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Update on FCU-FM Manufacturing Status and Challenges Faced

This report provides the latest updates on the FCU-FM manufacturing process overseen by Bert-Joost van Leeuwen at SRON-Utrecht. As of now, six PCBs have been assembled and passed functional tests, while housing production is ongoing. Recent challenges included two PCB rejections due to solder oxidation and irregular power-up behavior in HS508BRH analogue multiplexers. Solutions have been identified, including adjustments to cleaning processes and current limitations. Improvements in chopper control dynamics were noted, with future assembly and testing milestones highlighted.

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Update on FCU-FM Manufacturing Status and Challenges Faced

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  1. FCU FM status Bert-Joost van Leeuwen, SRON-Utrecht.

  2. Contents • FM manufacturing status • Chopper control • Planning

  3. FM manufacturing status [1] • 6 PCB’s assembled • 6 PCB’s have passed functional and dc performance tests • One PCB has final FPGA mounted (each PCB has one FPGA) • Housing is manufactured, only PUK paint to be applied (in progress now)

  4. FM manufacturing status [2]

  5. FM manufacturing status [3]

  6. FM manufacturing status [4]

  7. FM manufacturing status [5] Problems during manufacturing • 2 PCB’s rejected due to oxidation of solder. • Solution: other cleaning process • Irregular power-up behavior due to excess supply current drawn by HS508BRH analogue multiplexers (2-6mA, while 2mA max is specified). • Manufacturer admits undocumented behavior and states that it is harmless for the component. Unclear is the maximum inrush current that the component may draw (over lifetime, radiation). • Solution: increase of current allowed by limiter

  8. Chopper control [1] Recent problems • Excessive LVDT readout cable dependency (resistance and capacitance) of 1% FSR exceeded short term stability requirement of 0.02% FSR (= 0.2 arcmin) • Step response settling time exceeded the required 20msec significantly (factor 3 or more) Electrical and mechanical resonances caused both problems • LVDT readout frequency was reduced from 10 to 2.6KHz • Filtering in the position control loop was improved to reject resonances at 700 – 1000Hz

  9. Chopper control [2] Test results • Test on FCU-DM2 (com s/n5) + FPC QM-2 • Short term stability 0.03% FSR (RFW) • Step reponse settling time 38msec (RFW) • Test on FCU-FM (both common boards) + FPC QM-2 • Short term stability 0.03% FSR • Step reponse settling time 31msec

  10. Chopper control [3]

  11. Chopper control [4] • Improved dynamic behavior due to: • Improved actuator driver (DM2 setup used ISO stage for second actuator • Improved lay-out design • Chopper control now a rugged design with good performance

  12. Planning • Several technical problems have caused +/- one month delay • We are acquiring two additional test engineers to recover the time spent to solve the problems • Outlook • assembly of all FPGA’s within next 3 weeks • completion of board level tests in one month • start unit integration in one month • start environmental qualification/acceptance tests in 6 weeks • delivery FCU-FM: februari 2006

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