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PACS IBDR
27/28 Feb 2002
FPU
R. Graue, D. Kampf
Kayser-Threde
PACS FPU
PACS IBDR
27/28 Feb 2002
Primary Structure
Field Mirror for
Spectrometer
Collimator housing
Photometer housing
Chopper Cover
4 K Thermal Strap
Bolometer
housing
Alignment Cube
Entrance to
FPU
Top Optics housing
2K
Feed Thru
Red Spectrometer
Connector Panel
PACS FPU
FPU foot
2 axis
Spectrometer housing
FPU foot
1 axis
Blue Spectrometer
Connector Panel
PACS IBDR
27/28 Feb 2002
Primary Structure (continued)
Alignment Cube
Top Optics housing
Chopper Cover
Field Mirror
External Mirror Fixation
Collimator housing
2 K
Feed Thru
B_Mirror_2
External Mirror Fixation
Peri 1
External Mirror Fixation
Photometer housing
Grating
Connector Panel
4 K Thermal Strap
Bolometer
housing
Blue Spectrometer
Connector Panel
Grating Cover
(external mounting of grating)
PACS FPU
FPU foot
3 axis
PACS IBDR
27/28 Feb 2002
Primary Structure (continued)
FPU foot
1 axis
Red Spectrometer
Connector Panel
Spectrometer Cover
FPU foot 2 axis
Bolometer
housing
FPU foot
3 axis
Blue Spectrometer
Connector Panel
Collimator housing
Grating
Connector Panel
Photometer housing
Grating Cover
(external mounting of grating)
PACS FPU
PACS IBDR
27/28 Feb 2002
FPU Suspension
PACS FPU
PACS IBDR
27/28 Feb 2002
Detector Struts Side/Iso View
Fibre:
Resin:
PACS FPU
T300
Ciba Geigy
Araldit LY-3505
Hardener XP 3403
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 Straylight
Bottom view of TOP OPTICS
1st field stop
Aperture Stop
(complete closure of
entrance compartment)
Lyot stop for telescope secondary mirror edge
Baffle are shown in brown
Mirror FOLD 5
Closure of Entrance Optics
(quasi 2nd field stop)
PACS FPU
Chopper: 2nd aperture
stop
Lyot stop for aperture
stop
(2nd Lyot stop)
PACS IBDR
27/28 Feb 2002
FPU Structure, Baffles and Straylight
Photometer housing seen from Top Optics
2nd Field Stop
Focus Mirror
(to Spectrometer)
Entrance to Slicer / Spectrometer
Mirror FOLD 5 from Top Optics scetched
Entrance to Photometer
Focal planes of photometer
PACS FPU
PACS IBDR
27/28 Feb 2002
FPU Structure, Baffles and Straylight
Bottom view of Photometer housing (interface to bolometer)
4th aperture stop at conic baffle to thedetector arrays not shown
3rd field stop (blue photometer)
Separation wall between red and blue
compartment
contains Dichroic beamsplitter
(near 3rd aperture, not accessible)
3rd field stop (red photometer)
PACS FPU
PACS IBDR
27/28 Feb 2002
FPU Structure, Baffles and Straylight
Collimator housing
Grating drive
Grating
PACS FPU
PACS IBDR
27/28 Feb 2002
FPU Structure, Baffles and Straylight
Slicer seen from Photometer
Entrance to slicer / spectrometer
Focus Mirror scetched
PACS FPU
PACS IBDR
27/28 Feb 2002
FPU Structure, Baffles and Straylight
Slicer 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 Straylight
Slicer internal view
Focus mirror inside photometer
To collimator
To spectrometer
PACS FPU
PACS IBDR
27/28 Feb 2002
FPU Structure, Baffles and Straylight
Spectrometer seen from bottom
Filter wheel
Red spectrometer detector
Blue spectrometer detector
From slicer / collimator
PACS FPU
PACS IBDR
27/28 Feb 2002
FPU Structure, Baffles and Straylight
Spectrometer seen from bottom
Blue spectrometer detector
Red spectrometer detector
Filter wheel
PACS FPU
PACS IBDR
27/28 Feb 2002
2K - Feed Through Design
Fixation to housing
aluminum
CFRP Tubes
CFRP
A: Outside sleeve
B: Inside sleeve
Copper old Finger
C: Cold finger
D/E: Retainer ring 1/2
F: Muff
G: Ring
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
1
= 10°
96µm; ?i
0.1
BRDF (1/sr)
= 30°
96µm; ?i
= 50°
96µm; ?i
= 10°
184µm; ?i
= 30°
184µm; ?i
0.01
= 50°
184µm; ?i
0.001
-90 -80 -70 -60 -50 -40 -30 -20 -10 0 10 20 30 40 50 60
 angle of reflection
PACS FPU
PACS IBDR
27/28 Feb 2002
IR Coating - Specular reflection
Sample 24
speculare reflection
1.0E+00
KT-24, 96µm
1.0E-01
KT-24, 184µm
1.0E-02
1.0E-03
1.0E-04
1.0E-05
10 20 30 40 45 50 55 60 70 80
 angle of incidence
PACS FPU
PACS IBDR
27/28 Feb 2002
Design Envelope
R4000
from x,z=-3540,0
30
R
120
200
320
X
X
Y
Z
95
50
370
550
230
4010
75
R5
275
FPFPU Housing
210
FPFPU
suspension
150
20
470
60
Notice:
= Approved envelope
PACS FPU
eEEnvelope
PACS IBDR
27/28 Feb 2002
Optical Bench Interface
Z
Pi n
Tr ee ax i s s u s pens i on
15 H8 ( 2 x )
Mo unt i n g ar e a
8, 5 ( 9 x )
7 10
6 91 ± 0 ,
6 76 , 5
02
258, 1
2 Kel vi n connect i on
2 Kel vi n connect i on
6 2 7, 5
233
Y
16
82, 5
132, 5
459
182, 5
197, 5
4 29
489
± 0, 0 2
± 0, 0 2
14 2 , 5
PACS FPU
151
105
Z
PACS IBDR
27/28 Feb 2002
Optical Beam Stay Out Envelope
2 02
61 , 6
5
R
65
PACS FPU
2 8 39
75
30
308. 3
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
PACS FPU
27/28 Feb 2002
PACS IBDR
PACS FPU
27/28 Feb 2002
PACS IBDR
PACS FPU
27/28 Feb 2002
PACS IBDR
PACS FPU
27/28 Feb 2002
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 Plan
AKF at centre of the telescope secondary mirror
PACS FPU
PACS IBDR
27/28 Feb 2002
Alignment Plan
AKF and Laser assembly with top optics
AKF centered at
nominal position of telescope secondary mirror
(real aperture)
Top Optics
side view
Intermediate focal plane
splitting between spectrometer
and photometer section
PACS FPU
Chopper
Internal aperture stop
PACS IBDR
27/28 Feb 2002
Alignment Plan
Centering alignment of bolometer
Intermediate focal plane
splitting between spectrometer
and photometer section
Field Mirror
Peri 1
B_Mirror_2
PACS FPU
PACS IBDR
27/28 Feb 2002
Alignment Plan
Bolometer alignment
B_Mirror_2
B_Mirror_1
Filter Wheel
Bolometer
Blue Bolometer focal plane
PACS FPU
PACS IBDR
27/28 Feb 2002
Alignment Plan
Slicer Optics alignment
Focus Mirror at
intermidate focal plane
PACS FPU
PACS IBDR
27/28 Feb 2002
Alignment Plan
Setup for slicer element alignment
PACS FPU
PACS IBDR
27/28 Feb 2002
Alignment Plan
Collimator Alignment
PACS FPU
PACS IBDR
27/28 Feb 2002
Alignment Plan
Red 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
0° > 180° > 360°
(Optionally 90° & 270°)
• Precision of end stop
30 arcmin
• Power dissipation per position
change
< 50 mWs
• Transition time
 5 sec (average)
• Operating temperature
3-300 K
• Warming of parts within view
of detector
< 0.1 K (filter wheel assembly
requirement, only)
• Duty cycle
1 per 30 min.
• Life time
 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
Si Lens
12
30
Aperture
25
47
14
Calibration Source Sphere
4 K, high scatter surface with high reflectivity
Scatter Plate
4 K
Emitter at 100 K
2 x PT500
Emitter fixation
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 mg
Surface:
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
SCATTERSURFACE GOLD COATED
Reflectivity > 0.992
1
Specular Reflection
 = 96 m
 = 96 m
 = 184 m
KT-gold-2 sample
0.1
0.01
1E-3
0
20
40
60
Angle of Incidence i
PACS FPU
80
PACS IBDR
27/28 Feb 2002
Calibration Source - BRDF Measurements
SCATTERSURFACE GOLD COATED
Reflectivity > 0.992
 = 96 m
i= 10
0
i= 30
0
i= 50
0
-1
BRDF(sr )
10
 = 184 m
1
0.1
-140
-120
-100
-80
-60
-40
-20
0
Angle of Reflection i
PACS FPU
20
40
60
80
PACS IBDR
27/28 Feb 2002
Distribution Boards
and FPU Harness Concept
PACS FPU
PACS IBDR
27/28 Feb 2002
Sä mtl i ch e Urh e b e rre ch tl i ch e -i n sb e so n d e re g e m.Pa r.2 Ab s. 1 Urh .G si n d
vo rb e h a l te n
Ve r vi e l fä l ti g u n g , Ve rb re i tu n g , Au sst e l l u n g , Vo rfü h ru n g ,
Be a rb e i t u n g , u mg e stta l tu n g , so n sti g e W i e d e rg a b e so wi e Be n u tzu n g
b e d ü rfe n d e r a u sd r ü ckl i ch e n sch ri ftl i ch e n Ei n ze l g e n e h mi g u n g d e r
2K
level
with r adius center at
optical pupil
92 , 1
4K level
60
Bending begins at
z(detector)= -105
C A D D ra w i n g
N o m an ua l C ha ng es
Gen. tolerances
Surface
First support after
90° with R=20mm
DIN
--
A3
Name
Checked
File
04 Routing & Struts
23.01.02
KC
03 10mm <->15mm
09.10.01
KC
02 9 connectors ->7
24.08.01
01 First Issue
22.03.01
KC
Date
Name
State
Change
KC
0800w104.CatD rawing
Sheet
1
of
-Date
PACS FPU
Weight
1:2
Material
Prep.
Distribution board
Scale
FPFPU
Blue Detector Interface
Assembly
PACS-KT-ICD-0800W1.04
2
PACS IBDR
2
27/28 Feb 2002
M
Distribution Board
( 4 k l e v e l)
with radius at optical
pupil
60
( 4 K le v e l)
4K Level
92 , 1
Sä m tl i c h e Urh e b e rre c h tl i c h e -i n s b e s o n d e re g e m . Pa r.2 Ab s .1 Urh .G s i n d
v o r b e h a l te n
Ve r v i e l fä l ti g u n g , Ve r b re i tu n g , Au s s te l l u n g , Vo rfü h ru n g ,
2K Level
C A D D ra w i n g
N o m anu al C ha nges
Gen. tolerances
S urface
S cale
W eight
DIN
1:2
--
A3
Material
Date
Harnes
F irst support aft er 90°
with R= 20mm
PACS FPU
K C Checked
06
07
9 connectors->7
routing
& susp.
24.08.01
23.01.02
05
chamfer 10x10
23.07.01
04
COG / Handling P . 0705.01
03
2K S rap
22.03.00
02
09->08/09
12.03.00
01
First Issue
10.04.00
KC
Date
Name
S tate
Harness layout due to equal length of all detector modules
Name
P rep.
Change
K C File
KC
KC
KC
0900w107.CatDrawing
1
of
--
Bending begins at
z(detector)=-105
S heet
FPFPU
Red Detector Interface
Assembly
PACS-KT-ICD-0900W1.07
2
PACS IBDR
27/28 Feb 2002
Distribution Board - Design
• 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)
PACS FPU
PACS IBDR
27/28 Feb 2002
Distribution Board - Status
•
•
•
•
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
PACS FPU
PACS IBDR
27/28 Feb 2002
Distribution Board - Open Points
• Grounding of distribution board to housing (tbd by
MPE)
• Characteristic data of some resistance
• Release of circuit diagram
PACS FPU
PACS IBDR
27/28 Feb 2002
Distribution Board - Verification





PCB layout test against Gerber data (inspection
protocol)
Incoming inspection according to inhouse procedures
Pin to pin continuity
Insulation
Visual inspection (components, bonding points)
PACS FPU
PACS IBDR
27/28 Feb 2002
Distribution Board - Verification
-
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
PACS FPU
PACS IBDR
27/28 Feb 2002
T-Sensor
31s
JO1
JO2
C01
C02
P3O1
J301
31p
31s
J04
31s
P302
31s
J03
31p
31p
C03
C04
31s
Filter Wheel 1
J302 Spectometer
31s
T-Sensor
J303
P304
Filter Wheel 2
J304 Bolometer
31s
15s
J305
15s
15p
15s
J06
P306
J306
C05
PACS Inner FPU Harness
9p
P308
9s
9s
9p
C08
J08
J318
P318
P309
9s
9s
9p
C06
J09
J319
P319
9s
J309
Calibration
Source 1
Calibration
Source 2
9p
Outer FPU Harness
J07
Chopper
P305
J05
three axis mount
Photoconductor
Detector (red)
15p
one axis mount
two axis mount
MPE
15s
T-Sensor
T-Sensor
31s
P303
31p
J10 - Distribution J100- P100J18 Board 1
J124 P124
(red)
4K connection (TBC)
9s
J308
MPE
Photoconductor
Detector (blue)
Bolometer
Array
Grating
Assembly
JXX
PXX
P200- J200- Distribution J20 J28
P225 J225 Board 2
(blue)
CEA
CSL
(power)
CSL
(signal)
CSL
(power red.)
CSL
(signal red.)
JXX
J40
J41
J42
J43
Cable not manufactured at KAYSER-THREDE
PACS FPU
(50-99)
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
Harness - Procurement Status
•
•
•
•
Cable ordered
delivery time: end of February
Manufacturing of harness at Cannon
delivery time: about 12 weeks
PACS FPU
PACS IBDR
27/28 Feb 2002
Harness - Open Points
• 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
PACS FPU