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Reproduction interdite © ALMA EUROPEAN CONSORTIUM Reproduction forbidden

Design, Manufacture, Transport and Integration in Chile of ALMA Antennas

Design, Manufacture, Transport and Integration on-site in Chile of ALMA Antennas

Progress Meeting # 3 Alcatel Alenia Space / TORINO

DESIGN CONCEPT PHASEDESIGN CONCEPT PHASE

Dated April 5th, 2006



DEC JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC JAN

2006

PPDRK.O.

Antenna Detailed Concept Design Definition

Antenna Detailed Design

PPDR D.P

System Analysis & Budgets



Introduction to the Design Concept

AEM at the KOM presented an operating plan, regarding all the phases of ENGINEERING & DESIGN subdivided in 4 main sections:

T1 - Detailed Conceptual Design Definition

T2 - Freezing of Design & Industrial Processes

T3 - Finalization of all Construction Dwgs & Manufacturing Documentation

T4 - Preparation of all Construction & Workshop Dwgs and all Documentation for Production



DEC JAN FEB MAR APR MAY JUNE JULY AUG SEP OCT NOV DEC JAN

2006

AntennaDesign updating Antenna Detailed Design

PPDRK.O.PPDR

Data Pack.CDR

T1

T2

T3

T4



Detailed schedule and milestones for Design & Engineering activities

KOM

T1= Detailed Concept Design Definition Main Spec.s General Dwg.s for Pre-Industrialization

T2= Freezing of Design & Qualification Results Suppliers & Industrial Processes Definitions

T3= CDR AEM Critical Design Review

T4= PPDR Data Package Documentation Delivery

T5= PPDR Review Meeting

T6= Closure of PPDR

T7= AIPC1 Documentation Delivery

T8= Support of Manufacturing & Integration Activities

+3m

+3m

+AIPC1

+1m

+3m

+1m

+2m

+AIPC#

6m

……..

31.5m

12m 13m

11m9m

3m



END of PHASE T1: Detailed Concept Design Definition

OBJECTIVE:

Identify an Antenna Concept able to satisfy the main Requirements of the Specifications (geometrical, functional, etc…),

production of the basic documentation and distribution of the knowledge inside the Consortium

to guarantee the manufacturing and erection process of the antenna



END of PHASE T1: Detailed Concept Design Definition

MODALITY:

Development of drawings activities, modellization, analysis and calculation to support the solutions adopted.

INPUTS:

contract documentation knowledge of Prototype

OUTPUTS:

main specifications Assembly and interface drawings



T1 - technical documentation supporting this phase

From KOM (19-20 Dec ‘05) to T1 (13-14 Mar ‘06 )• General Design Assumption:

• Finite Element Analysis:

• Error Budget Calculations:

• System Engineering Activities:

- General Layout & Dimensions - Design Optimisation for Production - Global FEM Model - Preliminary Engineering Calculations - Static & Dynamic Analysis

- Survival Conditions Load Cases - Wind & Thermal Analysis

- Surface Accuracy - Absolute non reapeatable pointing error - Offset non reapeatable pointing error - Absolute reapeatable pointing error - Offset reapeatable pointing error - Non reapeatable residual delay - Reapeatable residual delay - Mass & Balance Budget

- Dynamic Servo Simulation - Lifetime, RAMS Analysis - EMC Plan

Detailed Concept Design Definition

Main Spec.s

General Dwg.s for Pre-

Industrialization




Main Spec.s

General




Dwg.s for Pre-

Industrialization



T2 - Freezing of Design & Industrial Processes

From T1 (13-14 Mar ‘06 ) to T2 (12-13 Jun ‘06 )• Freezing of Design & Qualification:

• Suppliers & Industrial Processes Definitions

- Detailed cross-check off all Requirements from Spec.s, Manufacturing Processes & Qualification Program - Start of all qualification tests of all major items - Identification of all main suppliers and relative products

- Definition of all main manufacturing processes

Scope of this phase is to acquire into the design of the main components the informations coming from the manufacturer and partners, for the production and industrialization.



Start and Organization of Phase T2FROM DEFINED CONCEPT TO CONSOLIDATED DESIGN

CROSS-CHECK OF ALL

SPECIFICATION REQUIREMENTS

CROSS-CHECK WITH MANUFACTURING

PROCESSES

DATA FROM QUALIFICATION

REPORTS

SPECIFIC REQUIREMENTS

SYSTEM REQUIREMENTS

ICD REQUIREMENTS

DATA SHEETS OF COMPONENTSCONSTRUCTION REQUIREMENTS

ASSEMBLY REQUIREMENTS

PACKING & TRANSPORT REQUIREMENTS

TESTS ON COMPONENTS

TESTS ON SUB-SYSTEMS

FROM VERIFICATION

PLANFROM

SUB-SUPPLIERS AND PARTNERS

FROM QUALIFICATION

PROGRAM



T3 - Finalization of all Construction Dwgs & Manufacturing Documentation

From T2 (12-13 Jun ‘06 ) to T3 (14-15 Sep ‘06 )• CDR

- Verification by compliance matrix of all performancies- Finalization of all construction drawins and manufacturing documentations (critical items)-Freezing af all the interfaces between AEM/Supplier and ALMA

The purpose of this part of the design phase is to develop all the activities of calculation, analysis and design, that may guaranty the total overview of the performances specification and meet the entire manufacturing process (from manufacturing to integration on site)

A specific internal review (CDR) will be performed at the and of this phase with the ESO presence




From T3 (14-15 Sep ‘06 ) to T4 (13 Nov ‘06 )• PPDR Data Package

- Finite Element Analysis (DRD-23)- Error Budget Computations (DRD-21)- Mass and Balance Budget (DRD-24)- Dynamic servo simulation analysis for fast switching and other dynamical performances of the antenna. (DRD-23)- HVAC system calculations (DRD-22)- Lifetime, reliability and maintainability analyses (DRD-25)- EMC Control Plan (DRD-32)- Engineering analysis and reports not specifically mentioned here, if necessary (DRD-22)- Preparation of spare parts list. The spare part list shall be the update of the spare part list provided in the Bid phase, and adapted to take into account the results of the reliability requirements and calculations (DRD-35).- Drawings

On the Base of the review performed in previous period, during this Design Phase will be made all the construction and workshop drawings and documents to support all the production Phase and all the required documentation of the PPDR.




From T4 (13 Nov ‘06 ) to T5 (12-13 Dec ‘06 )• PPDR Review Meeting

This task represents the moment for the verification of the entire design at all levels from antenna system to antenna components

Complete design review of the antenna



Documentation delivery to ESO:

END of T3 - Critical Design Review (CDR): no contractual ( cfr MoM of ALMA KOM)

END of T4 - Pre-Production Design Review (PPDR): contractual

Both phases need specific meetings with ESO for review with prior delivery of documentation on due date

AEM confirms its strong willingness to offer the relevant visibility to ESO along the ALMA Project.

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