HMI First Sun Test Review November 28, 2005

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HMIFirst Sun Test ReviewNovember 28, 2005
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Agenda
Topic Presenter Time
Overview Objectives Miles 15 min
Test Requirements Schou
Lessons Learned Bush
Test Plan Moskal
Test Descriptions Schou, Bush, Tarbell, Hoeksema, Miles
Test Data Processing Schou
Test Readiness Drake, Kirkpatrick, Miles
Concerns and Issues
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Objectives

• Objectives of the sun test review
• Verify that planned tests meet the verification
  requirements appropriate for the sun test.
• Show that all hardware, software, facilities,
  procedures, and personnel are available and
  prepared to support the test.
• Objectives of the sun test
• Learn how to operate the HMI optics package.
• Learn how to characterize/calibrate the
  instrument. In some cases, obtain initial
  calibration parameters.
• Discover gross errors in design or workmanship of
  the HMI optics package.
• Determine position of focus to set the final shim
  on the telescope secondary lens.
• Results of the sun test will directly feed into
  the plans and procedures for the formal test and
  calibration series.
• The sun test does not provide formal verification
  of any requirements.

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HMI Integration and Test Flow
Nov 05
Cnfg I
Cnfg II
Develop SW Accpt Test
Initial Sun Tests
In Air Calibration
HOP w/BB Functional Test
Roll Over
CIF BBHEB
Apr 06
Mar 06
Flight CCD DM Camera Install ISS
BB HEB (no CIF) DM CCD, DM Camera No ISS
Install Flt Cameras
Alignment Thermostats
Sine Vibration
Acoustics
Random Vibration
Quasi-static Loads
HOP w/BB Functional Test
HOP Vibration Prep
May 06
Complete Flight HOP Only - Functional Test w/
BBHEB
Repeated for X-, Y-, and Z-axes
Cnfg Flight
Flight Sftwr Acct Test
CPT
Special Test
EMI/EMC Prep
Aliveness Test
EMI/EMC
HOPHEB Functional Test
HEB FT
Flight HEB
Sine Vibration
Random Vibration
Quasi-static Loads
HEB Vibration Prep
HEB FT
HEB Flight
HEB FT
Jul 06
Aug 06
Conformal Coat
Repeated for X-, Y-, and Z-axes
Delivery to GSFC 40D Slack
Vacuum Calibration
TV/TB Prep
Aliveness Test
Thermal Balance
Thermal Vacuum
CPT
Special Test
Sept 06
Nov 06
Sine signature
Transport HOP
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HMI Instrument Test Configurations

• HMI Instrument Configuration 1
• Brassboard Electronics Box
• Brassboard Cables
• Optics Package Non-flight hardware
• Flight CCD with flight focal plane housing (one
  location)
• DM Camera (one location)
• Optics Package Flight hardware
• Structure with alignment mechanism, legs, and
  mounting brackets
• Telescope assembly front window filter, primary
  lens, secondary lens, mounting bracket
• Polarization selector and wavelength tuner (seven
  HCMs)
• Harness (mechanisms only)
• ISS mirror and beam-splitter
• Oven assembly
• BDS beam-splitter and fold mirror
• CCD fold mirror (two)

• HMI Instrument Configuration 2
• Brassboard Electronics Box
• Brassboard Cables
• Optics Package Install flight items
• Focal plane (two)
• ISS limb sensor and preamp box
• Oven controller electronics box
• More harness
• Finish heater routing
• Install vents
• Oven thermostat
• Replace Lyot elements one and two
• Replace NB Michelson

• Tests
• ISS Testing
• CCD Alignment
• In-air calibration
• HOP Vibration testing

• Tests
• Initial Sun Test
• Initial Functional Tests

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HMI Instrument Test Configurations

• HMI Instrument Flight Configuration
• Fight electronics box
• Flight Harness
• Flight HOP

• HMI HEB Flight Configuration
• Conformal coated boards in HEB
• Flight Harness
• Flight HOP

• Tests
• Software Acceptance Test
• Flight CPT
• EMI/EMC Test

• Tests
• HEB Vibration Test
• Vacuum Calibration
• Thermal Balance and Thermal Vacuum

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Test Article Configuration for Initial Sun Test

• Optics
• All flight optics in place except as noted below.
• Michelsons are likely to be replaced with a
  better set after the sun test.
• Lyot elements 1 and 2 are likely to be replaced
  with better elements after the sun test.
• Telescope not set in final focus final focus
  position to be determined from sun test data.
• No ISS actuation.
• Camera and Detector
• DM camera electronics and flight CCD with forward
  flight focal plane housing and flight-like
  headboard.
• No side camera.
• Thermal
• Flight oven and preamp, ETU oven controller.
• No operational heater thermal control.
• No MLI.

• Mechanisms
• All seven flight hollow core motors with flight
  optics.
• Both flight focus / calibration wheels with
  flight optics
• Flight alignment legs.
• Flight shutters.
• No front door mechanism.
• Mechanical
• Flight structure with legs and mounting brackets
• Non-flight HOP cover non-flight covers in place
  of radiators and vents.
• Cables
• Flight HCM, shutter, and cal/focus wheel
  harnesses non-flight alignment leg harness
• Non-flight CCD flex cable.
• Brassboard intra-instrument harness.
• Brassboard HEB
• No CIF.
• Environment
• Ambient temperature and pressure

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Test Requirements Jesper Schou
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Sun Test Overview Jesper Schou

• Test prerequisites
• Pre-test analysis
• Measurements
• Discuss measurements to be recorded during the
  test. Explain how the measurements will be used
  to verify that test objectives are met and how
  they will be used to provide quantitative
  pass/fail criteria.
• Go/no go criteria
• State the readiness criteria for conducting the
  test. What measurements, test conditions, or
  other parameters are absolutely required to
  perform the test? What parameters might be
  compromised?
• Pass/fail criteria
• Provide detailed criteria and/or methodology for
  declaring the test was a success or a failure.
  If the criteria involve processing data, provide
  a detailed procedure for processing the data.
• Schedule
• Provide a summary test schedule, including key
  dates for significant events.

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Lessons Learned from MDI FPP Rock Bush, Ted
Tarbell

• Have several standard stimulus setups, with
  more than one person knowing how to change from
  one to another.
• Keep a log of which setup is used for every test
  and any deviations from standard
• Test and cal procedures evolve by trial and
  error need prompt (not necessarily real time)
  data analysis and STOL/procedure editing.
• Have scientists analyze the data who are not
  involved in collecting the data.
• Decide on measurements for trending and start
  early keep standard, clear tables/web sites of
  results.
• Need quick look (almost real time) viewing of
  images during testing interactive X, Y, I ltIgt,
  etc. measurements

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Sun Test Plan Ryan Moskal

• Equipment
• Flow of testing
• Procedure (logs, shop orders, etc.)
• Facilities
• Provide a description of the required test
  facility, including floorplan.
• Describe the characteristics and capabilities of
  the test facility and required support equipment.
  (lasers, interferometers, stim tel, PCU,
  heliostat, etc.)

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Sun Tests

• Prepare a plan for each of the following tests,
  using the template on the following chart

• Image Quality
• Distortion Jesper
• Image scale Jesper
• MTF Jesper
• Field curvature and focus Jesper
• Ghost images Rock
• Scattered light John
• Flat field John
• Linearity Ted
• Contamination Jesper
• Image offset and distortion Rock

• Filter Transmission Rock
• Wavelength dependence
• Spatial and angular dependence
• Throughput
• Contrast
• Polarization Jesper
• Observables Todd
• Doppler
• Line of sight
• Vector
• Alignment Mechanism John
• Range and step size
• Repeatability

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Image Quality Linearity Ted

• Purpose
• Determine the calibration necessary to correct
  for CCD response non-linearities, and determine
  the exposure limit for calibratable response.
• Requirements
• Measure the CCD response as a function of
  exposure time, from dark to full-well.
• Description
• Flood illuminate the CCD with the lamp source via
  the stim tel. (Although not available in the sun
  test, would cal-mode work better for this?)
• Measure stability of lamp
• Test configuration
• Describe the test setup. State how the test
  article, test facility, instrumentation, and test
  equipment will be configured and checked out
  prior to the actual test. Include the light
  input.
• Test plan
• Describe the operational status of the test
  article during testing and the requirements for
  performance measurements before, during, or
  following the test.
• Data analysis
• Tools, utilities
• Procedure
• STOL status
• Shop order status (created from Ryans template)
• The test timeline
• Defined the required test personnel and their
  roles and responsibilities

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Alignment Mechanism Range and Step Size John

• Purpose
• Requirements
• Description
• Test configuration
• Describe the test setup. State how the test
  article, test facility, instrumentation, and test
  equipment will be configured and checked out
  prior to the actual test. Include the light
  input.
• Test plan
• Describe the operational status of the test
  article during testing and the requirements for
  performance measurements before, during, or
  following the test.
• Data analysis
• Tools, utilities
• Procedure
• STOL status
• Shop order status (created from Ryans template)
• The test timeline
• Defined the required test personnel and their
  roles and responsibilities

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Alignment Mechanism Repeatability John

• Purpose
• Requirements
• Description
• Test configuration
• Describe the test setup. State how the test
  article, test facility, instrumentation, and test
  equipment will be configured and checked out
  prior to the actual test. Include the light
  input.
• Test plan
• Describe the operational status of the test
  article during testing and the requirements for
  performance measurements before, during, or
  following the test.
• Data analysis
• Tools, utilities
• Procedure
• STOL status
• Shop order status (created from Ryans template)
• The test timeline
• Defined the required test personnel and their
  roles and responsibilities

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Test Plan Template

• Each sun test gets its own set of charts,
  including as a minimum
• Purpose
• Requirements
• Description
• Test configuration
• Describe the test setup. State how the test
  article, test facility, instrumentation, and test
  equipment will be configured and checked out
  prior to the actual test. Include the light
  input.
• Test plan
• Describe the operational status of the test
  article during testing and the requirements for
  performance measurements before, during, or
  following the test.
• Data analysis
• Tools, utilities
• Procedure
• STOL status
• Shop order status (created from Ryans template)
• The test timeline
• Defined the required test personnel and their
  roles and responsibilities

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Data Processing Jesper Schou

• Science/calibration analysis
• Image processing
• Real-time data turnaround needed?
• Facilities

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Hardware Readiness Kirkpatrick

• Alignment status
• Camera
• Safe-to-Mate
• GSE
• PCU
• Air-to-Vac Corrector
• Air-to-vac corrector lens used with either the
  heliostat or the Stim-Tel to produce images in
  focus at the location of the CCD with the
  instrument in ambient pressure.
• Stim-tel
• Heliostat
• Other GSE

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Software Readiness

• Topics
• Flight Software
• GSE
• Camera
• STOL
• Tables

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Flight Software

• Mechanism control software and state machines in
  place for
• HCMs (3 Polarization Selector mechanisms and 4
  Wavelength Tuning mechanisms)
• Shutters
• Calibration/filter wheels
• Two mechanism control software elements being
  completed
• Alignment legs (done but possible problem with
  limit switches)
• Front door mechanism (not needed for first sun
  test, problem with open/closed switches)
• Sequencer
• Works with hard-coded framelist
• Framelist table upload in development
• Initial tests will not use sequencer

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GSE and Camera

• LMSAL EGSE In place and ready
• Release 6.6 development
• RAL GSE Camera Control Interface
• PCU Control
• Stimulus telescope intensity control (not done)
• RAL GSE In place and ready
• Camera
• Development model camera control through RAL GSE
  from LMSAL EGSE STOL
• Work-around for lack of Camera InterFace (CIF)
  board in HMI brassboard
• Images have been taken through this interface and
  provided to Stanford for data analysis/processing
• Header content needs review and expansion

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Sun test STOL list

• Name Status
• hmi_focus Done
• hmi_pl_wobble Written, not tested
• hmi_wl_wobble Written, not tested
• hmi_pcu_ss_moda Written, not tested
• hmi_pcu_ls_modc Written, not tested
• ral_menu Works, needs revision
• ral_tp Works, needs revision
• hmi_picture_loop Not written
• hmi_set_all_hcm_zero Needs encoder values to set
  HCM to
• hmi_set_nom_pos Needs nominal positions
• hmi_move_legs_to_center Not written
• hmi_find_center Written, needs review/demonstratio
  n
• hmi_set_position Not written
• hmi_dop_seq5 Not written, use wl_wobble_10 table
• hmi_detune27 Not written, make table?

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Tables

• Name Status
• cal_focus Done
• pl_wobble_10 Written, not tested
• wl_wobble_10 Written, not tested
• pcu_ss_moda Discuss with Greg Card, Rock, Jesper,
  Ralph RogerC
• pcu_ls_modc Discuss with Greg Card, Rock, Jesper,
  Ralph RogerC

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Documentation

• Test Plan
• This review chart package, together with a cover
  sheet signature page, constitutes the the Sun
  Test Plan (HMI01567).
• Procedures (shop orders)
• The test procedures are documented in the shop
  orders under which all tests are carried out. No
  test may proceed without a signed shop order.
• Shop orders signed off by Test lead system
  engineer deputy program manager mission
  assurance
• Applicable Documents
• HMI IT Plan, HMI Contract Performance Spec, HMI
  Calibration Plan, HMI IPD
• Test Reports
• Each test lead will prepare a test report and
  attach it to the shop order associated with the
  test.
• Test reports explain results related to
  requirements and identify trended data.
• For any failures, discuss root cause, corrective
  action, and plan for retest.
• All test reports related to in-air calibration
  items are due Feb 06.
• All test reports related to functional test items
  are due Mar 06. (To support pre-environmental
  test review).
• All remaining test reports due Apr 06.

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Concerns Issues All