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Chopper

Max-Planck-Institut für Astronomie, Heidelberg. Chopper. PACS Instrument Hardware Design Review 12/13 Nov 2003 MPE, Garching. R. Hofferbert D. Lemke, U. Grözinger, O. Krause, A. Böhm, A. Bohm (Hardware) R. Vavrek, U. Klaas (ICC) J. Katzer, M. Salvasohn (ZEISS). Design Overview. top

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Chopper

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  1. Max-Planck-Institut für Astronomie, Heidelberg Chopper PACS Instrument Hardware Design Review 12/13 Nov 2003 MPE, Garching R. Hofferbert D. Lemke, U. Grözinger, O. Krause, A. Böhm, A. Bohm (Hardware) R. Vavrek, U. Klaas (ICC) J. Katzer, M. Salvasohn (ZEISS)

  2. Design Overview top view bottom view Chopper

  3. Hardware Overview QM • 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 LM DM Chopper

  4. Qualification Programme Overview • Qualification Model (QM): • EMC test • Cold 3-axis vibration, 77K, 25g sine, 8g rms random • Cold performance, 4K • Bake-out, 3 days, 80°C • 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) integration + inspection performance lifetime vibration Chopper

  5. Telecon! Now!! Non-Conformances • Status for Oct. 6th 2003 Chopper

  6. 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 Chopper

  7. 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 Chopper

  8. FM / FS Verification Flowchart 300K 77K 4K Chopper

  9. today Schedule * * PI‘s official release awaited Chopper

  10. ICC – Calibration Requirements Chopper

  11. ICC – Calibration Sequence Chopper

  12. ICC – Commanding and TM Analysis 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 $chop_def]WaitTime 500for {set z 1} {$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-ABSTCsend PC123420 [list PP079420 $chop_throw] WaitTime 500 }} # DMC-MOVE-CHOPPER-ABSTCsend PC123420 [list PP079420 $chop_def]WaitTime 500 part of the chopper verify function tcl script IA plot of chopper position data from DMC headers Setpoint value Chopper Array index

  13. 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 Chopper

  14. 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 Chopper

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