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AMS-02AMS-02Integration & Test Integration & Test

Plans & StatusPlans & Status

Trent Martin

24 January, 2007

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Agenda

• Integration Documentation• AMS Assembly Area/Clean Room 867 • STA & Flight Integration Hardware Status• Pre-integration of STAs in the Flight USS prior

to STA VC/CMR arrival• Pre-integration of Detectors on the STA VC &

Flight USS prior to Flight Cryomagnet arrival• Integration discussion items & plans for

resolutions• Final Flight Integration

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Integration Documentation

• All NASA developed AMS documentation can be found at– http://ams-02project.jsc.nasa.gov/html/Documents.htm– Includes payload Interface Control Documents and

AMS-02 Assembly and Testing Integration Plan

Assembled AMS 02

AMS 02 Shipping

Upper Part

Lower Part

AMS 02 Integration at CERN

- Beam Test- Experiment Calibration- Thermal Vacuum Test @ ESTEC

AMS-02

CERN / ESTEC

KSC Processing

KSC

Launch

3 Operational Years

ISS

AMS-02

Hurricane CoverSSPF

AMS 02 Assembly Sequence for Pre-Integration and Flight Integration

Upper USS & Magnet

Technical Interchange Meeting

July 23, 2004

R.Becker (MIT)

Magnet

USS-02

UPS

CAB

CVB

1) SCL delivers Magnet (Flight) or NASA delivers STA Magnet (Pre-Integration)2) NASA delivers USS3) USS main bolted to Vacuum Case (Magnet must be warm)

& placed into rotation assembly stand

Radiator Mounted Electronics Assembly

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Crate Installation using Jig

Electronics Assembly Jig Installed Electronics mounted in

sequence with detectors during pre-integration

Jig replaced with Radiator during flight integration when all crates are linked and form a self supporting structure

VC

ACC 

1) Finger brackets bolted to inner lower bore of VC2) 16 Scintilator panels placed in inner bore resting on finger brackets 3) Carbon composite cylinder and with compliant brackets mounted at upper and lower inner edge of VC securing the paddles4) PMT’s, fiber couplers, and optical fibers mounted to Conical flange

ACC 

VC

 

Star TrackerTracker Electronics Crates

Tracker 

VC

Flange of VC Tracker Cooling Box

Tracker, Cooling, & Star Tracker

1) Tracker Inner planes and upper conical flange lowered and secured2) Lower conical flange mounted3) Cooling loops, TTCS, & plumbing 4) Outer planes (1 & 5) 5) Crates & cabling*6) Star Tracker camera

1)

2)

3)

4)

4)

5)

6)

TRD & Upper TOF

TRD MLI

TRD GAS System

TRD

1) TRD with M-structure lowered onto USS & bolted2) Gas system installed and plumbed to TRD3) MLI enclosure 4) Crates & Cabling

Upper TOF:1) Upper TOF mounted to TRD

(6) RICH1) RICH lowered, shimmed and bolted to lower USS2) Crates and Cabling 

(7) ECALRICH/Lower USS assembly lifted & lowered onto ECAL –then bolted in placeCrates & Cabling

These steps can be done in parallel with upper USS integration and only need to be done once (ie. No pre-integration)

(5) Lower TOF1) Reinforced with Jig, rolled underneath AMS & lifted into position. Struts adjusted and bolted in place2) Crates and Cabling

Lower USS Integration

Upper Part

Upper & Lower Parts Integration

 

1) Lower part rolled underneath Upper2) Lifted in place, shimmed, and bolted3) Electrical connections made

Lower Part

Temporarily remove mid-brackets and lower struts

De-integration for Flight Magnet

Move Main Ram & Wake Radiators outward to allow installation of Flight VC & Magnet

Temporarily Reattach Top Brackets to Upper USS

RAM Radiator

Radiators & Electronics1) Zenith radiators with plumbing attached assembled in quadrants: bolted to TRD upper

honeycomb and heat exchangers to Cryocoolers2) Plumbing secured and insulated

3) Main radiators: jigs removed from self supporting crates and radiators bolted4) Tracker Radiators: Jigs holding heat exchangers removed and radiators lowered and

bolted to USS and exchangers

Zenith Radiator

Tracker Radiator

WAKE Radiator

Tracker Radiator

RAM Radiator

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AMS Assembly Area Clean Room 867

Everything in the AMS Assembly Area/Clean Room 867 needed to begin the STA integration will be ready no later than (NLT) February 2, 2007.

• Operation as a Clean Room (air conditioning, filters, sealed & positive pressure) will be ready in May, 2007

• Rotation Assembly Stand (RAS) delivered, assembled, installed, and ready for use

• Scaffolding delivered, assembled, and ready for use

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AMS Assembly Area Clean Room 867

• Information provided in the Resource Requirements checklists has been used to order common use supplies and to estimate facility requirements

• Work area required – with & without crane access & special access• Crate storage area, volume, and environment• Tables & chairs• Storage cabinets & open shelves• Air bearing pallet requirements• Cleaning fluids/supplies & vacuum cleaners• Supply gases (He, CO2, N2, Compressed air, etc.)• Fans for ventilation/cooling of hardware & personnel• Power requirements• ???

• If you didn’t ask for it on the checklists, do NOT expect it to be provided!

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Remov-able Ceiling Panels

NCeiling Panels

are NOT Removable

Airlock

AMS Assembly Area Clean Room 867

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• STA VC integration with the STA Magnet (Cold Mass Replica - CMR) was completed in December at SM• STA VC Arrived in Terni/INFN for Sine Sweep Tests

on January 10th• Test hardware was previously shipped to Terni and

testing has been completed• Ship STA VC to ESTEC for Acoustic Tests - March

’07 *• Return to CERN for integration in USS – late March

’07 *

* Depends on results of STA VC/CMR sine sweep & acoustic tests

AMS STA Integration Hardware

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•Flight USS is complete and has arrived at CERN with the Primary Support Stand (PSS) and the Primary Lift Fixture (PLF)

AMS Flight Integration Hardware

•Flight Vacuum Case is complete and will be shipped to SCL/SM when they have room in their facility to accommodate it (after Flight Cryomagnet tests are completed and the SFHe Tank is delivered and SFHe leak tested)

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Pre-integration of STAs in the Flight USS Prior to STA VC Arrival

STA Hardware Pre-integration in Flight USS

• On-line integration of the STA Crates/Radiators on the USS will begin the week of February 5, 2007– before the STA VC arrives

• This allows work to proceed even if the sine sweep & acoustic tests are delayed

• 10T crane installation will be delayed until after STA Pre-integration is complete at beginning of March• If necessary, the USS/STAs in PSS will be moved

away from crane installation• There are ~3-4 weeks available in March to use the flight

USS & STAs for fit checks, cable & plumbing runs, measurements, etc.

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STA Hardware assembly in Flight USS (cont)

• Integration of all STAs in USS to be completed by mid-April ’07 *

• Even though the STA VC delivery to Terni slipped ~5 weeks and the RAS readiness at CERN slipped ~3 weeks, this is only ~2 weeks later than previously reported at AMS TIM on October 27, 2006

Ship USS with STAs to Munich/IABG in April ’07 *• Static Tests• Modal Tests• Return USS with STAs to CERN in August ’07 *

* Depends on results of STA VC/CMR sine sweep & acoustic tests and USS/STA modal & static tests

Pre-integration of STAs in the Flight USS Prior to STA VC Arrival

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Interference between Flight VC/Magnet & Electronics Crates during Final Flight Installation

• R. Becker/MIT, J. Kastelic & P. Mott/JS, & R. Stafford-Allen/SM to determine how much room is required to clear the Flight VC/Magnet as well as how much room is available by Jan 29th.

• Provide estimate of additional length required for lower inter-radiator cables to M. Capell & A. Lebedev

• Final cable routing must accommodate additional length• Be sure there’s no interference with hardware mounted outboard of crate jigs

during pre-integration activities• Upper inter-radiator connections will be disconnected because the additional length

will be too much additional weight• C. Lauritzen/JS to determine if there is any problem on the USS if the brackets are

temporarily re-attached at a wider position by Feb 5th• M. Molina/CGS to determine if Radiator brackets are OK by Feb 5th

• Consider using blocks/spacers under the brackets and reattaching the lower struts• K. Bollweg & J. Heilig will arrange trial test using STA Crates/radiators in late February

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• All the detector groups have continued to evaluate the pre-integration proposal and have agreed that it should proceed according to the schedules thoroughly discussed at this TIM• Current estimate of Pre-integration start: August, 2007• Pre-integration finish: December, 2007

• Optical fibers between ACC & VC for TAS will be installed• Constantly monitor the Cryomagnet progress and decide

how much more flight hardware to pre-integrate• Current estimate of magnet delivery to CERN: February, 2008

• Do as little de-integration as possible – just in time to remove the STA VC and install the Flight VC & Cryomagnet in the USS

Pre-integration of Detectors on STA VC & USS prior to Cryomagnet Arrival

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• Consider removing the STA VC, Tracker, and ACC from the USS as an assembly so parallel work can continue during Flight VC/Magnet installation• Use VC rotation fixture and wheels/brackets developed at SM

• This could shorten deintegration by 2-3 weeks; thus allowing combined cosmic ray testing to be extended

Pre-integration of Detectors on STA VC & USS prior to Cryomagnet Arrival

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• All detectors must be integrated and functionally tested with the Flight VC and Cryomagnet at CERN by July, 2008

• Beam tests at CERN (~1 month reserved)• Thermal Vacuum Tests at ESTEC (~3 months reserved)• EMI Tests at ESTEC (~1 month reserved)

• Delivery to KSC in December, 2008

Final integration of Detectors on Flight VC & USS after Cryomagnet Arrival

What we have… sort of.

Where we must be by December 2008 at KSC...