FPU Structure, Baffle and Straylight

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FPU Structure, Baffle and Straylight

• R. Graue, D. Kampf
• Kayser-Threde

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Primary Structure
Chopper Cover
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FPU STM
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Bolometer Integration
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Straylight Analyses Top Optic Model

• ASAP Model of Top Optics
• Derived from optical ZEMAX Model
• Black Coated Walls (gt0.4 mm)

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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

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2K - Feed Through

• Cryo STM Vibration Tested
• Manufactured and Delivered

Outside sleeve Cold finger D/E Retainer ring
1/2 F Muff G Ring
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FPU Suspension Design Status and Material

• Status
• Design completed
• Documentation Completed
• Material
• Fibre T300
• Resin Ciba Geigy
• Araldit LY-3505
• Hardener XP 3403

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FPU Suspension Cryo Qualification Test Matrix

• Status
• Static load tests completed
• (Cold) material characterisation completed
• Cryovibration tests complete
  (CRYO STM FPU)

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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
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Mass Budget
IR Black Paint, Internal Harness, Screws
Contingency not needed
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Performed FPFPU Analyses Program
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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)
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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

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PACS Cool-Down Behaviour
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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

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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

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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

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Documents Status

• ICDs
• Chopper, FW, Calibration Source, Filters/
• Dichroics, GaGa 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)

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Configuration Control Documents
Document Description Doc.-No. Configuration Control
FPU Interface and Assembly Drawing Version 27 Yes
FPU Design Specification PACS-KT-SP-002 Yes
Ge detector ICD PACS-KT-ID-002 Yes
Bolometer ICD PACS-KT-ID-005 Yes
CS ICD PACS-KT-ID-007 Yes
FW ICD PACS-KT-ID-006 Yes
Distribution Board ICD PACS-KT-ID-004 Yes
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Approved Engineering Documents
Document Description
FPU Alignment Plan
FPU Thermal Analyses
FPU Structural Analysis
FPU Load Analysis
FPU AIV Plan
FPU Environmental and Functional Test Verification Plan
FW Environmental and Functional Test Verification Plan
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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

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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)

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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

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MAIV Status of Structural Items - OpenTasks

• CQM
• Thermal Contact Soldering and GeGa detector
  attachment (sapphire embedding) of CQM cooling
  straps in progress (until end of Nov. 2003)
• Development of GeGa 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

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FPFPU Cryo Vibration Qualification Breakdown
?See dedicated chapters
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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
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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)

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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