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PACS IBDR, Garching 27/28 Feb 2002
ChopperChopper
R. HofferbertR. Hofferbert
D. Lemke, U. Grözinger, O. KrauseD. Lemke, U. Grözinger, O. Krause
J. Katzer (ZEISS)J. Katzer (ZEISS)
PACS Instrument Baseline Design ReviewPACS Instrument Baseline Design Review27/28 Feb 200227/28 Feb 2002MPE, GarchingMPE, Garching
Max-Planck-Institut für Astronomie, HeidelbergMax-Planck-Institut für Astronomie, Heidelberg
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
mechanicalI/F
electrical I/F
housing
mirror
actuator
P-sensor
flex pivot
T-sensor
Design Status
• LM: • QM:– Major changes
• ITT Cannon/GORE pigtail • Cover with straylight baffles• “Vacuum cleaner” magnet• Black coating on housing and
cover• Pre-qualified parts
– Minor changes• FP bushings• Cable routing• Grounding pins• T-sensor internal
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
• Manufacture procedures completed:– Cryo motor coils
• High purity Al wires, laminated, pre-tempered Cryoperm cores, microscope controlled coiling, ~1100 windings
– Position sensor• Precision gluing of magneto resistive field
plates, optically aligned, cryo-qualified soldering
– Rotor• Precision gluing of
drive/sense magnets and flex pivots, ZEISS in-house procedures for mirror coating incl. Au diffusion blocker
cryo motor coil
Design Status - Details
P-sensor
rotor
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
AIV QA Activities
• KIP 1: QA checks…– Procurement/material certificates– Event records (“Logbuch”)– Inspection certificates– Non-compliances
• MIP 1: QA checks…– Event records (“Logbuch”)– Inspection reports– Non-compliances– As built documentation
• MIP 2: QA checks…– Event records (“Logbuch”)– Qualification or acceptance
reports– Non-compliances– Final inspection
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
Testmatrix
• 4 independent models• Test items:
– Performance at 4K, 77K, 300K
– Lifetime – Vibration capability– EMC– Thermal cycling– Bake-out
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
The 5th Model
• Engineering model:– pre-tests of parts and unit– Determination of control
parameters– Preparation of test
procedures– Handling of chopper wrt.
cleanliness, storage, mounting in cryostats, cool-down/warm-up requirements
– Dummy for first compatibility tests with warm electronics (MEC, CSL)
„dummy chopper“
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
LM Verification Flowchart
LIF ET IM E T EST:
BB e lectron icsa lignment te lescope
PAT E C
PAT E C
alignment te lescope
cold function check
zero position
inclination anglem odula tion functionpower consum ption
evacuationcool-down to 4K
warm function check
in tegration in toStöhr cryostat
a lignment te lescopePAT E C
visua l check
rem oval from cryostat
warm function check
warm -up to 300Kventing
life tim e cycling1/3 opereration1/3 ca libra tion
co ld function check
life tim e cycling1/3 opereration1/3 ca libra tion
co ld function check
life tim e cycling1/3 opereration1/3 ca libra tion
co ld function check
VIBRATION TEST :
warm function check
warm -up to 300Kventing
integration in toStöhr cryostat
77K function check
cold vibration x-axis
77K function check
integration in tovibration cryostat
evacuationcool-down to 77K
warm function check
integration in toStöhr cryostat
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
CuBe double-stage flex pivot
Engineering Lifetime Test of Flex Pivots
• Test at Fraunhofer LBF (Darmstadt):– 300K environment: Worst case
scenario (higher loads) due to reduction of fatigue strength by factor 1.3
– 6 FPs in 3 independent rotors (simult. excitation, 50Hz, 9°, goal: 2 x lifetime = 126 Mio. cycles)
– Damages of two flex pivots in first run, optical measurement indicated bad alignment of ONE FP HOLDER on mounting bench test setup has been crucially improved, second run presently underway
actuator
rotor
laser control
FP
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
Schedule
J ul
01
Aug
01
Sep
01
Okt
01
Nov
01
Dez
01
J an
02
Feb
02
Mrz
02
Apr
02
Mai
02
J un
02
J ul
02
Aug
02
Sep
02
Okt
02
Okt
02
Nov
02
Dez
02
Kick OffChopper PDR
Freezing of SpecsLM Manufacture (MPI A)
LM AssemblyDummy Chopper Tests
LM Pre- TestsLifetimetestDelivery LM
QM Manufacture (MPI A)QM Critical Parts Qualification
QM AssemblyQM Tests
Delivery QMChopper CDR
Development FMDelivery FM
Development FSDelivery FS
today
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
Open Points
• How to order space-qualified pigtails (via TECNOLOGICA or directly) ?
• When to put black coating on the chopper parts ?
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PACS IBDR, Garching 27/28 Feb 2002
Chopper
Conclusion
• Valuable experience wrt. flex pivot alignment and lifetime from tests at Fraunhofer LBF (Darmstadt)
• LM and QM test phases practically in parallel– Fastes way of completing verification plan– Critical wrt. transfer of lessons learned
• Start of cold lifetime tests in April 2002
• QM delivery in May 2002 critical due to– Tight schedule (no margins) – Pigtail procurement (GORE cables, ITT Cannon connectors +
manufacture)
