PROC-0274 Wavefront Correction System Factory Acceptance Test Plan

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Project Documentation PROC-0274 Revision A PROC-0274 Wavefront Correction System Factory Acceptance Test Plan Rachel Rampy, Luke Johnson, Kit Richards, Erik Johansson, Keith Cummings, Friedrich Woeger WFC Team March 18, 2019

WFC Factory Acceptance Test Plan REVISION SUMMARY: 1. Date: 3/18/2019 Revision: A Changes: Initial document. PROC-0274, Revision A Page ii

WFC Factory Acceptance Test Plan Table of Contents 1. 1.1 1.2 1.3 1.4 2. 2.1 INTRODUCTION . 1 SCOPE . 1 VERIFICATION METHODS . 1 DEFINITIONS AND TERMINOLOGY . 1 RELEVANT DOCUMENTS . 2 WFC FACTORY ACCEPTANCE TEST PLAN . 3 OVERVIEW. 3 2.1.1 Test Execution Plan . 3 3. 3.1 SUBSYSTEM REQUIREMENTS VERIFICATION . 4 ACTIVE OPTICS ENGINE . 4 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.1.7 3.1.8 3.1.9 3.1.10 3.1.11 3.1.12 3.1.13 3.1.14 3.1.15 3.1.16 3.1.17 3.1.18 3.1.19 3.1.20 Coordinate Rotation . 4 Wavefront Reconstruction Algorithm . 4 Wavefront Reconstruction Inputs . 4 Wavefront Modal Basis . 5 Wavefront Reconstruction Stability . 6 Wavefront Reconstruction Method . 6 Wavefront Error Monitoring . 7 Boresight Correction. 7 Reconstruction Matrix Calculations . 8 Calibrations. 8 Mode Requirements . 9 M1 Control .10 M2, M3 and M6 Control.12 Coordinate Transformation Angles .13 Update Cadence .13 Active Mirror Gain Settings .14 Calibration Step Sizes .14 Engineering User Interface .15 Active Optics Status Screen .15 Tools for LUT Refinement .16 3.2 COMMON ITEMS . 17 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 3.2.7 3.2.8 Relay Optics Image Quality .17 Field of View .18 Relay Optics Field Stop.18 Optical Tables .19 Manually-Adjustable Optical Mechanisms.19 Electronics Racks.21 Computers .22 Motion Control Requirements .23 3.3 CONTEXT VIEWER . 23 3.3.1 3.3.2 3.3.3 3.3.4 3.3.5 3.3.6 3.3.7 Plate Scale .23 Total Length .24 Filter .24 Objective Lens Assembly Automated Positioning.24 Objective Lens Assembly Manual Positioning .26 Camera Mount Assembly Manual Positioning .26 Camera Mask .27 PROC-0274, Revision A Page iii

WFC Factory Acceptance Test Plan 3.3.8 3.3.9 3.3.10 3.3.11 3.3.12 3.3.13 3.3.14 3.3.15 3.3.16 Strehl Calculation .27 Calibrations.28 Camera Exposure Time .33 Mode Requirements .34 Frame Rate, FoV, and Plate Scale Selection.34 Day/Night Configuration .35 Engineering User Interface .36 CV Display .36 Header Data .36 3.4 HIGH ORDER ADAPTIVE OPTICS . 37 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.4.6 3.4.7 3.4.8 3.4.9 3.4.10 3.4.11 3.4.12 3.4.13 3.4.14 3.4.15 3.4.16 3.4.17 3.4.18 3.4.19 3.4.20 3.4.21 3.4.22 3.4.23 3.4.24 Sensor Type .37 Pupil Imaging Capability .37 HOWFS Off-pointing.37 Subaperture FoV .38 Pupil Size and Plate Scale .38 Subaperture Image Separation .39 Total Length .39 Image Quality .39 NCP Wavefront Sensor .40 M5 Dummy .40 M10 Dummy .41 Manually-Adjustable Mechanisms .41 HOWFS Camera .43 Algorithm Functionality .44 Calibrations.52 Mode Requirements .59 aO Engine Offloads .60 System Settings .60 Reference Image Selection .62 Mechanism Control .63 Engineering User Interface .64 HOAO Status Screen .65 Real-Time System.65 Telemetry .66 3.5 LOW ORDER WAVEFRONT SENSOR . 67 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 3.5.6 3.5.7 3.5.8 3.5.9 3.5.10 3.5.11 3.5.12 3.5.13 3.5.14 3.5.15 3.5.16 Sensor Type .67 Pupil Imaging Capability .67 LOWFS Off-pointing .68 Subaperture FoV .68 Subaperture Configuration .69 Plate Scale .69 Total Length .69 Image Quality .70 Manually Adjustable Stages and Mechanisms .70 Motorized Stages and Mechanisms .71 Frame Grabber.72 Extract Regions of Interest .72 Algorithm Functionality .73 Calibrations.73 Mode Requirements .77 System Settings .78 PROC-0274, Revision A Page iv

WFC Factory Acceptance Test Plan 3.5.17 3.5.18 3.5.19 3.5.20 3.5.21 3.5.22 Mechanism Control .80 Broadcasting Results .82 Display of Images .82 Storage of Data .82 Monitor Camera Temperature .83 Engineering User Interface .83 3.6 LIMB TRACKER . 84 3.6.1 3.6.2 3.6.3 3.6.4 3.6.5 3.6.6 3.6.7 3.6.8 3.6.9 3.6.10 3.6.11 3.6.12 3.6.13 3.6.14 3.6.15 3.6.16 Latency.84 Extract and Sort Raw Intensity Values .84 Send Intensity Values to Limb Tracker Computer .84 Dark and Gain Array .85 Dark and Gain Correction .85 Kernel Convolution .86 Zero-crossing identification .86 Sub-pixel interpolation .86 Arcsecond conversion and offset subtraction .87 Coordinate calculation .87 PI Servo Loop .87 Coordinate Rotation .88 Send PIO Commands to M2 FTT .88 Mode Requirements .88 System Settings .89 Interfaces .92 3.7 WAVEFRONT CORRECTION CONTROL SYSTEM . 92 3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 3.7.6 Algorithm Functionality .92 Mode Requirements .97 WFC Startup and Shutdown .98 OCS Operator GUI .99 Engineering Screen .99 WFC Calibration .100 4. 4.1 SYSTEM LEVEL REQUIREMENTS VERIFICATION . 102 WFC DESIGN REQUIREMENTS DOCUMENT . 102 4.1.1 4.1.2 4.1.3 4.1.4 4.1.5 High Order Adaptive Optics.102 Active Optics .104 Context Viewer .104 Wavefront Correction Control System .105 Limb Tracker .106 5. USER ACCEPTANCE TESTING . 107 PROC-0274, Revision A Page v

WFC Factory Acceptance Test Plan 1. INTRODUCTION 1.1 SCOPE This document contains test plans for verification of requirements on the Wavefront Correction System (WFC) at the NSO facilities in Boulder, CO. 1.2 VERIFICATION METHODS Examples of verification methods include: 1.3 Design Review. Verification by design review means that it is shown during an appropriate design review that the system meets specification by way of its intrinsic design and configuration. Analysis. Verification by analysis demonstrates that the design meets the specification through use of performance modeling metrics. Test. Verification by test and/or measurement means that it is demonstrated that the as-built system meets the specification through measurements of its operation performance. Testing is performed during acceptance testing and/or as part of a pre-ship readiness review. Inspection. Verification by inspection means that visual inspection verifies that the specification has been achieved on the as-built system during preassembly and/or during Site assembly. DEFINITIONS AND TERMINOLOGY aO AO BS1 CLI CSF CV DHS DIQ DM FOCS FOV FSM FTT GIS GOS GUI HOAO HOWFS ICD LOWFS LT LUT NCP OCS OP PSD RTC QSA PROC-0274, Revision A Active optics Adaptive Optics Beam splitter #1, sends 4% of light to WFC and the rest to science instruments Command Line Interface Common Services Framework Context Viewer Data Handling System Delivered Image Quality Deformable Mirror Feed Optics Control System Field of View Field Steering Mirror Fast Tip-Tilt corrector Global Interlock System Gregorian Optical Station Graphical User Interface High-Order Adaptive Optics High-Order Wavefront Sensor Interface Control Document Low-Order Wavefront Sensor Limb Tracker Look-Up Table Non-common path optical aberrations Observatory Control System Observing Program Power spectral density Real-Time Controller Quasi-static alignment Page 1 of 107

WFC Factory Acceptance Test Plan TCS TEOA TEOACS TMA WCCS WFC 1.4 Telescope Control System Top End Optical Assembly Top End Optical Assembly Control System Telescope Mount Assembly Wavefront Correction Control System Wavefront Correction System RELEVANT DOCUMENTS PROC-0274, Revision A Page 2 of 107

WFC Factory Acceptance Test Plan 2. WFC FACTORY ACCEPTANCE TEST PLAN 2.1 OVERVIEW The Wavefront Correction System (WFC) is designed and built by the DKIST Instrumentation Group located at NSO Boulder (the “factory”). Before the WFC can be shipped to the DKIST summit for integration with the telescope, it must successfully complete Factory Acceptance Testing (FAT). The FAT is designed to ensure the WFC will function as intended before delivery to DKIST. Success is achieved by verifying, to the level possible in the “factory” environment, that all requirements of the WFC have been met. The requirements for the WFC flow from several high level science, operations, and engineering documents. SPEC-0058 WFC Design Requirements Document (DRD) derives these into lower level requirements for the instrument and its subsystems. Detailed requirements are contained in the eight subsystem DRDs which cover the active optics engine (aO), common items, the context viewer (CV), the high order adaptive optics (HOAO), the low order wavefront sensor (LOWFS), the limb tracker (LT), the wavefront correction control system (WCCS), and generic requirements. Each of these DRDs has an associated compliance matrix which is used to trace the requirements to test procedures and results. All SPEC-0058 requirements are captured within these subsystem compliance matrices. All requirements on the WFC have a unique requirement number and stated verification method. Verification by design review has been applied to all requirements before and during system construction. For the FAT, those requirements with a verification method of inspection or factory test will be checked. Many optical and mechanical components were manufactured by outside vendors and delivered with documentation demonstrating their compliance with requirements. These will be noted as verified by “vendor data” in the compliance matrix and their certifications may be reviewed during the FAT process. All other requirements being checked will have detailed procedures in this document that can be used to verify they are compliant. Note that in some cases multiple requirements may be verified with the same test procedure. 2.1.1 Test Execution Plan FAT tests are performed as the system is built, rather than all at once. This allows for problems to be identified and fixed early. The exception to this is the User Acceptance Tests (UAT). These tests are performed throughout construction as major functionality is released. However, UAT testing is also performed once all components of the system are fully developed to ensure the system as a whole works as expected. As tests are completed, results are captured into technical documentation. Once all tests have been completed, the results documents will be submitted to DKIST systems engineering for review. Any issues or questions will be identified and discussed at a ‘Readiness Review’. During that review, systems engineering may request that any test be demonstrated on the system. Once the review is complete, and systems engineering has signed off, the WFC may be shipped to the DKIST summit. PROC-0274, Revision A Page 3 of 107

WFC Factory Acceptance Test Plan 3. SUBSYSTEM REQUIREMENTS VERIFICATION 3.1 ACTIVE OPTICS ENGINE The aO Engine is a software controller that is part of the Wavefront Correction Control System (WCCS) and will be installed on the same computer hardware used to run the WCCS. Therefore, there are no hardware components associated with the aO Engine and many of the usual requirements for hardware installation, design, and handling do not apply. The DRD for this subsystem is SPEC-0175 and the Compliance Matrix is CMX-0017. 3.1.1 Coordinate Rotation Type Requirement Preconditions Test Steps Pass Criteria Test 2.1.2.2-3000: The aO Engine shall track the orientation of the telescope in altitude and azimuth and the rotation angle of the coudé lab. Any quasi-static wavefront or alignment corrections shall properly account for the telescope and coudé lab position. The aO Engine is installed and running on the Boulder E2E testbed Use the TCS simulator to generate positional information from the telescope and coudé lab. Send real or simulated wavefront measurements from the HOWFS. Verify aO Engine ingests the TCS info and performs the correct actions. Repeat with wavefront measurements from the LOWFS. Derotation into the co-moving coordinate frame is done on each wavefront measurement as it is received. Notes 3.1.2 Wavefront Reconstruction Algorithm Type Requirement Preconditions Test Steps Pass Criteria Notes 3.1.3 Test 2.1.2.2-3005: The aO Engine shall implement a wavefront reconstruction algorithm that calculates position error signals to the M1CS and TEOACS based on WFC wavefront measurements, as described in REQ# 2.1.2.2-3005 of the DRD. The aO Engine is running in the lab Send real or simulated wavefront measurements from the HOWFS. Verify aO Engine ingests the info correctly and calculates valid position error signals. Check that the events sent to the mirror control systems are correct. Repeat with wavefront measurements from the LOWFS. Results of the wavefront reconstruction algorithm are coherent and consistent. Wavefront Reconstruction Inputs Type Requirement PROC-0274, Revision A Test 2.1.2.2-3010: Page 4 of 107

WFC Factory Acceptance Test Plan Preconditions Test Steps Pass Criteria The aO Engine shall receive and accept quasi-static wavefront error inputs from the LOWFS and the HOAO in the form of 20-element arrays containing wavefront modal coefficients. The aO Engine shall have the ability to switch between the two input sources when commanded. 2.1.2.2-4265: The aO Engine shall allow the WFC Specialist to select which wavefront sensor it uses for wavefront reconstruction. The aO Engine is running in the lab The WCCS Engineering GUI is complete and fully functional From the engineering GUI, set the WFC mode to “diffraction limited ondisk.” Send real or simulated wavefront measurements to the aO Engine. Check that aO Engine is receiving and accepting 20-element arrays of wavefront modal coefficients from the HOAO. From the engineering GUI, change the WFC mode to “seeing limited ondisk.” Verify aO Engine inputs are in the same form but now come from the LOWFS. The aO Engine receives and accepts input from either source as commanded by the engineering GUI (i.e. the WFC Specialist tool), and returns valid outputs in both cases. Notes 3.1.4 Wavefront Modal Basis Type Requirement Preconditions Test Steps Pass Criteria Notes PROC-0274, Revision A Test 2.1.2.2-3015: The wavefront reconstruction algorithm shall operate in one of two wavefront modal bases, Fringe Zernike or M1 natural modes. The modal basis in use shall be userselectable. 2.1.2.2-4270: The aO Engine shall allow the WFC specialist to select the modal basis used for wavefront measurements and M1 offsets. The aO Engine is running in the lab The WCCS Engineering GUI is complete and fully functional In the aO Engine section of the WCCS Main tab of the GUI, select “Wavefront Modal Basis” to be “Zernike.” Send real or simulated wavefront measurements to the aO Engine. Check that inputs and outputs are consistent and coherent when the WFC mode is “diffraction limited on-disk.” Repeat the previous step with the WFC mode set to “seeing limited on-disk.” Change the “Wavefront Modal Basis” to be “M1 Natural” and repeat all steps. Changing the modal basis requires clearing of the low order mode averaging in the HOAO and LOWFS, and the WF estimate in the AO Engine. Verify that those actions occur properly for each basis change. Valid outputs are produced for both modal bases and both operating modes. Page 5 of 107

WFC Factory Acceptance Test Plan 3.1.5 Wavefront Reconstruction Stability Type Requirement Preconditions Test Steps Pass Criteria Test 2.1.2.2-3020: The wavefront reconstruction algorithm shall implement noise filtering techniques so that active mirrors are only moved when a measured wavefront error is both significant (large in magnitude) and reliable (high signal-to-noise ratio). The thresholds that define significance and reliability shall be user-selectable. 2.1.2.2-4315: The aO Engine shall allow the WFC Specialist to set the significance threshold for each of the 20 wavefront modal coefficients. 2.1.2.2-4320: The aO Engine shall allow the WFC Specialist to set the reliability threshold for each of the 20 wavefront modal coefficients. The aO Engine is running in the lab The WCCS Engineering GUI is complete and fully functional From the Direct Control tab of the GUI, launch the aO Engine subsystem GUI. Load a 20-element vector containing significance thresholds for each modal coefficient (the default thresholds will be loaded when the aO Engine is initialized). Send real or simulated wavefront measurements to the aO Engine with some significance values above, and others below, the specified thresholds. Monitor the aO Engine logs to make sure it is correctly calculating the significance and reliability of its internal wavefront estimate and that it only sends active mirror commands when the internal wavefront estimate exceeds both thresholds. Repeat the previous 3 steps for the reliability threshold. The aO Engine does not apply wavefront error modes that are outside the user-specified significance and reliability thresholds. Notes 3.1.6 Wavefront Reconstruction Method Type Requirement Preconditions Test Steps PROC-0274, Revision A Test 2.1.2.2-3025: The wavefront reconstruction algorithm shall support two methods for calculating mirror commands based on wavefront error measurements, one method that minimizes force on M1 axial actuators and one method that imposes neutral-pointing constraints on the M2 hexapod. 2.1.2.2-4331: The aO Engine shall allow the WFC Specialist to set the method used for wavefront reconstruction. The aO Engine is running in the lab The WCCS Engineering GUI is complete and fully functional From the Direct Control tab of the GUI, launch the aO Engine subsystem GUI. Page 6 of 107 pag

Factory Acceptance Test Plan . Rachel Rampy, Luke Johnson, Kit Richards, Erik Johansson, Keith Cummings, Friedrich Woeger . WFC Team . March 18, 2019. WFC Factory Acceptance Test Plan PROC-0274, Revision A Page ii REVISION SUMMARY: 1. Date: 3/18/2019 Revision: A Changes: Initial document.

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