrument Scientist
ITM Instrument Technical Manager
Elec Electronics and DAQ
Mech Mechanical Systems
IOC Instrument Operations Center
TKR Tracker
CAL Calorimeter
ACD Anticoincidence Detector
Martin Nordby
LAT I&T
WBS 4.1.9.6
I&T
Martin Nordby
Integration
WBS 4.1.9.6.1
Mechanical Integration
I&T
Verification Testing
WBS 4.1.9.6.2/.3
Env. Test Execution
I&T
Mission I&T Support
WBS 4.1.9.7
I&T
Martin Nordby
Calibration
WBS 4.1.9.6.4
Cal. Mech GSE
I&T
Mechanical GSE
I&T
Thermal Testing
Mech.
Cal. Elec GSE
Elec/IOC
Electrical Integration
Elec.
Structural Testing
Mech.
Calibration Operations
IOC
Electrical GSE
Elec.
EMI/EMC Testing
Elec.
I&T Support
TKR, CAL, ACD
Performance Testing
Elec./IOC
Mechanical I&T
I&T
Electrical I&T
Elec.
Operations, Test Ops
IOC
Flight Software
Elec.
4
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Integration, Test, and Calibration Activities
•
I & T “subsystem” is focal point of LAT integration activities
–
–
•
I & T team plans and manages activities
TKR, CAL, and ACD subsystem teams provide support for integration
Total effort involves:
–
–
–
–
–
I & T Subsystem
• LAT integration planning and management
• Mechanical integration and GSE development
• Environmental test execution
• Calibration test equipment development
Mechanical Systems
• Environmental test planning
• LAT qualification testing
Electronics and Data Acquisition
• LAT electrical integration
• Performance test planning and execution
• Flight software verification testing
• Electrical GSE development, including calibration DAQ system
IOC
• LAT performance test planning
• GSE operations and support during LAT I & T
Science Analysis Software
• Calibration analysis software development
Martin Nordby
5
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Integration, Test, and Calibration Activity Flow
Assemble, test
subsystem EM modules
TKR, CAL, ACD
Develop, fab mechanical
interface gauges
Mech
Assemble, integrate, test
subsystem Qual Modules
TKR, CAL
Develop, test EM2 Tower
Electronics Modules
(TEM’s)
Elec
Prototype calibration
equipment
I&T, Sci
Test calibration
equipment and plans
I&T, Sci, Elec
Develop calibration
analysis software
Develop LAT calibration
equipment and plans
I&T, Sci, Elec
Assemble, integrate, test
subsystem Flt Modules
TKR, CAL, ACD
SAS
Beam-Test Calibration
Unit
I&T, Sci, (IOC)
Integrate Calibration Unit
I&T, Sci, Elec
Upgrade EM2 TEM’s into
E-GSE for subsystem I&T
Elec
Integrate LAT
Develop, test Qual TEM,
SIU for Cal. Unit E-GSE
Elec
GSE Ground support equip.
M-GSE Mechanical GSE
E-GSE Electrical GSE
Cal.
Calibration Unit
EM
Engineering Model
Subsysteml I&T activities
Calibration activities
Electronics activities
Mechanical Systems activities
IOC pre-operations activities
Science Analysis Software
Martin Nordby
Develop, fab structural,
thermal Qual units
Mech
I&T, Elec
Environmental and
performance test LAT
I&T, Elec, Mech, (IOC)
Develop, test Flt TEM’s,
SIU’s
Elec
Env. Test Therm-Mech
Qual Unit (struc, thermal)
Mech
Develop, fab M-GSE for
structural, thermal env.
testing
Mech
Upgrade M-GSE and
plans for flight LAT env.
testing
Mech
Integrate and test GLAST
Observatory
I&T, IOC, (Mech), (Elec)
Develop Operations
Software and E-GSE
IOC
6
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Qualification and Verification Test Planning
• Validation and Qualification
– Incrementally validating models and qualifying processes
– We are in-process on this plan
• Prototypes: electrical/mechanical prototypes being built and
tested now, to validate analysis and develop fab. processes
• Engineering Models: CAL, TKR, ACD, Elec and Mech plan highfidelity models which use processes planned for flight units
• Qual Units: actual flight qualification will be done bottom-up
• Verification and Acceptance Testing
– Subsystem performance verified as part of the assembly process
• Provides immediate feedback for production line process control
• With world-wide production effort, this clarifies responsibilities
• Minimizes schedule and shipping risk if re-work is needed
– Test as you build
• Uses modularity to our advantage, reducing risk of high-level
failure/non-compliance
Martin Nordby
7
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Subsystem Test Flow
TKR: Vibe, T-C
EM Tray
Qual
TKR: Vibe, T-V
EM Module
Qual
TKR: Vibe, Ac,
T-V Qual Tray
PFQ
Tracker
TKR: Vibe, T-V
Q1 Qual Module
PFQ
TKR: Vibe, T-C
All Flight Trays
Acc
CAL: Vibe, T-V
EM Module
Qual
TKR: Q1 Module
to Cal. Unit I&T
TKR: Vibe, T-V
F1-16 Modules
Acc
CAL: Vibe, T-V
Q1 Qual Module
PFQ
TKR: F3-16 to
LAT I&T
CAL: Q1 Module
to Cal. Unit I&T
CAL: Vibe, T-C
F1-16 Modules
Acc
Calorimeter
TKR: F1-2 to
Cal. Unit I&T
CAL: F1-2 to
LAT I&T
CAL: F3-16 to
LAT I&T
Anticoincidence Detector
ACD: Vibe, Ac,
T-C EM ACD
Qual
Vibe
Ac
T-C
T-V
EMI
Random vibrate/sine sweep
Acoustic
Thermal-cycle at 1 atmosphere
Thermal-vacuum cycle test
Electro-magnetic interference test
Engineering model tests
Qualification unit tests
Martin
Nordby
Flight
unit/spare
tests
ACD: Vibe, T-V
ACD/Shield TM
PFQ
Acc
PFQ
Qual
Proof.
EM
TM
MM
GSE
Acceptance test level
Proto-flight qual test level
Prototype qual test level
Load test at proof level
Engineering Model
Thermal model
Mass model
Ground support equip.
ACD: ACD TM
to Grid Qual Test
ACD: Vibe, Ac,
T-V ACD/Shield
Acc
ACD: ACD to
LAT I&T
8
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
LAT System Test Flow
ACD: ACD TM
from ACD build
Mechanical Systems
Mech: T-V EM
Grid + Radiators
Qual
Mech: Vibe, Ac,
Flt Radiators
PFQ
Mech: T-V Flt
Radiators
PFQ
Mech: T-B Qual
Grid,Flt Rads,TM
PFQ
Mech: Flt Rad’s
to Obs. I&T
Mech: Vibe
Qual Grid + MM
PFQ
Mech: Proof test
Flt Grid
Proof
Elec: EM2 TEM
to TKR, CAL
Electronics
Elec: Perf, EMI
EM1 TEM, SIU
Perf
Vibe
Ac
T-C
T-V
EMI
Elec: Perf, EMI
EM2 Test Bed,
Flt SW
Perf
Random vibrate/sine sweep
Acoustic
Thermal-cycle at 1 atmosphere
Thermal-vacuum cycle test
Electro-magnetic interference test
Engineering model tests
Qualification unit tests
Flight unit/spare tests
Martin Nordby
Mech: Flt Grid
to LAT I&T
Acc
PFQ
Qual
Proof.
EM
TM
MM
GSE
Elec: Qual TEM,
SIU Cal. Unit I&T
Elec: Vibe, T-V,
EMI Qual TEM’s,
SIU’s
PFQ
Acceptance test level
Proto-flight qual test level
Prototype qual test level
Load test at proof level
Engineering Model
Thermal model
Mass model
Ground support equip.
Elec: Qual SIU
to Obs. I&T
Elec: Vibe, T-V,
EMI Flt TEM’s,
SIU’s
PFQ
Elec: Flt TEM’s,
to CAL fab
Elec: Flt SIU’s
to LAT I&T
9
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
LAT I&T Verification Test Flow
TKR: Q1 from
TKR fab
TKR: F1-2 from
TKR fab
CAL: Q1 from
CAL fab
CAL: F1-2 from
CAL fab
Elec: Qual TEM,
SIU from Elec
I&T: Beam test
Cal. Unit
Cal
CAL: F3-16 from
CAL fab
Acc
PFQ
Qual
Proof.
EM
TM
MM
GSE
Acceptance test level
Proto-flight qual test level
Prototype qual test level
Load test at proof level
Engineering Model
Thermal model
Mass model
Ground support equip.
Flight LAT
I&T: T-V, EMI
LAT
Acc
I&T: LAT
Calibration
I&T: Vibe/Ac
LAT
Cal
ACD: ACD to
LAT I&T
Mech: Flt Rad’s
from Mech
Elec: Flt SIU’s
to LAT I&T
Elec: Qual SIU
for elec GSE
Martin Nordby
Random vibrate/sine sweep
Acoustic
Thermal-cycle at 1 atmosphere
Thermal-vacuum cycle test
Electro-magnetic interference test
Engineering model tests
Qualification unit tests
Flight unit/spare tests
TKR/CAL: F1,2
from Cal. Unit
Mech: Flt Grid
from Mech
TKR: F3-16 from
TKR fab
Vibe
Ac
T-C
T-V
EMI
Calibration Unit
Acc
Obs: Vibe/Ac
Observatory
Obs: T-V
Observatory
Acc
Obs: EMI
Observatory
Acc
Acc
10
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Tracker
Qual Trays
Qual Module (TKR #1)
Trays
Modules (TKR #2-18)
M
M
M
M
Proof
Proof
Calorimeter
Qual Module (CAL #1)
Modules (CAL #2-18)
M
M
Proof
Anti-Coincidence Detector
ACD Flight Unit
M
M
M
M
M
M
Mechanical Systems
Grid Structure
Heat Pipes
Radiators
Qual. Grid Assembly
Flight Grid Assembly
Grid Ass'y w/ Radiators
M
M
M
M
Proof
M
M
Proof
M
Proof
Proof
Proof
Acc
PFQ
PFQ
Acc
Acc
PFQ
Acc
PFQ
Acc
PFQ
PFQ
PFQ
PFQ
PFQ
PFQ
PFQ, MM PFQ, MM
M
M
M
LAT Flight Unit
GLAST Observatory
M
M
M
M
M
M
M
Ana:
MM:
TM:
Martin Nordby
PFQ
M
Acc
Analysis
Test, using Mass Models
Test, using Thermal Models
PFQ
PFQ
Acc
PFQ
Acc
PFQ
Acc
M
PFQ
PFQ
M
16
1
1
Pr
es
Ana
Proof
PFQ
1
34
2
PFQ, TM
1
1
1
4
1
PFQ
Acc:
PFQ:
Qual:
Proof:
304
16
1
PFQ
PFQ
PFQ, TM
Acc
su
re
nt
Acc
10
1
28+20
1
Ana
Ana
PFQ
Acc
Acc
Ali
gn
me
EM
C
PFQ
Acc
PFQ
M
M
M
M
PFQ
PFQ
Fli
gh
tQ
t'y
Fli
gh
tS
pa
res
cu
um
Va
Th
erm
a l-
Th
erm
al
Ba
Cy
cli
ng
lan
ce
ho
ck
ls
ha
nic
a
Me
c
c
us
ti
Ac
o
Th
erm
al
Vib
e
do
m
Ra
n
sw
ee
p
Sin
e
rop
ert
ie s
Ma
s
s,
sP
C.G
.
ng
th
Ma
s
M
M
M
M
PFQ, TM
Electronic Systems
TEM, SIU, ACD Units
Cable Harness
Rev date: 26 Jan 01
tr e
St
ruc
S
Fit
/
Dim
Ch
e
ck
Environmental Test Matrix
Acc
Acceptance-level testing
Protoflight Qual-level testing
Prototype Qual-level testing
Test to Proof levels
PFQ
PFQ
Acc
Acc
Acc
M:
S:
Y:
M
M
Ana
20
Ana
1
1
3
Measure or Inspect
Test sample of total
Yes, this is performed
11
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Calorimeter
ASIC's
EEE Parts
Front-End Boards
CsI Logs
Qual Module (CAL #1)
Modules (CAL #2-18)
Ana:
MM:
TM:
Analysis
Test, using Mass Models
Test, using Thermal Models
Anti-Coincidence Detector
ASIC's
EEE Parts
Front-End Boards
ACD Tiles, Fibers, PMT's
ACD Flight Unit
Acc:
PFQ:
Qual:
Proof:
Acceptance-level testing
Protoflight Qual-level testing
Prototype Qual-level testing
Test to Proof levels
Mechanical Systems
EEE Parts
Grid Assembly
M:
S:
Y:
Measure or Inspect
Test on sample of total
Yes, this is performed
Electronic Systems
ASIC's
EEE Parts
TEM, SIU, ACD Boards
TEM, SIU, ACD Units
Y
Y
Acc
Proof
Y
Y
M, S
M, S
M
M
M
M
Proof, S
Proof, S
Acc
Proof, S
Proof, S
Proof
M
pa
r es
Fli
gh
tS
Fli
gh
tQ
t'y
ng
es
ti
lT
ec
ia
Sp
2016+
76+30
1152+518
288+64
Y
588
9216
2304
10
1
294
15
Y
3072
384+
8
192+24
Y
38+10
2
Acc
Acc
Acc
Acc
Y
Y
64
1536
1
15
Acc
Y
290
54
Acc
Acc
Acc
145
1
27
Y
Acc
Y
Acc
Y
Light output and uniformity
EMC testing on components
2
Proof, S
M
Y
Y
16128
Acc
Acc
Acc
Acc
Acc
Proof
Y
Y
Leakage current, bad channels
Leakage current, bad channels
M
M
M
Y
Y
ur
n-I
n
Fu
nc
tio
na
l
Ca
lib
rat
ion
m.
Di
Hi
Te
m
ua
l,
Vis
Proof, S
Proof, S
Y
pB
E
on
/ SE
ree
Sc
rts
Pa
Tracker
ASIC's
EEE Parts
Front-End Boards
Silicon Detectors
Silicon Ladders
Qual Trays
Qual Module (TKR #1)
Trays
Modules (TKR #2-18)
Ra
dia
ti
nin
g
Performance Test Matrix
Proof
Proof, S
Proof, S
Proof
PFQ
Acc
SC, GSE fit checks
1
Board-level EMC testing
62
20
10
3
Rev date: 26 Jan 01
Martin Nordby
LAT Calibration Unit
LAT Flight Unit
Acc
Acc
Y
Y
1
1
12
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Calibration Planning
• “Calibration” means
– Determining the fundamental response of detector elements
– Determining the performance of the instrument
• Characterizing variations over range of operations environments
• Characterizing variations over time
• Calibration plan flows from the requirements: ground and on-orbit
– integrated approach.
• Ground-based calibration effort is tightly coupled to the I&T plan:
– sea-level muons and sources for detector elements
– sea-level muons for LAT testing during environmental testing
– beam tests in photon, electron, and hadron beams
• I&T and Calibration Planning Committee formed to:
–
–
–
–
develop systematic flow of requirements to detailed tests
develop Calibration Plan and I&T Plan
evaluate personnel needs, baseline schedule and budget
assess the facilities, equipment, and resources needed
Martin Nordby
13
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Integration Planning Activities
• LAT integration planning
– Planning for subsystem integration has been included in
development of interfaces and LAT design integration
– Started developing concepts for integration GSE
• LAT integration facilities
– New clean room facilities being built at SLAC for GLAST
– Facilities include I&T infrastructure
• Clean room with high bay
• Storage for flight hardware
• Environmental chambers for
thermal-cycle testing
• Observatory integration support
– LAT team has been involved
in investigating options for
Observatory integrating
– LAT and Observatory require
combined GSE and coordinated plans
Martin Nordby
Concept of LAT Integration Frame
14
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
4.1.9 I & T Schedule
A c tivity
A c tivity
ID
D e scr i ption
Or ig
Re m
E a r ly
D ur
D ur
S tar t
E a r ly
Finish
FY 00
FY 01
FY 02
FY 03
FY 04
FY 05
FY 06
Gamm a Ray Large Area Space Telescope
4.1 .9 IN S TR U M E N T IN TE G R A TION AN D TE S TIN G
S u btota l
1,2 41
10 /02/0 0
09 /30/0 5
1,2 40
10 /02/0 0
09 /29/0 5
71 7
10 /02/0 0
08 /22/0 3
1,0 70
10 /02/0 0
01 /28/0 5
57 0
10 /15/0 1
02 /06/0 4
98 3
10 /15/0 1
09 /29/0 5
98 4
10 /15/0 1
09 /30/0 5
+ 4 .1.9. 1 IN TE G R A TIO N & T E S T MA N A G E M E N T
+ 4 .1.9. 2 R E LIA B IL ITY A N D Q U A LIT Y A S S U R A N C E
+ 4 .1.9. 3 I & T P R E P A R A TI O N
+ 4 .1.9. 4 C A LIB R A TIO N U N IT I & T
+ 4 .1.9. 6 FL IG H T LA T I & T
+ 4 .1.9. 7 M IS S I O N IN TE G R A TIO N & TE S TIN G
DRAFT
• Currently developing I&T schedule


o
o
Scoping work
Identifying key I&T milestones
Establishing linkages to other subsystems
Identifying key hand-offs with other subsystems
Martin Nordby
15
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
I&T Milestones
• Verification Test Plan Review
• TKR & CAL Modules A & B Ready for Integration
into Calibration Unit
• TKR & CAL Modules 1 & 2 Ready for Integration
into Calibration Unit
• Calibration Unit Beam Test Complete
• Flight Grid Ready for Integration
• Flight TKR & CAL Modules 3 & 4 Ready for Integration
06/15/01
•
•
•
•
•
•
•
12/24/03
01/26/04
01/26/04
04/09/04
10/07/04
12/22/04
9/05
Flight TKR & CAL Modules 15 & 16 Ready for Integration
Flight TKR & CAL Modules 1 & 2 Ready for Integration
Flight ACD Ready for Integration
LAT Instrument Ready for Environmental Testing
LAT Instrument Pre- ship Review
LAT Instrument Ready for Integration with Observatory
GLAST Launch
Martin Nordby
05/15/03
08/01/03
01/17/04
10/01/03
10/01/03
16
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Interim Integration & Test Cost Estimate*
4.1.9 Integration
& Test
FY00
FY01
FY02
FY03
FY04
FY05
Total
SLAC
(DOE)
0
222.0
618.4
792.3
262.4
272.9
2168.0
HEPL
(NASA)
0
0
0
802.1
1486.1
202.9
2491.2
0
222.0
618.4
1594.4
1748.5
475.9
4659.2
Total
Escalated k$
*DOE/NASA funding
• Interim estimate based on Proposal cost estimate
• Currently developing and checking I&T cost estimate
Martin Nordby
17
GLAST LAT Project
DOE/NASA Review of the GLAST/LAT Project, Feb. 13-15, 2001
Issues
• Integration schedule is tight
– Integration plans are for just-in-time delivery of subsystem modules
– Early and incremental verification testing assures high probability of
performance when integrating the LAT
– Subsystem delivery milestones are visible at the project level to
ensure close tracking of progress leading up to LAT integration
• LAT and Observatory verification activities require close
coordination
– We have been working on coordinated test plans with mission office
– Expect to advance this work during the upcoming accommodation
study
Martin Nordby
18