PEIRKIN-ELMERPERKIN-ELMER Report No. 11923 Principal performance goals for the mirror suspension...

(UAS&A-CE120237) LST SECONDARY HIRROR U74-27876ARTICULATICU BECHA~ISH Final Report 15727876Sepo 1973 -29 Bar. 1974 (Perkin-ElmerCorp.) 98 p HC 98.00 CSCL 14B Unclas

G3/14 43074

PEIRKIN-ELMER

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PERKIN-ELMERELECTRO-OPTICAL DIVISION

NORWALK, CONN ECTICUT

REPORT NO. 11923

LST SECONDARY MIRROR

ARTICULATION MECHANISM

FINAL REPORT

PREPARED FOR

NATIONAL AERONAUTICS AND SPACE ADMINISTRATION

GEORGE C. MARSHALL SPACE FLIGHT CENTER

HUNTSVILLE, ALABAMA

CONTRACT NAS 8-29723

DATE: MAY 1974

REF:

PEFRKIN-ELMER Report No. 11923

TABLE OF CONTENTS

Paragraph Title Page

1.0 SUMMARY 1

1.1 Contract Requirements 11.2 Performance Summary 1

2.0 SYSTEM DESCRIPTION 2

2.1 Summary of Performance Requirements 2

2.2 Description of Mirror Suspension System 2

2.2.1 Universal Flexure Suspension 3

2.2.2 Cruciform Flexure Suspension 6

2.3 Image Motion Control Drive Actuators 9

2.3.1 Piezoelectric Translator 9

2.3.2 Flexure Torque Motor Actuators 11

2.4 Alignment Drive System 13

2.5 Mirror Articulation System Selepted forManufacture and Test 14

3.0 SYSTEM DESIGN 15

3.1 Mirror Mass Properties 153.1.1 Simulated Mirror Weight 153.1.2 Simulated Mirror Inertia 15

3.2 Mirror Support Flexure Design' 173.2.1 Flexure Compliance Along Optic Axis 173.2.2 Radial Compliance 18

3.2.3 Compliance About Azimuth and ElevationAxes 20

3.2.4 Resonant Frequency of Simulated MirrorSupported by Cruciform Flexure 21

3.2.5 Actuator Stroke 21

3.2.6 Actuator Load Due to Cruciform FlexureStiffness 22

3.2.7 Alignment Drive Design 223.2.8 Thermal Design 23

4.0 SYSTEM TEST 25

4.1 Summary 254.2 System Test - PZT Actuator Configuration 254.3 System Test - Flexure Torque Motor Actuator

Configuration 304.4 Test of Mirror Suspension Stiffness PZT Actuator

Configuration 304.5 Test of Mirror Suspension System - Flexure

Torque Motor Configuration 33

ii

PERKIN-ELMER Report No. 11923

TABLE OF-CONTENTS (Continued)

Paragraph Title Page

5.0 CONCLUSIONS AND RECOMMENDATIONS 35

5.1 Conclusion 35

5.1.1 Piezo Ceramic (PZT) Actuator Performance 35

5.1.2 Flexure Torque Motor (FT) Actuator

Performance 35

5.1.3 Alignment Drive Performance 36

5.1.4 Mirror Suspension.System 36

5.1.5 Position Sensing Components 36

5.2 Recommendations 36

5.3 Documentation List 37

Appendices

A PZT ACTUATOR TEST DATA A-i

B FLEXURE TORQUE MOTOR ACTUATOR TEST DATA B-i

C PRECISION ANGLE INSTRUMENT C-i

D LATERAL STIFFNESS - CRUCIFORM FLEXURE D-i

E TORSIONAL STIFFNESS - CRUCIFORM FLEXURE E-i

iii


LIST OF ILLUSTRATIONS

Figure Title Page

2-1 Universal Circular Flexure 3

2-2 Compound Single-Axis Flexures 4

2-3 Secondary Mirror Actuating System 5

2-4 Two-Axis Cruciform Flexure 7

2-5 Piezoelectric Translator 10

2-6 Typical Flexure Torque Motor Actuator 12

2-7 Differential Beam Microposition Mechanism 13

4-1 Component Schematic Piezo Ceramic ActuatorConfiguration 26

4-2 PZT Actuator Configuration Test Setup 27

4-3 Component Schematic Flexure Torque MotorActuator Configuration 31

4-4 LST Secondary Mirror (Elevation Axis), Mirror.Deflectionversus Applied Load 32

4-5 LST Secondary Mirror (Elevation Axis), MirrorDeflection and Alignment Drive Deflectionversus Applied Load 34

iv

PERKIN-ELMERReport No. 11923

1.0 SUMMARY

This report describes the work performed by Perkin-Elmer under

Contract NAS8-29723 for the National Aeronautics and Space Administration,

George C. Marshall Space Flight Center, Huntsville, Alabama.

The period of performance covered by this report is from Septem-

ber 15, 1973 through March 29, 1974.

1.1 CONTRACT REQUIREMENTS

This contract required the analysis, design, manufacture, test,

and delivery of one secondary mirror articulation mechanism for the Large

Space Telescope (LST). The mechanism provides angular freedom about two

axes that are perpendicular to the optical axis of the secondary mirror.

Motion in each axis is controlled from two sources; one source provides

alignment, the other source provides stabilization.

Two articulation mechanism configurations were evaluated. In

one configuration the stabilization system was assembled with piezoelectric

actuators. In the second configuration the stabilization system utilized

flexure torque motor actuators. The alignment system was the same for both

configurations.

Contract Modification 1 (effective October, 1973) provided

for system size coordination with. LST optical design performed at Perkin-

Elmer and added two position transducers in each axis for a total of four

position transducers.

1.2 Performance Summary

System testing confirmed performance that met or exceeded all

operational requirements. The two types of stabilization actuators had

different performance characteristics. Both types demonstrated position

resolution and frequency response better than specified limits.

-------------------------------------.--------


2.0 SYSTEM DESCRIPTION

2.1 SUMMARY OF PERFORMANCE REQUIREMENTS

The mirror articulation mechanism provides angular freedom about

two axes that are perpendicular to the optical axis of the LST secondary

mirror. Motion in each axis (azimuth and elevation) is controlled from two

sources. One source performs an alignment function. The other source per-

forms an image stabilization function.

The performance requirements for each source are as follows:

a. Alignment (in both axes)

(1) Total angular range ±5 arc seconds

(2) Threshold: 0'.1 arc-second

(3) Response: 10 arc-seconds in 1 minute

(4) Environment: Laboratory ambient or hard vacuum, with

20 to 120OF temperature and ±2g vibration from 20 to

2000 Hz.

b. Stabilization (in both axes)

(1) Total Angular range: + 3 arc-seconds

(2) Frequency Response: Attenuation less than 3db at

4Hz for a sine wave input.

(3) Threshold: ±0.005 arc-second

(4) Environment: Same as for alignment.

2.2 DESCRIPTION OF MIRROR SUSPENSION SYSTEM

The motions specified for the secondary mirror require a mirror

suspension system that is capable of responding to commands of 1 part in

600 over a very small range of motion. Resolution to this degree of pre-

cision makes the use of flexure mechanisms in the mirror suspension and articu-

lation system mandatory. Elements that are critically dependent on manufac-

turing tolerance, operating clearances, finish of interfacing elements (such

as rolling element bearings, screws, or cams) are not suited to this appli-

cation.

2


Principal performance goals for the mirror suspension system

can be summarized as follows:

o Must be able to accommodate maximum range of motion

(±8 arc-seconds tilt) with limited lost motion compat-

ible with actuator resolution requirements.

o Provide minimum mirror motion response to external lateral

or rotational vibration (rigid body mirror motion).

o Minimize mirror figure degradation due to mechanical or

thermal disturbances (mirror figure change)

o Survive launch loads with minimum resonant amplification

without need for launch caging devices.

2.2.1 Universal Flexure Suspension

A mirror suspension system that was evaluated to meet the

performance goals defined above is shown in Figure 2-1. The central support

element is a circular flexure located with the axis of rotation coincident

with the mirror center of gravity. This configuration provides minimum

coupling of lateral or rotational vibration to mirror tilt, a key consider-

ation since the optical system is highly sensitive to secondary mirror tilt and

the corresponding image motion in the focal plane. It thus provides a good

decoupling from structural vibrations in orbit.

A simple form of this central flexure capable of motion about

two orthogonal intersecting axes is shown in Figure 2-1.

Azimuth Elevation AxisAxis

Optic Axis

Figure 2-1. Universal Circular Flexure

3


The flexure, however, has relatively low strength along its

longitudinal axis (z axis). Torsional strength about this longitudinal

axis is also poor, as is stiffness to lateral loads.

In order to increase strength along the longitudinal axis

the configuration of Figure 2-1 can be modified, as shown in Figure 2-2.

Here,. simple single-axis flexures were combined with an intermediate member.

Intermediate AzimuthMember Axis

'Elevat ion

AxisHousing Free

Member

Figure 2-2. Compound Single-Axis Flexures

This improved configuration has proven to be effective in a

Perkin-Elmer precision mirror suspension system, but requires additional

support against rotation about the mirror optical axis and lateral motion

perpendicular to the optic axis. The addition of lateral flexures to

provide this support produced the suspension system shown in Figure 2-3.

Analysis of this concept however disclosed undesirable char-

acteristics relative to the interaction of flexure loads on the mirror

figure. Flexure attachments at several widely spaced points across the

mirror can strain the mirror as a function of manufacturing tolerances

or thermal gradients in the structure.

4


Lateral Flexure(B)

Dummy Mirror

Central

J) Lateral

.u 1IActuator (C)

(D)

Figure 2-3. Secondary Mirror Actuating System

5

-~--------- 5


The overall telescope optical performance is a function of the

accumulated effects of surface tolerance on the primary and secondary mirrors.

Since the secondary mirror is much smaller in size than the primary mirror,

the secondary mirror will be manufactured to surface tolerances that approach

the limit of the state of the art, thereby making a greater part of the

surface tolerances available to the primary mirror. Accordingly, the sec-

ondary mirror suspension must assure minimum degradation of the mirror

figure. The cruciform flexure suspension concept was developed to meet

this requirement.

2.2.2 Cruciform Flexure Suspension

An optimum mirror suspension configuration consists of a mech-

anism that provides the required restraint or compliance in all six degrees

of freedom with all interface loads at the non-critical central area. The

two-axis cruciform flexure (Figure 2-4) meets these requirements.

A cruciform consists of two intersecting planes. The struct-

ural characteristics are high stiffness and lateral load capacity (edge

loading of the plates) and high compliance to torsion about the intersecting

axis of the planes (twist of the plates).

The configuration shown in Figure 2-4 provides rotational freedom

about two orthogonal axes (azimuth and elevation) together with high stiffness

and load capacity in the remaining rotational mode (rotation about the optical

axis). High stiffness in all three lateral modes is provided.

This configuration provides the following significant advantages:

o Precise location of axis of rotation for mirror balance

o Negligible free play

o High compliance and low hysteresis about two orthogonal

axes of rotation

o High stiffness and load capacity in remaining four degrees

of freedom

6


Bolt to Mirror

Optical Axis

Elevation Axis

Bolt to Mirrotr

Figure 2-4. Two-Axis Cruciform Flexure (Sheet 1 of 2)

7

Report No. 11923

I

CA 1 2 3 4 5

Figure 2-4. Two-Axis Cruciform Flexure (Sheet 2 of 2)

8


o High reliability, low stress. Entire mechanism manu-

factured from single part

o All interface loads applied at non-critical central

area of mirror.

2.3 IMAGE MOTION CONTROL DRIVE ACTUATORS

Previous programs conducted at Perkin-Elmer have required precise

position control of mirrors and lenses. Two types of actuators that have

demonstrated good operating characteristics in similar applications are described

in the following section.

2.3.1 Piezoelectric Translator (Figure 2-5)

Piezoelectric translators are available in several configurations.

All utilize a ceramic material that changes a physical dimension upon applica-

tion of static voltage. Typical configurations consists of cylindrical or disk

segments. The segments are wired in parallel and stacked so that the total

displacement is the summation of the displacement of each segment. The relation-

ship between total displacement and voltage is controlled by the number of

segments in the stack.

This type of actuator has the following significant advantages for

use in precision mirror position control.

o The translator can be designed with stroke compatible with

direct coupling to mirror - Typical stroke: extension 12.6 x-6

10 meters at 1000 volts.

o Very good position resolution. Resolution to 0.4 x 10- 8

meters has been demonstrated.

o Very high stiffness and force gain - Typical actuator force

required for maximum tilt 0.2 newton. Available translator

force 5000 'newtons.

o Simple mechanical configuration and structural reliability.

9

- -I

wcrlw

rr

M0

Atb

tJ~E

I--.

Figur 2-5.PiezolecticTasto

PERKIN-ELMER

Report No. 11923

o Flat frequency response to better than 10,000 Hz.

o Small size - typical envelope 2.5 cm diameter by 3 cm long.

The very high stiffness and force gain of this type of actuator

minimizes position errors caused by friction or extraneous loads in the

mirror suspension system. The actuator is a simple and effective structural

member when not electrically active. This characteristic is effective in

surviving launch vibration and can be used to provide electrical redundancy

by stacking two translators in a series mechanical arrangement.

PZT materials have a hysteresis characteristic of position

relative to voltage that can be undersirable in some applications. This

characteristic is not objectionable in a closed-loop. application.

2.3.2 Flexure Torque Motor Actuators

The flexure torque motor actuator consists of a permanent magnet

armature suspended on flexures in an electromagnetic field. A typical

actuator is shown on Figure 2-6. This type of actuator has the following

operating characteristics:

o Relatively high stroke - Typical stroke ±1.5 x 10- 4

meters (±0.006 in)

o Good linearity and low hysteresis - Typical value 2

percent

o Spring constant controlled by design

o Relatively low force. Typical force at center = 9

newtons (2 pounds)

The high stroke, low force characteristic is compatible with

the requirement for precise mirror postion control. This enables the

frequency response and stiffness to ground of the mirror suspension to be

improved by driving the mirror through a high reduction flexure linkage.

11

PERKIN-ELMERReport No.. 11923

Output

Support Flexure

Armature

Figure 2-6. Typical Flexure Torque Motor Actuator

12


The magnetic circuit has a negative spring characteristic. This

opposes the positive spring constant of the armature support flexure so that

the actuator spring constant can be designed to be negative, zero, or positive.

The acceleration forces required to drive the mirror are neg-

ligible because of the low amplitude and frequency. The forces required

of the actuator are predominantly those to deflect the support flexure. Al-

though the actuator force is relatively low (9 newtons), it is high relative

to the required force (0.2 newton). Maximum power requirement is approxi-

mately 1.4 watts.

2.4 ALIGNMENT DRIVE SYSTEM

The two axis tilt alignment is provided by a differential beam

microposition mechanism. The output motion of the microposition mechanism

biases the position of each image motion control actuator. The design concept

is based.upon the use of two relatively long thin flexures mounted back-to-

back and riveted at one end. If one blade is bent in an arc, the other blade

on the outside of the arc and the free ends of the blades will be displaced

depending upon the arc parameters and thickness of the blades. The design-

is shown in Figure 2-7. The radius of the arc may be either positive or

negative, giving a positive or negative range of adjustment.

Input Command

II---Motion

Figure 2-7. Differential Beam Microposition Mechanism

13

PERIKIN-ELMERReport No. 11923

2.5 MIRROR ARTICULATION SYSTEM SELECTED FOR MANUFACTURE AND TEST

The final system design envolved from the elements described

above. The mirror suspension consists of a centrally mounted cruiform

flexure. The alignment drive consists of a differential beam micropositioner

remotely controlled by a gear motor and cam. Interchangeable installation

of stabilization actuators of two different types is provided. The piezo

ceramic actuator configuration is shown in Perkin-Elmer Engineering drawing

660-0267. The flexure torque motor configuration is shown in drawing

660-0301.

14

PERKIN-ELMEFR Report No. 11923

3.0 SYSTEM DESIGN

3.1 MIRROR MASS PROPERTIES

3.1.1 Simulated Mirror Weight

Conditions Mirror Diameter = 0.508 meter (20 inches)

D 0.508 mMirror Thickness - - 0.0846 m

6 6

Mirror Density CerVit (2.50 M 3 machined tocm.

reduce weight to 40 percent

solid weight.2 2

Volume d 2 3.14 (50.8 cm) x 846 cmVolume- x x 846 cm

4 4= 17,138 cm3

Weight = 0.4 x 17,138 cm3 x 2.50 gm3cm

= 17,138 gm (37.79 lbs)

3.1.2 Simulated Mirror Inertia

Inertia (I) = - (3r2 + h2

I = 1 K [(3 x 0.254m)2 + (0.0846m)2]

I = 0.8394 (Kgm) (m2 )

The mass properties of the mirror were simulated in the test system

by an assembly of aluminum plate 1.27 cm (0.5 in) thick.

Weight (considered as mass)

Front and back plates:

Volume = dx x 2

r (50.8 cm) 3

= 4 x 1.27 cm x 2 = 5145.54 cm

15

PEFIKIN-ELMERReport No. 11923

Central Hub:

Volume = 8.89 cm x 8.89 cm x 5.72 cm = 452 cm3

Ribs:

Volume = 20.95 cm x 5.84 cm x 1.27 cm x 4 = 621.53 cm3

Total Volume = 5145.54 cm3 + 452 cm3 + 621.53 cm = 6219 cm3

Total Weight = 6219 cm3 x 2.702 3 16,804 gcm

16.804 Kg (37.05 Ibs)

Inertia

Ig = Igl' - Ig2

m 2 2Ig = - (3r + h )12

V - cm) 8.57 cm = 17,361 cm3

4 1 4

M1 = 17,361 cm3 x 2.702 gm3 = 46,909 gm

cm1 2 2Ig (3r + h

46.9 Kgm 2 212 [3(0.254 m) + (0.086 m)2 ]

16


Ig1 = 3.908 Kgm (0.1935 m 2 + 0.0074 m 2 )

Igl = 0.7851 (Kgm) (m2 )

2 2Rd 7(50.8 cm)V - x 6.03 cm

2 4 4

3= 12,215.6 cm

M2 = 12,215.6 cm3 x 2.702 3 = 33,006 gmcm

M2 2 2I g (3r +h)2 12

33.006 Kgm [3(0.254 m) 2 + (0.0603 m)2 ]12

= 2.750 Kgm [0.1935 m2 + 0.0036 m

2 ]

= 0.542 (Kgm) (m2 )

Ig total = Igl - Ig2

= 0.7851 - 0.542

= 0.2431 (Kgm) (m2 )

3.2 MIRROR SUPPORT FLEXURE DESIGN

The central flexure compliance was determined by test of a single

axis flexure of the same size but different material. The flexure characteristics

were corrected for the dual axis configuration and material change (aluminum

to steel).

3.2.1 Flexure Compliance along Optic Axis

Test flexure stiffness (aluminum) axial compliance = 3.833 x-6 in

10 - (Ref. Appendix D).lb

-6 in -2 meter 1 lbAxial . ... = 3.833 x 10- 6 x 2.54 x 10 xCompliance lb in 4.448 newton

17


-8 meterAxial = 2.1888 x 10 in aluminum

newtonCompliance

K(single axis) = 1 meter x 29 1.2499 x 108 newton-8 newtonn 10.6 meter

in steel 2.1888 x 10- 8 10.6

Bolt to Mirror

2Optical Axis

P2 Elevation Axis

Bolt to Mirrort

1 1' 1 1 1

axial KT K K 8 8(Dual Axis). 1 2 1.2499 x 10 1.2499 x 10

K = 0.6249 x 108 newton

3 meter

3.2.2 Radial Compliance

1 1 1- + -

Kradial 1 K2 3

18


P2

Bolt to Mirror P

Optical A-xis

P2 Elevation Axis

Bolt to Mirro l 2

PL1 2 AE

P1Let P = - i newton2

PI/2£ = 1.27 cm 1

1.834 cm(0.722 in)

0.0762 cm

6 (0.030 in)

1.27 cm

19


A = 1.834 cm x 0.0762 cm + 1.758 cm x 0.0762 cm

= 0.1397 + 0.1339 = 0.2736 cm2

P _ 1 newton x 1.27 cm

1 AE 2 6 newtons0.2736 cm x 19.63 x 10 ---

6 = 0.2364 x 106 cm1 newton

1 1. 6 newton

61 0.2364 x 10- 6 cm cm

newton

= 423.0 x 106 newtonmeter

1 1 1

K K+K + Kradial 1 2 3

1 1 + 11 +

K 8 newton. 8 newtonKradial 2(4.23 x 10 newton) '1.2499 x 108 newtonmeter meter

1 = 1.182 x 10-9 meter + 8.000 x 10-9 meter

K dil newton newton

9.182 x 10 9 meternewton

K 1 = 1.089 x 108 newtonradial -9 meter meter

9.182 x 10newton

3.2.3 Compliance About Azimuth and Elevation Axes

in-lbK = 283 Rad (Ref. Appendix E aluminum flexure)4 Rad

in-lb 29 -2 meter newtonK = 283 x x 2.54 x 10 x 4.448

4 Rad 10.6 in lb

= 0.8747 meter newtonRad.

20


3.2.4 Resonant Frequency of Simulated Mirror Supported by Cruciform Flexure

3.2.4.1 Axial Direction

n 27T M

1 0.6249 x108 newton

fn 2 17.138 Kg meter

= 304.06 Hz

3.2.4.2 Radial Direction

1 1) 1.089 x 108 newton

n 2r 17.138 Kg

= 401.39 Hz

3.2.5 Actuator Stroke

0 = 3 arc-sec x 4.848 x 10-6 radsec

= 14.544 x 10-6 rad.

X = Mirror Rad = 0.254 meters

-6Y = 0 x = 14.544 x 10-6 rad x 0.254 meter

= 3.694 x 10-6 meter (145.4 x 10-6in)

-6Actuator Stroke = + 3.694 x 10-6 meter.

21


3.2.6 Actuator Load Due to Cruciform Flexure Stiffness

max = stabilization + 9 alignmentmax

= 3 arc-seconds + 5 arc-seconds

= 8 arc-seconds x 4.848 x 10-6 rad

sec-6

38.784 x 10- 6 radian

meter newton -6Q = K 0 = 0.8747 tad x 38.784 x 10 rad.

rad

= 3.392 x 10-5 meter newton.F = Q 3.392 x 10 5 meter newton

-5F Q - 3.392 x 10 meter newtonact R 0.254 meter

= 1.335 x 19-4 newton (3.002 x 10-51b)

3.2.7 Alignment Drive Design

9

From beam theory,

FP.2 F93

S6=-2 El 3 El

Then,

362

For small value of 0

3t6E = Qt =2k

22


Required stroke (e) for 10-arc-second alignment range

E alignment angle x actuator attachment radius

-6 rad10-arc-second x 4.848 x 10 --rad x 22.23 cm

sec-6

= 1077.5 x 10- 6 cm

6 =2 let k = 8.64 cm3t

t = 0.096 cm

-32 x 8.64 cm x 1.077 x 10 3 cm 6.462 x 10- 2= 6.462 x 10 cm

3 x 0.096 cm

Cam angle 0:

--l 1.90 cm

-26 _ 6.42 x 102 cm x 1.6 (overtravel)d 1.9 cm

= 5.44 x 10- 2 rad (3.1 degree)

3.2.8 Thermal Design

The simulated mirror was designed to represent the weight and

inertia of a lightweight CerVit mirror. Aluminum plates were selected for

two major reasons

o Minimum manufacturing cost

a Low density permits thicker plates and greater stiffness

without exceeding weight and inertia limits.

The high coefficient of expansion can cause high sensitivity of

mirror angle to temperature change.

23

PEFRKIN-ELMEFR Report No. 11923

The best material for minimum thermal sensitivity would have a

low coefficient of expansion, such as Invar. Cost and weight, however, would

not be acceptable.

An alternate concept was to balance the effect on mirror angle by

selecting elements in the thermal loop from either aluminum or stainless steel

in such a way that all thermal dimensional changes add to zero. This provides

a structure that is capable of operating over a wide temperature range without

a mirror angle index change. Since .small and large elements will respond

dimensionally at different rates to a temperature change, the structure must

be permitted to stabilize at the environmental temperature prior to operation.

The thermal response of the system is determined by adding the

dimensional change of each element in the mirror position loop. Reference to

Perkin-Elmer drawing 660-0267 for dimensions and material.

Thermal coefficient of expansion are as follows:

-6Stainless Steel 17-4 PH H1075 = 6.3 x 10- 6 in/in/oF

Stainless Steel Type 304 = 9.6 in/in/*F

Aluminum 2024 T4 = 11.74 in/in/°F

Stainless Steel Type 310 = 8.0 in/in/OF

PZT Material = 2.222 in/in/OF

AX = -(3.236 - 0.36) in x 8.0 i in + (4.06 - 3.50) 9.6 p inoF oF

-[0.718 - (2.12 - 1.62 - 0.25)] 8.0 p in + (0.200) 9.6 p inoF oF

+(1.200) 2.22 p in + (1.85) 9.6 p in + (2.05) 11.74 P ino F oF OF

-(0.722) 6.3 p in - (1.62) 11.74 p in - (0.36) 11.74 p ino F oF oF

AX = -2.759 D inoF

3.0 arc-secA0 = x - 2.759 u in = - 0.0646 arc-sec

128 p. inoF OF

= (- 0.1163 arc-sec)oC

24


4.0 SYSTEM TEST

4.1 SUMMARY

System testing was performed in accordance with Report No. 11783,

Test Procedure - LST Secondary Mirror Actuation System. This document defines

test procedures to verify the calibration and performance of components and

system. Appendix A documents the results of system testing of the PZT actuator

configuration. Appendix B documents results of system testing of the flexure

torque motor actuator configuration. This testing was performed using test

instruments calibrated in conventional units. Therefore, the data and data

reduction in the appendices is in conventional units. Significant performance

characteristics derived are listed in the preferred SI units in this section.

Appendix C describes a test performed using a precise interferometric angle

sensing device that confirmed system performance.

4.2 SYSTEM TEST - PZT ACTUATOR CONFIGURATION - 660-0267

(REFERENCE APPENDIX A)

The component .schematic diagram is shown in Figure 4-1. A Hewlett-

Packard Model 202A Ultra Low Frequency Signal Generator was used to drive a

Burleigh PZ-70 High Voltage Operational Amplifier in each axis. Mirror position

was monitored by four position transducers. All four were basically Brown and

Sharp Model 599-986 Super Gage Sensors and Brown and Sharp Model 599-991 ampli-

fiers. During syltem calibration, the position sensors that are provided to

monitor alignment drive position in each axis were relocated to sense mirror

angle. A position sensor is built into each axis (azimuth and elevation).

B and S Model 599-986 gage heads were disassembled to remove the magnetic core

and sensing coils. The core was mounted to the mirror and the sensing coils

were mounted to the support structure. This was done to eliminate sensor force

that could affect mirror position. Since such disassembly could invalidate the

manufacturer's calibration, the remaining two gage heads were calibrated by the

Perkin-Elmer Quality Control Department and used to monitor mirror position.

Two monitor gages were mounted to measure mirror tilt angle in each axis during

calibration. The average of the two monitor gages was used to determine a scale

factor for the single gages built into each axis. The test setup is shown in

Figure .4-2. Results of the test are tabulated in Table 4-1.

25

- LST SECONDARY MIRROR ACTUATION SYSTEM660-0267

BURLETGH PZ-70 PZT TRANSLATOR MIRROR POSITION MIRROR POSITIONHIGII VOLTAGE AAZIMUTE HEAD - AZIMUTH READOUT-AZIMUTHMU- 6EA-2792 - AZIMUTH -----------O.P AMP. - AZIMUTH 6 2 & S MODEL 599-986 D& S MODEL 599-991

DURLEIGH PZ-70 PZT TRANSLATOR MIRROR POSITION MIRROR POSITION

IIG VOLTAGE GAGE IIEAD- ELEVATION READOUT- ELEVATIONOP.AMP.- ELEVATIO 600-2792 - ELEVATION 1G S MODEL 599-986 & SR MODEL 599-991

LEFTALIGNMENT DRIVE ALIGNMENT POSITION ALIGNMENT POSITION

. AZIMUTH GAGE IIEAD - AZIMUTH READOUT- AZIMUTHRIGHT 4 GLOBE 59A112-2799 DBS MODEL 599-986 D& S MODEL 599-991ALIGNMENTCOMMAND

ALIGNMENT DRIVE ALIGNMENT POSITION ALIGNMENT POSITION--ELEVATION -- GAGE HEAD- ELEVATION --- READOUT- ELEVATION

DOWN CLOBE 59A112-2799 B& S MODEL 599-986 D&S MODEL 599-991

ULTRA LOW CHART RECORDERFREQUENCY

SIGNAL GENERATOR

O

rt

Figure 4-1. Component Schematic Piezo Ceramic Actuator Configurationbo

rg'

. *W

Figure 4-2. PZT Actuator Configuration Test Setup (Sheet 1 of 2)

9,

Figure "-2. PZT Actuator Configuration Test Setup (Sheet 1 of 2°

+ + ++ e i , + , . ,

(D

0

Figure 4-2. PZT Actuator Configuration Test Setup (Sheet 2 of 2)

. .i

0l

-UTABLE 4-I. TABULATION OF TEST RESULTS 11

PZT Configuration Flex Torque

Characteristic Spec AZ EL AZ EL Z

Alignment M

Total Range ±5 ±6.04 ±5.83 ±5.83 ±5.042arc-sec arc-sec arc-sec arc-sec arc-sec

Threshold 0.1 0.042 0.052 0.08 0.063arc-sec arc-sec arc-sec arc-sec arc-sec

Response 10 10.36 10.001 10.003 8.664arc-sec/min arc-sec/min arc-sec/min arc-sec/min arc-sec/min

Stabilization

Total Range ±3 ±7.58 ±7.3 ±3.93 ±3.26arc-sec arc-sec arc-sec arc-sec arc-sec

Response 3 db @ 4 Hz +1.86 db 9 -0.26 db 8 -2.59 db ( -2.0 db 970 Hz 70 Hz 20 Hz 20 Hz

Threshold ±0.005 ±0.0007 ±0.0007 ±0.003 ±0.0017arc-sec arc-sec arc-sec sec arc-sec

0

o-


4.3 SYSTEM TEST - FLEXURE TORQUE MOTOR ACTUATOR CONFIGURATION - 660-0301(REFERENCE APPENDIX B)

The component schematic diagram for this configuration is shown

in Figure 4-3. The test procedure was the same as that used for the PZT actua-

tor configuration. The detailed test results are documented in Appendix B and

tabulated in Table 4-1.

4.4 TEST OF MIRROR SUSPENSION STIFFNESS PZT ACTUATOR CONFIGURATION (660-0267)

The stiffness of the mirror suspension system-to.ground was measured

by placing the mirror system on the isolation table with the optic axis vertical.

Weights were placed on the mirror surface at a 9.9-inch radius, directly over

the supporting actuator. A position transducer sensed deflection at the point

of load application. The relationship between applied load and mirror deflec-

tion is shown on Figure 4-4.

The mirror support stiffness is:

-6500 x 10 in -6e = = 50.5 x 10 rad

9.9 in

Q = 5.5 lb x 9.9 in = 54.45 in lb

-650.5 x 10 rad -6 rad

Stiffness = 54.45 in lb 0.927 x 10 in-lb54.45 in ib in-lb

= (8.21 x 106 rad)meter-heating

NOTE

Bracket (Item 3, 660-0267) was found to cause exces-sive compliance. It was replaced with a stiffer bracket(660-2855) for test of the 660-0301 configuration. The660-0267 configuration was not retested with the stifferbracket.

30

7LST SECONDARY MIRROR ACTUAON SYSTEM r

KEPCO BOP-3.-1.5 R[ MIRROR POSITIONSERVOTRONICS ACTUATOR MIRROR POS OBIPOLAR OP. AMP CAGE HEAD - AZIMUTH READOUT- AZIMUTH TAZIMUTH MODEL 21-1 - AZIMUTH BL S MODEL 599-086 ID& S MODEL 599-991

KEPCO DOP-36-1.5 MIRROR I'OSITION RO POITINBIPOLAR OP. AMP3-.5. SERVOTRONICS ACTUATOR GAGE IIIAD- ELEVATION READOUT- ELEVATION

ELEVATION MODEL 21-1 - ELEVATION 1 3S MODEL 599-986 D& S MODEL 599-991

LEFT ALIGNMENT DRIVE ALIGNMENT POSITION ALIGNMENT POSITIONAZIMUT GAGE EAZIZUTLUT GG IA READOUT-AZIMUTH

RIGHT GLOBE 59A112-2799 D S MODEL 599-980 DL S MODEL 599-991ALIGNMENTCOMMAND

UP ALIGNMENT DRIVE ALIGNMENT POSITION ALIGNMENT POSITIONELEVATION GAGE IIEAD- ELEVATION READOUT- ELEVATION

DOWN GLOE 59A112-2799 DL S MODEL 599-86 D S MODEL 599-991

ULTRA LOW CHART RECORDER (DFREQUENCY o

SIGNAL GENERATOR o

0

Figure 4-3. Component Schematic Flexure Torque MotorActuator Configuration

600

Tension -- Compression

400 Z

r200 -

I-(U

L0

SO200

-4

400

600

"8

6 4 2 2 4 6 8Applied Loads (Pounds)

Figure 4-4. LST Secondary Mirror (Elevation Axis), Mirror Deflection versusApplied Load


4.5 TEST OF MIRROR SUSPENSION SYSTEM - FLEXURE TORQUE MOTOR CONFIGURATION(660-0301)

The stiffness of the mirror suspension system with the flexure

torque motor actuators was measured using the same method. The relationship

between applied load and mirror deflection is shown in Figure 4-5.

The mirror stiffness is

-6550 x 10- 6 in - 6

9 - . i 5 5 . 5 5 x 10 rad9.9 in

Q = 8.37 lb x 9.9 in = 82.86 in-lb

-655.55 x 10 rad -6 rad

Stiffness = x 106 rad= 0.67 x 106 Tad82.86 in-lb in-lb

= (5.93 x 10 6 radmeter newton

33

600

Tension - Compression J

400 -4O Mirror Z

Deflection r

r200

m

" Alignment Deflecti

010

0.

Q 400

600

8 ,6 4 2 0 2 4 6Applied Load (Pounds)

Figure 4-5. LST Secondary Mirror (Elevation Axis), Mirror Deflection andAlignment Drive Deflection versus Applied Load


5.0 CONCLUSIONS AND RECOMMENDATIONS

Review of the test results leads to the following conclusions.

5.1 CONCLUSION

5.1.1 Piezo Ceramic (PZT) Actuator Performance

The piezo ceramic actuator demonstrated position resolution that

significantly exceeded the specified requirements. The maximum range was 2.5

times the required ±3 arc-seconds. The threshold was 7 times better than.the

required ±0.005 arc-second. The resolution range was 10,800 to 1 compared to

the required 600 to 1. It is probable that the resolution limit demonstrated

was determined by the position sensors rather than the mirror position control

system.

The high stiffness and force capability of the PZT actuator provides

very high frequency response capability. The response of the system tested

,was limited by a structural resonance at 70'to 90 Hz. This 'was traced to ex-

cessive compliance in an actuator support bracket. The bracket was replaced

for test of the flexure torque motor (FT) actuator.

The PZT actuator demonstrated a high hysteresis characteristic ap-

proximately 14 percent. The percentage hysteresis is relatively constant for

all amplitudes so that good response at very small amplitudes is possible. This

characteristic must be considered in the design of a closed loop control system.

5.1.2 Flexure Torque Motor (FT) Actuator Performance

The position resolution of the FT actuator also significantly ex-

ceeded the specified requirements. The maximum range was slightly greater than

the required ±3 arc-seconds and is limited by the stiffness of actuator stroke

reducing flexures and the reduction in actuator force as the actuator approaches

the stroke limit. These factors affect linearity of actuator current relative

to mirror angle.at maximum mirror angle. The resolution range is approximately

1500 to 1 compared to the required 600 to 1. Hysteresis was approximately 2 per-

cent.

35

Vtr


The frequency resp6nse of the FT actuator system was not as flat

as the PZT actuator configuration. Refer to the response plot in Appendix B.

The amplitude is +3 db at 2 Hz and falls rapidly above 10 Hz. Structural

resonance was 100 to 120 Hz.

5.1.3 Alignment Drive Performance

The alignment drive performed with good precision and stability.

Minimum pulse was approximately 0.05 arc-second and was limited by the start-

stop characteristic of the motor. A stepper motor drive could provide better

resolution if required.

5.1.4 Mirror Suspension System

The cruciform flexure performance was excellent. Cross coupling,

and hysteresis were negligible.

5.1.5 Position Sensing Components

The Brown and Sharpe electromagnetic position sensors performed

with resolution that exceeded expectation. The meter provided for visual in-

dication of position is limited to approximately 1 microinch resolution. By

taking the modulated 10,000-Hz carrier from the gage amplifier, filtering, and

examining on a Type 502 HP oscilloscope, it was possible to resolve better than

0.04 microinch. It is significant to note that these measurements were accom-

plished under typical laboratory environmental conditions of atmospheric pres-

sure turbulence, and temperature gradients.

5.2 RECOMMENDATIONS

Although both actuator configurations demonstrated the capability

of meeting all performance requirements, the configuration considered to have

the greatest overall merit is the piezo ceramic actuator configuration. The

cruciform flexure suspension and flexure microposition alignment drive were

common to both configurations tested. Performance of these common elements was

excellent throughout testing of both actuator configurations.

36


The performance characteristics that favor the PZT actuator are

listed below. The differences are not so significant that the flexure torque

motor actuator should not receive further consideration for the LST application.

o PZT actuators had best range and resolution

o Structural simplicity and reliability of the PZT actuator

approaches that of simple structural members. Redundancy

can be accomplished by series stacking of actuator compo-

nents.

o Stroke range is compatible with direct coupling of actuator

to mirror.

o High stiffness and load capacity provides launch survival

without caging devices.

o High force and frequency response better than 10,000 Hz

provide capability to follow square wave forms.

5.3 DOCUMENTATION LIST

Engineering drawings and reports covering both actuator mechanisms

are listed below:

Drawing Number Title

660-0267 LST Secondary MirrorActuation System (PZT Actuator)

660-0301 LST Secondary MirrorActuation System (Flexure Torque Motor)

660-0306 System Wiring Diagram -LST Secondary Mirror

660-2792 PZT Translator Assembly

660-2841 Alignment Control Panel

660-2855 Support, Flexure

Reports

11602A Proposal - LST Secondary MirrorArticulation System

11783 Test Procedure - LST SecondaryMirror Actuation System

37

V.


APPENDIX A

PZT ACTUATOR TEST DATA

A-i

THE PERKIN-ELMER CORPORATION 1SENSOR SYSTEMS

Scientific Payloads Department

74-SS-1468

January 23, 1974

TO: File - LST Secondary Mirror

FROM: W. E. Kohman

SUBJECT: FINAL ACCEPTANCE TEST

LST SECONDARY MIRROR ACTUATION SYSTEM

PZT ACTUATOR CONFIGURATION660-0267

REFERENCE: (1) Contract NAS 8-29723 SPO 33117

The attached data sheets and calculation sheets document the final

acceptance test of the subject LST Secondary Mirror actuation system.

This test confirms that the system meets the requirements of the

Reference (1) contract and is accepted and approved for disassembly and

conversion to the flexure torque motor configuration 660-0301.

W. E. Kohman Perkin-Elmer

Engineering

(-V.--

A.- Meffzies Perkin-Elmer

Quality Assurance

" Engineering

WEK:mb

Attachments

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N o 2-01 5-00 PERKI N-ELMIER


APPENDIX B

FLEXURE TORQUE MOTOR ACTUATOR TEST DATA

B-i

PERKIN-ELMER OPTICAL GROUP

THE PERKIN-ELMER CORPORATION

NORWALK, CONNECTICUT 06852

TELEPHONE: (203) 762-1000

CABLE: PECO-NORWALK

74-SS-1491

March 1, 1974

TO: File - LST Secondary Mirror

FROM: W. E. Kohman

SUBJECT: FINAL ACCEPTANCE TESTLST SECONDARY MIRROR ACTUATION SYSTEMFLEXURE TORQUE MOTOR ACTUATOR CONFIGURATION660-0301

REFERENCE: (1) Contract NAS 8-29723 SPO 33117

The attached data sheets and calculation sheets document the finalacceptance -test-of the subject LST Secondary Mirror actuation system.

This test confirms that the system meets the requirements of the Reference (1)

contract and is accepted and approved for delivery to MSFC.

W. E. Kohman Perkin-ElmerEngineering

J. Mortellaro Perkin-ElmerQuality Assurance

WEK:mb

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APPENDIX C

PRECISION ANGLE INSTRUMENT

C-i

IrJTER-COM'ANY COMMUNICATION

PERKIN-ELMER

Date: February 8, 1974 cc: C1Minihan DRehnbergJBeardsley DMcCarthyJDixon WRizzi

To: RCBabish JCallahan WArmstrong

CMorser

From: RCrane

Subj: PRECISION ANGLE INSTRUMENT

The attached write-up titled "Interferometric Angle Sensing"

describes a very precise angle measuring technique which was

used to monitor a secondary mirror control system on the LST

Program. This memo is being circulated in the hope of findingother applications and markets for an instrument using this

technique.

Comments are solicited.

R. Crane

RC:em

attachment

C.C-

0-0532-02

Interferometric Angle Sensing

Experimental Data

An optical experiment was conducted to demonstrate anability to measure small angle variations in the alignmentof a large mirror using an equal-path interferometer.The optical arrangement, as shown in Figure 1, in-cluded'a solid-glass interferometer ..which has aneven number of reflections in each beam path, with the re-sult that the output fringe pattern is uniphase for allangles of the mirror under test. An equal path arrangementwas used so that the output fringe pattern would be inde-pendent of the input beam angle. Output fringe phase fora given wavelength is determined by the angle between theinterferometer output face and the mirror surface. Forsmall values of the angle, e one fringe is generated bya mirror rotation of:

The following constants were used:

Experiment procedure consisted of first varying C over anangle large enough to generate more than one fringe, whichprovided the data needed to calculate the calibration factor

, where:

where: d = separation of two beams at the mirror= wavelength

V = detector peak-to-peak output

This calibration, as indicated by Figure 2, is correct overan angular range small compared to that which generates onefringe.

Figure 3 shows typical results from testing the LSTsecondary mirror mock-up. Trace 3a shows a calibration scangenerated by a triangular-wave cyclic scan of the mirror.This shows a peak-to-peak output. of V = 32 mm, which re-sulted in

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The second and third traces show ambient mechanical noisein mirror angle position and typical signal response fora sine wave drive applied to the mirror actuators.

Figure 4 was generated with a second. arrangement inwhich the laser beam of 10 - 4 watts was fed directly intothe interferometer with no collimator. For this arrangement

The middle trace in Figure 4 shows details of the ambientnoise with a recording speed of 100 mm per second. Thecyclic signal is characteristic of band limited noise. Inthis case this is the response of the high-Q mirror mountto the local mechanical ambient, i.e. building noise. Thiswas measured to be approximately 1/300 sec peak-to-peak.The bottom trace shows the mirror system response generatedby a truck starting up at a light on the local highway.The quiescent noise level was approximately 0.001 sec peak-to-peak. Intrinsic noise of the interferometer sensor asdetermined by the detector and laser photon noise was cal-culated for a bandwidth of 100.0 cps to .be 2 order.s of mag-nitude below building noise.

Figure 5 shows the output of the interferometer dis-played on an oscilloscope. The top picture shows calibrationdata in which the upper trace is the mirror actuator controlsignal and the lower trace is the interferometer output.This picture indicates

The middle picture in Figure.5 shows the square wave responseof the mirror system with the drive at the top and the re-sponse at the bottom. Note the effect of the high-Q in themirror suspension which caused severe ringing. This data in-dicates a mechanical Q of approximately 12. The bottom traceof Figure 5 shows the response to a low level control signal.

.: Signal and noise are both approximately 0.007 sec peak-to-peak.

This interferometer has essentially equal paths so it willoperate well with quasi-coherent light. Therefore a GalliumArsnide LED was tried. Results are shown in Figure 6 wherethe top trace is calibration data indicating:

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Note that the mirror was scanned over several fringes whichproduced a variable fringe contrast. This is due to thefact that the LED does not have a long coherent length.The equal path position is at the right-hand side of therecording. The bottom trace in Figure 6 shows ambient noiseagain, with an indicated level of approximately 1/300 secpeak-to-peak.

Application Notes

If an-angle sensor of this type is to be used as anabsolute angle meter it will be necessary to resolve theambiguity due to the multiple fringes. This can be doneusing a white light source. Because-the interferometer isequal-path this source need not be well collimated and asmall lamp may be used. Figure 7 shows 2 interferogramsgnnerated using a tungsten lamp made by Sylvania and a sil-icon detector made by EG&G. In this case the equal pathfringe is dark and readily recognized at the center of thepattern.

If an equal path interferometer is to be consideredfor precision angle measurements such as described aboveit.should b.e recognized that these measurements were madein subdued light and with less than 1 mm air space betweenthe interferometer face and the rotating mirror. This tech-nique can be extended to high ambient light conditions oroutdoor operation by modulating the LED with a carrier fre-quency.

The limited dynamic range indicated by Figure 2 maynot be adaquate for many applications. This can be ex-tended to several iln by incorporating an optical frequencyshifter in one arm of the interferometer combined withelectronic fringe phase detection, as described in Perkin-Elmer Report 10692.

Angle measurements thru an air path to a precision ofseconds of arc or less require very very careful stabilizationof the air path. This should be kept in mind in consideringapplications of the technique.

Conclusion

Very precise angle measurements can be made with rel-atively simple optical and electronic equipment plus care-ful attention to air stabalization. Figure 8 is a photograph

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of the experimental interferoneter with an LED source and

a silicon photo-detector. In this picture the rotatable

mirror has been removed to permit a better view of the

interferometer. Limiting precision will be determined in

most applications by the ability to minimize a) ambientmechanical vibrations; b) air path thermal fluctuations.

An instrument based upon the simple configuration ofFigure 8, i.e. solid-glass equal-path interferometer (perPE Patent Disclosure Docket D-1557), with a modulated LED

source will be capable of providing the following perform-ance specification:

Dynamic Range 1 secPrecision 10-10 radian rms uncertaintyResponse Time <10 msecOutput analog voltageOperation very stable air environment

An interferometer with the added complexity of an opticalfrequency shifter (per PE Patent No. 3536374), a white lightsource, plus an electronic phase detector could be made cap-able of providing the following performance specification.

Dy-namic Range 3 minPrecision 10-10 radian rms-or 0.1%

full scaleAccuracy 0.1% of full scaleResponse Time < 10 msecOutput digital displayOperation very stable air environment

The latter configuration would have a linear response withscale changes to accomodate the full dynamic range. in ac-cordance with Figure 9.

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APPENDIX D

LATERAL STIFFNESS - CRUCIFORM FLEXURE

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APPENDIX E

TORSIONAL STIFFNESS - CRUCIFORM FLEXURE

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