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SOFIA Telescope Manufacturing - Lessons Learned

SOFIA Telescope Manufacturing - Lessons Learned. Hans J. Kaercher, Senior Telescope Engineer MT Mechatronics GmbH, Mainz, Germany hans.kaercher@mt-mechatronics.de. Experience with Telescopes at Exposed Sites Radio Telescopes. 50m LMT Mexico. 30m IRAM Spain. 9m O‘Higgins Antarctica.

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SOFIA Telescope Manufacturing - Lessons Learned

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  1. SOFIA Telescope Manufacturing - Lessons Learned Hans J. Kaercher, Senior Telescope Engineer MT Mechatronics GmbH, Mainz, Germany hans.kaercher@mt-mechatronics.de Hans J. Kärcher

  2. Experience with Telescopes at Exposed Sites Radio Telescopes 50m LMT Mexico 30m IRAM Spain 9m O‘Higgins Antarctica 15m IRAM France APEX, ALMA Hans J. Kärcher

  3. Experience with Telescopes at Exposed Sites Optical Telescopes 2.7m Airborne Telescope SOFIA 1m Solar Balloon Telescope Sunrise 1.5m Solar Telescope GREGOR Hans J. Kärcher

  4. SOFIA Main Telescope Components Hans J. Kärcher

  5. SOFIA Main System Requirements • Access to the Science Instrument during flight • Research flight hours per year 960 hours • Time per flight at 12.5 km altitude  6 hours • Unvignetted elevation range 20 - 60 degrees • Effective telescope aperture 2.5 m • Telescope optical image quality 1.5 arcsec • Telescope pointing stability rms 0.2 (0.8) arcsec Hans J. Kärcher

  6. SOFIA Telescope Optics will be in Cold Environment (- 50° C, 0.2 bar) Hans J. Kärcher

  7. SOFIA Telescope Science Instrument Flange Accessible during Operations from the Cabin Side Hans J. Kärcher

  8. Steady State Type Environmental Influences on the Telescope 0,8 bar + 20° C - 50° C 0,2 bar Thermal Barrier Cabin Pressure Barrier Cavity Hans J. Kärcher

  9. SOFIA Structural SystemCarbon Fiber Composites Metering Structure Nasmyth Tube Bearing Sphere Mirror Cell Hans J. Kärcher

  10. SOFIA Primary Mirror System Hans J. Kärcher

  11. Suspension Assembly Hans J. Kärcher

  12. Attitude Control with fiber-optical gyros Secondary Mirror Assembly Hans J. Kärcher

  13. M2 Mirror SiC/C 35cm Ø Hans J. Kärcher

  14. M2 Focus-Center Mechanism Hexapod Qualified for – 50°C Operational Environment Hans J. Kärcher

  15. Hans J. Kärcher

  16. Environmental Influences on the Telescope Cabin Shear Layer at Cavity Opening Standing Waves Excited by the Shear Layer Science Instrument Wind in Cavity Induced by the Shear Layer Aircraft Vibrations Hans J. Kärcher

  17. End-to-endSimulationModel Hans J. Kärcher

  18. End-to-end Simulation Results „Low“ structural damping (0,5 – 1 %) Servo Domain Aero-acoustic Domain RMD for 32,2 Hz mode (5 %) „High“ structural damping (1 – 2 %) ~ 75 Hz rocking mode 32,2 Hz mode 22,4 Hz dumbbell Image Quality Influence of SMM via FBC Hans J. Kärcher

  19. Summary of SOFIA Experience • Material Selection etc. • Structures in Carbonfiber Composites • Dedicated Metals for Mechanisms • Same for Motors, Drives etc. • System Level • Thermal System Design • Pointing System Design • Subsystem Level • Optics, Structure • Suspension Assembly • Secondary Mirror Mechanism • Servo Control System • QA, RAMS • Quality Control absolute essential • Reliability, Maintainability same • Methods qualified in Aircraft and Space Business are adequate • Management has to accept Hans J. Kärcher

  20. Sunrise Carbonfiber Technology Recommendations for Arena < 2m • Material Choice • Low Temperature qualified Mechanical Component • Low Temperature qualified Motors, Encoders • Thermal Concept for Optics, Controllers • QA, RAMS Hans J. Kärcher

  21. Thermal Concept for Sunrise Heat Rejection Cooler Primary Mirror Cooling Hans J. Kärcher

  22. Recommendations for Arena > 2m Combination of O’Higgins Pedestal with SOFIA Mirror Compare with exposed design (e.g. Gregor) Hans J. Kärcher

  23. Conclusions from Engineers Point of View • Challenging! • Interesting! • Nice, Funny! Let’s do it! Hans J. Kärcher

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