gnirs quarterly review august 15, 2000

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Quarterly ReviewAugust 15, 2000

GNIRS Quarterly Review

August 15, 2000

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Overview• Project management• Systems engineering• Optics design and fabrication• Mechanical design and fabrication• Electronics design and fabrication• Software• Procurement• Images

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Project Management

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Project Management

• Project Summary• Review Committee Concerns and Responses • Status and Plans• Problems and Concerns• Planning• Milestones, Cost and Manpower• Budget and Expenditures to date• Organizational Changes

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Project Summary• Current activities

– Prototyping– Bench design and analysis– Mechanism design– Mechanism fabrication– Electronics design– Software coding

• Prototyping– Optical, Rotary and Linear Prototyping effort is complete – Enough data collected to justify proceeding with mechanism design

• Bench design and analysis– Bench deflection analysis is complete

• The manufactured bench should meet deflection requirements

– Bench drawings will go to vendors this week for fabrication bids • Bench fabrication is scheduled to start with the OIWFS bench on 9/5/00• All benches scheduled for release for fabrication by 9/29/00

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Project Summary• Mechanism designs in process

– Filter wheel assembly• Starting 2D detailing

– Camera turret assembly• Two of 4 camera barrels through 3D solid model design

– This work is currently on hold

• Camera drive and hub in 3D design– Key design element requiring some development testing– Results will be propagated to the Grating and Prism Turrets

– Acquisition mirror assembly• 2D design, currently on hold

– Focus mechanism assembly• 3D design starts on August 15

– Slit/Decker assembly• 2D detailing in process

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Project Summary• Mechanism fabrication

– Environmental cover assembly– Motor drive assemblies– Camera turret assembly

• Some parts in fabrication

• Electronics design– Mechanism and dewar functional simulator

• For software debug and checkout

– Dewar and mechanism wiring definition– Array interface wiring definition– TE wiring design

• Software coding activity – Components controller – System software (thin EPICS layer)

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Review Committee Concerns and Responses

• It is premature to assume that the aggressive 0.1 pixel flexure per 15º attitude change specification will be met by this design.

– The bench analysis presented here predicts low image degradation due to flexure of the pre and post slit bench structures.

• Further develop the fall back plan of active flexure compensation. Identify an optimal compensator in the system. Determine if adequate space/mass budget is available to retrofit a mechanism.

– A fall back plan has been adopted, namely correction at the collimator (as suggested by Tom O'Brien). We are not pursuing the implementation unless and until evidence shows it is needed.

• Consider running ultimate lifetime tests using the prototypes.– We have decided not to run the lifetime tests on the prototypes, on the ground that

the prototypes are not representative enough of the real mechanisms for the tests to be helpful. We have carried out inspections on the mechanisms (disassembly) and have seen no wear problems for use that represents >10% of a "lifetime".

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Review Committee Concerns and Responses • Go straight to rotary prototype #2.

– We are working on the camera turret design, with the idea that it is not a prototype. We are accelerating fabrication and test of the camera hub to ensure we have time to detect and remedy and deficiencies.

• There is no need for additional prototype testing of the lens mount. We recommend contacting Klaus Hodapp to understand what difficulties he has had with this design.

– We have finished these tests and are proceeding. Klaus's design is somewhat different.

• If NOAO wants to pursue the idea of IfA installing elements in this module and testing it as a unit, that should be explored quickly.

– We are pursuing this. Klaus wants to see how NIRI does at the telescope before proceeding much further.

• Consider the use of invar bushings on the bolts that “permanently” connect parts of the main bench.

– We are following this suggestion. We are incorporating partially compensating collars in the bench design.

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Review Committee Concerns and Responses

• We expect that the (software) architecture described will meet existing ICDs and support all key functionality. (The software) must conform to all principal system interfaces.

– We acknowledge these comments and are proceeding accordingly.

• Clarify what will be delivered in the (software) engineering system.– At this time, we do not envision delivering a system which would require any special

software licenses. It may be desirable to use an improved version of the EPICS display manager, or to incorporate some new TCL code. However, we will neither deliver nor require any software that is not a part of the standard Gemini environment without approval from Gemini.

• Thoroughly document the S/W that operates below the proposed “thin EPICS layer” to permit long-term support.

– The software maintenance manual manual will contain a thorough documentation of the software.

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Review Committee Concerns and Responses • Rectify the discrepancy between CAS and Neil’s costs, by reporting in real

dollar values. Specifically, reconcile the difference between accounting for scientists’ time between the cost schedules maintained.

– We are struggling to do this. We have subtracted out all scientist labor charges from our planning to better reflect what the actual charges represent. We are still working with CAS on a more permanent solution.

• Release some parts for fabrication to (1) test the entire off-site fabrication process with a vendor and (2) stimulate a change in the psychology of the team, from one of only designing to actually building the instrument.

– The prototype fabrication was intended to "test the process". We are releasing parts as ready and have completed the environmental cover.

• Use an engineer independent of the GNIRS team to double check drawings that depict key interfaces between the main bench and mechanisms and optical assemblies.

– We have effectively done this using our “new” mechanical engineer. Also, one of the points of the 3-D modeling is to avoid the dependence on building up the ray-trace from individual drawings.

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Statement of Work to IFA for OIWFS integration and test

• Install all OIWFS components onto the provided optical bench.– This bench is especially designed to receive the Gemini provided components and

to fit into the GNIRS Instrument.

• Perform a mechanical and optical alignment of these components.• Connect and test the OIWFS using the actual electronics and boards that will

be delivered to the GNIRS Project.• Checkout and test the integrated OIWFS as a subsystem

– IFA is uniquely qualified to do this work– IFA possesses the needed test cables, equipment and software needed to do this

work.

• Conduct an acceptance test which will demonstrate basic operation of the OIWFS as a subsystem, preferably in a vacuum and at representative cryo temperatures which will be seen in actual operation.

• Pack and ship the completed OIWFS subsystem in a suitable shipping container to the GNIRS Project at NOAO, Tucson.

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Plans for Next Review• The Next Quarterly Review will be held in the November-December

timeframe.

• The project expects to make significant progress in fabrication.– All benches should be to vendors

– Several mechanisms will be in fabrication

• 3D designs of all remaining mechanisms will be complete– Focus, prism turret, grating turret, camera assembly, acquisition mirror

• Lens delivery should be complete; all optics on order/delivered

• Work will have started on several fixed assemblies

• Electronics fabrication will have started

• OIWFS components integration will be underway

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Status and Plans

• The project is 29% complete overall

• We have completed 29 of 208 scheduled milestones

• The planned Systems Engineering effort is 97% complete

• Software low-level code development is 56% complete

• Mechanism design is underway for several mechanisms

• Procurement of optics, mirrors, filters, gratings, materials, etc., is proceeding per plan

• Currently qualifying additional vendors for outside fabrication

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Status and PlansProgress from August ’99 • Overall project 29%

• Management & Reporting 35%

• Systems Engineering 97%

• Mechanical 16%– Benches 16%

– Mechanisms 24%

– Fixed Assemblies 1%

• Electronics 4%

• Software 27%

• Integration 0%

• Procurement 31%

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Problems and Concerns

• Bench solid models and details for fabrication• Contracting for bench fabrication

– Contractor selection

– Work start and schedule/cost

• Aluminum billet cutting & distribution– Complete by 9/5, start of vendor fabrication

• Electronics technician shortage– The software effort is outpacing the electronics

build schedule needed to support software checkout.

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Project Planning

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Summary PlanN D J F M A M J J A S O N D

CY-2000

Risk Reduction Prototypes

PFR

Structural Analysis

Bench Design/Fab/Assy

OIWFS/Post-Slit/Pre-Slit

WFS Integration/Alignment

Mechanism Design/Fab/Assy/Test

9 Mechanisms

Electronics Design/Fab/Test

Optics Procurement

MFR

OIWFS Hardware

J F M A M J J A S O N D J F M A M J J A S O N DCY-2001 CY-2002

Fixed Assemblies Design/Fab

Integration/Alignment

WFS Integration/Alignment

Mechanism Design/Fab/Assy/Test

IFU Modules

Software Development/Code/Test

SW Plan/Low-Level/High-Level Code

Electronics Design/Fab/Test

Manuals

ATP

Ship

Training

GNIRS SUMMARY PLAN8/15/00

MFR

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Project Plan

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Critical Path

• There is no one assembly on the critical path• We review the schedule on a continuing basis

– critical path changes as a function of time

• We periodically adjust priorities and resources

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Fabrication Schedule

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Project Milestones

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Milestones by Quarter

Calendar Year Quarter

Number of Milestones

Due

Number of Milestones

Comp1999 4th 1 1

2000 1st 18 172000 2nd 35 112000 3rd 32 02000 4th 28 0

2001 1st 32 02001 2nd 38 02001 3rd 10 02001 4th 5 0

2002 1st 1 02002 2nd 3 02002 3rd 5 0

TOTAL 208 29

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Milestones since PFRWBS Milestone Date Due Comp

5.3.1.2.3.1.3 Long Blue Camera Design Complete 05/31/00

5.8.1.3.1 Flat Mirrors Acceptance 06/02/00

5.3.1.1.3 Complete Final Revision Mechanism Test Plan 06/06/00 06/07/00

5.3.1.8.2.6 Grating Turret Drafting Complete 06/07/00

5.3.2.1.7.1.5 Top Camera Cover Design Complete 06/12/00

5.3.2.1.8.1.5 Bottom Camera Cover Design Complete 06/12/00

5.4.1.1.1.4 Temperature monitor board (VME) spare Complete 06/12/00

5.3.2.4.1.1.6 Pick-Off/Fold Mirror Assembly Complete 06/14/00

5.3.2.4.2.2.6 Offner Assembly Drafting Complete 06/14/00

5.3.2.1.6.1.5 LCFMH Design Complete 06/14/00

5.8.1.1.1 RMI Optics Acceptance 06/16/00

5.3.2.1.7.2.6 Top Camera Cover Drafting Complete 06/19/00

5.3.1.7.2.6 Filter Wheel Assembly Drafting Complete 06/21/00

5.3.2.1.8.2.6 Bottom Camera Cover Drafting Complete 06/21/00

5.4.4.1.5 Dew ar Connector Interface Boards Complete 06/28/00

5.3.2.3.1.1.5 Collimator Mount Design Complete 06/29/00

5.3.2.1.6.2.6 LCFMH Drafting Complete 06/30/00

5.3.2.4.1.2.6 Pick-Off/Fold Mirror Assembly Drafting Complete 06/30/00

5.5.2.7 Component Controller Softw are Complete 06/30/00

5.4.1.1.6 VME Chassis Wiring & Assy Complete 07/03/00

5.2.8.3 Validate Structural Analysis 07/11/00

5.3.3.2.1.6 Detector Mount Assembly Design Complete 07/17/00

5.3.2.1.7.3.3 Top Camera Cover Fabrication Complete 07/19/00

5.3.2.1.8.3.3 Bottom Camera Cover Fabrication Complete 07/21/00

5.3.2.1.7.4.4 Top Camera Cover Assembly Complete 07/24/00

5.3.3.7.1.4 Optical Bench Mount Assembly Design Complete 07/25/00

5.3.2.1.8.4.4 Bottom Camera Cover Complete 07/26/00

5.3.1.103.2 Motor Drive Assembly Fabrication Complete 07/26/00

5.3.2.1.2.7 Post-Slit Bench Drafting Complete 07/27/00

5.3.2.3.1.2.6 Collimator Mount Drafting Complete 07/28/00

5.3.1.6.1.1.6 Slit/Decker Housing Assembly Design Complete 08/01/00

5.3.2.1.6.3.3 LCFMH Fabrication Complete 08/01/00

5.3.1.2.4.3.5 Short Red Camera Barrel Complete 08/02/00

5.3.1.104.5 Motor Drive Assembly Complete 08/02/00

5.3.1.4.3.6 Environmental Cover Assembly Fabrication Complete 08/03/00

5.3.2.1.6.4.4 LCFMH Complete 08/04/00

5.3.1.4.4.2 Environmental Cover Assembly Testing Complete 08/07/00

5.3.2.3.2.2.4 Collimator Cover Box Drafting Complete 08/07/00

5.3.2.3.2.3.2 Collimator Cover Box Fabrication Complete 08/08/00

5.3.1.2.6.2.6 Camera Hub Drafting Complete 08/08/00

5.3.2.2.1.2.6 OIWFS Assembly Drafting Complete 08/11/00

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Project Costs

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Project Costs• Baseline Estimate (Jan 99 to completion)

– Labor $3,391,232– Capital $ 836,462– Total $4,227,694

• Current Forecast (revised 7/31/00)– Labor $3,309,187– Capital $ 877,842– Total $4,187,029

• Performance ratios– BCWS = $ 1,181,581 (budgeted cost of work scheduled)– BCWP = $ 816,464 (budgeted cost of work performed)– ACWP = $ 846,211 (actual cost of work performed) (source:

CAS)– CPI = 0.96 (BCWP/ACWP) – SPI = 0.69 (BCWP/BCWS)

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Project Costs

This report is given to Gemini monthly.

GNIRS Project as of July 2000 PreviousBudget Actual Delta Cum Plan Cum Actual Cum Delta Total Cum

this Month this Month this Month to Date to Date to Date Budget to Dec 1998Manpower 77,368$ 80,531$ -$3,163 $1,100,647 1,060,084$ $40,563 3,127,063$ 1,629,705$

Capital $4,141 $10,176 -$6,035 240,126$ $262,820 -$22,694 906,513$ 748,851$

Total 81,509$ 90,707$ -$9,198 1,340,772$ 1,322,904$ $17,869 4,033,576$ 2,378,556$

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GNIRS WBS

• WBS Elements shown to 3rd level

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Planned vs Actual Expenditures WBS Title Total Planned Actual

Plan to date to date

5.0 GNIRS Total $3,752,409 $928,845 $888,283 5.1 Management $1,148,014 $285,982 $281,710

5.2 Systems Eng $ 225,686 $213,472 $236,524 5.3.1 Mechanisms $ 904,104 $238,409 $196,130 5.3.2 Bench Assemblies $ 301,081 $ 50,915 $ 50,393 5.3.3 Fixed Assemblies $ 501,174 $ 13,800 $ 9,852 5.4 Electronics $ 150,014 $ 4,135 $ 11,586

5.5 Software $ 95,122 $ 40,291 $ 27,1615.6 Integration $ 201,960 $ 0 $ 0

5.7 Deliverables $ 37,164 $ 0 $ 05.8 Procurement $ 188,090 $102,469 $ 95,364

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GNIRS Staffing FTE by Month

0.0

5.0

10.0

15.0

20.0

25.0

30.0

Month

FT

E

Plan FTE Actual FTE

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GNIRS Cumulative Work

0

10000

20000

30000

40000

50000

60000

70000

80000

90000

Month

Ho

urs

Actual Baseline May00 Plan Aug00 Plan

76,391

79,725

70,974

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GNIRS Capital Spend Plan

$0

$100,000

$200,000

$300,000

$400,000

$500,000

$600,000

$700,000

$800,000

$900,000

Month

Do

llar

s

Actual Baseline May'00 Plan Aug'00 Plan

$800,572

$759,192

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Organization

Gemini ProjectsProject Manager

N. Gaughan

Director, NOAOS. Wolff

Project AssistantD. Eklund (.5)

Administrative AssistantM. Bowersock

Project Scientist,Systems

EngineeringJ. Elias

Mechanical Engineers E. Hileman G. Muller

Electrical Engineer

J. Penegor

Optical EngineerM. Liang

Procurement & Vendor Liaison

A. Davis

SoftwareR. Wolff

Support ScientistsD. Joyce*

B. Gregory**

Mechanical DesignersJ. AndrewD. Rosin

E. DowneyR. Robles

Electrical TechniciansS. Nguyen

Staff Added: No changesStaff Transferred: No changes

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Systems Engineering

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Systems Engineering

• Two Main Areas:– Analyses

• Thermal analysis (completed 5/00)

• Flexure analysis (completed 8/00)

– Prototyping

• Motor testing (completed 12/99 [report 5/00])

• Lens mount tests (completed 5/00)

• Rotary prototype (completed 7/00, except final report)

• Linear prototype (completed 8/00, except final report)

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Analyses• Thermal Analysis

– Thermal design presented 5/00– Additional analysis as required in support of design (not systems engineering - e.g.

wire cold-station details)

• Structural Analysis– Flexure analysis interacts with bench design– Specific analyses were used to support prototype design– Prototype results confirm mechanism analyses– Additional structural analysis in support of design (e.g, dewar shell)

• Flexure Analysis Results– Bench appears to perform adequately– XY control could be implemented at collimator

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New Prototype Results• Rotary Prototype Final Results

– Drive mechanism meets repeatability, torque, wear specifications

– Pre-load redesigned to meet flexure specifications; early testing of most demanding implementation (camera) to confirm performance

• Linear Prototype Final Results– Multiple design changes - either tested or straightforward

– Drive mechanism will meet repeatability, torque, wear requirements

– Motor isolation mount meets requirements (<10% of heat into structure)

– Mechanism will meet flexure requirements

• Design Changes Implemented

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Optics Design and Fabrication• Lenses and Windows

– large lenses & windows in fabrication with RMI; 11 of 18 accepted

– small lenses (2) will be fabricated by RMI

• Mirrors– Powered mirrors (3) delivered by II-VI (accepted); Alumiplate surface delivers

required low scattering (<40Å rms, require 50Å)

– Flat mirrors to be ordered as individual mechanism design proceeds; 2 aluminum substrates & 7 glass substrates

• Gratings– Master rulings (3) completed and measured

– Replicas will be done when turret 3-D design nears completion

• Filters– 7 filters ordered through UH consortium; 2 fail spec and should be replaced

• Prisms– Preliminary quotes on prisms; will initiate procurement once 3-D design of prism

turret nears completion (9/00)

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Mechanical

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Mechanical• Overview

– Work in the Mechanical WBS element has primarily concentrated on the bench structures, mechanisms and mechanism interfaces to the benches

– Starting August 15th we will finish mechanism 3D design definition in order to release the benches for fabrication

• This will include the focus, grating turret, and prism turret mechanisms

– Bid packages for the three benches will be released to four vendors and our own Instrument Shop in the week of August 14th

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Mechanical Design and Fabrication• Mechanical design

– Bench detail design• Pre-slit, Post-Slit, OIWFS benches

– Mechanisms• Filter wheel• Camera barrels• Camera hub assembly• Slit/Decker assembly

• Mechanical fabrication– Environmental cover assembly – Motor drive assembly– Bench assembly bid packages

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Problems and Concerns

• Fabrication times are internal estimates– Actual fabrication times for the benches is an unknown at

this time

• We will use multiple vendors to insure that mechanical fabrication supports our schedule commitment. – Multiple vendors and in-house fabrication may affect the

estimates

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Electronics design and fabrication

• Design activities– Mechanism Motor Simulator for software testing

– Dewar, mechanisms and WFS cabling

• Fabrication– The software simulation tool is fabricated and ready for

test/checkout.

– Fabrication of the deliverable electrical hardware will start in September.

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Software• Software is under control • Not on the critical path.• The software schedule includes a several month

period, for test and debug using the real electronics, prior to going into the project integration phase.

• Status – Low level (Component Controller) code 56% complete

– High level (EPICS) code 5% complete

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• Optics Status– RMI – 8 Parts left including two pupil viewers

– Filters – Received 6 of 7 Filters

– 3 Master Rulings Have Been Ordered

• Benches– All 3 benches out for bid this week

• Future procurement– Flat Mirrors

– Prisms

– CRYO Heads/Lines

– Electronics connectors/boards

Procurement Status

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Images

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Full Assembly

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Full Assembly

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Tangent Rings

50


Tangent Rings

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Single Bulkhead

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Twin Bulkheads

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Slit-Decker Assembly

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Slit-Decker Assembly

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Slit-Slide

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Linear Prototype

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Rotary Prototype

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Lens Mount

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Bench Assembly F. E. A. Model

Weights: All benches & Housings = 696 lbs

Mechanisms & Optics = 273 lbs

Total Weight = 969 lbs

Model Size: 866,000 degrees of freedom Nodes: 288,503

Solve Time: 5 hours Elements: 145.529

Main Bench (comprised of upper and lower hogouts bolted together)

Offner Housing

Slid/Decker Fore & Aft Housings

Tangent Bar Support Bracket

Upper Camera Cover

Long Camera Fold Mirror Housing

Collimator Mirror

Collimator Housing

OIWFS Bench

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Instrument Assembly F.E.A. ModelDeformed shape scaled by 7500x loading; gravity in the –y direction scale in inches.

Note: Much of the Offner deflection is due to rigid body motion of the assembly with respect to its support bulkhead, and will not contribute image decenter.

10m

gnirs quarterly review august 15, 2000

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