Integration and Test 14 October 2008 Martin Nordby.

Integration and TestIntegration and Test

14 October 200814 October 2008

Martin Nordby

LSST Camera Systems Integration

2

ContentsContents

• Introduction

• Cryostat assembly and integration flow

• Test plans during focal plane integration

• Focal plane integration process

• Cryostat integration process

• Camera integration

• Integration facilities


3

IntroductionIntroduction

• Guidelines we have used in developing the camera design and I&T plans

– All sub-assemblies are pre-assembled and fully verified by unit-level testing prior to delivery and integration into the Camera

– “For-the-record” verification tests of deliverable sub-assemblies are used as gates for accepting hardware prior to integration

– The integration process—and subsequent de-integration and servicing—should minimally disturb neighboring components or break their verification

• Documents describing integration and test plans (collection-87 in the Camera I&T directory):

– LSST-1141-D, “Cryostat Assembly and Integration Sequence”• Detailed, step-by-step sequence for assembling the cryostat and integration raft towers• Includes mechanical and electrical integration process and the fixturing and test equipment needed• Identifies verification testing

– LSST-6175-A, “Camera Integration and Test Plan”• Overall plan for I&T operations, including facility operations, standard operating procedures, safety• Includes detailed sequence for integrating the camera• Identifies verification testing and calibration efforts• Includes mechanical and electrical integration process and the fixturing and test equipment needed

– LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout”• Detailed layout of the SLAC clean room facility and concepts for the big mechanical fixturing

– LSST-2119-D, “Camera Integration and Test Flow Chart”• Graphical flow-chart showing the integration and test sequence for all major camera components


4

Cryostat Integration and Test FlowCryostat Integration and Test Flow

Legend

Sensor package

L3 Lens Assembly

Raft Tower Acceptance Test

Raft Plate

Assemble, test Raft

assemblies

Assemble Raft Towers

Front End Electronics

cards

FEE Cage

Sensor-FEE flex cables

Thermal straps

Cold Plate

Cryo Plate

Grid Assembly

Cryo Shroud

Cryostat Housing

Close out Cryostat

Assembly

Install Grid, Cryo Plate,

into Cryostat

Cryostat cold functional tests

Vacuum pumps

Blank-Off Flange

Feedthrough Flange

Cryostat pressure and

leak tests

Guide sensors, electronics

Wavefront sensors,

electronics

Assemble Corner Raft

Towers

Corner Raft Acceptance Test

Raft Control Crates

Flexures

Integrate Raft Towers into

Cryostat

Integrate Corner Rafts into Cryostat

Assemble, test Instrument.

Ring

Pattern generating

gratings

X-Ray Calibration wiper arms

Close Cryostat front end

Cryostat Assy cold acceptance

teststo Page 2

LLNL

BNL

HarvardSLAC

TBD

Acceptance test (color denotes responsibility)

FEE-RCC flex cables

Support Ring

Utility Trunk structure and

panels

Valve Box

Control/Valve Panel

Install Cold Plate, back

end in Cryostat

Timing and Control module

Power and conditioning

module

Ethernet switch

Cryostat Integration and Test Sequence

Pumping chimneys,

plenum

Close Cryostat back end and Utility Trunk

Cryostat Close-out and Utilities IntegrationCorner Bay Int.Science Bay Int.

Cryostat Close-outBack End Install.Front End Install.

From LSST-2119-D, “Camera Integration and Test Flow Chart”For details, see LSST-1141-D, “Cryostat Assembly and Integration Sequence”


5

Verification Test Cycle for Raft TowersVerification Test Cycle for Raft Towers

• Raft Tower assembly

– CCD acceptance testing at BNL

– Raft tower verification testing

• Raft Tower acceptance testing

– Incoming re-testing of raft towers as they arrive at SLAC

– Functional test of raft towers in preparation for integration in the cryostat

• Post-integration testing

– Warm functional/continuity check of raft towers and RCC modules

– Periodic cold performance testing of the partially-integrated focal plane

• Full cryostat verification testing

– Cold verification testing of the entire focal plane

– Final cold metrology flatness measurements


6

Test Progression for Focal Plane IntegrationTest Progression for Focal Plane Integration

• Prerequisite tests

– Engineering cryostat• To work through details of the design, integration plans, and operations of the cryostat

– Full-up cryostat functional testing• The cryostat is tested as an assembly before any silicon is installed• This include structural proof testing, vacuum- and pressure-testing, thermal system performance testing, and

early work on the metrology system

• Four integration and test phases

– Functional rafts• Install “dummy rafts” that function like real ones (mass, cg, structural pre-loads, thermal, heaters and sensors)• Test the cryostat and the insertion tooling with these rafts

– Dead silicon• Install rafts with dead silicon to partially populate the focal plane• Prove out the system using assemblies with tight clearances• Run metrology scans to qualify the flatness measurement process

– Engineering-grade rafts• Mechanically and electrically integrate fully functioning raft towers with out-of-spec detectors• Run warm and cold metrological and electrical systems tests• Cool down and test the entire data-flow chain

– Science-grade rafts• Integrate raft towers with science-grade CCD’s• Run successive metrology scans and functional tests as the focal plane is being built up


7

Focal Plane Integration ProcessFocal Plane Integration Process

1. Insert Raft Towers from below

3. Install Raft Control Crates from above

Cryostat held in its nominal zenith-pointed orientation

Grid

Front flange where L3 mounts

Feedthrough flange

Cryo Plate

Cold Plate

2. Connect flex cabling


8

Cryostat Exploded ViewCryostat Exploded View

L3 Flange Assembly

Grid with Raft and Flexures

Cryo Plate and Pumping Chimneys

(Shroud not shown)

Cold Plate

Back end MLI Cage

Feedthrough Flange, Pump Plate, and Pumping Plenum

Cryostat Housing


9

Cryostat AssemblyCryostat Assembly

Grid with Flexures

Cryostat Housing

Cryo Plate

Cold Plate

Back end MLI Cage and pump chimney

Cryo Shroud


10

Cryostat Close-OutCryostat Close-Out

L3 Flange Assembly

Pump Plate

Feedthrough Flange

Pumping Plenum

Vacuum-jacketed inlet/outlet lines


11

Camera IntegrationCamera Integration

1. Camera body assembly

2. Filter exchange system integration

3. Shutter installation

4. Cryostat and Utility Trunk integration

5. Optics integration


12

SLAC I&T Facility LayoutSLAC I&T Facility Layout

Cleaning and gowning

3'-0" wide walkway

3'-0" wide walkway

9'-0" limited-height area

9'-3" limited-height area9'-3" limited-height area9'-3" limited-height area

101'-2"

28'-0"

36'-6"

4'-4"

9'-7"

5'-0

"

6'-5

"

Oven

6'-0"

1'-1

0"

2'-7"

19'-9"

Em

erg

Room 10436'-6" X 22'-5"

Room 10228'-0" X 11'-9"

Ante Room28'-0" X 13'-3"

11'-10" 18'-9"

5-Ton Crane:21'-0" X 12'-8" X 10'-0" Hook Ht

1'-8"

10'-0

" W

X 9

'-0"

H

22'-5

"13

'-3"

11'-9

"

72'-6"

Em

erg

Em

erg

Oven

4'-4" 15'-8"

4'-3

"

2'-9

"1'

-8"

1'-2"

4'-5

"5'

-4"

7'-6"

8'-0"

12'-3

"

5'-0" clr

3'-0

" cl

r

12'-8

" (1

2' t

rave

l)

4'-1

" cl

r

D

C

22'-6

"

5'-0" clr

Single-Bay Cold Test

Station

Raft Test Station

5'-0" clr

48'-9

"

44'-0"

9'-7

"

22'-0

"

Cryostat Electronics

Mechanisms Assembly and Test

Electronics

Receiving Storage

OpticsLenses Filters

Materials and Thermal

Testing

Welding, Pressure/Vacuum

Testing11

'-2 1

/2"

D

1'-0

" cl

r

C

A

B

B

A

19'-11"

12'-8

" (1

2' t

rave

l)

Class 10K Clean RoomCryostat Integration

Room 104: camera integration Room 103B: cryostat integration

Room 103A: mechanisms, optics, materials workstations Receiving, storage

Welding, leak testing

Support electronics and workstations


13

Cryostat Integration Facility—Plan ViewCryostat Integration Facility—Plan View

3'-0" wide walkway

4'-4"19'-9"

Em

erg

4'-4"

22'

-6"

Single-Bay Cold Test

Station

Raft Test Station

Cryostat Electronics

1'-0

" cl

r

A A

19'-11"

Class 10K Clean RoomCryostat Integration

3'-6

" cl

r

12'

-8"

(12'

tra

vel)

7'-0" clr

44'-0"

From LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout”

Metrology system Assembly stand Integration gantry Cart


14

Cryostat Integration Facility—Elevation ViewCryostat Integration Facility—Elevation View

2"1-Ton Crane min hook height

8'-6

"

Clean Room Elevation

9'-1

1"

Room 103 Elevation A-A: Integrate Raft Towers into Cryostat

44'-0"

1'-8

1/1

6"

7'-10 1/2" clr

3'-9

"

9'-6" clr

4'-6

"

11'-5 1/2"

4'-10 1/2" clr

From LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout”

Metrology system Assembly stand Integration gantry Cart

Cryostat with valve box in cold-test configuration

Integration and Test 14 October 2008 Martin Nordby.

Documents

Transcript of Integration and Test 14 October 2008 Martin Nordby.