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PACS IHDR, Garching 12/13 Nov 2003
ChopperChopper
R. HofferbertR. Hofferbert
D. Lemke, U. Grözinger, O. Krause, A. Böhm, A. Bohm D. Lemke, U. Grözinger, O. Krause, A. Böhm, A. Bohm (Hardware)(Hardware)
R. Vavrek, U. Klaas (ICC)R. Vavrek, U. Klaas (ICC)
J. Katzer, M. Salvasohn (ZEISS)J. Katzer, M. Salvasohn (ZEISS)
PACS Instrument Hardware Design ReviewPACS Instrument Hardware Design Review12/13 Nov 200312/13 Nov 2003MPE, GarchingMPE, Garching
Max-Planck-Institut für Astronomie, HeidelbergMax-Planck-Institut für Astronomie, Heidelberg
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
Design Overview
topview
bottomview
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
• Three independent and fully functional models available (DM, LM, QM)
• Similarity partly allowed parallel testing to save time and money in the AIV program
• QM main characteristics– Pre-qualified parts (pigtail, EEE parts,
etc.) – Black coating on housing and
straylight baffle
• “Released to the public”– DM 3 times at CSL, once at KT,
also in JWST MIRI Phase A study – LM presented at Paris Air Show,
also during DLR visit at MPIA– QM officially delivered to PI
on June 27th 2003
Hardware OverviewQM
DM
LM
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
• Qualification Model (QM):– EMC test– Cold 3-axis vibration,
77K, 25g sine, 8g rms random
– Cold performance, 4K– Bake-out, 3 days, 80°C
Qualification Programme Overview
• Development Model (DM):– Qualification of components– AIV experience, handling– Interface check with PACS
and warm electronics
• Lifetime Model (LM):– 630Mio lifetime cycles– 15 thermal cycles
(300K - 4K - 300K)
vibration
performancelifetime
integration +
inspection
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
Non-Conformances
• Status for Oct. 6th 2003Telecon!
Now!!
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
QM Acceptance Data Package – IHDR Documents
• More than 230 individual documents
• All required management + PA/QA plans
• Complete chain of test reports systematically structured by chopper models
• One summarizing NCR list
• Reviewed CD delivered to PI
• Entered IHDR package to ESA
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
Remaining Testmatrix
• Test variations– Thermal cycling
with LM (similar to QM)
– Additional test of redundant/failure modes (1..3 coils)
– “Fail save position” no longer on requirements list
– Bake-out added
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
FM / FS Verification Flowchart
VIBRATION:
2x
warm function check
warm -up to 300Kventing
integration in toperformance cryostat
77K function check
cold vibration x-axis
77K function check
integration in tovibration cryostat
evacuationcool-down to 77K
warm function check
integration in toperformance cryostat
AC C EPTAN C ETEST:
3D m easuring deviceO G SE for m irror
precision ba lance
vibration test facility
a lignment te lescopecryostat
BB e lectron ics
warm function check
in tegration in to cryostat
vibration test
Determ ination ofcontrol param eters
4K, 77K, 300K
m easurem ent o f m ass
assem bly
m easurement o f dim ensionsm irror size and position
optica l qua lity
com ponents
position measuringdevice
a lignment te lescope
alignment te lescope
visua l checkbake-out
rem oval from cryostat
warm function check
warm -up to 300Kventing
co ld function check
zero positioncross axis stab ility
inclination anglem odula tion functionpower consum ption
evacuationcool-down to 4K
300K
77K
4K
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
Schedule
Nr. Activity Duration Starting
1 Manufacture FM/FS + 2 spares 65 Tage Fr 01.08.03
2 Black painting at KT 7 Tage Mo 03.11.03
3 Assembly FM 21 Tage Mi 12.11.03
4 Assembly FS + 2 spares 29 Tage Do 11.12.03
5 FM control parameters, 300K 10 Tage Do 11.12.03
6 FM function/performance check, 300K 8 Tage Do 15.01.04
7 FM control parameters, 4K 10 Tage Di 27.01.04
8 FM function/performance check, 4K 7 Tage Di 10.02.04
9 FM function/performance re-check, 300K 2 Tage Do 19.02.04
10 FS control parameters, 300K 5 Tage Mo 23.02.04
11 FS function/performance check, 300K 4 Tage Mo 01.03.04
12 FS control parameters, 4K 5 Tage Fr 05.03.04
13 FS function/performance check, 4K 4 Tage Fr 12.03.04
14 FS function/performance re-check, 300K 2 Tage Do 18.03.04
15 FM/FS Vibrationstest 2 Achsen warm, 14t 14 Tage Mo 22.03.04
16 FM/FS qualification test, 4K 16 Tage Di 13.04.04
17 FM/FS bake-out 3 Tage Mi 05.05.04
18 Preparation of documents 15 Tage Mo 10.05.04
19 Final Design Review 1 Tag Mi 02.06.04
20 Delivery FM/FS 1 Tag Do 03.06.04 03.06.
Jul Aug Sep Okt Nov Dez Jan Feb Mrz Apr Mai Jun Jul Aug3. Quartal 4. Quartal 1. Quartal 2. Quartal 3. Quartal
today
* PI‘s official release awaited
*
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
Test phase (ILT, PV) PCD procedures
Subsystem checkout 0.7.5 Verify function of PACS chopper0.7.6 Performance test of chopper and synchronous operation with detectors
Functional tests TBD Optimization of PID control loop parameters for plateau stabilization (TBW)2.3.2 Duty cycle of chopper waveforms2.3.3 Optimal positioning of chopper on internal calibration sources
Spatial performance 2.3.1 Angular calibration of chopper (coarse calibration on instrument level)3.1.2 Relation between chopper position and angular displacement on the sky (fine calibration on full system level)
AOT Try-out 5.1.1 Optimized observing strategy for photometry of small sources (on-array chopping)
ICC – Calibration Requirements
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PACS IHDR, Garching 12/13 Nov 2003
ChopperDouble stars
OGSE black body &
hole mask for point source(s)
OGSE BB,xy(z) stage &
hole mask
Verify function• Electrical health (in HK measures)• Chopper position info (in DMC headers)
Performance test• Synchronous operation with detectors• Modulation with different waveforms and throws
Angular calibration (ILT)• Position sensor signal vs. pinhole position• Chopper throw vs. position sensor signal
Calibration sourcesOptimal positioning of chopper on internal calibration sources
Duty cycleDependence on chopper throw,Frequency and modulation function
Photometer & spectrometer central pointing position
Photometer & spectrometer field of view distortion
Angular calibration (in-orbit)chopper throw vs. double star separation
Optimization of PID control loop parameters
ICC – Calibration Sequence
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
set chop_def 0set chop_pos_max 2set step 0.05set reproc 2
# Conversion from degrees (max/min +/- 13.89 deg) to setpoint (32 bit signed integer)set chop_max [expr round(2358. * $chop_pos_max)]set chop_min [expr $chop_max * -1]set chop_incr [expr round(2358. * $step)]set loop [expr (round($chop_pos_max / $step) * 2) + 1]set chop_throw 0.0
# DMC-MOVE-CHOPPER-ABSTCsend PC123420 [list PP079420 $chop_def]WaitTime 500
for {set z 1} {$z<$reproc} {incr z} { for {set x 1} {$x<$loop} {incr x} { if {$x/2 == $x/2.} {set y 1} else {set y -1} set chop_throw [expr round($chop_throw+($chop_incr*$x*$y))] # DMC-MOVE-CHOPPER-ABS TCsend PC123420 [list PP079420 $chop_throw] WaitTime 500 }}
# DMC-MOVE-CHOPPER-ABSTCsend PC123420 [list PP079420 $chop_def]WaitTime 500 S
etpo
int
valu
e
Array index
ICC – Commanding and TM Analysis
part of the chopper verify function tcl script
IA plot of chopper position data from DMC headers
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
Ongoing Work - Open Points
• Chopper operation modes and control schemes– Transfer from MPIA/Zeiss breadboards to flight-like warm
electronic boxes Intensification of exchange process with CSL
– Definition and limitation of operation modes (observation, calibration, launch, redundancy in failure cases, …)
Intensification of definition process with PI and PACS commanding group
• Official FM manufacture release
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PACS IHDR, Garching 12/13 Nov 2003
Chopper
Conclusion
• Qualification program completed on subunit level – no critical throwbacks– Chopper QM + complete acceptance data package delivered to
PI– Support on instrument level available and already used– Industrial PA/QA accompanied all development stages– Extensive transfer phase between QM and FM, no major changes
• Flight program started – Manufacture on the way – Components procurement completed, selection process + pre-
qualification running– Subunit AIV planning presently starting (preparation of ground
support equipment, overall test plan, detailed procedures)– FM + FS development in parallel (time + cost saving reasons)– Delivery to PI: June 2004