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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