PACS IBDR 27/28 Feb 2002 PACS FPU FPU R. Graue, D. Kampf Kayser-Threde.

PACS FPU

PACS IBDR 27/28 Feb 2002

FPU

R. Graue, D. KampfKayser-Threde

PACS FPU


Primary Structure

Photometer housing

Bolometerhousing

Red SpectrometerConnector Panel

Collimator housing

Top Optics housing

Spectrometer housing

Chopper Cover

FPU foot 1 axis

FPU foot2 axis

Blue SpectrometerConnector Panel

2 K Feed Thru

Alignment Cube

Entrance toFPU

Field Mirror forSpectrometer

4 K Thermal Strap

PACS FPU


Primary Structure (continued)

Collimator housing

FPU foot3 axis

4 K Thermal StrapGrating Connector Panel

Grating Cover(external mounting of grating)


2 K Feed Thru

Photometer housing

Bolometerhousing

Alignment Cube

Top Optics housing Chopper Cover

Field MirrorExternal Mirror Fixation

Peri 1External Mirror FixationB_Mirror_2

External Mirror Fixation

PACS FPU


Primary Structure (continued)

Bolometerhousing

Collimator housing

Spectrometer Cover


Red SpectrometerConnector Panel

FPU foot 1 axis

FPU foot3 axis

Photometer housing

Grating Connector Panel

Grating Cover(external mounting of grating)

FPU foot 2 axis

PACS FPU


FPU Suspension

PACS FPU


Detector Struts Side/Iso View

Fibre: T300Resin: Ciba Geigy

Araldit LY-3505Hardener XP 3403

PACS FPU


FPU Structure, Baffles and Straylight

Entrance Baffle

PACS FPU


FPU Structure, Baffles and StraylightBottom view of TOP OPTICS

Baffle are shown in brown

1st field stop

Aperture Stop(complete closure of entrance compartment)Lyot stop for telescope secondary mirror edge

Chopper: 2nd aperture stopLyot stop for aperture stop (2nd Lyot stop)

Closure of Entrance Optics(quasi 2nd field stop)

Mirror FOLD 5

PACS FPU


FPU Structure, Baffles and StraylightPhotometer housing seen from Top Optics

Mirror FOLD 5 from Top Optics scetched

2nd Field StopFocus Mirror (to Spectrometer)

Entrance to Photometer

Focal planes of photometer

Entrance to Slicer / Spectrometer

PACS FPU


FPU Structure, Baffles and StraylightBottom view of Photometer housing (interface to bolometer)4th aperture stop at conic baffle to thedetector arrays not shown

Separation wall between red and blue compartmentcontains Dichroic beamsplitter (near 3rd aperture, not accessible)

3rd field stop (blue photometer)

3rd field stop (red photometer)

PACS FPU


FPU Structure, Baffles and StraylightCollimator housing

Grating drive

Grating

PACS FPU


FPU Structure, Baffles and StraylightSlicer seen from Photometer

Focus Mirror scetched

Entrance to slicer / spectrometer

PACS FPU


FPU Structure, Baffles and StraylightSlicer seen from collimator

Area blocked by housing

Beam to collimator

Beam to spectrometer, exit from collimator

PACS FPU


FPU Structure, Baffles and StraylightSlicer internal view

Focus mirror inside photometer

To collimator

To spectrometer

PACS FPU


FPU Structure, Baffles and StraylightSpectrometer seen from bottom

Filter wheel

Blue spectrometer detector

Red spectrometer detector

From slicer / collimator

PACS FPU


FPU Structure, Baffles and StraylightSpectrometer seen from bottom

Filter wheel

Blue spectrometer detector

Red spectrometer detector

PACS FPU


2K - Feed Through Design

A: Outside sleeve

B: Inside sleeve

C: Cold finger

D/E: Retainer ring 1/2

F: Muff

G: Ring

Fixation to housingaluminum

CFRP Tubes

CFRP

Copper old Finger

PACS FPU


IR Coating• Trade Off selection of baseline coating

• Material: Suede 3101 with glas beads (deep black, rough surface)

• Thickness (average): 430µm

• Test verification

• BRDF and specular measurements (Delft University)

• liquid nitrogen test

• contamination test

• Outgasing tests (CVCM, TML) to be performed

• Problem: (particulates drop off) Solution: Update of procedure

(brushing, intermediate drying, materials of layers)

PACS FPU


IR Coating - BRDF

Sample No. 24

0.001

0.01

0.1

1

-90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60

angle of reflection

BR

DF

(1/

sr)

96µm; ?i = 10°

96µm; ?i = 30°

96µm; ?i = 50°

184µm; ?i = 10°

184µm; ?i = 30°

184µm; ?i = 50°

PACS FPU


IR Coating - Specular reflection

Sample 24

1.0E-05

1.0E-04

1.0E-03

1.0E-02

1.0E-01

1.0E+00

10 20 30 40 45 50 55 60 70 80

angle of incidence

sp

ec

ula

re r

efl

ec

tio

n KT-24, 96µm

KT-24, 184µm

PACS FPU


Design Envelope

95

50

550

320

370

XY

210

470

275

20150

755R

60

FPFPU Housing

FPFPUsuspension

= Approved envelope

eEEnvelope

Notice:

30

200

1040230

120R

XZ

R4000from x,z=-3540,0

PACS FPU


Optical Bench Interface

42

9

45

9±

0,

02

48

9

82

,5

13

2,

51

42

,5

±0

,0

2

18

2,

51

97

,5

10

5

15

1

233

25

8,

1

676, 5691 ±0, 02

710

16

627, 5

Z

Y

Mount i ng ar ea

8, 5( 9x)

Pi n 15 H8 ( 2x) Tr ee axi s suspens i on

2 Ke

lvi

n con

necti

on

2 Kel

vin c

onnec

tion

Z

PACS FPU


Optical Beam Stay Out Envelope

20

2

61, 6

755

R

65

30

3 08 . 3

28

39

PACS FPU


Design and MAIV Status of Structural Items

• Top Optics & Slicer manufacturing drawings completed

• Top Optics manufacturing in progress

• Collimator detailed design completed

• Bolometer & Spectrometer detailed design in progress

• CFRP Struts (Breadboard) under manufacturing

• Cleanroom set up in progress

PACS FPU


Documents Status

– ICDs• Chopper, FW, Calibration Source, Filters/Dichroics, Ga:Ga

Detector, Grating: approved• Bolometer, Distribution Boards: several open points under

evaluation• Cryogenic harness : approved• External interface drawing: to be approved

– Procurement specifications (structures, mirror, coating, screws/helicoils, Si -lens, emitter for CS , etc.) issued

– AIV and functional/environmental test plan issued

PACS FPU


PA Activities

• Documents– PMP– CIDL– PA Plan– MIP/KIP plan– Inputs to FMECA

• Approval of procurement/manufacturing documentation/drawings

• Configuration Control

PACS FPU


MIP / KIP List

Inspection of FW assembly (CQM/PFM) after functional and environmental verification testing at TTL

Inspection of calibration source (CQM/PFM) after environmental and functional testing at MPE

Inspection of coated mirrors (CQM/PFM) at KT (tbc)

Substructure fit check inspection after manufacturing and coating of aluminium structure (STM/CQM/PFM) at KT

Inspection of all distribution boards and harness after manufacturing and functional testing (CQM/PFM) at KT

Functional performance verification after FPU alignment (CQM/PFM) at KT

FPU performance inspection after vibration tests (CQM/PFM) at MPE

PACS FPU


SCHEDULE• Manufacturing

– STM/CQM primary/secondary structures thermal treatment /manufacturing /IR coating sequentially to be completed until 7/02

– CQM/PFM optical components to be completed until 6/02– STM/CQM/PFM CFRP struts and 2 K feed through material test

program in progress, manufacturing to be completed until 5/02– Filter Wheel BB completed, CQMs hardware partly

manufactured, tests completed until 8/02– Calibration source BB component tests in progress, CQMs

hardware delivery until 7/02 (tbc)– Distribution board manufacturing to be completed 12/02 (tbc -

CPP delivery on critical path)• AIV

– STM in 7/02– CQM from 7/02 to 4/03

PACS FPU


Optical Mirrors

PACS FPU


PACS FPU


Status of Optical Mirrors

• Manufacturing drawings completed (incl. Alignment mirrors)

• Coarse manufacturing of CQM/PFM completed

• Thermal treatment completed

• Optical surface finish in progress

• Cryogenic pretests (thermo-optical behavior) of mirror

samples completed

PACS FPU


Alignment Plan

PACS FPU


Alignment Tasks

• Optical axis of telescope to FPU (alignment cubes/mirrors)

• Top Optics with Calibration Sources and Chopper

• Slicer optics

• Spectrometer/Collimator optics with Grating Assembly

Dummy, Dichroic, FW1, Ge:Ga Detectors

• Bolometer optics with Dichroic, FW2

• Integration of bolometer assembly (CEA)

PACS FPU


Alignment PlanAKF at centre of the telescope secondary mirror

PACS FPU


Alignment PlanAKF and Laser assembly with top optics

AKF centered at nominal position of telescope secondary mirror (real aperture)

Top Optics side view

Chopper

Intermediate focal planesplitting between spectrometer and photometer section

Internal aperture stop

PACS FPU


Alignment PlanCentering alignment of bolometer

Intermediate focal planesplitting between spectrometer and photometer section

Field Mirror

Peri 1

B_Mirror_2

PACS FPU


Alignment PlanBolometer alignment

B_Mirror_2B_Mirror_1

Blue Bolometer focal plane

Filter Wheel Bolometer

PACS FPU


Alignment PlanSlicer Optics alignment

Focus Mirror at intermidate focal plane

PACS FPU


Alignment PlanSetup for slicer element alignment

PACS FPU


Alignment PlanCollimator Alignment

PACS FPU


Alignment PlanRed and Blue spectrometer channel alignment

PACS FPU


Alignment Status

• Updated Alignment plan issued

• Alignment procedure engineering in progress

• Preliminary OGSE procurement plan

• CVSE procurement in progress (cryostat)

PACS FPU


OGSE• Autocollimation telescope• Optical mounts• 4 x CCD array with optics• PC with framegrabber• 2 x alignment telescope• 4 x HeNe Laser (laser diode)• Set of pinholes from nickel with LED's (point sources)• Support structure for pinholes• Masks for mirrors (plexiglas with 3 point orientation to the

front surface)• Scatter-plates• Lateral translation stages• 2 x Rotary table• Alignment mirrors during alignment (temporary)• Alignment mirrors for FPFPU alignment

PACS FPU


Structural and Thermal Analysis

PACS FPU


Filter Wheels and Calibration Sources

PACS FPU


FW Design

• Flip angle

• Precision of end stop

• Power dissipation per position change

• Transition time

• Operating temperature

• Warming of parts within view of detector

• Duty cycle

• Life time

0° > 180° > 360°(Optionally 90° & 270°)

30 arcmin

< 50 mWs

5 sec (average)

3-300 K

< 0.1 K (filter wheel assembly requirement, only)

1 per 30 min.

20000 cycles

PACS FPU


Filter Wheel Assembly

PACS FPU


Filter Wheel Assembly (side view)

PACS FPU


Calibration Source - Surface with Exit Aperture

PACS FPU


Calibration Source

– 0.0005 homogeneity integrated over aperture

– 5 mK temperature stability

– 50 K - 100 K thermal range

– power dissipation at 100 K < 1.5 mW

PACS FPU


Calibration Source - Scatter Mirror and Source

25

14

12

Calibration Source Sphere 4 K, high scatter surface with high reflectivity

Scatter Plate4 K

Emitter at 100 K2 x PT500

Emitter fixation

Si Lens

Aperture

PACS FPU


Calibration Source with Scatter Plate

PACS FPU


Calibration Source

• Baseline Design – Emitter : 2 x PT500 resistor for heating and emission

with 4 wire setup (measurement current used for heating)

– Emitter size: Volume : 6.4mm x 5.2 mm x 6 mm

Weight: 550 mgSurface: 205 mm² (tbc)

Heat capacity:0.45 J/K (tbc)

PACS FPU


Calibration Source - Feet Design

4 Feet 24 mm x 0.25 mm x 0.25 mm 16 layers of GFRP Interglas Style 106 (quasiistropic)

Coating 2 x Ti , 200 nm thickness reduction of feet emission increase of thermal conductance electrical connection to emitter increase of resistance

3 x stiffening rings to prevent buckling (not shown) 0.4 mW feet conductance 1 mW emitter radiance

PACS FPU


Calibration Source

Previous emitter size

PACS FPU


Calibration Source - Specular Reflection

0 20 40 60 801E-3

0.01

0.1

1

KT-gold-2 sample = 96 m

= 96 m

= 184 m

Spe

cula

r R

efle

ctio

n

Angle of Incidence i

SCATTERSURFACE GOLD COATEDReflectivity > 0.992

PACS FPU


Calibration Source - BRDF Measurements

-140 -120 -100 -80 -60 -40 -20 0 20 40 60 800.1

1

10

= 96 m = 184 m

i= 10

0

i= 30

0

i= 50

0

BR

DF

(sr-1

)

Angle of Reflection i

SCATTERSURFACE GOLD COATEDReflectivity > 0.992

PACS FPU


Distribution Boards and FPU Harness Concept

PACS FPU


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Blue Detector Interface

Material

CAD Drawing No manual Changes

FPFPU

of

SheetDINWeightScaleSurfaceGen. tolerances

NameDateChangeState

File

Checked

Prep.

NameDate

1:2 -- A3 1

2

Assembly01 First Issue 22.03.01KC

--

02 9 connectors ->724.08.01KC

03 10mm <->15mm09.10.01KC

PACS-KT-ICD-0800W1.04

0800w104.CatDrawing

KC23.01.0204 Routing & Struts

60

92

,1

Bending begins at z(detector)= -105

First support after 90° with R=20mm

Distribution board

with

rad

ius c

en

ter a

t o

ptic

al p

up

il

4K level

2Klevel

PACS FPU


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bs

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sin

d

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rvie

lfältig

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reitu

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, Au

ss

tellu

ng

, Vo

rfüh

run

g,

Red Detector Interface

Material

CAD Drawing No manual Changes

FPFPU

of

SheetDINWeightScaleSurfaceGen. tolerances

NameDateChangeState

File

Checked

Prep.

NameDate

1:2 -- A3 1

2

Assembly01 First Issue 10.04.00KC

--

02 09->08/09 12.03.00KC

22.03.002K Srap03 KC04 COG / Handling P.0705.01KC

KC23.07.01chamfer 10x1005

06 9 connectors->724.08.01KC07 routing & susp.23.01.02KC0900w107.CatDrawing

PACS-KT-ICD-0900W1.07

2K Level

60 (4k level)

92

,1(4

K l

eve

l)

First support after 90° with R=20mm

with

rad

ius a

t op

tica

l

pu

pil

Harnes

Bending begins atz(detector)=-105

4K Level

Distribution Board

Harness layout due to equal length of all detector modules

PACS FPU


• Rigid-flex boards• Material

– PCB: FR4– Flexible Harness: Polyimide

• Layout shall be designed according to CNES QFT/SP.0019

• Connectors: Cannon MDM 3401029 01B .... FR139• Capacitors: WIMA MKS 6,8 micro Farad, 50 VDC,

30 VAC• Resistors: RNC 55 according to ESA SCC 40001

001 (TBC)

Distribution Board - Design

PACS FPU


• Circuit diagram completed, except some open points

• ICD update in preparation for release• Capacitors are ordered, delivery time:

31.10.02 (tbc)• Connectors will be delivered on 30.03.02,

except later ordered connectors• Test board is manufactured • Cryogenic test of test board planned in cw 8

Distribution Board - Status

PACS FPU


• Grounding of distribution board to housing (tbd by MPE)

• Characteristic data of some resistance • Release of circuit diagram

Distribution Board - Open Points

PACS FPU


PCB layout test against Gerber data (inspection protocol)

Incoming inspection according to inhouse procedures

Pin to pin continuity Insulation Visual inspection (components, bonding

points)

Distribution Board - Verification

PACS FPU


- Thermal cycling (tbc) of the boards- Microscopic tests (e.g. cracks)- Cross talk ohmic resistance test- Use of ESA qualified capacitors and resistors- Functional test with full detectors chain (i.e.

detectors, read out electronic, etc.) at MPE

Distribution Board - Verification

PACS FPU


Filter Wheel 1SpectometerJ302P302JO2

J301P3O1JO1

Filter Wheel 2Bolometer

J303

J304

P303

P304

J03

J04

Calibration Source 2

J306P306J06

C01

C02

C03

C04

Calibration Source 1

J305P305J05C05

C06

Chopper J07

J308T-Sensor 4K connection (TBC)

T-Sensorone axis mount

P308

J318 P318

J08C08

Cable not manufactured at KAYSER-THREDE

PACS Inner FPU Harness

PhotoconductorDetector (red)

DistributionBoard 1 (red)

J100-J124

J10 -J18

P100-P124

MPE Distribution Board 2(blue)

J200-J225

P200-P225

PhotoconductorDetector (blue)

J20 -J28

MPE

GratingAssembly

J40

CSL

Bolometer Array

JXX PXX JXXCEA

(50-99)

J41

CSL

J42

J43

CSL

CSL

(power)

(power red.)

(signal)

(signal red.)

Outer FPU Harness

J309T-Sensortwo axis mount

T-Sensor three axis mount

P309

J319 P319

J09

31s

31s

31s

31s

31s

31s

31s

31s

31p

31p

31p

31p

9p

9p

9p

9p

9s

9s

9s

9s

9s

9s

15p

15p15s

15s

15s

15s

PACS FPU


Harness - Design

• Cable– shielded, jacketed multicore cable; Gore SPL 41-28,

4 cores– Conductor: silver plated copper– Insulation: polyimide

• Connectors: Cannon MDM connectors 3401029 01B

PACS FPU


• Cable ordered• delivery time: end of February• Manufacturing of harness at Cannon• delivery time: about 12 weeks

Harness - Procurement Status

PACS FPU


• Heater wire– Type not yet defined – planned 4 core brass cable AWG 38 with stainless

steel shield according to GSC 6769– Request for Quotation submitted to Cannon– No confirmation from Cannon concerning the use of

AWG 38 cable

Harness - Open Points

PACS IBDR 27/28 Feb 2002 PACS FPU FPU R. Graue, D. Kampf Kayser-Threde.

Documents

Transcript of PACS IBDR 27/28 Feb 2002 PACS FPU FPU R. Graue, D. Kampf Kayser-Threde.