PACS IHDR 12/13 Nov 2003 PACS FPU FPU Structure, Baffle and Straylight R. Graue, D. Kampf...

PACS FPU

PACS IHDR 12/13 Nov 2003

FPU Structure, Baffle and Straylight

R. Graue, D. KampfKayser-Threde

PACS FPU


Primary Structure

Chopper Cover

Photometer housing

Bolometerhousing

Red SpectrometerConnector Panel

Collimator housing

Top Optics housing

Spectrometer housing

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


FPU STM

PACS FPU


Bolometer Integration

PACS FPU


Straylight Analyses – Top Optic Model

ASAP Model of Top Optics• Derived from optical ZEMAX Model • Black Coated Walls (>0.4 mm)

PACS FPU


Straylight Analyses – Results and Status

• High straylight suppression

• Neglible straylight impacts in consequent boxes

• Inputs considered for Baffle Design

• Straylight suppression 1e-10 to focal plane

• Modell delivered to ASTRIUM

PACS FPU


2K - Feed Through

Outside sleeve

Cold finger

D/E: Retainer ring 1/2

F: Muff

G: Ring

• Cryo STM Vibration Tested

• Manufactured and Delivered

PACS FPU


FPU Suspension Design Status and Material

•Status: •Design: completed•Documentation: Completed

•Material•Fibre: T300•Resin: Ciba Geigy

Araldit LY-3505Hardener XP

3403

PACS FPU


FPU Suspension Cryo Qualification Test Matrix

Status

• Static load tests: completed

• (Cold) material characterisation: completed

• Cryovibration tests: complete (CRYO STM

FPU)

PACS FPU


MGSE and CVSE Status

• MGSE design, procurement and

functional test completed

– Vibration test adapter

– Lifting device

– Integration Tools

– FW Test Box

• CVSE design, procurement

(cryostat) and functional test

completedKT Cryostat Test Faciliy for Stability Tests

PACS FPU


Mass Budget

Measured structural items (KT) 52.7 kg 71.7 %

Estimated mass (KT)* 4kg 5.4 %

Measured Bolometer 7.4 kg 10.0 %

Measured Grating 4 kg 5.4 %

Measured Chopper 0.6 kg 0.8 %

Measured Ge: Ga Detector 4.9 kg 6.7 %

Total 73.6kg 100 %

*IR Black Paint, Internal Harness, Screws Contingency not

needed

PACS FPU


Performed FPFPU Analyses Program

PhysicalAnalyses

Optical AnalysesThermalAnalyses

MechanismsAnalyses

StructuralAnalyses

TolerancingAnalyses/Budgets

StraylightAnalysis

Strength Analysis

Deformation/DistortionAnalysis

Load Analysis

Ray Tracing ,Spot Spot DiagramQuasi Static

AnalysisFunctionalAnalysis

Natural ModesAnalysis

Mass PropertiesAnalysis

PACS FPU


PACS Thermal Model

PACS-Thermal Model (Input-Status: May 2003)

- PACS thermal model used as submodel of the H-EPLM reduced thermal model

- PACS submodel consists of 154 thermal nodes

PACS-TMM includes:

- All mechanisms, all harness, radiative environment

- Possibility of transient analysis (cool-down and operational time-line)

PACS FPU


Thermal Analyses - Status - Completed Tasks

• Thermal Analyses– Quasisteady state and transient thermal analyses – Calibration of thermal model (cooling down curves) after

Cryo STM tests– Analyses of thermal links (2 K) wrt conductivity

• Documentation released

PACS FPU


PACS Cool-Down Behaviour

0

50

100

150

200

250

300

0 0.5 1 1.5 2 2.5 3 3.5 4

Time [d]

Tem

per

atu

re [

K]

CSL-Measurem.: Base Plate L1-Strap Red Detector Grating Top Optics

Calculation: L12-Housing I/F Red Detector Grating Housing Avg.

PACS FPU


PACS Thermal Analyses - Open Tasks

- Update of the cryostat-TMM (Sept. 2003) not yet included

- Dissipation values of the grating and the calibration sources are no measured values

-Impact of Electrical insulation between spectrometers and cooling-straps not yet defined

- Results of the discussion of the cooling-strap-IFs not yet included

- Contact resistances at the cooling-strap-I/Fs only assumed, but not measured

PACS FPU


Structural Analyses - Status - Completed Tasks(see H/O wrt. STM warm/cold vibration)

• Structural Analyses– Evaluation of ambient and cold vibration tests – FEM calibration– Load analyses with calibrated model (cryo-vibration test)– Strength analyses for FPU metallic and CFRP components – Cryogenic material properties analyses – CoG, MoI analyses– Displacement, distortion, deformation analyses

• Documentation released

PACS FPU


FPU Structure Status – External Interfaces

Design envelope frozen

Optical beam stay out frozen

OB envelope frozen

DCNs of Assembly and IF Drawing version 27 to be approved

PACS FPU


Documents Status

– ICDs• Chopper, FW, Calibration Source, Filters/

Dichroics, Ga:Ga Detector, Grating: approved• Bolometer, Distribution Boards: approved• Cryogenic harness and connectors: approved

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

– AIV and functional/environmental test plan: updated– Filled in verification matrix: latest status

(10.2003)

PACS FPU


Configuration Control Documents

Document Description Doc.-No. Configuration Control

FPU Interface and Assembly Drawing Version 27 Yes

FPU Design Specification PACS-KT-SP-002 Yes

Ge detector ICD PACS-KT-ID-002 Yes

Bolometer ICD PACS-KT-ID-005 Yes

CS ICD PACS-KT-ID-007 Yes

FW ICD PACS-KT-ID-006 Yes

Distribution Board ICD PACS-KT-ID-004 Yes

PACS FPU


Approved Engineering Documents

Document Description

FPU Alignment Plan

FPU Thermal Analyses

FPU Structural Analysis

FPU Load Analysis

FPU AIV Plan

FPU Environmental and Functional Test Verification Plan

FW Environmental and Functional Test Verification Plan

PACS FPU


PA Activities (KT)

• Approved Documents– PMP (Update)– CIDL (Update)– CIL (Issue1)– PA Plan (Update)– MIP/KIP plan (Update)– Inputs to FMECA (Update)

• Approved procurement/manufacturing documentation/drawings

• Configuration Control

PACS FPU


MIP / KIP List

Inspection FW assembly (CQM/PFM) after functional and environmental testing Calibration source (CQM/PFM) after environmental and functional

testing Coated mirrors (CQM/PFM) FPU after vibration tests (CQM/PFM) Distribution boards and harness after manufacturing and functional

testing (CQM/PFM)

Fit check inspection after manufacturing and coating of aluminium structure (STM/CQM/PFM)

Functional performance verification after FPU alignment (CQM/PFM)

PACS FPU


MAIV Status of Structural Items -Completed Tasks

• CQM– Mechanical items design and manufacturing drawings

completed and released– STM/ CQM metallic items manufactured and IR black coated– Mechanical Fit check/Preintegration of all mechanical items

(on boxes and FPU level)– STM/ CQM CFRP items manufactured and static load tested– Cooling straps manufactured

• PFM– Structural items design and manufacturing drawings

completed and released– CFRP items manufactured and static load tested

PACS FPU


MAIV Status of Structural Items - OpenTasks

• CQM– Thermal Contact Soldering and Ge:Ga detector attachment (sapphire

embedding) of CQM cooling straps in progress (until end of Nov. 2003)– Development of Ge:Ga Detector electrical isolation (thick layer

coating) under progress (until end of Nov. 2003)• PFM

– Substructures and metallic components manufacturing in progress until April 2004

– Preassembly/fit check until June 2004– Finish and black Coating until July 2004

PACS FPU


FPFPU Cryo Vibration Qualification Breakdown

FPFPU Qualif ikationKT Units

Filter Wheels(Bolometer andSpectrometer)

DistributionBoards (Blue and Red)

2K Thermal StrapsFPFPU

SuspensionFPFPU

HousingDetector Suspension

Similar to CQM

Qualif ication TestsComplete

Housing Qualif ied

Similar to CQM


Suspension Qualif ied

Similar to CQM


Filter WheelsQualif ied

Similar to CQM


Distribution BoardsQualif ied

CQM


Hardw are w ill berew orked

Qualif ication inprogress

CalibrationSource

Similar to CQM


Calibration SourceQualif ied

2K StrapsQualif ied

See dedicated chapters

PACS FPU


PACS FPU Verification

Similarity• CQM and STM were

manufactured parallel with the same drawingsout of the same lot

Qualification Tests• STM vibration tests

Reduced Functional Test

Functional Test(LHe)

Vibration Test - tbc(LHe)

Ambient VibrationTest (Qualification )

Physical Measurement

Functional Tests

Prel. OpticalPerformance Tests *

CQM

Vibration Test(LHe - tbc)

Vibration Test(ambient)


Mass / StructuralDummy


Functional Test(LHe)

Cold Vibration Test

Ambient VibrationTest (Acceptance)


Functional Tests


PFM


Functional Tests(LHe)

Ambient VibrationTest (Acceptance)


Functional Tests


FS

F PF PU Test Pro g ra m

Tests completedConclusion:

FPFPU Housing is structurally qualified

PACS FPU


CQM SCHEDULE

• Manufacturing– CQM primary/secondary structures thermal treatment

/manufacturing /IR coating sequentially completed – CQMoptical components delivered– CQM CFRP struts and 2 K feed through material test

program and manufacturing completed

• AIV (Final assembly and alignment) – CQM from 7/03 to 1/04 (tbc)

PACS FPU


PFM SCHEDULE• Manufacturing

– PFM primary/secondary structures thermal treatment /manufacturing /IR coating to be completed until 6.2004

– PFM optical components delivered– PFM CFRP struts and 2 K feed through material test

program and manufacturing completed

• AIV (Final assembly and alignment) – PFM from 7/04 to 11/04

PACS IHDR 12/13 Nov 2003 PACS FPU FPU Structure, Baffle and Straylight R. Graue, D. Kampf...

Documents

Transcript of PACS IHDR 12/13 Nov 2003 PACS FPU FPU Structure, Baffle and Straylight R. Graue, D. Kampf...