GLAST LAT ProjectTEM/TPS MRR, September 16, 2004 4.1.7 DAQ & FSWV1 1 GLAST Large Area Telescope: B. Estey, Production SLAC (650)

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Presentation transcript:

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 1 GLAST Large Area Telescope: B. Estey, Production SLAC (650) Gamma-ray Large Area Space Telescope TEM/TPS MRR Part 2

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 2 Parts, Materials, and Processes EEE Parts –All EEE parts have been approved for use by the Program Parts Board –Status of TEM Parts Qualification (highlighted yellow items=part approved, not in use):

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 3 Parts, Materials, and Processes EEE Parts –Status of TEM Parts Qualification, cont’d (highlighted yellow items=part approved, not in use):

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 4 Parts, Materials, and Processes EEE Parts, cont’d –Status of TPS Parts Qualification (highlighted yellow items=part approved, not in use):

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 5 Parts, Materials, and Processes EEE Parts, cont’d –Status of TPS Parts Qualification, cont’d (highlighted yellow items=part approved, not in use):

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 6 Parts, Materials, and Processes EEE Parts, cont’d –Status of TPS Parts Qualification, cont’d (highlighted yellow items=part approved, not in use):

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 7 Parts, Materials, and Processes Materials –All Materials have been approved by the Program MPRB in accordance with LAT-SS-00107, LAT Mechanical Parts Plan GLAST/LAT Material Usage Agreement #002 (MAR DID No. 313; LAT Document # LAT-TD )- Approved 9/13/04 Processes –All processes have been reviewed and approved by the Program MPRB in accordance with LAT-SS , LAT Mechanical Parts Plan

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 8 Procurement Status Assembly Subcontractor –GTC Corp. was awarded the contract to provide the assembly service and some environmental testing for all levels of the TEM/TPS (Reference LAT-PS-03078, SOW LAT TPS and LAT-PS-02615, SOW LAT TEM) GTC Corp. is located in Albuquerque, New Mexico EEE Parts –All EEE parts are SLAC furnished and have been procured for the TEM and TPS Outstanding receipt of Novacap Capacitors expected 9/16/04 –Part no. 1210B563K251YHTM Outstanding receipt of balance of tantalum capacitors expected 9/20/04 –Part nos. CWR11FH475KDB and CWR11FH105KDB Metal Fab Parts and Fasteners –All Metal Fab parts and Fasteners are SLAC furnished and have been procured for the TEM and TPS Outstanding receipt of TPS Box Bases, LAT-DS expected 9/16/04 Outstanding receipt of TEM Connector Plates, LAT-DS-01026, expected 9/17/04 Outstanding receipt of balance of Heat Sinks, TPS, LAT-DS-04101, expected 9/24/04 Outstanding receipt of balance of Cable Harness Support, TPS, LAT-DS-03598, expected 9/24/04 PWBs –The PWBs for TEM and TPS are SLAC furnished and have been contracted to DDI Fabrication complete on Qual + 2, balance of PWBs to be fabricated pending successful data review of TEM and TPS Module performance

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 9 Procurement Status FPGA Programming –Programming of the FPGAs has been contracted to ACTEL Programming complete on Qual + 2, balance of FPGAs to be programmed pending successful data review of TEM and TPS Module performance Materials –Assembly materials are furnished by GTC Corp. in accordance with drawing requirements (adhesives, conformal coating, wire, primer, etc.)

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 10 Manufacturing Facilites Assembly contract has been awarded to General Technology Corporation, located in Albuquerque, New Mexico –Capabilities Overview DS/Multilayer PC Boards assembled to Mil-Spec Thru-hole and Surface Mount Technology (SMT) Electro/mechanical Assembly Cables and Harnessing Conformal Coating Testing (Including ESS) –Facilities Overview 72,000 ft 2 Custom Built Manufacturing Facility –TEM/TPS assembly and test to be performed in an environmentally controlled area with monitoring capabilities for temperature and relative humidity –Facility complies with the ESD control requirements specified in ANSI/ESD Manufacturing Engineering Test Stockroom Administration –Certifications GTC performs to the intent of the following certifications assuring quality assembly –MIL-STD -2000A –IPC-A-610C –IPC/WHMA-A-620 –MIL-STD-454 –IPC/EIA J-STD-001C –MIL-I –ISO 9002

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 11 Manufacturing Process Flow- GTC Materials notes –Receiving inspection will be performed on all materials supplied by the customer using documents supplied –All discrepancies shall be documented and relayed to the customer in 24 hours from their discovery –All moisture sensitive materials used in the manufacturing of the TEM will be stored and handled in accordance with GTC-2025A -Moisture Sensitive Component Handling, Use of Dry Room Storage. –Materials issued in the production of TEM/TPS for assembly will be traced in a manner that would enable traceability from the assy S/N to the individual part /piece and production lot/date code. –Every TEM and TPS assembly will have its own traveler issued to facilitate traceability of IC serial numbers installed on that particular CCA.

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 12 Manufacturing Process Flow-GTC Materials Receive KIT OK Not OK Contact SLAC/ Resolve issue Issue Kit To prod. Clean and bake PCB Inspect

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 13 Manufacturing Process Flow-GTC SMT area notes –Operators will record all IC serial numbers and location at which they are installed on a particular CAA for traceability purposes. All IC’s used in the production of TEM assemblies are serialized. –Operators will inspect and measure the solder paste height on every print at 3 predetermined locations. The results will be recorded in the SMT printer log along w the printing parameters

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 14 Manufacturing Process Flow-GTC SMT Production Area Inspect Kit Set Up P&P and SP Screen print Solder side OK P&P all SMT components 1 st art. Inspection Reflow Inspect Not OK Clean OK Not OK Touch up Clean Not Ok Contact SLAC Correct root cause ok Inspect/ Measure

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 15 Manufacturing Process Flow-GTC Second Operations Install connectorsSolder connectors Inspect OK Clean Not OK Touch up Move to test Contact SLAC MRB

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 16 Manufacturing Process Flow-GTC CCA Test ICT Top/Bt Pass Fail Touch up Functional test Fail Pass Stake HW & components Touch-up Contact SLAC MRB

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 17 Manufacturing Process Flow-GTC Module assy/conformal coating/thermal cycling Conformal coat. Inspect OK No Apply thermal Adhesive And mount CCA in Chassis base Touch up Conformal coat Functional test CCA level Thermal cycling Apply Kapton to Back side of CCA Move to next op. Contact SLAC MRB

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 18 Manufacturing Process Flow-GTC Module Level Test Vacuum de-gas Adhesive cure Inspect ok no Install chassis Top cover Stake HW Contact SLAC MRB Module Assy level Thermal Cycling Functional test Move to next op. Functional test

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 19 Manufacturing Process Flow-GTC Top assembly/final test/final inspection Assemble TEM/TPS Stake HW Top Assy level Thermal Cycling Source inspection &EIDP review Pack & ship to SLAC Vibration test Functional test Final functional test Functional Test

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 20 Configuration Management Required changes to documentation during the manufacturing phase at GTC will be immediately documented on an NCMR and forwarded to SLAC for disposition All outstanding changes to documents will be incorporated and a new revision released into LAT DOCs prior to final inspection at each manufacturing level (CCA, Module, Top Assembly)

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 21 Configuration Management All change notices will include full disposition of hardware Disposition of Hardware

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 22 GTC Test Requirements Figure 1. Vibration Levels, Duration, and Spectra

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 23 GTC Qualification and Acceptance Test Matrix

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 24 Production Schedule

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 25 Production Schedule

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 26 Production Schedule

GLAST LAT ProjectTEM/TPS MRR, September 16, DAQ & FSWV1 27 Issues/Concerns Actel FPGAs pose a reliability concern Maxim 724 is rated at V, we are biasing to operating at 1.5V. Parts were not screened for this application, PCB reviewing screening requirements.