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FPU Structure, Baffle and Straylight

FPU Structure, Baffle and Straylight. R. Graue, D. Kampf Kayser-Threde. Field Mirror for Spectrometer. Collimator housing. Photometer housing. Alignment Cube. Blue Spectrometer Connector Panel. Top Optics housing. 4 K Thermal Strap. Entrance to FPU. Bolometer housing. 2 K

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FPU Structure, Baffle and Straylight

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  1. FPU Structure, Baffle and Straylight R. Graue, D. Kampf Kayser-Threde PACS FPU

  2. Field Mirror for Spectrometer Collimator housing Photometer housing Alignment Cube Blue Spectrometer Connector Panel Top Optics housing 4 K Thermal Strap Entrance to FPU Bolometer housing 2 K Feed Thru FPU foot 2 axis Red Spectrometer Connector Panel Spectrometer housing FPU foot 1 axis Primary Structure Chopper Cover PACS FPU

  3. FPU STM PACS FPU

  4. Bolometer Integration PACS FPU

  5. Straylight Analyses – Top Optic Model • ASAP Model of Top Optics • Derived from optical ZEMAX Model • Black Coated Walls (>0.4 mm) PACS FPU

  6. Straylight Analyses – Results and Status • High straylight suppression • Neglible straylight impacts in consequent boxes • Inputs considered for Baffle Design • Straylight suppression 1e-10 to focal plane • Modell delivered to ASTRIUM PACS FPU

  7. 2K - Feed Through • Cryo STM Vibration Tested • Manufactured and Delivered Outside sleeve Cold finger D/E: Retainer ring 1/2 F: Muff G: Ring PACS FPU

  8. FPU Suspension Design Status and Material • Status: • Design: completed • Documentation: Completed • Material • Fibre: T300 • Resin: Ciba Geigy • Araldit LY-3505 • Hardener XP 3403 PACS FPU

  9. FPU Suspension Cryo Qualification Test Matrix • Status • Static load tests: completed • (Cold) material characterisation: completed • Cryovibration tests: complete (CRYO STM FPU) PACS FPU

  10. MGSE and CVSE Status • MGSE design, procurement and functional test completed • Vibration test adapter • Lifting device • Integration Tools • FW Test Box • CVSE design, procurement (cryostat) and functional test completed KT Cryostat Test Faciliy for Stability Tests PACS FPU

  11. Mass Budget *IR Black Paint, Internal Harness, Screws Contingency not needed PACS FPU

  12. Performed FPFPU Analyses Program PACS FPU

  13. PACS Thermal Model PACS-Thermal Model (Input-Status: May 2003) - PACS thermal model used as submodel of the H-EPLM reduced thermal model - PACS submodel consists of 154 thermal nodes PACS-TMM includes: - All mechanisms, all harness, radiative environment - Possibility of transient analysis (cool-down and operational time-line) PACS FPU

  14. Thermal Analyses - Status - Completed Tasks • Thermal Analyses • Quasisteady state and transient thermal analyses • Calibration of thermal model (cooling down curves) after Cryo STM tests • Analyses of thermal links (2 K) wrt conductivity • Documentation released PACS FPU

  15. PACS Cool-Down Behaviour PACS FPU

  16. PACS Thermal Analyses - Open Tasks • - Update of the cryostat-TMM (Sept. 2003) not yet included • - Dissipation values of the grating and the calibration sources are no measured values • Impact of Electrical insulation between spectrometers and cooling-straps not yet defined • - Results of the discussion of the cooling-strap-IFs not yet included • - Contact resistances at the cooling-strap-I/Fs only assumed, but not measured PACS FPU

  17. Structural Analyses - Status - Completed Tasks(see H/O wrt. STM warm/cold vibration) • Structural Analyses • Evaluation of ambient and cold vibration tests • 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 • Documentation released PACS FPU

  18. FPU Structure Status – External Interfaces • Design envelope frozen • Optical beam stay out frozen • OB envelope frozen  DCNs of Assembly and IF Drawing version 27 to be approved PACS FPU

  19. Documents Status • ICDs • Chopper, FW, Calibration Source, Filters/ Dichroics, Ga:Ga Detector, Grating: approved • Bolometer, Distribution Boards: approved • Cryogenic harness and connectors: approved • Procurement specifications (structures, mirror, coating, screws/helicoils, Si -lens, emitter for CS , etc.) approved • AIV and functional/environmental test plan: updated • Filled in verification matrix: latest status (10.2003) PACS FPU

  20. Configuration Control Documents PACS FPU

  21. Approved Engineering Documents PACS FPU

  22. PA Activities (KT) • Approved Documents • PMP (Update) • CIDL (Update) • CIL (Issue1) • PA Plan (Update) • MIP/KIP plan (Update) • Inputs to FMECA (Update) • Approved procurement/manufacturing documentation/drawings • Configuration Control PACS FPU

  23. MIP / KIP List • Inspection • FW assembly (CQM/PFM) after functional and environmental testing • Calibration source (CQM/PFM) after environmental and functional testing • Coated mirrors (CQM/PFM) • FPU after vibration tests (CQM/PFM) • Distribution boards and harness after manufacturing and functional testing (CQM/PFM) • Fit check inspection after manufacturing and coating of aluminium structure (STM/CQM/PFM) • Functional performance verification after FPU alignment (CQM/PFM) PACS FPU

  24. MAIV Status of Structural Items -Completed Tasks • CQM • Mechanical items design and manufacturing drawings completed and released • STM/ CQM metallic items manufactured and IR black coated • Mechanical Fit check/Preintegration of all mechanical items (on boxes and FPU level) • STM/ CQM CFRP items manufactured and static load tested • Cooling straps manufactured • PFM • Structural items design and manufacturing drawings completed and released • CFRP items manufactured and static load tested PACS FPU

  25. MAIV Status of Structural Items - OpenTasks • CQM • Thermal Contact Soldering and Ge:Ga detector attachment (sapphire embedding) of CQM cooling straps in progress (until end of Nov. 2003) • Development of Ge:Ga Detector electrical isolation (thick layer coating) under progress (until end of Nov. 2003) • PFM • Substructures and metallic components manufacturing in progress until April 2004 • Preassembly/fit check until June 2004 • Finish and black Coating until July 2004 PACS FPU

  26. FPFPU Cryo Vibration Qualification Breakdown See dedicated chapters PACS FPU

  27. PACS FPU Verification Similarity • CQM and STM were manufactured parallel with the same drawingsout of the same lot Qualification Tests • STM vibration tests Tests completed Conclusion: FPFPU Housing is structurally qualified PACS FPU

  28. CQM SCHEDULE • Manufacturing • CQM primary/secondary structures thermal treatment /manufacturing /IR coating sequentially completed • CQMoptical components delivered • CQM CFRP struts and 2 K feed through material test program and manufacturing completed • AIV (Final assembly and alignment) • CQM from 7/03 to 1/04 (tbc) PACS FPU

  29. PFM SCHEDULE • Manufacturing • PFM primary/secondary structures thermal treatment /manufacturing /IR coating to be completed until 6.2004 • PFM optical components delivered • PFM CFRP struts and 2 K feed through material test program and manufacturing completed • AIV (Final assembly and alignment) • PFM from 7/04 to 11/04 PACS FPU

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