Transcript Mechanical Qualification Status

PACS IQR
ESTEC 13 January 2005
PACS IQR
Mechanical Qualification Status
and Plans for PFM
Reinhard Katterloher
R. Graue, D. Kampf, R. Hofferbert, M. v.Berg
Mech Qual Status
1
PACS IQR
ESTEC 13 January 2005
Overview Mechanical Qualification Status
and Plans for PFM
• FPU
structure - mirrors - baffles - black paint impact of additional heaters and flashers
• Filter wheels
• Calibration sources
• Grating assembly
• Chopper
• WE units
• Delta Cryovibration Qualification Matrix
• (PhFPU presented by LR)
• (Ge:Ga arrays presented by JS)
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU structure, mirrors, baffles: main data
• Total mass allocation in IID-A for PACS is 140 kg,
mass requirement is met (margin 13.2 kg), FPU CQM has 74.1 kg
• Eigenmodes of complete FPU above 100 Hz,
requirement is met for all axes (x,y,z = 188,122,104 Hz)
verified by cryogenic vibration of FPU STM
• Mirror environmental tests OK,
Au coating no concern (initial NCR closed),
optical alignment check/stability on FPU CQM not done,
after FPU STM cryo-vibration dummies mechanically checked
• Baffles structural OK
• Upgrades for PFM: none, except
- additional baffles required to reduce stray light inside the FPU
spectrometer section (see presentation by AP),
- modification of detector baffles to carry flashers for curing
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
PACS FPU Architecture –
6 Stand Alone Modular Substructures
 Top Optics with Chopper (C.Z.)
and 2 Calibration Sources
 Image Slicer
 Bolometer Optics with Filter Wheel
 PhFPU with 0.3 K Cryo-Cooler
(CEA)
 Collimator with Grating Assembly
(CSL)
 Spectrometer with Ge:Ga –
Photoconductor Arrays (MPE),
Filter Wheels, Distribution Boards
(Cold Electronics)
Level 0 Thermal Links Thermal Feed Throughs (1.7 K)
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU Analyses
Physical
Analyses
Structural
Analyses
Mechanisms
Analyses
Thermal
Analyses
Mass Properties
Analysis
Natural Modes
Analysis
Functional
Analysis
Quasi Static
Analysis
Optical Analyses
Ray Tracing ,
Spot Diagram
Load Analysis
Straylight
Analysis
Deformation/
Distortion
Analysis
Tolerancing
Analyses/
Budgets
Strength Analysis
All FPU Analyses Performed
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
PACS FPU Structural
Verification
Similarity
•
CQM and STM were
manufactured parallel with
the same drawings
out of the same lot
Qualification Tests
•
FPFPU Test Program
CQM
Mass / Structural
Dummy
PFM
FS
Prel. Optical
Performance Tests *
Physical Measurement
Prel. Optical
Performance Tests *
Prel. Optical
Performance Tests *
Functional Tests
Vibration Test
(ambient)
Functional Tests
Functional Tests
Physical Measurement
Vibration Test
(LHe - tbc)
Physical Measurement
Physical Measurement
Vibration res.src.
Ambient Vibration
Test (Acceptance)
Ambient Vibration
LHe-Vibration
Test (Acceptance)
Cold Vibration Test
Functional Tests
(LHe)
Functional Test
(LHe)
Functional Test
(LHe)
Reduced Functional Test
Reduced Functional Test
Reduced Functional Test
STM vibration tests
Conclusion:
FPFPU Housing is
structurally qualified
Ambient Vibration
Test (Qualification)
Tests
completed
Vibration Test - tbc
(LHe)
Mech Qual Status
Tests
completed
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PACS IQR
ESTEC 13 January 2005
FPU Cryovibration Qualification Breakdown
FPFPU Qualifikation
KT Units
FPFPU
Suspension
Filter Wheels
(Bolometer and
Spectrometer #)
Calibration
Source
Distribution
Boards (Blue and Red)
2K Therm Strap #
Similar to CQM
Similar to CQM
Similar to CQM
Similar to CQM
Similar to CQM
CQM
Qualification Tests
Complete
Qualification Tests
Complete
Qualification Tests
Complete
Qualification Tests
Complete
Qualification Tests
Complete
Qualification Tests
Complete
Housing Qualified
Suspension Qualified
Filter Wheels
Qualified #
Calibration Source
Qualified
Distribution Boards
Qualified
2K Straps
Qualified #
FPFPU
Housing
Det Suspension #
CQM
Detector
Suspension
Qualfiied #
All Items Qualified
# means remaining problems to be solved resp. delta-vibration to be done
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
Structural Analyses - Status
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Evaluation of ambient (STM) and cold vibration tests (Cryo STM)
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
All Documentation released
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
Approach to FPU PFM Cryovibration
• Protection of sensitive subsystems during acceptance vibration,
random loads not to exceed 10 g rms
• Dynamic analysis of PACS on CSL shaker performed by ESA
- response of red and blue bolometer FPA and their relation
with a point on the outside of PhFPU housing determined
- mounting of a triplet-accelerometer foreseen
• Frequencies and Q-values are to be checked during warm FPUSTM vibration at MPE
• Notching at the PACS feet during PFM cryovibration at CSL
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU PFM Test Plan and PFM MAIV Status
•
Subsystem level (FW, CS, DBs, Substructures)
– Mechanical and Thermal Test program as given in Test Plan
(similar to CQM)
– Outbaking at 80 °C (minimum)
– Functional test program as given in test plan (similar to CQM)
•
– Substructures alignment verification -Cryogenic stability tests (tbc)
System level (FPU)
– Cryovibration test (KT support at CSL)
– Functional test (KT support at MPE)
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MAIV Status
Metallic items manufactured
CFRP items manufactured and static load tested
Calibration Sources manufactured and partly assembled
FW assemblies manufactured, pre-tested on motor drive level, partly assembled
Pre-assembly (fit check in progress)
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU Black Paint: main data of KT72
•
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PACS-RFW-0003 agreed: out-gassing requirements met
Optical performance: satisfying
Adhesion on Al surfaces: satisfying
Particle release below 100ppm, improvement advised:
impact of pre-vibration under investigation,
additional cryogenic vibration planned in February 2005,
CEA: concerned about particle fall-out onto bolometer FPAs,
MPE: protection of grating/FW bearings might be advisable
• Upgrade for PFM: very likely none
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
Impact of additional Heaters and Flashers
For detector curing PACS needs to implement additional
heaters and flashers in the FPU.
The impact on the mechanical properties of both detector
arrays (Upgrade for PFM) is estimated as follows (detailed
design in progress):
• 2 heater resistors on the red detector array:
mass increase 0.2% > no impact on mechanical behaviour
• 2 flashers mounted at the end of each detector array baffle:
mass increase few % > no impact on mechanical behaviour
• Additional wiring inside the FPU required (mass negligible)
• Re-routing on both distribution boards required (redesign)
mass increase on one board due to a new connector
> no impact on structural properties expected
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU Filter Wheels
• Photometer FW : OK (initial blocking by a screw resolved)
• Spectrometer FW problematic:
- during CQM ILT blocked at 4K
- during warm-up partial movement at 90K
• Currently investigations on CQM wheel at KT in progress:
- at 77K higher friction observed
- ball bearing sensitive to abrasion during warm vibration?
- baffle removed for better inspection of drive
- blocking of rotor on one Hall sensor found
- new cryogenic verification test planned
• Upgrade for PFM: revised tolerance of bearing support
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
Filter Wheel Assembly

Required Torque to Leave
the Filter Position : 0.5 Ncm
 Maximum Motor Torque Performance :
4.2 Ncm.
 Motor & Position Indicator are in
Powerless Dormitory Mode between
Operations
 Position Locking Principle:
Contact-less Magnetic System
 No Launch Lock Mechanism Required
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU Calibration Sources
• Cryogenic qualification on EM during FPU STM vibration
• Upgrade for PFM: None
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
Calibration Source Lay-out
Wavelength/scattering optimised surfaces
• 2 identical Calibration Sources mounted in FPU
• Operation at 4 K, Emitter temperature 50 - 100 K
 Sphere (inner diameter 51 mm)
 Redundant Combined Sensor and Emitter (PT 500)
 Circular aperture (diameter 12 mm) with Si lens put in front of aperture
 Surface with Lambertian stray light behaviour and high reflectivity (> 0.992)
 Emitter suspension:
 4 filigree GFRP struts with 24 x 0.25 x 0.25 mm³
 Titanium coated for 4 wire connection to the source
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU Grating Assembly
• Cryogenic vibration qualification on EM plus additional
qualification (vibration, cryo-cycling) on CQM incl.
launch lock mechanism at subsystem level: OK
• Movement quality of grating CQM: OK
• Functionality of launch lock mechanism of CQM: OK
• Upgrades for PFM:
- modified routing of internal harness needed
- Inductosyn transformer needs to be mounted
inside the grating assembly (for CQM currently on
FPU outside)
- Fixation of grating plate on axis has to be improved
- cleanliness before delivery for integration with FPU
to be improved and protection cover advised
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
FPU Chopper
• Development performed as specified in IHDR presentation
(environmental tests, lifetime test …)
• Minor deviations for CQM:
- envelope violation of cable housing (solved)
- cryovibration done on subunit level at 77K only (agreed)
(no LHe vibration with CQM performed)
• Upgrades for PFM:
- no deviation from MPIA/ZEISS development plan foreseen
- Au coating of mirror very likely to be changed
(thickness and coating process to be improved)
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
WE Units
•
AVM / STM WE Unit testing
- No structural tests required in general
- STM BOLC: Vibration tests done :
validation of design > Problem with displacement of boards
- STM BOLC PSU sub-unit vibrational tested : OK
•
CQM / AVM ILT
- No structural test on WE Units foreseen
•
PFM (QM) WE Units
- Full environ. test program agreed before FM delivery to MPE
- First structural results for QM SPU available (> some NCRs)
- New mechanical design for DPU CFM / PFM, will be fully tested
•
Mass margin for PACS is 13.2 kg in total
(DECMEC mass uncertainty not critical in this respect)
Mech Qual Status
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PACS IQR
ESTEC 13 January 2005
Delta Cryo-vibration Qualification Matrix of FPU Subunits
FPU Subunit
Delta cryovibration
qualification
Scheduled
ILT
phase
AVM
CQM
PFM
FS
FPU
STM
CQM
PFM
CQM
refurb.
DPU
AVM
AVM
PFM
QM
SPU
AVM
AVM
PFM
EM
DECMEC
AVM
EM
PFM
QM+
(QM2)
PFM
QM2
PhFPU
(bolom.+cooler)
Done
(upgraded STM)
October 04
Ge:Ga-array
internal cooling
link with I/Fs
Open
(STM housing +
FM components)
March 05
Ge:Ga-array
suspension strut
electr. insulation
Open
(STM housing +
FM components)
March 05
Grating assembly
CQM incl. L Lock
Done
(CQM)
February 04
Approval of PACS-RFW-0007 expected !
Mech Qual Status
BOLC
BOLCSIM QM1
WIH
AVM
AVM
PFM
QM
EGSE
ILT
ILT
ILT
ILT
Unchanged Development Concept
& Model Philosophy since IHDR
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