PACS IHDR 12/13 Nov 2003 PACS FPU FPU Structure, Baffle and Straylight R. Graue, D. Kampf Kayser-Threde

PACS IHDR 12/13 Nov 2003 PACS FPU Primary Structure Chopper Cover Photometer housing Bolometer housing Red Spectrometer Connector Panel Collimator housing Top Optics housing Spectrometer housing FPU foot 1 axis FPU foot 2 axis Blue Spectrometer Connector Panel 2 K Feed Thru Alignment Cube Entrance to FPU Field Mirror for Spectrometer 4 K Thermal Strap

PACS IHDR 12/13 Nov 2003 PACS FPU FPU STM

PACS IHDR 12/13 Nov 2003 PACS FPU Bolometer Integration

PACS IHDR 12/13 Nov 2003 PACS FPU Straylight Analyses – Top Optic Model ASAP Model of Top Optics Derived from optical ZEMAX Model Black Coated Walls (>0.4 mm)

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU 2K - Feed Through Outside sleeve Cold finger D/E: Retainer ring 1/2 F: Muff G: Ring Cryo STM Vibration Tested Manufactured and Delivered

PACS IHDR 12/13 Nov 2003 PACS FPU FPU Suspension Design Status and Material Status: Design: completed Documentation: Completed Material Fibre: T300 Resin:Ciba Geigy Araldit LY-3505 Hardener XP 3403

PACS IHDR 12/13 Nov 2003 PACS FPU FPU Suspension Cryo Qualification Test Matrix Status Static load tests: completed (Cold) material characterisation: completed Cryovibration tests: complete (CRYO STM FPU )

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU Mass Budget *IR Black Paint, Internal Harness, Screws Contingency not needed

PACS IHDR 12/13 Nov 2003 PACS FPU Performed FPFPU Analyses Program

PACS IHDR 12/13 Nov 2003 PACS FPU 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)

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU PACS Cool-Down Behaviour

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU Documents Status –ICDs Chopper, FW, Calibration Source, Filters/ Dichroics, Ga:Ga 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 ( )

PACS IHDR 12/13 Nov 2003 PACS FPU Configuration Control Documents Document DescriptionDoc.-No.Configuration Control FPU Interface and Assembly DrawingVersion 27Yes FPU Design SpecificationPACS-KT-SP-002Yes Ge detector ICDPACS-KT-ID-002Yes Bolometer ICDPACS-KT-ID-005Yes CS ICDPACS-KT-ID-007Yes FW ICDPACS-KT-ID-006Yes Distribution Board ICDPACS-KT-ID-004Yes

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU 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)

PACS IHDR 12/13 Nov 2003 PACS FPU 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

PACS IHDR 12/13 Nov 2003 PACS FPU MAIV Status of Structural Items - OpenTasks CQM –Thermal Contact Soldering and Ge:Ga detector attachment (sapphire embedding) of CQM cooling straps in progress (until end of Nov. 2003) –Development of Ge:Ga 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

PACS IHDR 12/13 Nov 2003 PACS FPU FPFPU Cryo Vibration Qualification Breakdown  See dedicated chapters

PACS IHDR 12/13 Nov 2003 PACS FPU PACS FPU Verification Similarity CQM and STM were manufactured parallel with the same drawings out of the same lot Qualification Tests STM vibration tests Tests completed Conclusion: FPFPU Housing is structurally qualified

PACS IHDR 12/13 Nov 2003 PACS FPU 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)

PACS IHDR 12/13 Nov 2003 PACS FPU PFM SCHEDULE Manufacturing –PFM primary/secondary structures thermal treatment /manufacturing /IR coating to be completed until –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