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Chopper

Max-Planck-Institut für Astronomie, Heidelberg. Chopper. PACS Instrument Baseline Design Review 27/28 Feb 2002 MPE, Garching. R. Hofferbert D. Lemke, U. Grözinger, O. Krause J. Katzer (ZEISS). actuator. electrical I/F. mechanical I/F. mirror. housing. T-sensor. flex pivot.

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Chopper

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  1. Max-Planck-Institut für Astronomie, Heidelberg Chopper PACS Instrument Baseline Design Review 27/28 Feb 2002 MPE, Garching R. Hofferbert D. Lemke, U. Grözinger, O. Krause J. Katzer (ZEISS)

  2. actuator electrical I/F mechanical I/F mirror housing T-sensor flex pivot P-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 Chopper

  3. Design Status - Details • 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 P-sensor Chopper rotor

  4. 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 Chopper

  5. Testmatrix • 4 independent models • Test items: • Performance at 4K, 77K, 300K • Lifetime • Vibration capability • EMC • Thermal cycling • Bake-out Chopper

  6. „dummy 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) Chopper

  7. LM Verification Flowchart Chopper

  8. CuBe double-stage flex pivot actuator laser control FP rotor 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 Chopper

  9. Schedule today Chopper

  10. Open Points • How to order space-qualified pigtails (via TECNOLOGICA or directly) ? • When to put black coating on the chopper parts ? Chopper

  11. 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) Chopper

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