PACS IHDR, Garching 12/13 Nov 2003 Chopper R. Hofferbert D. Lemke, U. Grözinger, O. Krause, A. Böhm, A. Bohm (Hardware) R. Vavrek, U. Klaas (ICC) J. Katzer,

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

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Non-Conformances

• Status for Oct. 6th 2003Telecon!

Now!!

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PACS IHDR, Garching 12/13 Nov 2003

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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

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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

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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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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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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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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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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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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