GLAST LAT Project Gamma-ray Large Area Space Telescope CDR/CD-3 Review, May 12-15, 2003 GLAST Large Area Telescope: Electronics, Data Acquisition & Flight Software Gunther Haller Stanford Linear Accelerator Center Manager, Electronics, DAQ & FSW LAT Chief Electronics Engineer haller@slac.stanford.edu (650) 926-4257 LAT-PR-01967 4.1.7 Electronics, DAQ, FSW 1 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Outline • • • • • • • Management & System Engineering Components & Assemblies Thermal & Mechanical Verification & Test Fabrication Risks Budget & Schedule LAT-PR-01967 4.1.7 Electronics, DAQ, FSW 2 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Management & System Engineering LAT-PR-01967 4.1.7 Electronics, DAQ, FSW 3 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Organization Charts Electronics, DAQ & Flight Software G. Haller SU-SLAC WBS 4.1.7 Reliability D. Nelson SU-SLAC WBS 4.1.7.2 Quality Assurance D. Marsh/N. Virmani SU-SLAC/NRL WBS 4.1.7.2 DAQ M. Huffer SU-SLAC WBS 4.1.7.4/4.1.7.5 Enclosures/Harness M .Freytag SU-SLAC WBS 4.1.7.7/4.1.7.8 Power System D. Nelson SU-SLAC WBS 4.1.7.6 Instrument Software J. Russell SU-SLAC WBS 4.1.7.9 GSE & Operation R. Claus SU-SLAC WBS 4.1.7.A Instrument I&T G. Haller SU-SLAC WBS 4.1.7.C Front-End Elex G. Haller SU-SLAC Tracker Elex WBS 4.1.4 CAL Elex WBS 4.1.5 ACD Elex WBS 4.1.6 LAT-PR-01967 4.1.7 Electronics, DAQ, FSW 4 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 LAT Electronics ACD TKR Front-End Electronics (MCM) ACD Front-End Electronics (FREE) CAL Front-End Electronics (AFEE) 16 Tower Electronics Modules (TEM) TKR – – CAL DAQ electronics module (DAQ-EM) Power-supplies for tower electronics Global-Trigger/ACD-EM/SignalDistribution (GAS) Unit* Spacecraft Interface Unit (SIU) (1+1 spare) – Storage Interface Board (SIB): EEPROM Storage, Spacecraft MIL1553 interface, control & data – LAT control CPU – LAT Communication Board (LCB): LAT command and data interface LAT-PR-01967 3 Event-Processor Units (EPU) (2+1 spare) – Event processing CPU – LAT Communication Board (LCB) – Storage Interface Board (SIB) EPU-1 EPU-2 Pw r Dist. Box spare spare GASU spare spare spare SIU-P SIU-R EPU-3 Power-Distribution Unit (PDU)* – Spacecraft interface, power – LAT power distribution – LAT health monitoring * Primary & Secondary Units shown in one chassis 4.1.7 Electronics, DAQ, FSW 5 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Evolution and Heritage of DAQ Design Current Design: – Global trigger, ability to reduce hardware trigger rate from tracker – Event building in hardware – Data switch to move complete event fragments from hardware event builder to processor and to spacecraft – 2 processors for event processing – Communication to TKR/CAL/ACD systems unified Heritage: – Similar data-acquisition system was used on balloon flight (TEM, one event-processing CPU, one spacecraft-interface-equivalent control CPU) – Electronics components: mostly components with flight-heritage (FPGA’s, LVDS converters, memories) – ASIC technology same as for tracker, calorimeter, ACD systems – Trigger, dataflow, event assembly, and event filter processing very similar to past high-energy physics experiments LAT-PR-01967 4.1.7 Electronics, DAQ, FSW 6 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Data-Acquisition (DAQ) System Overview • • • • • • Configuration, triggering, event-flow control and readout, monitoring, and supply of power to – 16 Calorimeter and Tracker towers with a total of ~850,000 tracker channels and ~3,000 calorimeter channels – 12 ACD front-ends with a total of 208 ACD channels Interface to spacecraft for control, data, monitoring, and power Trigger system (hardware selection of possibly interesting events) Event filtering Housekeeping Operational thermal control LAT-PR-01967 Spacecraft LAT VCHP Heater Control 4.1.7 DataAcquisiton (DAQ) System C A L T K R Tower 0 C A L T K R Tower 1 C A L T K R Tower 15 A C D A C D A C D 0 1 11 4.1.7 Electronics, DAQ, FSW 7 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 DAQ Technical Budget Summary Technical Resources • DAQ Mass (Contingency is held at the project level) – Sub-system allocation: 220 kg – Detailed estimate: 199.3 kg • DAQ Power (Contingency is held at the project level) – Subsystem allocation: 327.5 W – Detailed estimate: 326.2 W • CPU Cycles – Allocation: 2 CPU’s – Detailed estimate: < 1 CPU LAT-PR-01967 v9 4.1.7 Electronics Overview 8 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 LAT Electronics Hierarchy • • • SC SC Science Commanding Data Tower Electronics Module – Interface to calorimeter and tracker on each tower – Monitoring – Combination of sub-system trigger signals to primitives – Event buffering GAS Unit – Command-response unit receives and distributes command, clock, and data – Global trigger unit generates LAT-wide readout decision signals based on trigger primitives from TEM’s and ACD – Event-builder unit builds complete LAT events out of asynchronous event-fragments; Forward complete events to dynamically selected target EPU’s or spacecraft (SC science interface) – ACD electronics module tasks much like TEM for TKR/CAL EPU: Event processor unit runs filter algorithm to reduce 10kHz input event rate down to 30 Hz (with two EPU’s) • SIU: Spacecraft interface unit controls LAT and contains command interface to spacecraft • Instrument software – runs on EPU and SIU processors only • There are – 2 prim EPU’s, 1 redundant EPU (not shown) – 1 prim SIU, 1 redundant SIU (not shown) – 1 prim GAS, 1 redundant GAS (not shown) – 1 prim PDU (not shown), 1 redundant PDU (not shown) LAT-PR-01967 EPU 0 EPU 1 SIU GAS Unit Event Builder TEM 0 C A L T K R Command Response Unit Global Trigger TEM 1 C A L T K R v9 TEM 15 C A L T K R ACD Electronics Module A C D A C D A C D 0 1 11 4.1.7 Electronics Overview 9 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 LAT Power Distribution • • • • • • SIU’s are powered directly by spacecraft on dedicated feeds Rest of LAT electronics is powered via SC main feed to PDU – Prime and redundant SC feeds connected to prime and redundant PDU circuits PDU controls power to towers, to GASU, and to EPU’s – Either PDU circuit can supply power to clients GASU switches power to ACD – Prime and redundant GASU circuit can supply power to ACD TEM’s switch power to TKR/CAL – No redundancy in tower power system Heater power circuit not shown LAT-PR-01967 SC Main Feed P EPU P0 EPU P1 SC SIU P Feed SC Main Feed R SC SIU R Feed SIU P EPU R PDU Board P SIU R PDU Board R PDU Power Distribution ACD PS P TEM 0 PS Brd DAQ B DAQ B C A L T K R GASU DAQ P C A L T K R GASU DAQ R ACD PS R TEM 14 TEM 1 PS Brd Power Distribution Prime Redundant GASU A C D A C D A C D 0 1 11 v9 TEM 15 PS Brd PS Brd DAQ B DAQ B C A L T K R C A L T K R 4.1.7 Electronics Overview 10 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 LAT Electronics (Signals) • • • • • • • TKR: Tracker CAL: Calorimeter ACD: Anti-Coincidence Detector TEM: Tower Electronics Module EPU: Event Processor Unit SIU: Spacecraft Interface Unit GAS Unit: Global TriggerACD-Signal Distribution Unit From SC P/R 1 PPS/GRB Alert To SC P Science Data Filtering Software EPU P0 EPU P1 EPU R SIU P SIU R Command/ Control/Monitor Software GAS Board P GAS Board R GAS Unit Command Response Unit Global Trigger Event Builder ACD Electronics Module TEM 0 C A L T K R Command Response Unit Global Trigger Event Builder ACD Electronics Module Prime Redundant TEM 7 C A L T K R TEM 8 A C D 0 LAT-PR-01967 To SC P/R MIL1553/ Discretes To SC R Science Data A C D A C D 1 C A L T K R TEM 15 C A L T K R 11 v9 4.1.7 Electronics Overview 11 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Example: Control Path • • • • Control from either SIU to either GASU CommandResponse Unit (CRU) Control from either GASU CRU to each TEM Control from TEM to CAL/TKR Use “Look-At-Me” command to switch between redundant receivers EPU P0 EPU P1 EPU R SIU P Command/ Control/Monitor Software GAS Board P GAS Board R GAS Unit Command Response Unit Global Trigger Event Builder ACD Electronics Module TEM 0 C A L T K R Command Response Unit Global Trigger Event Builder ACD Electronics Module Prime Redundant TEM 7 C A L T K R TEM 8 A C D 0 LAT-PR-01967 SIU R A C D A C D 1 C A L T K R TEM 15 C A L T K R 11 v9 4.1.7 Electronics Overview 12 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Example: Event Path • • • • • Sub-system event-data fragments from CAL/TKR to TEM Tower-event assembly and transmission to GASU Event-Builder (P and R) LAT event assembly and transmission to EPU (all EPU’s) Event-filtering and transmission of CCSDS coded data to GASU (P and R) GASU transmits data to SC C&DH data ports (P and R) (Event-Data goes/comes from all EPU’s, only EPU P1 shown) EPU P0 To SC C&DH P Event-Data Port EventFiltering EPU P1 Raw Data EPU R SIU P SIU R Filtered Data GAS Board P GAS Board R Command Response Unit Global Trigger Event Builder ACD Electronics Module Prime (P) Redundant (R) Command Response Unit Global Trigger Event Builder ACD Electronics Module GAS Unit TEM 0 C A L T K R TEM 7 C A L T K R TEM 8 A C D 0 LAT-PR-01967 To SC C&DH R Event-Data Port A C D A C D 1 C A L T K R TEM 15 C A L T K R 11 v9 4.1.7 Electronics Overview 13 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Datapath & Building Events Tower Front-End Latch on trigger Assemble TEM Event ~50,000 TKR GTFE MEM Cells With 2 Events Digitize on trigger GASU Event Builder TEM Cable TKR FIFO With 1 Event EPU LCB-> Processor -> LCB Assemble LAT Event SW Filter CAL ADC Data Trigger Data CAL-TRG FIFO With 3 Events GASU Event Builder Spacecraft From other TEM’s FIFO for each Tower LAT-PR-01967 v9 4.1.7 Electronics Overview 14 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Summary of July Delta-PDR Review • • • • • “Work with GSFC branch to qualify poly-switches for use in the LAT electronics” – Approved “Ensure that FPGA design practices adhere to GSFC guidelines and recommendations for space-flight applications” – Working with Rich Katz at GSFC to review LAT FPGA designs. Submitted designs in April 03. “Determine the need date for processor down-select based on software design impact” – Have selected and placed order for BAE RAD750 “Finalize the flight-software management plan and test plan” – Flight software management plan (LAT-MD-00104-02) and Flight software test plan (LAT-TD-00786-01) released and in cyberdocs “Identify solution path to replace the functionality that would have been provided by SCL COTS tool in the flight software. Coordinate with I&T and mission operations” – I&T has adopted a low level toolset (Python, Qt, XML, MySQL) to implement the EGSE side of the I&T test environment. FSW provides the hardware drivers for the embedded system. Code already exists and is running on test stands to replace the SCL register manipulation model. FSW has adopted the I&T low level toolkit for its Test Executive. LAT-PR-01967 v9 4.1.7 Electronics Overview 15 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Peer-CDR Review RFA Status RFA # 1 6 7 8 8 12 14 15 16 17 20 23 24 26 RFA Status GBM Signal Use Change Control of Docs SIIS 1PPS Timing Accuracy SIIS Redundancy Population of SIB in EPU/SIU retracted/merged with other RFA retracted/merged with other RFA Event Builder Switch Error Handling in RAD750 RAD750 Exchange Info Hardware Protection of ACD PMT SPICE Analysis of Power Grounding Diagram TEM Mechanical Accepted Accepted Accepted Pending Accepted Accepted Accepted Accepted Accepted Accepted Accepted Accepted Accepted Accepted RFA’s #2, 3, 4, 5, 10, 11, 13, 18, 19, 21, 22, 25: see FSW presentation LAT-PR-01967 v9 4.1.7 Electronics Overview 16 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Specification Tree Mission Science Requirements Document LAT IOC/MOC/ SSC Interface Control Documents Mission System Specification Interface Rqmts Ground System Rqmts Science Rqmts LAT-SC Interface Requirements Document Mission Rqmts Interface Rqmts LAT LAT Performance Specification LAT-SS-00010 LAT Environmental Specification LAT-SS-00778 LAT IOC Performance Specification LAT-SS-00015 LAT-SC Interface Control Documents LAT Subsystem Mechanical Subsystem Specification LAT-SS-00115 Trigger & Dataflow Subsystem Specification LAT-SS-00019 TKR Subsystem Specification LAT-SS-00017 ACD Subsystem Specification LAT-SS-00016 Radiator Design Specification LAT-SS-00394 TCS Performance Specification LAT-SS-00715 X-LAT Plate Design Specification LAT-SS-01240 Grid Box Design Specification LAT-SS-00775 LAT-PR-01967 ACD Design Specification LAT-SS-00352 LAT Trigger Specification LAT-SS-00284 Power Subsystem Specification LAT-SS-00136 SAS Subsystem Specification LAT-SS-00020 CAL Subsystem Specification LAT-SS-00018 LAT Flight SW Specification LAT-SS-00399 LAT TKR Design Specification LAT-SS-00134 LAT Dataflow Specification LAT-SS-00285 LAT Readout Electronic Specification LAT-SS-00152 Tower Power Supplies Specification LAT-SS-01537 LOF Subsystem Specification LAT-SS-00021 SAS Design Specification LAT-SS-00505 CAL Design Specification LAT-SS-00210 v9 LAT Operations Facility Specification LAT-SS-01783 Design Specification 4.1.7 Electronics Overview 17 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Level III Key Requirements Summary Electronics Ref: LAT-SS-00019 Adjust Input timing resolution TACK latency Timing Jitter Dead-time contribution Event Deadtime Report <100 ns Trigger acknowledge output < 1.3 s < +/- 50 ns < 5 s Acknowledge blocking Dead time cause < 500 ns Event Data Contribution Diagnostics Mode Test Test/Demonstration Test Test Test Test/Demonstration Test/Demonstration Test Test/Demonstration Test/Demonstration 50 ns Meet Requirement < 1.3 usec < 50ns < 200 nsec Meet Requirement Meet Requirement < 500 ns Meet Requirement Meet Requirement Verify commanding interface GRB response Test/Demonstration Test/Demonstration Meet Requirement Meet Requirement Readout and overwrite protection Filtering functions Pointing & coordinate system Dead-time for average orbit condition < 5% Test/Demonstration Test/Demonstration Test/Demonstration Test/Demonstration Meet Requirement Meet Requirement Meet Requirement < 5% for T&DF Monitoring & calibration < 0.25 m3 < 188 kg Test/Demonstration Inspection Inspection Meet Requirement < 0.25 m3 < 188 kg < 142 W (dayly average) < 330 W (peak, average over 1 sec) Test Test < 142 W (daily average) < 330 W (average over 1 sec) Control System Event Data Volume Mass Power LAT-PR-01967 v9 4.1.7 Electronics Overview 18 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Flowdown – Requirements to Design Parameter Requirement Constraint Characteristics Needed Design Trigger Adjust Input timing resolution TACK latency Timing Jitter Dead-time contribution Event Deadtime Report <100 ns Power < 1.3 us < +/- 50 ns < 5 us < 500 ns Mass Volume Complexity Reliability Readout and overwrite protection Power Efficient Event Assembly Filtering functions Dead-time for average orbit condition < 5% Buffering for burst up to 20,000 photon events Mass Volume Complexity of hardware versus software Reliability Hardware/Firmware system Central Trigger Decision Block (Global Trigger, located in GAS Unit) Dataflow Event buffering in Front-end electronics, TEM, GASU Central Event Builder Hardware event assembly (Hardware, located in GAS Unit) Processor for filtering PowerPC Processor Farm Error Recovery LAT-PR-01967 v9 4.1.7 Electronics Overview 19 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 External/Internal Interfaces • • All external DAQ interfaces released with the exception of final spacecraft interface All internal interfaces released External Interfaces Interface Document Internal Interfaces Status Interface Document Status LAT-TD-00605 Released Calorimeter LAT-SS-00238 released Tower Electronics Module Tracker LAT-SS-00176 released TEM PowerSupply Unit LAT-SS-01281 Released GAS Unit LAT-SS-00363 released Mechanical/ Thermal LAT-SS-01794 released LAT-SS-01544 LAT-TD-00639 LAT-TD-01545 LAT-TD-01546 LAT-TD-01547 Released ACD Spacecraft GSFC-433-IRD in progress at GSFC but content stable SIU/EPU LAT-SS-01539 Released PDU LAT-SS-01542 Released VCHP Control Unit LAT-SS-00715 Released LAT-PR-01967 v9 4.1.7 Electronics Overview 20 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Redundancy at Assembly Level • • • • • • FMEA and Reliability Analysis: see System Engineering presentation Spacecraft Interface Unit (SIU) – 1 prime and 1 redundant , either one can run the LAT electronics, including any combination of PDU P and R, GASU P and R, EPU P and R • Note that SC science interface, 1 PPS, and GRB signal are connected to GASU, not to SIU Event Processor Unit (EPU) – 2 prime and 1 redundant , each can be used in any combination of PDU P and R, GASU P and R, SIU P and R GAS Unit (GASU) – 1 prime and 1 redundant , each can be used in any combination of PDU P and R, EPU P and R, SIU P and R Power Distribution Unit (PDU) – 1 prime and 1 redundant , each can be used in any combination of GASU P and R, EPU P and R, SIU P and R Tower Electronics Module (TEM) – 16 prime and 0 redundant , each can be used in any combination of GASU P and R, EPU P and R, SIU P and R LAT-PR-01967 v9 4.1.7 Electronics Overview 21 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Components & Assemblies • Design • Mechanical • Thermal • As an example, TEM assembly is presented in more detail LAT-PR-01967 v9 4.1.7 Electronics Overview 22 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Tower Electronics DAQ Module • TKR (8 cables) CAL (4 cables) CAL Cable ASIC TKR Cable ASIC Control, Event & HSK Signals Power Trigger Power to TEM Elex Trigger Controller Common Controller LAT-PR-01967 Power from TEM PS Module Trigger signals to/from Global Trigger on GAS Unit Control & HSK signals from/to SIU, Event data to EPU, all via GAS Unit Main DAQ module, one on each tower – Controls and reads out data from TKR MCM and CAL AFEE front-end electronics – Zero-suppresses CAL event data – Buffers events in cable ASIC FIFO’s – Assembles CAL and TKR event fragments to tower event – Transmits data to GASU – Contains monitoring and low-rate science circuits – LVDS interface to front-end electronics and GASU – Hardware with software controlled configuration and mode registers • CAL ICD: LAT-SS-00238 • TKR ICD: LAT-SS-00176 • TEM ICD: LAT-SS-00363 v9 4.1.7 Electronics Overview 23 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Tower Electronics DAQ Module (Con’t) • • • • Engineering Model with full functionality and interfaces as flight has been used extensively in 18 copies in the field, controlled and readout with real-time software from the FSW group, and I&T software from the I&T group Not just tested in TEM test-setup at SLAC, but more importantly fully integrated in set-ups with real subsystem electronics – at NRL and at SLAC with CAL electronics – In Italy and at SLAC with TKR electronics – At SLAC, NRL with DAQ electronics Flight Model with 8 GTCC and 4 GCCC ASICs, plus 2 ACTEL’s: design finished, layout complete, ready for fabrication LAT-TD-00605 LAT-PR-01967 v9 4.1.7 Electronics Overview 24 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Tower Electronics Module GCCC ASIC • • • • • • • TEM interface to calorimeter AFEE – Configuration and readback data – Trigger and event data handling – Log suppression algorithm – Event buffers Contains – Two 64x16 FIFO’s – Three 128x16 FIFO’s – Core Logic (generated from synthesized VHDL code) – LVDS drivers/receivers VHDL code compiled into XILINX FPGA, is used on TEM’s which are operating with CAL electronics First ASIC prototype (GCCC1) came back from fabrication end of March 03 DAQ tests show full functionality, performance up to 40 MHz (nominal f=20 MHz) – Need more testing with full set of calorimeter AFEE boards – Need to perform radiation tests If ASIC is ok, have full flight production in hand LAT-TD-01549 LAT-PR-01967 CORE FIFO LVDS IO GCCC v9 4.1.7 Electronics Overview 25 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Tower Electronics Module GTCC ASIC • • • • • • • TEM interface to tracker MCM’s – Configuration and readback data – Trigger and event data handling – Data reformatting – Event buffers Contains – Two 64x16 FIFO’s – Three 128x16 FIFO’s – Core Logic (generated from synthesized VHDL code) – LVDS drivers/receivers VHDL code compiled into XILINX FPGA, is used on TEM’s which are operating with TKR electronics First ASIC prototype (GTCC1) came back from fabrication end of March 03 DAQ tests show full functionality, performance up to 40 MHz (nominal f=20 MHz) – Need more testing with full set of TKR MCM boards – Need to perform radiation tests If ASIC is ok, have full flight production in hand LAT-TD-01550 LAT-PR-01967 LVDS IO FIFO CORE GTCC v9 4.1.7 Electronics Overview 26 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Design & Verification for GCCC/GTCC VHDL Simulation Netlist Manual: Schematic of IO, LVDS Automatic: Layout, Place&Route Automatic: Generate Schematic Layout: Add IO and LVDS. Result: Complete Chip Layout Compare Simulation: Spice Full Chip Schematic Netlist w/o Parasitics Netlist with Parasitics Netlist Full-Chip Compare/Verific ation Full-Chip Simulation with Synopsys Full-Chip Simulation with Synopsys Stress & Timing Analysis Fabrication Flight-Model Status 4/03 LAT-PR-01967 Test v9 4.1.7 Electronics Overview 27 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 TEM Drawing Tree 2 3 Tower Electronics Module LAT-DS-01481 Tower Electronics Module DAQ Assembly, TEM Power Supply LAT-DS-01643 LAT-DS-01482 TEM Box Base Specification, TEM Power Supply Assy. LAT-DS-00554 LAT-DS-01651 TEM Box Lid TEM Connector Plate Box Base, Power Supply Assy. Box Lid, Power Supply Assy. LAT-DS-00555 LAT-DS-01026 LAT-DS-00995 LAT-DS-00996 TEM Connector Pin Flange Screw Bracket A Bracket B LAT-DS-01031 LAT-DS-01487 LAT-DS-01027 LAT-DS-01028 Bracket C Bracket D LAT-DS-01029 LAT-DS-01030 Specification, TEM Power Supply CCA. Interface Control Document, Power Supply CCA Circuit Card Assembly, TEM DAQ Specification, TEM DAQ Test Procedure, TEM DAQ LAT-DS-01646 LAT-DS-01644 LAT-DS-01645 Specification, TEM DAQ CCA LAT-DS-01647 Test procedure, TEM Power Supply Assy. LAT-DS-01652 Test Procedure, TEM DAQ CCA LAT-DS-01648 Printed Wire Board, TEM DAQ CCA LAT-DS-01649 Schematic Diagram, LAT_DS_01650 LAT-DS-01537 LAT-DS-01281 LAT-PR-01967 v9 4.1.7 Electronics Overview 28 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 TEM Assembly Drawing (Example) LAT-PR-01967 v9 4.1.7 Electronics Overview 29 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Tower Electronics Module (TEM) PSU TEM – PSU Stack Tower Electronics Module LAT-PR-01967 v9 4.1.7 Electronics Overview 30 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 TEM Temperature Profile GCCC ASIC GTCC ASIC ACTEL FPGA LAT-PR-01967 v9 4.1.7 Electronics Overview 31 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 TEM Component Thermal Data • TEM Cooling; Hottest single component – PWB mounted flat to 2 mm 6061 Aluminum • FPGA 3.1 OC J/C for ½ watt – Polyimide PWB 0.33 W/m-K • Using 9 cm2 footprint • 2.7 OC for ½ watt – CV2943 1.2 W/m-K • 0.23 OC for ½ watt FPGA 10 mil CV2943 62 mil PWB 10 mil CV2943 2 mm Aluminum – Temperature rise from edge of TEM box to center of TEM box • 2.1 OC • Total Delta T for FPGA Junction Temperature • = XLAT interface + SIU + PSU+ TEM + TEM Center + FPGA – Delta T = 5.2+3.1+2.7+0.23+2.1 = 13.33 OC LAT-PR-01967 v9 4.1.7 Electronics Overview 32 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Tower Power Supply Module • TKR enable TKR Bias Set CAL enable 28 V TKR 1.5V Filter TKR 2.5V Filter CAL Bias Set TKR 1.5V TKR 2.5V Analog Filter TKR 2.5V Digital TRK 0150V Filter TKR Bias 0150V Adj. CAL 3.3V Filter CAL 3.3V Analog Input filter Engineering model tower power supply built and used in EGSE test-stands at SLAC, NRL, GSFC, Italy – Flight like interfaces and functionality Filter CAL 3.3Digial CAL 0100V Filter CAL Bias 0100V Adj. DAQ 3.3V Filter DAQ 3.3V A Thermister A B Thermister B • • • • LAT-PR-01967 Built 1.5V supply with mostly flight-components Supplies went out for RFP, responses are being evaluated Statement of Work: LAT-SS01537 ICD: LAT-TD-01281 v9 4.1.7 Electronics Overview 33 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 SIU/EPU Crate Electronics • • • • • Storage Interface Board (SIB) – EEPROM – MIL1553 Communication with spacecraft* – Power Control of PDU/GASU power switches in PDU* – Power Control of VCHP switches in heater box* LAT Communication Board (LCB) – Communication with GASU • Commanding • Read-back, house-keeping & event data Power Supply Board (PSB) – 28V to 3.3V/5V conversion – LVDS-CMOS conversion of spacecraft discretes* – System clock to GASU CPU Board Backplane (passive) VCHP Heater Box BackPlane SIB Heater Control* Power Control* PDU PCI Interface EEPROM Spacecraft MIL1553 MIL1553* LCB CommandResponse GASU PCI Interface FIFO Event Data GASU Spacecraft Discretes PSB LVDS Convertion Spacecraft Power 28-V DC/ DC Power-On Reset GASU 3.3V/5V System Clock CPU Discrete I/O PCI Interface Power PC * Only used in SIU crate LAT-PR-01967 v9 4.1.7 Electronics Overview 34 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 LCB and SIB • • • • • • • • • LAT Communication Board (LCB) PCI-interface engineering model in operation since early 03 (has PMC connector) Flight Model has cPCI connector: design finished, layout close to complete ICD: LAT-TD-00860 Storage Interface Board (SIB) Designed/implemented by Silver Engineering (Dennis Silver, Greg Clifford) under contract by NRL (Kent Wood, Michael Lovellette) – Driver by Dan Wood (NRL) Engineering model has been in test since mid 02 Flight Model adds npn transistors for heater control – Schematic updated, waiting for layout modification ICD: LAT-SS-01539 LAT-PR-01967 v9 4.1.7 Electronics Overview 35 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Power Allocation Example: SIB AT 33MHZ CPCI BUS SPEED SIC OPERATE STATE EEPROM UPDATE STATE OPERATE STATE CURRENT (ma) TYPICAL MAX 3.3V 227 423 5V 79 79 3.3V 275 471 POWER (WATTS) TYPICAL 5V 158 1.1 158 1.8 CURRENT (ma) TYPICAL MAX 3.3V 5V 3.3V FPGA, RT54SX32S-1CQ208B (PCI) 153 178 Pullup Resistors pulled low 1 7 1 OMR9601CSCK (2.5V Reg) (EST) 8 10 SUMMIT DXE ** 30 EEPROM (8) *** 32 32 SRAM (2), HLX6228TSR 6.8 ACQ245 (8) 0.64 0.64 AC138 (2) 0.16 0.16 AC273 (2) 0.16 0.16 ACT74 1.2 Transistor Drive On, 50% typ, 100%max 21.6 43.2 OSC 22.5 Misc 10 10 10 POR X2 1 TOTALS 227 79 275 **Assume 1553 at 1% duty cycle (which is nearly the same as idle) ***Assume EEPROMs not in write cycle MAX 1.7 2.3 CURRENT (ma) TYPICAL MAX EEPROM UPDATE 5V 7 100 8 1.6 30 10 1 158 3.3V 5V 3.3V FPGA, RT54SX32S-1CQ208B (PCI) 153 178 Pullup Resistors pulled low 1 7 1 OMR9601CSCK (2.5V Reg) (EST) 8 10 SUMMIT DXE ** 30 EEPROM (8) *** 228 228 SRAM (2), HLX6228TSR 6.8 ACQ245 (8) 0.64 0.64 AC138 (2) 0.16 0.16 AC273 (2) 0.16 0.16 ACT74 1.2 Transistor Drive On, 50% typ, 100%max 21.6 43.2 OSC 22.5 Misc 10 10 10 POR X2 1 TOTALS 423 79 471 **Assume 1553 at 1% duty cycle (which is nearly the same as idle) ***Assumes One EEPROM in write cycle 5V 7 100 8 1.6 30 10 1 158 Courtesy of Dennis Silver, Silver Engineering LAT-PR-01967 v9 4.1.7 Electronics Overview 36 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Processor • • BAe750 compact PCI board • 750 class Power-PC • 240 MIPS at 133 Mhz, • Less Than 12W • 128 Mbytes main memory • 256 Kbytes SUROM • VxWorks real-time operating system – LAT ordered prototype, was received Spring 02 – Since then used for software development at NRL • Boot-code • Bench-mark for LAT filtering code • Test with SIB MIL1553 prototype – Same board selected/ordered by GLAST spacecraft contractor Order placed April 03, – < 6 months delivery of 3 prototype boards – 12 months for flight articles – Weekly telecon has started with SAI & BAE LAT-PR-01967 v9 4.1.7 Electronics Overview 37 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 GAS Unit (Signal Distribution and Trigger) • • • • • Uses GLTC ASIC to receive LVDS signals and to logically mask and combine 228 ACD trigger signals Global Trigger controller (LAT-TD-01545) – Combines trigger inputs from TKR, CAL, ACD and makes trigger decision – Distributes trigger message with target CPU for event, time-stamp, event-number, and trigger type to sub-systems – Total time from particle in detector to receipt of trigger accept signal: 2 sec Command Response Unit (LAT-SS00416/0606) – Distributes control from SIU to TEM’s, GLT, ACD EM, EB – Transmits readback data from TEM’s, GLT, ACD, EB to EPU’s Hardware with software controllable configuration & mode registers One prime and one redundant DAQ board LAT-PR-01967 Command-Response Trigger EPU P0 EPU P1 EPU R SIU P SIU R GAS Board P Global Trigger P GAS Board R CMDResp. Unit P GAS Unit Event Builder P ACD EM P TEM 0 C A L T K R Control, Commanding Event Builder R TEM 8 T K R A C D 0 v9 Global Trigger R ACD EM R TEM 7 C A L CMDResp. Unit R A C D A C D 1 C A L T K R TEM 15 C A L T K R 11 4.1.7 Electronics Overview 38 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 GAS Unit (ACD EM & Event Data) • • • ACD EM (LAT-SS-00363/00639) – Controls and reads out data from ACD front-end electronics – Buffers events – Assembles 12 ACD event fragments into ACD event – Transmits data to EB – Contains monitoring circuits Event Builder (LAT-TD-01546) – Receives event fragments from TEM’s, AEM, and GLT at up to 10 KHz rate – Builds LAT event and transmits to EPU’s/SIU’s at up to 10 KHz rate – Receives CPU data, forwards to • other CPU’s, or • to SC (science data interface) Hardware with software controllable configuration & mode registers To SC P Science Data Filtering Software EPU P0 EPU P1 EPU R SIU P SIU R GAS Board P Global Trigger P GAS Board R CMDResp. Unit P GAS Unit Event Builder P ACD EM P TEM 0 C A L T K R Event Builder R Prime Redundant C A L T K R CMDResp. Unit R TEM 8 A C D v9 Global Trigger R ACD EM R TEM 7 0 LAT-PR-01967 To SC R Science Data A C D A C D 1 C A L T K R TEM 15 C A L T K R 11 4.1.7 Electronics Overview 39 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 GAS Unit & GLTC ASIC • • • • • Engineering Model with partial functionality and interfaces as flight has been used in several copies in the field, controlled and readout with real-time software from the FSW group, and I&T software from the I&T group ACD EM at SLAC and GSFC, with real ACD front-end electronics Trigger input signal received and trigger accept message generated via SLAC COM-module (either CAL, TKR, and ACD programmed) Model with 14 GLTC and 9 ACTEL’s: in fabrication GLAST LVDS Translator Chip (GLTC) ASIC – LVDS receivers for ACD veto and CNO trigger signals – Maskable logical-OR function of ACD trigger signal – Handles 18 input signal channels – Contains • Core Logic (generated from synthesized VHDL code) • LVDS receivers – First version ASIC was received in Dec 02 – Fully working, is flight design – Flight quantity is on shared LAT wafer-run back from fab March 03, in testing • Need radiation testing – LAT-TD-0148 LAT-PR-01967 v9 4.1.7 Electronics Overview 40 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 GASU Stress Model FEM Model Analysis Approach - Plate, Brick and Beam Elements - Pinned Boundary Conditions - Model Weight 31.4 lbs. (14.3 kg) - First Mode 136.3 Hz - Machined Aluminum 6061-T6 - Ultimate Strength 42000 psi - Simplified Approach to Application of Dynamic Load Factor defined by Miles Equation - Applied Maximum Response at QUAL Level uniformly to each of the three orthogonal axes - 3s Load Levels used to account for peak excitation. - Ignored Mass Participation Effects and Non-uniform Distribution of acceleration loads throughout the structure. - Q = 10 - Safety Factor of 1.4 x Ultimate Strength - Applied 3s DLF 134.52 Grms (44.84 Grms peak) GASU ASSEMBLY SUMMARY Load Axis Maximum Stress psi Allowable psi Margin X Y Z 4054 3692 11380 30000 30000 30000 6.40 7.13 1.64 LAT-PR-01967 v9 4.1.7 Electronics Overview 41 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 GASU Stress Model X-Axis Load Case Displaced Shape and Stress Contour Maximum Stress Natural Frequency First Mode 136.3 Hz Y-Axis Load Case Displaced Shape and Stress Contour Maximum Stress Z-Axis Load Case Displaced Shape and Stress Contour Maximum Stress LAT-PR-01967 v9 4.1.7 Electronics Overview 42 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 PDU Power Distribution • • • • • • • Discrete signal from SIU selects which SC main power to use 28V/3.3V PDU converter is powered when SC Main feed is powered Discrete signal from SIU turns on power to GASU prime or redundant DAQ board PDU FPGA controls power switches for TEM’s, EPU’s, and ACD supplies in GASU Power switches are implemented with PMOS transistors ICD: LAT-SS-01542 and LAT-SS-01543 Status: layout complete, ready for fabrication SC Main Feed P SC Main Feed R Prime Redundant SIU P PDU Prime Board SC Feed Select PDU Redundant Board LC Filter SIU R GASU Power Switches Filter 28V/3.3V Converter TEM/EPU Power Switches PDU FPGA Control GASU P DAQ Power Supplies GASU R DAQ Power Supplies 16 Towers, 3 EPU’s, ACD Supplies 0 LAT-PR-01967 v9 1 11 4.1.7 Electronics Overview 43 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 DAQ Thermal & Mechanical • Thermal and Mechanical Analysis documented in LAT-TD02138 LAT-PR-01967 v9 4.1.7 Electronics Overview 44 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Thermal • • • • • • • TEM 3.4 watts TEM Power Supply (PS) 11.7 watts GASU 24.9 watts PDU 18.1 watts EPU 24.3 watts SIU 27.2 watts Stackups – TEM, TEM PS, EPU -> 39.4 watts – TEM, TEM PS, SIU -> 42.3 watts – TEM, TEM PS, PDU -> 33.2 watts – TEM, TEM PS, GASU ->27.5 watts LAT-PR-01967 • • Assumptions Thermal boundaries for DAQ – -40C to +55C for Qualification – Uniform thermal connection to X-LAT plates – Only thermal conduction considered – No thermal conduction to calorimeter base plates. – 100 OC maximum Si junction temp Thermal Resistances/Conductance's – Al 6061 154 W/m-K – Polyimide 0.33 W/m-K – CV2943 adhesive 1.26*W/m-K – Wedge-Lok 0.14 OC/W, 2 each 6” – Actel FPGA 6.2 OC/W J-C – Thermal Via, 12 mil, 2*103 OC/W each • 3.4 OC/W for an array of 64X8 v9 4.1.7 Electronics Overview 45 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 SIU/EPU Stackup Only show SIU/EPU stack-up as an example in this presentation, results are also available for other LAT cases SIU 27.2 W/ EPU 24.3W PSU 11.7 W TEM 3.4 W TEM, TEM-PSU, and SIU/EPU/EMPTY Stack 10x Typical • • • LAT-PR-01967 Top & bottom covers are 0.08 in Al Side walls are 0.15 in 6061 Al Temperatures – TEM = 0.2 OC Rise – PSU = 0.7 OC Rise • Thermal resistance for box below • -> 0.11K/watt – SIU = 2.0 OC Rise • Thermal resistance for box below -> 0.17K/watt – Total temp rise • 0.2 + 0.7+(3.4*.11)+2+(11.7*.17) = 5.2 OC Rise v9 4.1.7 Electronics Overview 46 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 TEM-PSU-EPU/SIU FEM Model Analysis Approach - Plate, Brick and Beam Elements - Model Weight 28.1 lbs. (12.77 kg) - First Mode Natural Frequency = 238 Hz - Machined Aluminum 6061-T6 * Ultimate Strength 42000 psi - Modal Survey Run Applied QUAL Level Random Vibration Spectrum - Results Show Combined Effects of Random Excitation - 3s Load Levels Used to Account for Peak Excitation. - Damping = .05 (5 %) - Safety Factor of 1.4 x Ultimate Strength - 14.14 Grms Input Level - Ti 6Al-4V Standoffs - Ti 6Al-4V M6x1 Socket Head Cap Screw Mounting Bolts * Ultimate Strength 160ksi STRESS SUMMARY - Maximum Stresses are produced in the Titanium Standoffs - Stress Summary shows Standoff Stresses and Margins STRESS SUMMARY Load Case QUAL Units s max d max psi inch 14.14 14.14 14.14 Grms Grms Grms 31073 31073 17059 Y Y Z 10.464 0 8.5 Allowable MARGIN psi RANDOM X Y Z STATIC Load Case Worst Combination LAT-PR-01967 v9 .002 .002 .002 s max d max 15676 .002 114286 114286 114286 2.678 2.678 5.699 Allowable MARGIN 114286 6.291 4.1.7 Electronics Overview 47 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Harness • • • • • • Almost exclusively point-to-point cables Connectors are Micro-D and Sub-D Cables are shielded-twisted pair, 24 AWG Installation in layers (see I&T); assembly drawings close to complete Designed and fitted on 1:1 LAT model Assembled by qualified vendor LAT-PR-01967 v9 4.1.7 Electronics Overview 48 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification & Test LAT-PR-01967 v9 4.1.7 Electronics Overview 49 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification Matrix (Doors Example Page) ID TDF L3 Performance Specification VM TDF3-7 The Level 1 Trigger (L1T) system shall be used to detect an interesting event and provide a signal to the detector subsystems to capture and read out the event data. Demo TDF3-105 The trigger (TRG) system shall determine whether the event is interesting based on trigger input signals received from the detector systems. Demo TDF3-9 The L1 trigger system shall accept trigger inputs from the ACD, TKR, CAL and dataflow subsystems. Demo TDF3-11 The L1 trigger system shall time-align trigger inputs from the ACD, TKR, CAL and dataflow subsystems to a precision better than 100 ns. Test TDF3-13 The L1 trigger system shall implement multiple overlapping triggers to allow cross-trigger monitoring. Test TDF3-15 The L1 trigger logic shall generate a trigger acknowledge signal (L1TACK) and a trigger type (e.g. CNO) for distribution to the subsystems. Demo TDF3-17 The L1 trigger logic shall generate the Trigger Acknowledge output with a latency of less than 1.3 mus. Test TDF3-106 The latency from the time the particle traverses the LAT to when the input signals need to be recorded at the earliest shall be 2 ms. Test TDF3-19 The L1 trigger contribution to the overall trigger jitter shall be less than ± 50 ns. Test TDF3-107 The overall trigger jitter for the LAT shall be ± 200 ns. Test TDF3-51 LAT-PR-01967 The dataflow system shall reduce the event rate accepted by the L1T to an output rate commensurate with the spacecraft interface as specified in 433-IRD-0001, keeping events meeting the science objectives. v9 Verif. Demo 4.1.7 Electronics Overview 50 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Test Matrix Applies to each board and assembly. In this slide the tests at each level are listed Sine Sweep Random Vib Acoustic Pressure Profile Mass Property Interface Verification EMI/EMC ESD Compatibility (Grnding) Functional/Performance Thermal Vacuum Thermal Balance Thermal Cycle Humidity Backout Radiation Inspection Comments Sine Burst Environmental/Other - - - - - - M TA - - TA - - TA M A A I C Board 1 E C Board 1 Q - - C Chassis 1 Q A A C Pow er Supply 1 Q - - C Board 17 F - C Chassis 17 F - C Pow er Supply 17 F S Box 1 S Box 16 S Box 1 - - - - M TA - - TA - - TA M A A I A A - - M TA - - TA - - TA M A A I - - - - M TA - - TA - - TA M A A I - - - - - M TA - - TA - - TA M A - I - - - - - M TA - - TA - - TA M A - I - - - - - - M TA - - TA - - TA M A - I Q TQ TQ TQ TQ A A M TQ TQ TQ TQ TQ A - M A - I F TA - - TA - - M TA - - TA TA A - M A - I 4 cycle T/V S TA - - TA - - M TA - - TA TA A - M A - I 8 cycle T/V Assem bly Level S= Subsystem C=Component LAT-PR-01967 Electrical Static Load Unit Type Component (ITEM) Mechanical Quantity Assembly Level Hardware Unit Type PF=Proto Flight F=Flight S=Spare Q=Qual E=Engineering / VerificationModel Verification Method T=Test A=Analysis M=Measurement I=Inspection Buy-Tested at supplier Buy-Tested at supplier QS=Qual by Similarity TQ=Test, Qual Levels TA=Test, Acceptance Levels v9 4.1.7 Electronics Overview 51 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Testing Plan • • • ASIC’s are 100% acceptance tested before assembly on boards – Radiation performance is lot tested for single event effects and total ionizing radiation. Function/Performance is tested at the board level Qualification and acceptance tests including performance, vibration, EMI/EMC, and thermal vacuum are performed at the component sub-assembly (box) level. Vibration test to qual levels of EM TEM passed LAT-PR-01967 v9 4.1.7 Electronics Overview 52 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification & Test Model Development Hardware Design Software Design/Develop • Fab Test Develop/Test Formal Test Release to I&T Hardware and software development closely integrated – Design of hardware versus software complexity optimized continuously – Software runs with LAT engineering model electronics – Continuous hardware versus software verification – Full system including sub-system electronics from and at other institutions – Independent verification process • Exchange of hardware and software -> – – – – – ACD hardware, TKR hardware, CAL hardware DAQ hardware Flight software, I&T software ACD Scripts, TKR scripts, CAL scripts, DAQ scripts No integration at flight- LAT integration stage of components which have not operating fully integrated in earlier stages • Exception is spacecraft, since simulator is only simulating and is not real hardware/software LAT-PR-01967 v9 4.1.7 Electronics Overview 53 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification & Test (Con’t) Development Cycles EM 1 Release to I&T EM2 Release to I&T FU • • • Release to sub-systems Release to sub-systems Release to I&T Three development cycles – Engineering Model 1 • Single tower, single CPU – Engineering Model 2 • Multiple tower, single CPU – Flight Model • Multiple towers, multiple CPU’s Peer-Reviews after end of each development cycle In addition regular LAT reviews (Manufacturing Readiness Review, etc) LAT-PR-01967 v9 4.1.7 Electronics Overview 54 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification & Test: Example TEM & FSW Power-PC Processor Flight Software 28-V Power Supply LCB: LAT Communication Module Transition-card: Trigger Module TEM DAQ Assembly Tower Power Supply Assembly (1.5V/2.5V/3.3V/ 0-100V/0-150V) • • • • • • • • TKR Engineering Tower with TEM Processor: Motorola Power-PC Flight Software PMCIA LAT Communication Board for – LAT Communication Transition Board – Trigger TEM DAQ Assembly TEM Power-Supply Assembly 28-V Supply LAT-TD-00861 LAT-PR-01967 v9 4.1.7 Electronics Overview 55 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification & Test: RAD750/SIB • • • 3u-cPCI BAE RAD750 processor prototype 6u-cPCI Storage Interface Board (Silver Engineering) – MIL1553 interface SIB Flight Software – Boot code development – SIB board code driver/interface – Benchmark of event filtering performance CPU Courtesy of Dan Wood, NRL LAT-PR-01967 v9 4.1.7 Electronics Overview 56 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification & Test: Front-End Data Simulator One of 16 Towers 7 PC (one for 2 TEM’s) 0 T C P I P • • • • • H a r d D i s k PCI Bridge Card PCI Bridge Card PCI Bridge Card TEM High-Speed Serial Connection P C I CAL FrontEnd Data Simulator P C I TKR FrontEnd Data Simulator PCI Bridge Card System uses 9 PC’s – 8 PC’s for 16 TEM’s – 1 PC for ACD Data transported to towers via high-speed data link; PCI bridge to local bus on simulator Data Simulators interface to TEM like CAL and TKR sub-system electronics – CAL and TKR simulator board identical except code in FPGA’s – Patch cable connect simulator to CAL and TKR TEM connectors Can operate TEM or LAT with data generated from simulations Data simulator board fabricated and loaded, in test LAT-PR-01967 Data into TEM like CAL and TKR subsystem electronics v9 Moselle PCI bridge 4.1.7 Electronics Overview 57 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Verification & Test: Testbed • • • • • • • • Full DAQ set with EM2 hardware (each with identical interfaces and functionality as flight) Incremental built according to plan (complete testbed Feb04) All DAQ modules including 16 TEM’s Harness like flight TKR and CAL front-end electronics for 1 tower, front-end simulator boards for other 15 towers Full set of ACD EM2 electronics Excellent hardware and software testbed Spectrum Astro SC interface simulator (SIIS) for – – TKR and CAL Electronics Simulators TEM DAQ Modules TEM Power Supplies Power, Control & Data Handling (C&DH) Present plan is for SIIS to only provide primary interface • Work in progress EPU-1 EPU-2 Pwr Dist. Box spare spare GASU spare spare ACD spare SIU P SIU R SC simulator EPU-3 12 ACD Electronics Cards LAT EGSE Spectrum Astro SIIS LAT-PR-01967 v9 4.1.7 Electronics Overview 58 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Fabrication LAT-PR-01967 v9 4.1.7 Electronics Overview 59 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Fabrication Plan • • • • • • • ASIC’s – Design: SLAC – Fabrication: Agilent – Packaging: ASAT Printer-Circuit Boards – Design: • Storage Interface Board: Silver Engineering • All other DAQ custom modules: SLAC – Fabrication: qualified vendor – Parts procurements: SLAC – Assembly: qualified vendor Enclosures – Design: SLAC – Fabrication: qualified vendor Module Assembly (PCB’s/cables/enclosure) – Design: SLAC – Assembly: qualified vendor Tower Power Supplies – Circuit & board design, fabrication, assembly: qualified vendor – Enclosure design: SLAC – Assembly: qualified vendor Harness – Design: SLAC – Assembly: qualified vendor Installation at SLAC LAT-PR-01967 v9 4.1.7 Electronics Overview 60 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Spares Plan Item Need for Flight Qual Flight Spares Spare PCI boards Tower DAQ Module Assembly 16 1 2* n/a Tower Power Supply Module Assembly 16 1 1* n/a GASU Assembly (contains prime and redundant unit) 1 1 0* n/a PDU Assembly (contains prime and redundant unit) 1 1 0* n/a SIU Assembly 2 1 0* CPU/SIUSIB/PSB/LCB EPU Assembly 3 0** 0* EPU-SIB * Qualification Models are flight spares ** EPU does not have separate qualification since crate is the same as SIU crate LAT-PR-01967 v9 4.1.7 Electronics Overview 61 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Parts List & Procurements • Almost all DAQ EEE components approved – Main remaining components • ASICs need radiation test of flight lot before approval • Long-Lead Procurements – Tower power supplies (RFP’s in, responses in evaluation) – Processor (order placed) – Voltage regulators (after CDR) Major Upcoming Procurements Near-Term (< 4 months) – FPGA’s – Connectors – MOS Transistors – DC/DC Converters & Filters – ASIC’s Major Upcoming Procurements Long-Term (>4 months) – Enclosures – Harness • • LAT-PR-01967 v9 4.1.7 Electronics Overview 62 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Work Flow GCCC, GTCC ASICs TEM DAQ Board TEM DAQ Enclosure TEM PS Board TEM Power Supply Enclosure GLTC ASIC GASU DAQ Board GASU Enclosure GLTC ASIC PDU DAQ Board PDU Enclosure SIB Board GLTC ASIC LCB Board CPU Board TEM DAQ Assembly First layer DAQ modules Acceptance Test TEM Assembly TEM PS Assembly Acceptance Test GASU Assembly Acceptance Test PDU Assembly Acceptance Test SIU Assembly Acceptance Test EPU Assembly Acceptance Test Harness Acceptance Test LAT Integration 1st stage Second layer DAQ modules LAT Integration 2nd stage LAT Integration 3rd stage PS Board Crate Enclosure Software LAT-PR-01967 Acceptance Test v9 4.1.7 Electronics Overview 63 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Work Authorization and Manufacturing Flow • All manufacturing tasks will be performed on approved Assembly and Inspection Data Sheets (work orders) • Order parts per LAT procedures • Kitting per LAT procedures • End-item assembly parts are issued to assembly work orders and sent to assembly supplier(s) • Assembly and test instructions • End items are received into project stores as they are received from the assembly supplier • End items are issued to test work order for acceptance testing • Upon completion of acceptance testing, end items are returned to project stores where are ready for issue to I&T • More detail, see appendix LAT-PR-01967 v9 4.1.7 Electronics Overview 64 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Issues, Risk & Mitigation Plans LAT-PR-01967 v9 4.1.7 Electronics Overview 65 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Technical Issues and Status • No known technical issues in respect to functionality and performance except potentially – TEM GTCC and GCCC ASICs • Need radiation testing LAT-PR-01967 v9 4.1.7 Electronics Overview 66 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Risk • No single DAQ system failure can degrade LAT Electronics capabilities below minimum science requirements • Failure in SIU, PDU, or GASU can require use of the respective redundant unit • Failure in one of the two EPU’s can require use of the redundant EPU unit. A second failure will reduce the available EPU CPU power by a factor of 2 • Failure in TEM power-supply or TEM DAQ module can lead to – Loss of a full tower (most of the assembly is single string) – Loss of the calorimeter or parts of it – Loss of the tracker or parts of it LAT-PR-01967 v9 4.1.7 Electronics Overview 67 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Electronics Risk Summary ID # Risk Rank Risk Description •Flight-Software schedule is tight • Depends on execution of LAT software development approach. Elec/224 Moderate • Delays in incremental review process may impact cost & schedule Risk Mitigation •Detailed software development plan, schedule and review points established (3/24/03). • Early integration of software to target hardware via EM plan (Sept 03) • Extensive use of test bed (Feb 04 and beyond) • Tower Power Supplies Cost & Schedule depend on bids received in response to RFP • Proposals may exceed allocated schedule & funding Elec/221 Moderate • Assess schedule problem • Determine cost impact to maintain schedule • Negotiate with vendor to minimize impact • Develop minimum impact re-plan & pursue CCB approval • Two types of Tower Electronics Module ASICs submitted 1/18/03. • 3 month turn around results in late reaction required if flaw is found upon delivery and test resulting in schedule and cost impact Elec/223 LAT-PR-01967 Low • Protect schedule for additional ASIC run. • Evaluate work arounds to mitigate late delivery of flight ASICs and recover schedule margin. • If untenable ASIC flaws occur, implement worst case backup (FPGAs) v9 4.1.7 Electronics Overview 68 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Cost & Schedule LAT-PR-01967 v9 4.1.7 Electronics Overview 69 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 CCB Actions Affecting 4.1.7 Change Request # Description Status LAT-XR-01159-01 Move Procurements from FY04 Approved, to FY03 $0K LAT-XR-01242-01 Flight Software Labor Increase (SLAC) (due to accounting change, no net labor increase) Approved, $739K LAT-XR-01753-01 Flight Software Labor Increase (NRL) Approved, $300K LAT-XR-01752-02 SLAC/HEPL Labor Escalation Rates Approved -$105K LAT-PR-01967 v9 4.1.7 Electronics Overview 70 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 4.1.7 Key Deliverable Milestones Activity Description FY 04 FY 05 JAN FE B MAR AP R MAY JUN JUL AUG SE P OCT NOV DE C JAN FE B MAR AP R MAY JUN JUL AUG SE OCT P 4.1.7 Electronics Flight TEM Assy 3,4-Elec to I&T Flight TEM PS Assy 3,4-Elec to I&T Flight TEM Assy 5,6-Elec to I&T Flight TEM PS Assy 5,6-Elec to I&T Flight TEM Assy 7,8-Elec to I&T Flight TEM PS Assy 7,8-Elec to I&T Flight TEM Assy 9,10-Elec to I&T Flight TEM PS Assy 9, 10-Elec to I&T Flight TEM Assy 11, 12-Elec to I&T Flight TEM PS Assy 11, 12-Elec to I&T Flight TEM Assy 13, 14-Elec to I&T Flight TEM PS Assy 13,14-El ec to I&T Flight TEM Assy 15, 16-Elec to I&T Flight TEM PS Assy 15,16-El ec to I&T Flight SIU-Elec to I&T Flight Event Processor Units-Elec to I&T Flight ACD Elec Modul e-Elec to I&T Flight Harness-Elec to I&T Run Date 04/21/03 15:05 Data Date 04/01/03 © Primavera Systems, Inc. LAT-PR-01967 Forecast Baseline Product Available Date Forecast Baseline Integration Need Date LT-T7: Level 3 to AV :(tb) FL-D7 Integration Mil estones CDR AV : Up Triangle, L3: Down Triangl e G LA ST L A T PR OJ EC T A V: F loa t to Le ve l 3 M ile sto nes v9 Sheet 4 4.1.7 Electronics Overview 71 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Critical Path • TEM DAQ Assembly – Flight TEM DAQ PC Board fab and loading Feb 04 • Requires flight TEM ASICs • Tower Power Supplies – Flight assemblies by March 04 • RFP came back, being evaluated – Needs negotiations with supplier LAT-PR-01967 v9 4.1.7 Electronics Overview 72 GLAST LAT Project Budget vs Actuals vs Performance CDR/CD-3 Review, May 12-15, 2003 DOE + NASA Project Expenditures 4.1.7 Electronics Budget, Cost, Performance 20 $M, Then-Year Dollars 15 10 5 Actual Commitments ACWP BCWP BCWS+ Planned Commitments BCWS 0 . . . . FY00 LAT-PR-01967 . . . . FY01 . . . . . . . . FY02 . . . . . . . . . . . . . . FY03 . . . . FY04 v9 . . . . . . . . . . FY05 4.1.7 Electronics Overview 73 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Cost/Schedule Status • Status as of March 31, 2003: Item In k$ Budget at Complete 16,672 Budgeted Cost for Work Scheduled (a) 4,898 Budgeted Cost for Work Performed (b) 4,834 Actual Cost for Work Performed 4,828 Cost Variance 6 0.1% of (b) Schedule Variance -64 -1.3% of (a) LAT-PR-01967 v9 4.1.7 Electronics Overview 74 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Summary • • • • • Most documentation in release cycle – Have completed parts list for each module, submitted to Parts Control Board. Most of those parts (90%) were already approved by PCB on DAQ parts list. – Need to complete Parts Stress Analysis for each module, close to complete, to be submitted to PCB one week after CDR No major technical issues Design mature Technical, cost & schedule status consistent with baseline objectives Management structure in place to guide the project to completion • Manufacturing process defined • Ready to buy flight components LAT-PR-01967 v9 4.1.7 Electronics Overview 75 GLAST LAT Project LAT-PR-01967 CDR/CD-3 Review, May 12-15, 2003 v9 4.1.7 Electronics Overview 76 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Backup LAT-PR-01967 v9 4.1.7 Electronics Overview 77 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Work Authorization • All manufacturing tasks will be performed on approved Assembly and Inspection Data Sheets (work orders) – Responsible Engineer – Manufacturing Engineer – Quality Engineer • Assembly or test instructions – Step-by-step procedures – Provisions for operator and inspector sign off – May reference other documents, such as test procedures • Work order remains with item until item has passed final inspection • Work order completion results in the delivery of an item to project stores • Completed work orders are archived by LAT Quality Assurance Manager LAT-PR-01967 v9 4.1.7 Electronics Overview 78 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Manufacturing Flow - Continued • Order Parts – All parts approved and on the program PIL – PWBs to be ordered from qualified suppliers – Mechanical parts manufactured at SLAC and qualified machine shops – All parts received into LAT project stores • Kitting – Triggered by Assembly and Inspection Data Sheet (work order) – Parts issued from inventory to kit LAT-PR-01967 v9 4.1.7 Electronics Overview 79 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Manufacturing Flow – Continued • Assembly – Performed by approved suppliers – Completed assembly entered into inventory to close work order Circuit cards tested at SLAC – CCAs issued to test work order – CCAs are tested and returned to stores to close out the test work order • End-item assembly parts are issued to assembly work orders and sent to assembly supplier(s) • End items are received into project stores as they are received from the assembly supplier • End items are issued to test work order for acceptance testing • Upon completion of acceptance testing, end items are returned to project stores where are ready for issue to I&T LAT-PR-01967 v9 4.1.7 Electronics Overview 80 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Manpower Plan 4.1.7 Electronics 25.0 FTEs 20.0 15.0 10.0 5.0 0.0 FY00 FY01 FY02 FY03 DOE + NASA Project LAT-PR-01967 FY04 FY05 Contributed v9 4.1.7 Electronics Overview 81 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Power Distribution +Y Side LAT Radiator +Y Side LAT Radiator Bay 12 EPU-B Bay 13 Empty Bay 14 Empty Bay 15 Empty Bay 12 EPU-B Bay 13 Empty Bay 14 Empty Bay 15 Empty 0 0 0 0 0 0 0 0 Bay 8 PDU-B Bay 9 GASU Bay 10 GASU Bay 11 SIU-B Bay 8 PDU-B Bay 9 GASU Bay 10 GASU Bay 11 SIU-B 9.9 0 0 12.4 0 Bay 6 GASU Bay 7 SIU-A Bay 6 GASU Bay 7 SIU-A 9.9 21.6 18.11 12.4 27.2 0 -X Side Bay 4 PDU-A Bay 5 GASU 14.4 -X Side Bay 4 PDU-A Bay 5 GASU Bay 0 EPU-A Bay 1 Empty Bay 2 Empty Bay 3 EPU-A Bay 0 EPU-A Bay 1 Empty Bay 2 Empty Bay 3 EPU-A 19.4 0 0 19.4 24.3 0 0 24.3 Boxes 118.8 -Y Side LAT Radiator TEM/TPS: 241.0 X-LAT Tot 359.9 Boxes 94.4 TEM/TPS: 191.7 X-LAT Tot 286.2 LAT-PR-01967 +X Side Sun Side -Y Side LAT Radiator LAT Top View v9 +X Side Sun Side LAT Top View 4.1.7 Electronics Overview 82 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 Materials List FINISHES Finish Specification Color Hard Anodize Electroless Nickel Part Marking MIL-A-8625F Type III Class 2 (.002") AMS-2404C Class 1 Grade A (MIL-C-26074) (.0005 Thick) Mark Using Epoxy Ink A-A-56032 5mm Characters, Color: Black ro White Black Nickel MATERIAL DATA Material Specification Manufacturer Aluminum 6061-T6 Aluminum 5052 Titanium Torlon (Polyamide) Ultem 2300 CV 2943 Cho-Therm 1671 DC 6-1104 Conformal Coating Staking AMS-QQ-A-250/11 AMS-QQ-A-250/8 Ti 6AL-4V 4203PAI Ultem 2300PEI Thermally Conductive, CV, RTV Silicone Thermally Conductive Elastomer Insulator Pad RTV Silicone Adhesive CV URALANE 5750LV A/B AS 18/100 BW/F URALANE 5753LV A/B AS 1/5 BW POLYURETHANE Chomerics Chomerics Dow Corning Furane Products Furane Products A286 High Tensile 160ksi Fasteners 300 CRES 80ksi Fasteners NAS1351, NAS1352 NASM16995, NASM16996 Ink, Marking Ink, Marking CAT-L-INK 50-100R/CAT 9 AS 100/6 BW WHITE INK/F CAT-L-INK 50-700R/CAT 9 AS 100/7 BW BLACK INK/F Aircraft Wire M22759/33 LAT-PR-01967 Dexter Hysol Dexter Hysol v9 TML % >1% CVCM % >.10% .430 .50 .76 .29 .65 .87 .01 .01 .07 .05 .01 .01 .64 .74 .01 .01 4.1.7 Electronics Overview 83 GLAST LAT Project CDR/CD-3 Review, May 12-15, 2003 EEE Parts List • Parts list submitted to Parts Control Board – Resistors – Capacitors – Connectors/wire – Integrated Circuits • ACTEL 54SX32/72 FPGA • BAE FIFO • INTERSIL POR • HONEYWELL RAM • Summit MIL1553 IC • Almost all parts are approved • Main parts remaining are – ASIC’s • Requires radiation testing on flight production, can only be implemented when flight-production is in hand LAT-PR-01967 v9 4.1.7 Electronics Overview 84