fame - astro-opticon.org · actuators/sensor inventory prepared metrology ideas present ‐actuator...
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FAME
Freeform Active Mirror Element (WP5)OPTICON Board
Granada, Oct 29th 2014
On behalf of the FAME team:ATC: Martin Black, Chris Miller, Hermine SchnetlerKonkoly Observatory: Evelin Banyai, Attila JaskóLAM: Zalpha Challita, Emmanuel HugotNOVA‐ASTRON: Tibor Agócs, Gabby Kroes, Lars Venema (+ Felix Bettonvil, Rik ter Horst)
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FAME/GRANADA – LARS VENEMA 2
OUTLINEClassic freeforms, extreme freeforms, active freeforms,
Definitions, overview and interests
I. FAME optical design studyF/2‐4, 7x5.4deg, 2‐mirrors design and performance
II. FAME optical fabrication studyHydroforming thin freeform shapes: FEA and experiments
III. FAME optical active array studyopto‐mechanical design, FEA and performance
IV. Metrology and controldepending on tools developed in III – local and global
Towards an integrated system
Programmatics
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FAME/GRANADA – LARS VENEMA 3
GOALFreeform Active Mirror production development to
simplify systems complexity and boost performance of (Astronomical) optical systems
Opticon Phase 2 – a strong focus on realizing FAME
• WP 5.1: System studies, E‐ELT instrument optimisation• WP 5.2: Conception, simulations and preparatory tests of
models• WP 5.3: Manufacturing, assembly, integration and
performance characterisation of the Active Freeform Mirror
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FAME/GRANADA – LARS VENEMA 4
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FAME/GRANADA – LARS VENEMA 5
INCREASING FOCUSActive mirrors used in industry
ASML, Power laser systems, Drone applications (AO‐DMs useless)
Active Optics in SpaceRecent ESA tender: “(cryogenic) deformable mirror and correction”Many parties interested: University of Münster – Thales – TNO –LAM – NOVA ‐ …
Extreme shapesGenerally specials – Used in molds (mobile phones) ‐ beamers
Problem for general approachEach application has very different requirements
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FAME/GRANADA – LARS VENEMA 6
MOTIVATION OF PARTNERS
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Active Optics
Freeform Optics
Non Pupil plane correction
Cryogenic
Space Optics
Primary Observing Path Metrology
Long Term Stability
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FAME/GRANADA – LARS VENEMA 7
DEFINITIONSClassic Freeform
No‐rotational symmetryNot defined by conicoids
Extreme FreeformA freeform with a deviation from the BFS higher than 100µm on small diameters
Active FreeformCombining extreme freeforms and deformable mirrors R&D developments on optical design, opto‐mechanics, optical fabrication, control/command
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Provided by any good deformable mirror on
the market
THIS is a challenge!
Manufacturing issues
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FAME/GRANADA – LARS VENEMA 8
Face sheet
Active Array
Actuation Layer
BREAKDOWN
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FAME/GRANADA – LARS VENEMA 9
OPTICAL DESIGN(SELECTION)
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FAME/GRANADA – LARS VENEMA 10
PAST• non‐Zernike polynomial extension for ZEMAX• Optimization method limiting and steering DOF in design• Developing translation method projecting wfe of pupil plane to location of
actual optics
DEVELOPED TOOLS
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FAME/GRANADA – LARS VENEMA 11
METISmid‐IR instrument for the EELT – impact of freeform on design
MOS SpectroscopeA freeform with a deviation from the BFS higher than 100µm on small diameters
Extreme systems (3 freeforms in one system)Work also done by CeFO very nice but also expensive
CASES
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FAME/GRANADA – LARS VENEMA 12
3‐freeform mirrors f500No central obscurationNo corrective field lensFlat focal planeDistortion free,Diffraction limited 0.2µm – 1µmField 2x4 deg²
F/4 THREE FREEFORMS DESIGNBased on Fürschbach system (2011)Uses extreme freeform mirrors (sag BFS:1.2 – 1.3 mm and 0.4 mm respect.
x (mm)
y (m
m)
Residuals
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y (m
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y (m
m)
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100
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0.15
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0.25
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0.35
0.4
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FAME/GRANADA – LARS VENEMA 13
“METIS” SPECTROMETER• DL at shortest λ• Except extreme• corners• Optics costly
• Alternatives:Better quality
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FAME/GRANADA – LARS VENEMA 14
“METIS” “VERSION 2”Move all complexityinto one component
Optical quality“improved”
Sag
Deviation from BFSIs 0.06mm PV
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FAME/GRANADA – LARS VENEMA 15
“MOS” TYPE SYSTEM
Deviation fromBFS is 0.06mm PV
Sag
Only one non sphericalMirrorPerformance very good
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FAME/GRANADA – LARS VENEMA 16
F2‐4* TWO MIRROR SYSTEMCompact freeform based optical system (re‐imaging systems)
Very good image qualityFast F‐ratio
Freeform mirror M2Size 100mm diameterDeviation from BFS: 0.3mm PVHandled in ZEMAX:
Optimized set of Zernike
Testing & controlUsing the optical system itselfAccessible entrance pupil for Phase diversity
* Made slower to fit det. pixels
M2 (freeform)
Entrance pupil 25x12.5mm² M1 Convex
oblate ellipsoid
7x5.4deg²
For 1.7µm pix, 3800x2700pix pix size = 6.6x7.2arcsec.
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FAME/GRANADA – LARS VENEMA 17
0
0,5
1
1,5
2
2,5
3
3,5
4
µm RMS
FAME M2 mid order terms (5µm RMS)
051015202530354045
µm RMS
FAME M2 freeform shape (60µm RMS)
00,050,10,150,20,250,30,350,40,45
X Tetrafoil
Y Tetrafoil
X Trefoil
Y Trefoil
X Astig
Y Astig
X Co
ma
Y Co
ma
Sphe
rical
X Pe
ntafoil
Y Pentafoil
X Tetrafoil
Y Tetrafoil
X Trefoil
Y Trefoil
X Astig
Y Astig
X Co
ma
Y Co
ma
Sphe
rical
µm RMS
FAME M2 high order terms (0.6µm RMS)
x (mm)
y (m
m)
Residuals (PV = 0.303347 mm)
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(5μm RMS) (0.6μm RMS)
(60μm RMS)
ZERNIKE DESCRIPTION
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FAME/GRANADA – LARS VENEMA 18
FACE SHEET
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FAME/GRANADA – LARS VENEMA 19
Active Optics techniquesBeyond the elastic limit: plasticizing
Permanent deformations Large sags extreme shape Elastic domain recovered active compensation system
High material history dependency need of simulations & experimentation High material history dependency need of simulations & experimentation In-situ actuation
[Hugot et al., 2012]
[Ferrari, 1998]
Elasticity theory
Circular plates
Rigidity
Large displacements
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thicknessntsdisplaceme
Dqz22
)ν-(112EtD 2
3
Variable curvature mirrors(VCM/VLTI delay lines)
Stress polishing (Sphere/VLT toric mirror)
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FAME/GRANADA – LARS VENEMA 20
Operating modeFast (few minutes) & simple
• Thin substrate• Specific mould• High hydraulic pressure
Optical interests No high spatial frequencies residuals
No tool-marks Low spatial frequencies actively compensated Flat or spherical polishing
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FAME/GRANADA – LARS VENEMA 21
Operating modeFast (few minutes) & simple
• Thin substrate• Specific mould• High hydraulic pressure
Optical interests No high spatial frequencies residuals
No tool-marks Low spatial frequencies actively compensated Flat or spherical polishing
Pressures:‐ deformation: 450 bars‐ clamping: 100 bars
zmould(vertex) = 13.397 mm zmirror(vertex) = 11.899 mm
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FAME/GRANADA – LARS VENEMA 22
EQUIPMENT
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Dedicated hydroforming engine• 700 bars hydraulic oil pressure • Clamping system with hydraulic jack• Adaptable mold shape/material
Internal cavity with blank‐holder
Mirror & mold integration
Mirror deformed after processing AISI420b stainless steel
1 mm & 2 mm thicknessestotal 140 mm
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FAME/GRANADA – LARS VENEMA 23
MANUFACTURING STEP – PLASTICIZED MIRRORS QUALITY
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Residuals
Mid aspherical mirror
Moderate aspherical mirror
Spherical mirror
• Full‐size tool polishing ‐ Roughness: 10 nm rms, Focus: 5 µm rms, Astig. : 3 µm rms• Thickness: 1 mm (case 3) & 2 mm (case 1 and 2) – AISI 420b stainless steel• Optical surface: 100 mm
RoughnessEVM stress repartition
70 20 nm rms
15 4 nm rms
8 1 nm rms
• Depart. from BFS:280 µm ptv66 µm rms
• F/0.5 aperture
• Depart. from BFS:61 µm ptv17 µm rms
• F/4 aperture
• Error from BFS:1.8 µm ptv0.38 µm rms
• F/10 aperture
◌ Optical performance: FEA vs. Experiment
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FAME/GRANADA – LARS VENEMA 24
MANUFACTURING STEP – ENJOY ;) !
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◌ Plasticizing operation needs 5 minutes◌ Tests realized on thickness 2 mm & 1 mm◌ Tests on 1.5 mm are in preparation
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FAME/GRANADA – LARS VENEMA 25
ACTIVE ARRAY
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FAME/GRANADA – LARS VENEMA 26
Aim of the active array within FAMEGenerate the full freeform shape or compensate for manufacturing errors
Face Sheet Deformation1. Towards additional stiff structure (Conventional AO mirrors)2. Reshaping stiff structure
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ACTIVE ARRAY
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FAME/GRANADA – LARS VENEMA 27
ACTIVE ARRAY ISSUES
Pillars distributionPattern optimizationRelated performance
Pillars shapeReduce print throughImprove influence function shape and surface generation
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FAME/GRANADA – LARS VENEMA 28
PATTERN OPTIMISATION3 different shapesShearing actuators
Optimization based on gradient method + FEA
Directly inspired from optimized pattern developed @ CalTech(M. Laslandes SPIE 9148‐151)
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FAME/GRANADA – LARS VENEMA 29
PERFORMANCE OF ARRAYS
Generated shape
Residuals
42 102 126Actuator count
lay‐out
15.1
μm RMS
61μm
RMS
8.7μm
RMS
4.5μm
RMS
62μm
RMS
62.5
μm RMS
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FAME/GRANADA – LARS VENEMA 30
REDUCTION D.O.F.53 38 actuators, removing those with less impact. The active 38 actuators are highlighted but the others’ stiffness is also taken into account ‐> uniform stiffness distributionPerformance similar – needs some further improvementRemoving Zernike Bias will reduce #actuators
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FAME/GRANADA – LARS VENEMA 31
ERROR BUDGET ON BUILDING BLOCKSOptical fabrication
Provide a freeform surface as accurate as possibleFocused on form generationNo high spatial frequencies
Target: WFE <50µm
Active ArrayProvide the second stage of freeform generation
Target: WFE < 1µmProvide a fine tuning of the surface Compensate for environment variations
Target: WFE <1µm
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FAME/GRANADA – LARS VENEMA 32
ACTUATION LAYERActivities on hold – depends on final scale of system –
information available within few monthsActuators/Sensor Inventory preparedMetrology Ideas present
‐ Actuator verification (local)‐ PSF analysis (for large deviation)‐ PD when errors sufficiently small (first tests this year)
DemonstratorStarts next year – to be completed in 2016
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FAME/GRANADA – LARS VENEMA 33
GLOBAL METROLOGYOne flavour of Phase DiversityPre‐selection ongoing
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FAME/GRANADA – LARS VENEMA 34
TOWARD FAME PROTOTYPEOn going work
Identify actuators solutions Command Control systemInterface thin mirrors with active array ‐> manage the integration WFE
Issues to be addressedShape of pillars to reduce High spatial frequency residualsTwo stage approach for coarse and fine correctionsDesign a characterization test bed
PrototypingStarts next year – to be completed in 2016
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FAME/GRANADA – LARS VENEMA 35
DEMONSTRATOR
Shack Hartmann sensor to validate principle
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~500 mmPupil
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FAME/GRANADA – LARS VENEMA 36
PLANNINGGGANT chart went wrong this week….
March 2015 – metrology and actuation layer design report
Start final design FAM(E) & demonstrator setup March 2015
Procuring, manufacturing, integration August 2015System ready for characterization and test January 2016Demonstrator @ SPIE June 2016
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FAME/GRANADA – LARS VENEMA 37
OUTREACHPapers/presentations/posters @ conferencesPapers in scientific magazinsDemonstrator at SPIE 2016 (Edinburgh)
Technology TransferExpertise @ LAM often shared with industry to develop new technologies in industry (PhDs with confunding from Industry)Expertise @ ATC and NOVA shared with industrial partners
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FAME/GRANADA – LARS VENEMA 38
PAPERSRefereed:Challita Z, et al., “Design and development of an active freeform mirror
for an astronomy application”, Opt. Eng. 0001;53(3):031311. (2014)
SPIE 2014E. Hugot et al, “Freeform Active Mirrors Experiment”Z. Challita et al, “Freeform mirrors and active optics: development of a
thin freeform manufacturing process for the FAME project”T. Agócs et al, “Freeform mirror based optical systems for FAME”A. Jaskó et al, “Active array design for FAME: Freeform Active Mirror
Experiment”
ICSO 2014T. Agócs, R. Navarro, L. Venema, “Variations on a theme: Novel
Immersed Grating Based Spectrometer Designs For Space”
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FAME/GRANADA – LARS VENEMA 39
MEETINGSKick Off 26/27‐03‐2013TM1 02/03‐10‐2013TM2 11/12‐02‐2014TM3 02/03‐09‐2014
Great team!!!
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FAME/GRANADA – LARS VENEMA 40
CONCLUSIONSWell on track
Very important partial results achieved – tools developed
Budget is very tight, but spending match expectations
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FAME/GRANADA – LARS VENEMA 41
HORIZON 2020Active Optics and Freeform Optics become even more
importantShould consider how to shape this in the European context?
Cf. American example – concentrate on specific Optical problem
Extend into space and cryogenic development…Explore Additive manufacturing Capabilities (3D printing of
lightweight structures, Mirror substrates, Layered materials)Active structures
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