EO1 Hyperion

1
Hyperion
Steve Carman, Hyperion Project Manager TRW
Space and Technology Division January 22, 1999
2
Hyperion Schedule and Issues

• Schedule Status
• Risk Assessment
• Critical Problem Summary

3
Hyperion Project Schedule
Hyperion Schedule Status
4
Schedule Development
Hyperion Schedule Status

• Project schedule broken into 10 subschedules,
  integrated in top-level project schedule using MS
  Project (gt3000 tasks).
• Goal plan for instrument delivery 6/22/99 with
  30-45 days slack.
• Additional Scope incorporated within 12-month
  schedule
• Change to stand-alone instrument
• Add current ripple reduction circuit to CEA
• Add 1553/1773 conversion to HEA
• Add parts screening requirements, re-buy 55 lots
  of parts
• Add 4 cycles to T/V test
• TRW senior schedule manager, Ron Roberts,
  supported schedule development update process
• Detailed refinement with APMs improved delivery
  from 8/20 to 6/22/98
• NASA GSFC conducted a Hyperion Schedule Review on
  10/7/98 at TRW
• GSFC reviewers complimented TRW on quality and
  detail of schedule, approved schedule as baseline

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Hyperion Schedule Weekly Update Process
Hyperion Schedule Status

• Weekly schedule review and reporting process
• Monday Weekly status report generated for NASA
  GSFC, emailed to EO-1 Project Office
• Tuesday Parts procurement screening status
  updated
• Participate in EO-1 project status telecon
• Wednesday AM Fabrication, assembly test status
  updated by APMs
• Wednesday PM Project manager schedule manager
  reviews and updates schedule with team
• Thursday Schedule changes incorporated into
  master schedules, critical path analyzed
• Friday Weekly executive report of project
  schedule status emailed to Exec VP GM of SEG,
  VP GM of STD by noon.
• All MS schedule files emailed to GSFC EO-1
  Schedule manager

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Hyperion Weekly Metrics
Schedule Status 1/18/98 Contractual Delivery
Date 6 July 1999 Current Projected Delivery
Date 9 June 1999 Days Slack to Contractual
Date 28 Slack to Delivery
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Weekly Metrics, Contd

• Summary Assessment (GGreen, YYellow, RRed,
  arrows indicate change from previous week á
  Improved, â Worsened)
• Date 12/11 12/18 1/8 1/15 1/22 NOTES
• Technical Y Y Y Y Y á See Critical Problems
• Cost G G G G G
• Schedule G G G G G
• Overall G G G G G
• Significant Progress
• OMS completed VNIR SWIR grating alignment and
  SWIR ambient alignment.
• SWIR FPA hexapod support structure failed Option
  1 Proof Load test.
• SWIR FPA hexapod structure Option 2 began
  assembly.
• Cryocooler completed testing with new cold head
  port welded shut.
• CEA Control Slice completed testing with Test
  cryocooler ahead of schedule, validating flight
  software. New Test PROMs installed, correcting
  long-standing periodic data error retest with
  flight cooler planned.

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Hyperion
Sensor Assembly (HSA) Flow
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Schedule As of 1/5/99
Page 3 of 4
Housing Panels
Proof Load test
Adjust Filter Position?
SWIR FPA
required
HSA Housing
SWIR Mounting
Assembly
Hardware
SWIR FPM
SWIR ASP
12/7/98
VNIR ASP EParts
Heaters
50
SWIR Thermal
10/20/98
12/15/98
VNIR ASP 4CCA
Analog 1 PWB
Thermistors
A2A1
Strap
10/22/98
Analog 2 PWB
95
A2A2
VNIR ASP Hsg
VNIR ASP A2
8/18/98
8/7/98
Digital PWB
A2A3
VNIR FPA
VNIR Thermal
8/18/98
VNIR FPM
Clk Driver PWB
A2A4
Strap
Hyperion
VNIR Mounting
12/18/98
Hardware
Sensor
1/7/99
Test MLI
11/11/98
Assembly
VNIR FPE CCA
VNIR FPE PWB
A1
(HSA)
1/5/99 (Heat Pipe)
Cryo Radiator
11/11/98
VNIR FPE EParts
Panels
Carbon-Carbon
65
Radiator alternative
Cover Assy
preferred
Baffle/Aperture
94
Moog/SMD
Cover Actuator
Assembly
97
Baffle Assy
Inflight Cal
Baffle/Feedthru
13
7
Lamps
Assembly
Assembly
10/8/98
Optical Cube
IFCA Reflector
Cables
Pg. 2
10/6/98
Telescope
Mirrors
Opto-
Mechanical
Telescope
1/8/99
11/30/98
10/9/98
Telescope
LEA
Subsystem
Housing
Pg. 2
(OMS)
GIS
10/21/98
Housing
Pulse
Grating
12/8/98
12/3/98
Tube
Imaging
Beam Splitter
Cooler
Pg. 2
Spectrometer
10/2/98
12/1/98
GIS Mirrors
10/26/98
SWIR Grating
Feet
10/26/98
VNIR Grating
9/15/98
Slit
SSG Subcontract
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Hyperion
Assembly Flow
Schedule As of 1/5/99 Page 4 of 4
Hyperion
Electronics
4/1/99
Assembly
(HEA)
Flight MLI
Hyperion
Hyperion
Environmental
Install Flight MLI,
Hyperion
Sensor
5/27/99
6/7/99
6/8/99 w/o Contingency
4/10/99
Acceptance
Pack Ship
Delivery
Assembly
Tests
(HSA)
3/15/99
Interconnecting
Cables (Swales)
Cryocooler
Electronics
2/26/99
Assembly
(CEA)
2/5/99
Hyperion
Instrument
Test Set
(HITS)
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Top Five Critical Path Items
Hyperion Schedule Status
Total Slack
Critical Path
Status (Changes as of 1/20)
to 7/6/99
As of 1/15/99
(days)
4-day improvement in SWIR FPM alignment
SWIR Focal
27-31
enabled by test tool to stand in for hexapod
Plane Module
structure (Option 2).
HSA
Shop priorities changed upon DR disposition
28- 31
Honeycomb
and call to F.
Deninger schedule improved 3
Structure Assy
days.
SWIR
Engineering calculation of design details
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Done
Alignment
accuracy of alignment process took longer
Mask
than expected.
(See CR3.) Flight Cooler complete, welded.
Cryocooler
33-36
Electronics control slice completed test S/W
Assembly
validation with Test Cryocooler.
Hyperion
Delays in final assembly due to delay in
33
Electronics
release of top assembly drawing.
Assembly
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Risk Management Process
Hyperion Risk Management Status
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Risk Evaluation Status
Hyperion Risk Management Status
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Risk Issue Watch List
Hyperion Risk Management Status
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Risk Issues Retired
Hyperion Risk Management Status
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Critical Problem Status
Critical Problem Initiated Status CR1 New
Vibration Loads 11/13/98 Open CR2 Dichroic
Filter Performance 11/30/98 Closed CR3
Cryocooler Performance Anomaly 12/8/98 Closed
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New Loads and Vibration Test CriteriaCritical
Problem No. 1

• Dichroic beam splitter from supplier Opticoat
  failed to meet TRW specification in time
  required.
• Large number of layers (gt50) were crazing under
  stresses of application.
• Quality of filter performance so poor it would
  significantly impact Hyeprion performance.
• TRW had contracted another vendor, ZCR, to
  produce the same coating as a risk reduction task
• ZCR had come very close at time Opticoat called
  to request spec relief.
• They successfully completed the coating a few
  days later, delivering 3 parts.
• The part from ZCR meets all TRW specs except the
  wavelength at the 50 crossover point is 0.92
  microns instead of 0.95 microns. Science impact
  of this difference is negligible.
• The ZCR filters were delivered to SSG in time to
  maintain schedule!
• A victory for risk management
• Thanks to excellent work by Don Wolpert in
  selecting and monitoring ZCR

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SWIR Hexapod Reinforcement

• Two-piece ring reinforces
• lower SWIR hexapod cup.

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Dichroic Beam Splitter Performance and Delivery
Critical Problem No. 2

• Dichroic beam splitter from supplier Opticoat
  failed to meet TRW specification in time
  required.
• Large number of layers (gt50) were crazing under
  stresses of application.
• Quality of filter performance so poor it would
  significantly impact Hyeprion performance.
• TRW had contracted another vendor, ZCR, to
  produce the same coating as a risk reduction task
• ZCR had come very close at time Opticoat called
  to request spec relief.
• They successfully completed the coating a few
  days later, delivering 3 parts.
• The part from ZCR meets all TRW specs except the
  wavelength at the 50 crossover point is 0.92
  microns instead of 0.95 microns. Science impact
  of this difference is negligible.
• The ZCR filters were delivered to SSG in time to
  maintain schedule!
• A victory for risk management
• Thanks to excellent work by Don Wolpert in
  selecting and monitoring ZCR

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Cryocooler Performance AnomalyCritical Problem
No. 3

• After the by-pass line tuning (11/18), the
  Hyperion pulse tube cooler passed the in-process
  performance test with .835W cooling at 110K
  (Hyperion spec) using 14.3 W power, and achieved
  1.2W cooling at 110K (Hyperion Upper Margin)
  using 19.9W.
• The cooler completed the final purge and fill,
  followed by the pre-weld final performance test.
  During the pre-weld test (11/19), the cooler
  behavior was abnormal Less power was required to
  move the compressor with the same stroke.
• For example, 13.5W power was input into the
  compressor with 90 stroke yielding a no-load
  temperature of 100K, in comparison to the normal
  case of 17.1W power for 90 stroke yielding a
  no-load temperature of 66.4K during the
  in-process performance test.
• This sudden change in cooler performance was
  thought due to particle contamination in the
  by-pass line affecting the phase change. There
  was no detection of He leakage from the cooler.
• Continued...

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Cryocooler Performance Anomaly (contd)Critical
Problem No. 3

• Corrective Actions
• Purged filled cryocooler repeatedly through
  Thanksgiving holiday period to clear particle no
  improvement.
• X-rays of assembly found no contamination, though
  some areas were opaque.
• Check of compressor verified resonant frequency
  had not changed.
• Disassembly found particles near entrance to
  feed-back line analysis verified the particles
  were residual stop-off material used in brazing
  operation.
• Spare cold head production accelerated to replace
  failed unit.
• Spare cold head encountered plating problems Cu
  plating and epoxy seals leaked badly. Replating
  after removal.
• MP investigated plating problem while a third
  cold head was assembled, successfully plated,
  purged filled, and integrated with the
  compressor.
• Testing successfully completed, final fill and
  weld done.
• Problem Closed 1/19/99

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Hyperion Design Overview
(Backup Charts)
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EO-1 Coordinated Image Collection Opportunities
ALI and Hyperion Science on EO-1
L
Excludes thermal channel
Hyperspectral Analysis derives from the use of
contiguous spectral channels, allowing the use of
derivatives and sophisticated analyses
techniques. The large number of bands allows
complex systems to be addressed without concern
for under sampling typical of multispectral
systems.
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Proven Designs Enable Rapid Hyperion Production
Hyperion Design Overview
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Hyperion Subsystem Units
Hyperion Design Overview
Hyperion Electronics Assembly (HEA)
Hyperion Sensor Assembly (HSA)
Cryocooler Electronics Assembly (CEA)
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Hyperion HSA Components
Hyperion Design Overview
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OMS Exploded View
VNIR FPM
GIS
Alignment Cube
SWIR FPM
Fore-optic Primary Metering Structure
Strut/Flexure 4X
Housing Baseplate
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Hyperion Sensor Assembly
Hyperion Design Overview
VNIR FPA farside (not shown)
Dual Channel Grating Image Spectrometer
SWIR FPA
Fore Optics EOC baseline
Common Slit Assy