APOLLO OPTICAL SUBSYSTEM A N D LM ALIGNMENT OPTICAL TELESCOPE FINAL REPORT It VOLUME ( 1 of 2 ) February 1970 Prepared For AC Electronics Division General Motors Corporation Milwaukee, Wisconsin 5 sle Kollsman Instrument Corporation Syosset, New York APOLLO OPTICAL SUBSYSTEM AND LM ALIGNMENT OPTICAL TELESCOPE FINAL REPORT VOLUME O[ ( 1 of 2 ) February 1970 Prepared For A t Electronics Division General Motors Corporation Milwaukee, Wisconsin ..c Kollsman Instrument Corporation Syosset, New York APOLLO OPTICAL SUBSYSTEM AND LM ALIGNMENT OPTICAL TELESCOPE FINAL RE PORT VOLUME II (1 of 2) Subcontract No. FNT 12776 NASA Prime No. NAS-9-497 February 1970 Approved by: KOLLSMAN INSTRUMENT CORPORATION Syosset, New York KOLLSMAN INSTRUMENT CORPORATION CONTENTS Section Page .. SECTION 1 INTRODUCTION 1- 1 .. SECTION 2 ABOLLO PROGRAM WNAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . INTRODUCTION* 2-1 CONTRACT VALUE * * . . . . . . . . . . . . . . . . . . . . .2- 2 * * * . . . . . . . . . . . . . . . . . . . m ORGANIZATION* 2-2 . . . . . . . . . . . . . . . . . MANPOWER 2.10 2.5.1 MITResidentSupport .. . . . .. . . . . . a .. . .. . .. 2 .10 2.5.2 Field Assignments . . . . . . . . . . . . . . . .2 -10 l 2.5.3 In-HouseEnqineerinq 2.16 . . . . . . . . . . . . . . e r n 2.5.4 M a n u f a ~ t \ a r i n q * . ~ 2.16 . . . . CONTRACT ACTIVITY 2-20 2.7.1 Prior to .N.ov.a..ti.on. .. .. .. .e .. .. .. .. .. .. .. .. .. .. .. .. . 4.2- 20 2.7.2 Novation 2-25 . . . . . . . . . . . . . . e . . . 2*7.3 AfterNovation0 2-32 . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8.1 PERT 2-49 . . . . . . . . . . . . . . . 2.8.2 configuration Control 2-50 2.9.1 Risk Assumption 2-57 . . . . . . e e . . . . . . . . . . 2.9.2 Early Recognition of Pzroblems 2-59 . . m e . . . . . . KOLLSMAN INSTRUMENT CORPORATION CONTENTS (Cant. ) -- SECT1O N 3 TECHNICAL APPROACH DESCRIPTION OF OPTICAL SUBSYSTEM 3-1 0 . 3.2.1 optical Base and Navigation Base Interface 3-2 3.2.2 Optical Base, Sextant, and Telescope . . Alignment* .3-4 . . . . . 3.4.1 m s c r i p t i o n * . .3-5 e w 3.4.2 Precision Requirements 3-5 3.4.3 Targetoptics .3-5 * * 3.4.4 Telescope Servosystem 3-8 3.4.5 Readout Provision . 3-8 3.4.6 Drive Assembliesa 3-11 . . 3.5.1 bscription* . 3-11 3.5.2 Precision Requirem.e nta . . . 3-13 . a 3.5.3 Targetoptics . . 3-13 3.5.4 Servosystem* 3-16 3.5.5 D r i v e A s s e r n b l i e ~ * * * * * ~ * * * ~ ~ * * * * ~ ~ ~ ~ 3 - 1 6 OPTICAL SUBSYSTEM MECHANIZATION 3-18 3.6.1 Modes of Operation 3-19 Subsystem 3.6.2 CDU Mechanizatien 02 Optics 3-19 . 3.6.3 Integrating Servo Loops 3-21 3.6.4 Zero Optics Operatione 3-25 3.7.1 Sextant Position Servo mop Operation 3-27 3.7.2 Telescope Position Servo Loop Operation 3-27 3.8.1 Optics 800-Cycle Power Supply 3-30 3.8.2 Optics 25.6-KCPwerSupply* * * * . 3-30 KOLLSMAN INSTRUMENT CORPORATION CONTENTS (Cont.) Section Page I I I 30 9 DISPLAY AND CONTROLS PANELS 3-31 • I . . . 3.9.1 G and N Indicator. C. ontr.o l Pa.n e.l . . . . 3-31 3.9.2 Optical Panel* 3-33 9 w . 3.10 MAPANDDATAVIEWER* * * * 3-34 1 3.10.1 Functional and Operational Descript.i o.n 3-34 3.10.2 Description of Optics 3-36 3.10.3 Cartridge and Gear Box Assemblye 3-36 3.10.4 Panel and Door Assembly 3-39 3.10.5 Electronics Package 3-39 , 3.11 ALIGNMENT OPTICAL TELESCOPE 3-39 - ". 3.21.1 Telescope Shaft. Assembly . . . . 3-41 +I .. 3.11.2 Telescope Eyepiece Assembly 3-44 5 -- * i l SECTION 4 ENGINEERING - 1 . 1 4.1 ENGINEERING PERIOD ENDING 31 DECEMBER L962 4-1 . . . . 4.1.1 External Engineering . . . 4-1 - 4.1.2 Internal Engineering. . . . . . . 4-3 4 1 . 3 Study Analysis* 4-4 - I ENGINEERING PERIOD ENDINC 31 DECEMBER 1963 4-6 4.2 . . . . . . . . . . . . . . 4.2.1, External Engineering - . . . . . . . . . . 4-6 4.2.2 External Engineerinq L.M . . . . . . . . . . . . 4-12 4.2.3 Internal Engineering 4-15 - I i 4.3 ENGSNEERINC PERIOD ENDING 31 DECEMBER 1964. 4119 4.3.1 Externa1,Enqineering 4-19 - 4.3.2 Internal Engineering 4-19 4.3.3 Internal Engineering Block .1 .1 . (with Electronics) - . 4-28 * 4.3.4 Internal Engineering MDV 4-30 - 4.3.5 Internal Engineering t AOT . 4-34 4.3.6 Internal Engineering PTE/GSZ 4-34 KOLLSMAU ~NSTRUMENTC ORPORATION . CONTENTS ( Cont ) - Section I - 1 4.4 ENGINEERING PERIOD ENDING 31, DECEMBER 1965 4-35 I . . . . . . - 4.4.1 Externa1,Engineerinq . . . . . . . . 4-35 4.4.2 External Engineering . LM . . . . 4-37 44.3 Internal Engineering 4-45 - I 40 S ENGINEERING PERIOD ENDING 31 DECEMBER 1966 4-77 . . . 4 . 1 Cornand Module Engineering 4-77 4.5.2 OUA Components. an.d .S .u bas.s e.m .b .lv . . . . . . . . . performance* . . . 4-78 4.5.3 Lunar Module Engineering. 4-152 - I I 4.6 ENGINEERING PERIOD ENDING 31 DECEVBER 1967 4-157 1 . . . . . . I 4.6.1 Engineering Activiti.e s. . . . . . . . . . . . 4-157 1 4.6.2 GSEEngineerinq . . . 4-181 4.6.3 Lunar Module Project En.g i.n e.e .r in. g. . . . . . . . 4-181 4.6.4 Engineering Activities . . . . . . . . . . . 4-182 4.6.5 Qualification Proqram 4-184 1 - hid - . I 4.7 ENGINEERING PERIOD 1968 1969 4-185 . . . . . . 4.7.1 Command Module Engineering . . . . 4-185 4.7.2 Engineering Activities . . . . . . 4-185 4.7.3 Lunar Module Project Engineer.i n.g . . . . . . 4-187 4.7.4 EngineeringActivities . . . . . . . . 4-188 4.7.5 Field S i t e Activity 4-188 4.7.6 R a n g e f i n d e r * * * e m * * * * * * * * m * * * * * . 4 - 1 8 9 -- SECTION 5 RELIABILITY . 5.1 SUMNARY OF YEAR ENDING 31 DECEMBER 1962 5-1 5.1.1 Establishae~tro f. S.t an.d a. rds. a.n .d . . . . . Techniques . . . . 5-1 5.1.2 Preparation of Reliabf l i t y Plan 5-1 5.1.3 Assignments . . ~ . .. .. .. ... . m . . . . . . . . . .. 5 - 1 5.1.4 Accomplishments 5-3 SUMMARY OF 'YEAR ENDING 31 DECEMBER 1963 * 5-12 . . . . . . . . . . . . . . . I 5.2.1 Assignmnts 5-12 5.2.2 TD K-11 Vendor Re. liabil.it .y .a nd. . . . . . . . Quality Control 5-12 I i w iv 3 , I I CONTENTS (Cont.) Section -- SECTION 5 RELIABILITY (Cant, ) . . . . . . . TD K-28 Reliability Analysis . TD K-29 Reliability Test and E.v a. l.u a.t i.o n. . TD K-30 Reliability Training TD K-42 Design Evaluation and. . . . . . . Qualification Test Program . . . TD K-48 Shipping Containe.r .D e.s .i g.n . . . . . TD K-60 Thermal Analysis . . TD K-62 Optical Unit Stress Analysis TD K-61 AGE-2 Mechanical Integrity Tests. TD K-8 1 Optics-Navigation Base Ass.e m. b.l y. Shipping and Handling Container. TD K-83 AGE-1 Optica.l Sub.s yst.e m. . . . . . Thermal Vacuum Test TD K-79 AGE-1 and -2, MDV Thermal- . . Vacuum and Mechanical Inteqrity Tests TD K-76 Failure f.t e.p o. r.t i.n g S.y s. te. m. . . . . (Datacenter). TD K-103 Fab. r.i catio.n 4. O. S.S .S h. i.p p.i n. g. . . . Containers 5.3 SUMMARY OF YEAR ENDING 31 DECEM5ER 1964 . . . . . . . . . . . C/M Reliability Plan TD K- 11 Vendor R e.l i.a .b il i. t y .a nd . . . . QualityControl . . . TD K-28 Reliability Analysis . . TD K-30 Reliability T r a h i n g TD b . 4 2 Design Evaluation and. . . . . Ilualification Test Program . . . TD K-76 Failure Reporting System TD K-79 AGE-1 MDV Thermal Vacuum and . . Mechanical Integrity Tests . . TD K-48 Shippizg Container Design. TD K-103 Fabr.i c.a t.e .F .o u.r .O .S S. S. h..i p.p .in .g . . . Containers TD K-81 Optics-Navigation Base Ass.e mb.l y . Shipping and Handling Container . . 5,3.11 TD S-60 and K-98 Thermal Analysis 5.3.12 TD K-61 AGE-2 Mechanical Integrity Te.s .ts 5.3.13 TD K-62 Optical Unit Stress Analysis 5.3.14 TD K-83 AGE-1 Optical .S u.b syst.a m . . . . Thermal/Vacuum Tests 5.3.15 TD K-104 Failure Effects Analysis KOLLSMAN INSTRUMENT CORPORATION llrl COtWENTS (Cont. 1 Soc tion Page - I SECTION 5 RELIABILITY (Cont.) I I 5.3.16 TD K-127 Block ZI Reliabi.l ity. . . . . . . . Programplan rn rn l rn 5.3.13 TL) K-80 Parts Qualification Program l l 5.3.18 TD K-126 LM Reliability Analysis l 5.3.19 Reliabi l i t y Report Analyses . (Reports No, AAR-1 thru AAR-6). l SUMMARY OF YEAR ENDING 31 DECEMBER 1965. . l . . . I n t r o d ~ c t i o n rn rn rn rn Reliability Activitie. s Component Data l l. rn rn rn rn l SCD Upgrading rn l Support s f Manrrf acturing Modified C l a ~ s A P a r t ~ . . . . . . . . . . . . . r n a r n r n Extended Performance T.e at (EPT) Program Vendor Design Review l l Failure Analysis Reports l l l l Reliability Repart Analyses (Report No.; AAR-8 thru AAR-47) l SUMMARY OF YEAR ENDING 1966 l l l l l . . Introduction rn Major Reliability Problems Parts and Materials Program l Reliability Training Program fot Personnel Certification* l l Extended Performance Testing Program l l l Qualiffcation Test Progr.a m FailureAnalyses* . rn Reliability Reports l l l SUMMARY OF YEAR ENDING 31 DECEMBER 1967 l l l l 5.6.1 I n t r o d u c t i o n * r n * . * r n * * . r n * * a a a a a a . 5.6.2 Major Reliability Problems . l 5.6.3 Parts and katerials Program l 5.6. Reliability .TrainingeP rogram f o r ' Personne1:Certification l rn 5.6.5 Extended Performance Testing Program 5.6.6 Qualification Test Program 5.6.7 Design Change Activity * a' l l KO1 ' $MAN INSTRUMENT CORPORATJON CWTEAJTS (Con to) Section Page -- SECTION 5 RELIABILtITY (Cont ) 5.6.8 F a i l ~ r e R e p o r t a ~ 5-*149 ~ ~ ~ ~ ~ ~ * ~ ~ ~ ~ ~ ~ ~ ~ So6 .9 Reliability Report Analyses . (Reports ARR-64 throuqh ARR-78) 5-156 - . . SUMMARY OF YEARS 1968 1969 5- 161 a . . . . . . . . . . . Introduction . a Yajor Reliability Problems . Parts and Materials Program ~ e l i a blii t y Fai lure Action Summary Extended Performan. c.e .T es. t i.n q. .P roq.r am Design Activity- . Failure Report Summary* ~ e l i a b i ltiy Report Analysis (ARR-7.9 ) . Reliability Effort on Rangefinder Waiver Summary -- SECTION 6 QUALITY ASSURANCE SUMMARY OF YEAR ENDING 31 DECEMBER 1962 6-1 6.1.1 ProgramEffort * 6-1 SUMWRY OF YEAR ENDItJG 31 DECEMBER 1963 6-3 . 6.2.1 ProqramEffort 6-3 SUMMARY OF YEAR ENDING 31 DECEMBER 1964 6-13 . . . 6.3.1 ProgramEffort . 6-13 6.3.2 Accomplishments . 6-14 6.3.3 Problem Areas 6-16 SUMMARY OF' YEAR ENDING 31 DECEMBER 1965 6-17 . . . . . . . . . Management* . . . . . . . . . . . . . . . . Motivatioh. . . . Problem Areas and C.o rrecti.v e. .A c.t i.o .n . . . . . Procurement . . . . . . . . Quality Engineering . . . . . . . . . Fabrication Control . . . . . . . Material Review Board . Problem Areas and Corrective Aation . . . . . A ~ d i t ~ * * * . m . . . e e * . . . . a s vii