Andy Stefanik 1July 2006 Mechanical Overview WBS 1.5 Opto-Mechanical System Andy Stefanik - Fermilab.

Andy Stefanik

1July 2006

Mechanical Overview

WBS 1.5 Opto-Mechanical System

Andy Stefanik - Fermilab

Andy Stefanik

2July 2006

Optical Element Positioning Requirements

• Corrector optical design 2605-v3.

• Sensitivity analysis.

C1

C2 C3 C4 C5

Filters &Shutter

PackagedCCDs

Andy Stefanik

3July 2006

Cells and CCD Focal Plane Support

• Conceptual cells for C1, C2, C3 and C4 by B. Bigelow @ UM.

• Conceptual cell for C5 and focal plane support by H. Cease @ Fermilab.

C1 cell

C2 – C3cell

C4cell

C5 cellring (blue)

retainer (yellow)

Focal plane

All cells bolt to the barrel.Forward ring welds to the camera vessel shell.

Bipods

Forwardring

Andy Stefanik

4July 2006

Cells and CCD Focal Plane Support

• Cells for C1, C2, C3 and C4 (WBS 1.4.6): Designed and provided by University College London (UCL), Peter Doel.

• Lenses installed in cells at UCL.• Cells installed in barrel at UCL.• C5 cell (WBS 1.4.7) and focal plane support (WBS 1.5.2.4): Designed and provided

by Fermilab, Herman Cease. Breakout Session 2.• C1 (current model): 140 Kg (309 Lbs), 940 mm OD, 237.2 mm overall axial length.• C2 (current model): 72 Kg (159 Lbs), 658 mm OD, 158.7 mm overall axial length.• C3 (current model): 41 Kg (90 Lbs), 610 mm OD, 76.8 mm overall axial length.• C4 (current model): 40 Kg (88 Lbs), 578 mm OD, 127.8 mm overall axial length.• C5 (current model): 24 Kg (60 Lbs), 508 mm OD, 83.3 mm overall axial length.• Filter (current model): 578 mm OD.• Focal plane: Cast aluminum tooling plate.• C5 cell: Stainless steel ring, PVC retainer.• Bipod leg: Titanium 6AL4V Grade 5.• Forward ring: Stainless steel.

Andy Stefanik

5July 2006

Multi-CCD Test Vessel (WBS 1.5.2.1)

Monsoon crate

C5

C4

Andy Stefanik

6July 2006

Prime Focus Camera

• Prime focus camera (WBS 1.5.2.3 and 1.5.2.5): Designed and provided by Fermilab, Herman Cease. Breakout Session 2.

• Multi-CCD test vessel (WBS 1.5.2.1) is the prototype camera. It arrived at Fermilab on July 14, 2006. Herman Cease. Breakout Session 2.

• Material of construction: Electropolished stainless steel.• Weight empty: 205 Kg (450 lbs).• Weight fully equipped (includes C5 and its cell): 590 Kg (1300 lbs).• Shell OD: 609.6 mm.• Overall length: 764.4 mm.• Operates at 10-6 torr.• Bolts to the C5 cell.• Cryogenic cooling of the CCD’s in the multi-CCD test vessel: Pool boiling

liquid nitrogen; copper straps connect the focal plane to the copper heat sink. Designed for horizontal use only.

• Cryogenic cooling method of the CCDs in the prime focus camera: TBD.

Andy Stefanik

7July 2006

Multi-CCD Test Vessel

C4

Andy Stefanik

8July 2006

Multi-CCD Test Vessel at UCEC

Andy Stefanik

9July 2006

Barrel and Prime Focus Camera

Opening for filter changer and shutter. Shutter is installed directly in front of C4.

Stray light baffles(not shown)

PrimeFocus

Camera

Andy Stefanik

10July 2006

Barrel and Prime Focus Camera

Cone Body

PrimeFocus

Camera

Andy Stefanik

11July 2006

Barrel

• Barrel (WBS 1.5.4.1): Designed and provided by Fermilab, Andy Stefanik.• Material alternatives: Plated/coated carbon steel. Electropolished 304L SS. • Weight: 820 Kg (1800 lbs). Overall length: 1505.6 mm.• Outside dimensions: 1030 mm at C1, 1016 x 1016 mm at opening for filter changer

and shutter, 865 mm flange OD at camera vessel.• Opening for filter changer and shutter: 233 x 763 mm.• Cone and body are separate weldments that are stress relieved before machining.

Cone final machining takes place after it is bolted and pinned to the body.• Cone, body and camera vessel bolt together.• Two concepts being considered: Round body and square body.• Drawings for round body concept have been prepared to get a budget cost estimate

and to check feasibility of the fabrication tolerances.• Longitudinal (axial) fabrication tolerance: +/-25 microns. (alternative: cell spacer)• Radial (decenter) fabrication tolerance: +/-25 microns. (alternative: locating pins)• Deflection requirement: 25 microns maximum droop at the CCDs and at C1. 6

arcseconds tilt at the CCDs and 5 arcseconds tilt at C1.• The barrel carries a cantilevered load from each of its ends to the hexapod.• Cost drivers: Deflection requirement, machining tolerances and material choices.

Andy Stefanik

12July 2006

Hexapod

Hexapod with 6 actuators

Payload center of gravity offset: 136 mm.

Andy Stefanik

13July 2006

Hexapod Actuator Example

CompetitionSensitive

Andy Stefanik

14July 2006

Hexapod

• Hexapod (WBS 1.5.6.2): Specified and provided by Fermilab, French Leger. Breakout Session 4.

• Specification: Range of travel for each of the 6 degrees of freedom, repeatability, payload, payload offset, geometry constraints, attachment constraints, control system, power supply.

• Minimum adjustments are specified in DES Document 20-v9, Science and Technical Requirements. Stephen Kent. Breakout Session 4.

• A budget quotation for a turnkey system has been obtained from an experienced supplier.

• Payload: 2275 Kg (5000 Lbs)• Extra weight might have to added to the C1 end of the barrel to minimize the payload

offset.

Andy Stefanik

15July 2006

Filter Changer and Shutter

Light-tight,dust-tight

cover

Andy Stefanik

16July 2006

Filter Changer, Shutter & Stray Light Baffles

• Filter changer (WBS 1.5.5.1): Designed and provided by University of Michigan, Bruce Bigelow.

• Filter changer requirements are being developed.• Four (4) DES filters.• Two (2) guest filters.• Filter diameter: 570 mm.• Filter thickness: TBD. Current estimate is 10 to 30 mm.• Shutter (WBS 1.5.5.2): Provided by University of Michigan, Bruce Bigelow.• Shutter: Designed and built by Bonn University. A budget quotation has been

obtained.• Stray light baffles (WBS 1.5.4.3): Designed and provided by University of Michigan,

Bruce Bigelow.

Andy Stefanik

17July 2006

Filter Changer

Andy Stefanik

18July 2006

Example of a Bonn shutter (PanSTARRS)

PanSTARRSLength: 1664 mmWidth: 632 mmDepth: 50 mmShutter aperture: 480 x 480 mmMass: 30 Kg

DECamLength: 2060 mmWidth: 760 mmDepth: 56 mmShutter aperture: 600 mm diameterMass: 40 Kg

Andy Stefanik

19July 2006

Prime Focus Cage

840 mm offset from cage flip axis tocenter of gravity for DECam and F8

F8 Mirror

Andy Stefanik

20July 2006

Prime Focus Cage

• Prime Focus Cage (WBS 1.5.6.1): Redesigned and provided by Fermilab, French Leger.

• Discard existing pedestal.

• Reuse existing components: F8, petal covers, mounting rings and fins.

• Redesign rails to anchor the hexapod.

• Extra weight must be added to the C1 end of the prime focus cage to balance the weight about the flip axis.

• Estimated weight of equipment for DECam: 2700 Kg (6000 Lbs).

Andy Stefanik

21July 2006

Prime Focus Cage

Andy Stefanik

22July 2006

Taking Data in the Blanco

Andy Stefanik

23July 2006

Auxiliary Systems

• New C1 cover (WBS 1.5.4.2): A recent suggestion but probably not needed.

• Camera calibration/response system (WBS 1.5.9.1): Future work.

• Cloud camera (WBS 1.5.9.2): Future work.

• Guide system (WBS 1.5.9.3): Future work.

Andy Stefanik

24July 2006

Telescope Finite Element Modeling

WBS 1.5.8

Andy Stefanik

25July 2006

Process Systems

• Prime focus camera cooling (WBS 1.5.3.1): Designed and provided by Fermilab, Richard Schmitt. Several methods are being considered. Breakout Session 4.

• Electronic crate cooling (WBS 1.5.3.2): Water-alcohol coolant. Future work.

• Barrel dry gas purge (WBS 1.5.3.3): Dry nitrogen gas is currently available in the prime focus cage. The existing system must be evaluated and modified or replaced if necessary. The existing corrector is not purged but dry nitrogen is used to keep the dewar window from fogging up.

• Cage dry air: Dry air is currently available in the prime focus cage. The existing system must be evaluated and modified or replaced if necessary. An air supply reservoir might have to be added.

• Cage temperature monitoring (WBS 1.5.3.4): Future work.

• I/O system (WBS 1.5.3.5 – 1.5.3.13): Future work. Designed and provided by Fermilab, Herman Cease.

Andy Stefanik

26July 2006

Camera Cooling

7-14-06 - RLS

Andy Stefanik

27July 2006

Camera Cooling – Heat Loads

• Focal Plate Supports: 10 Watts

• CCDs: 20 Watts

• Wiring and Cables: 25 Watts

• Radiation heat load: 70 Watts

• Add safety factor

• Total heat load: 200 Watts

7-14-06 - RLS

Andy Stefanik

28July 2006

Component Testing

• All components will be fully tested by the responsible institution before shipment to CTIO or to the telescope simulator at Fermilab.

• Telescope simulator (WBS 1.5.7): Designed and provided by Fermilab, Andy Stefanik.

• Primary purpose of the telescope simulator is to load test the hexapod and to flip test the cable runs and process lines at all operating positions. Secondary purpose is to perform additional testing of other components at all operating positions.

• Assure fabrication and functional requirements are met.• Typical mechanical testing of components and systems: alignment,

dimensional check, deflection, assembly repeatability, motion repeatability, thermal cycle, thermal shock, mechanical shock, motion cycle, operating position, control, failure modes, vibration, loss of vacuum, rate-of-rise test.

• A 360° flipping cart (WBS 1.5.2.2) is planned to test prime focus camera operation in various positions. The cart will be designed and provided by UCEC.

Andy Stefanik

29July 2006

WBS 1.5 Mechanical Integration

• Fermilab – Prime focus camera, barrel, telescope simulator, process systems, auxiliary systems.

• Fermilab: SDSS telescope, Apache Point Observatory, NM – Hexapod, prime focus cage.

• CTIO – Design, installation, operation, maintenance requirements for the new components. Telescope details.

• NOAO – Telescope drawings.

• UCEC – Multi-CCD test vessel fabrication, 360° flipping cart.

• University of Michigan – Filter-changer, shutter, stray light baffles.

• UCL – Cells.

Andy Stefanik

30July 2006

WBS 1.5 Cost Summary

Costs are unburdened and unescalated.

WBS Task Name CostIn-Kind

ContributionTPC w/o

Contingency

Total Project

Cost

Andy Stefanik

31July 2006

WBS 1.5.10 Opto-Mechanical Systems Milestones

• 1.5.10.3 L3 – Multi-CCD test vessel ready for CCD installation Oct 06

• 1.5.10.4 L3 – Design review for cage and F8 plans complete Jun 07

• 1.5.10.6 L4 – 360° test of cooling system complete Aug 07

• 1.5.10.7 L3 – Design review of focal plate complete Nov 07

• 1.5.10.1 L3 – Design review of camera and cooling complete Dec 07

• 1.5.10.5 L4 – Camera cooling plant review complete Jan 08

• 1.5.10.11 L3 – Shutter and filter delivered to Fermilab Oct 08

• 1.5.10.9 L3 – Camera vessel ready for installation on barrel Nov 08

• 1.5.10.8 L3 – Cage ready for telescope simulator Apr 09

• 1.5.10.12 L3 – Barrel ready for telescope simulator May 09

• 1.5.10.13 L3 – All process input/output systems complete May 09

• 1.5.10.10 L3 – Electronic crate cooling system complete Jun 09

• 1.5.10.14 L4 – Telescope simulator tests complete Sep 09