pacs ibdr 27/28 feb 2002 pacs fpu fpu r. graue, d. kampf kayser-threde
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PACS FPU
PACS IBDR 27/28 Feb 2002
FPU
R. Graue, D. KampfKayser-Threde
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Primary Structure (continued)
Collimator housing
FPU foot3 axis
4 K Thermal StrapGrating Connector Panel
Grating Cover(external mounting of grating)
Blue SpectrometerConnector Panel
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
PACS IBDR 27/28 Feb 2002
Primary Structure (continued)
Bolometerhousing
Collimator housing
Spectrometer Cover
Blue SpectrometerConnector Panel
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
PACS IBDR 27/28 Feb 2002
FPU Suspension
PACS FPU
PACS IBDR 27/28 Feb 2002
Detector Struts Side/Iso View
Fibre: T300Resin: Ciba Geigy
Araldit LY-3505Hardener XP 3403
PACS FPU
PACS IBDR 27/28 Feb 2002
FPU Structure, Baffles and Straylight
Entrance Baffle
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
FPU Structure, Baffles and StraylightCollimator housing
Grating drive
Grating
PACS FPU
PACS IBDR 27/28 Feb 2002
FPU Structure, Baffles and StraylightSlicer seen from Photometer
Focus Mirror scetched
Entrance to slicer / spectrometer
PACS FPU
PACS IBDR 27/28 Feb 2002
FPU Structure, Baffles and StraylightSlicer seen from collimator
Area blocked by housing
Beam to collimator
Beam to spectrometer, exit from collimator
PACS FPU
PACS IBDR 27/28 Feb 2002
FPU Structure, Baffles and StraylightSlicer internal view
Focus mirror inside photometer
To collimator
To spectrometer
PACS FPU
PACS IBDR 27/28 Feb 2002
FPU Structure, Baffles and StraylightSpectrometer seen from bottom
Filter wheel
Blue spectrometer detector
Red spectrometer detector
From slicer / collimator
PACS FPU
PACS IBDR 27/28 Feb 2002
FPU Structure, Baffles and StraylightSpectrometer seen from bottom
Filter wheel
Blue spectrometer detector
Red spectrometer detector
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Optical Beam Stay Out Envelope
20
2
61, 6
755
R
65
30
3 08 . 3
28
39
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
PA Activities
• Documents– PMP– CIDL– PA Plan– MIP/KIP plan– Inputs to FMECA
• Approval of procurement/manufacturing documentation/drawings
• Configuration Control
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Optical Mirrors
PACS FPU
PACS IBDR 27/28 Feb 2002
PACS FPU
PACS IBDR 27/28 Feb 2002
PACS FPU
PACS IBDR 27/28 Feb 2002
PACS FPU
PACS IBDR 27/28 Feb 2002
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Alignment Plan
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Alignment PlanAKF at centre of the telescope secondary mirror
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Alignment PlanCentering alignment of bolometer
Intermediate focal planesplitting between spectrometer and photometer section
Field Mirror
Peri 1
B_Mirror_2
PACS FPU
PACS IBDR 27/28 Feb 2002
Alignment PlanBolometer alignment
B_Mirror_2B_Mirror_1
Blue Bolometer focal plane
Filter Wheel Bolometer
PACS FPU
PACS IBDR 27/28 Feb 2002
Alignment PlanSlicer Optics alignment
Focus Mirror at intermidate focal plane
PACS FPU
PACS IBDR 27/28 Feb 2002
Alignment PlanSetup for slicer element alignment
PACS FPU
PACS IBDR 27/28 Feb 2002
Alignment PlanCollimator Alignment
PACS FPU
PACS IBDR 27/28 Feb 2002
Alignment PlanRed and Blue spectrometer channel alignment
PACS FPU
PACS IBDR 27/28 Feb 2002
Alignment Status
• Updated Alignment plan issued
• Alignment procedure engineering in progress
• Preliminary OGSE procurement plan
• CVSE procurement in progress (cryostat)
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Structural and Thermal Analysis
PACS FPU
PACS IBDR 27/28 Feb 2002
Filter Wheels and Calibration Sources
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Filter Wheel Assembly
PACS FPU
PACS IBDR 27/28 Feb 2002
Filter Wheel Assembly (side view)
PACS FPU
PACS IBDR 27/28 Feb 2002
Calibration Source - Surface with Exit Aperture
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Calibration Source with Scatter Plate
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Calibration Source
Previous emitter size
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
Distribution Boards and FPU Harness Concept
PACS FPU
PACS IBDR 27/28 Feb 2002
Sä
mtlic
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erre
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e-in
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de
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r.2 A
bs
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sin
dv
orb
eh
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, Ve
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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
PACS IBDR 27/28 Feb 2002
Sä
mtlic
he
Urh
eb
erre
ch
tlich
e-in
sb
es
on
de
re g
em
.Pa
r.2 A
bs
.1U
rh.G
sin
d
vo
rbe
ha
lten
Ve
rvie
lfältig
un
g, V
erb
reitu
ng
, 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
PACS IBDR 27/28 Feb 2002
• 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
PACS IBDR 27/28 Feb 2002
• 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
PACS IBDR 27/28 Feb 2002
• Grounding of distribution board to housing (tbd by MPE)
• Characteristic data of some resistance • Release of circuit diagram
Distribution Board - Open Points
PACS FPU
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
- 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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
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
PACS IBDR 27/28 Feb 2002
• Cable ordered• delivery time: end of February• Manufacturing of harness at Cannon• delivery time: about 12 weeks
Harness - Procurement Status
PACS FPU
PACS IBDR 27/28 Feb 2002
• 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