integration and test 14 october 2008
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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
LSST Camera Systems Integration
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
LSST Camera Systems Integration
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”
LSST Camera Systems Integration
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
LSST Camera Systems Integration
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
LSST Camera Systems Integration
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
LSST Camera Systems Integration
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
LSST Camera Systems Integration
9
Cryostat AssemblyCryostat Assembly
Grid with Flexures
Cryostat Housing
Cryo Plate
Cold Plate
Back end MLI Cage and pump chimney
Cryo Shroud
LSST Camera Systems Integration
10
Cryostat Close-OutCryostat Close-Out
L3 Flange Assembly
Pump Plate
Feedthrough Flange
Pumping Plenum
Vacuum-jacketed inlet/outlet lines
LSST Camera Systems Integration
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
LSST Camera Systems 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
LSST Camera Systems Integration
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
LSST Camera Systems Integration
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
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