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SELEX GALILEO SPACE Line of Business Major Technologies and Facilities

SELEX GALILEO SPACE Line of Business Major Technologies and Facilities. May 2008. From Officine Galileo to G alileo A vionica. Since 1864. Plant of Hedquarters. Background information. Two major Product lines for space : Attitude Sensors Mission Payloads

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SELEX GALILEO SPACE Line of Business Major Technologies and Facilities

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  1. SELEX GALILEO SPACE Line of Business Major Technologies and Facilities May 2008

  2. FromOfficine Galileoto Galileo Avionica Since 1864 Plant of Hedquarters

  3. Background information • Two major Product lines for space : • Attitude Sensors • Mission Payloads • Wide range of key technologies: • Optics • Structural mechanics and thermics • Mechanisms • Detection Electronics • Digital Processing Electronics & SW • Recognised Leadership: • World Leaders in Attitude Sensors • National and European Leadership among Equipment Suppliers for Electro Optical payloads.

  4. Design technologies = ERICA : 3^ generation of IR camera for ground applications Design technologies • thermo - mechanical design capabilities & tools • optical design capabilities & tools • electronics design capabilities & tools

  5. Thermo-mechanical design capabilities & tools Mechanical design of high stable optomechanical structure Using CATIA v. 5 AUTONOMOUS STAR TRACKER

  6. Thermo-mechanical design capabilities & tools Mechanical design of integrated electro-optical instruments involving thermo-mechanics, electronics, optics. ALADIN OPTICALBENCH

  7. Thermo-mechanical design capabilities & tools Mechanical design of microgravity experiment for fluid science Using CATIA v: 5 FLUID CELLS FOR FASTER EXPERIMENT (interfacial surface tension measurament)

  8. Thermo-mechanical design capabilities & tools VIRTIS STRUCTURE Structural analysis for static and dynamic verification using ANSYS or PATRAN / NASTRAN

  9. Thermo-mechanical design capabilities & tools Thermal design and analysis using ESARAD or THERMICA for radiative coupling and ESATAN for temperature evaluation ASTR THERMAL MODEL

  10. CODE V Optical Resarch Associates PROGET Galileo Avionica Software ZEMAX Focus Software Optical Design SWs Optical design capabilities

  11. Optical design capabilitiesStray Light Analysis ASAP - BRO From ray-tracing to energy distribution on the Focal Plane

  12. Optical design Simulation of Structural Deformations STEP 1 FEM CODE Stressed surface coordinates files for each surface STEP 2 STEP 3 FITTING PROGRAM Stressed surface coefficients file for each surface third analytical tool OPTICAL MODEL Optical analysis of system (WFE zernike coefficient – encircled energy …)

  13. Electronic design capabilities Digital electronics and software • From requirement definition to the preparation of manufacturing documents • Includes the component selection, the preparation of design justification files and analyses (reliability, FMECA, part stress analysis, worst case analysis, …) • Competencies for the full sw life-cycle, from requirements to validation, including the design and test documentation, according to ESA PSS 05-0 or ECSS E40 Distintive capabilities on Microelectronics and Software • Space application: radiation tolerant design of hardware, design and development of complex FPGAs and ASICs, also for space application, and CPU-based electronic equipment/boards (Leon, ERC32, DSP21020, …) • Software capabilities range from hard real time embedded designs to workstation-based test equipment. The standard sw design flow is supported with specific tools (requirements, tests, quality measurements,…).

  14. Electronic design capabilities Electronics of Autonomous Star Tracker ACC4KDX ASIC

  15. Electronic design capabilities • ASIC design • IRES project (Scan logic and pitch & roll computing) • (25Kgates ASIC,1.2um for the first release, 0.6um for the second release,1MRad) • CASSINI project (Stellar Reference Unit Logic) • (20Kgates ASIC, 0.6um, 1MRad) • XMM project (Star Tracker logic) • (35Kgates ASIC, 0.6um, 1MRad) • SETIS project (Autonomous Star Tracker Logic) • (90Kgates ASIC, 0.5um, 35 KRad) • ROSETTA project (Autonomous Star Tracker and Camera Logic) • (135Kgates ASIC, 0.5um, 100 KRad) • A - STR project logic (A-STR) • (360Kgates ASIC, 0.5um, 100 KRad) • Digital Sun Sensor project (APS scan and pixel elaboration) • (115Kgates ASIC, 0.5um, 100 KRad)

  16. Electronic design capabilities SW DESIGN CAPABILITIES SW DESIGN METHODOLOGY • Requirements: structured analysis • Architecture: HOOD, UML SW DESIGN TOOLS • Requirement definition: Innovator • Architecture design: HOOD- Nice, UML • Development: ADSP21000, ERC32CCS, LEONCCS, TLDADA • Operating systems: Virtuoso (for 21020), Rtems (for ERC32) • SW configuration: MKS • Unit and Integration testing: Cantata, AdaTest LANGUAGES: Ada, C (C++ for EGSE/Test equipment)

  17. FPA & proximity electronics capabilities • Visible and IR detector procurement specification • Low Noise Electronics with high reliability for space applications STR FPA VIRTIS-Rosetta IR FPA VIRTIS-Rosetta VIS FPA – 512x512 px

  18. Cryo techniques CryoTechniques • QSS Electronic for ISO (3 K) • Planck HFI proxy Electronics • VIRTIS Spectrometer (70 K) • MIMR cryo calibrator (70 - 300 K) • SiC mirrors cryogenic Tests

  19. Precision mechanisms capabilities • Mechanisms • Scan and Pointing Mechanisms • Interferometer Mechanisms • Linear and rotating Actuators • TribologySpecial requirements: • long operating life (up to 7 years) • very high operation capability (tens of million operations) • dry lubrication (vacuum operation) • high accuracy (exact re-positioning) Hypseo Pointing Mechanism(with optical encoder)

  20. Detectors characterisation VIS and IR detector Characterisation (from UV to 14m) with different set-up, at ambient and cryogenic temperatures CCD test bench CCD cryogenic set-up

  21. Mechanical production Mechanical Workshop Environmentally controlled room 20° ± 1°C spatially and over 24 h.

  22. Mechanical production Electro Discharge Machine Mod. Robofil 330 F (Charmilles Tec.) Boring machine Hydroptic 6 A Accuracy axes x y z : ± 2 µm. N° 5 axes CNC Machining Centre

  23. Optical production Optical Workshop • Area: 2000 m2 • Manpower: 30 people • over 90 optical machines • 3500 optical masters and relevant tools • All kinds of glasses, electro-optical materials, metals, ceramics, SiC etc. Conventional Polishing technology Automatic high speed grinding & polishing machines

  24. Mirrors polishing Mirrors Polishing

  25. Lenses, mirrors up to 600 mm dia. Prisms, from 3 to 350 mm, 2 arcsec Materials: glass, germanium, metals, SiC Single Point Diamond Machining up to  300 mmfor: TMA Telescopes Spectrometers (prism or grating) Optical products SiC Mirrors SiC (320x200 mm)

  26. Vacuum technology Galileo Avionica – Site of Carsoli Center of excellence for vacuum technologies applied to material surface treatment •  Optical treatments / coatings •  Hardwearing treatments •  Functional treatments • Micronic photolitography •  Industrial process development •  Electronic microscopy

  27. Optical production: coating facilities • Vacuum Technology Unit (Carsoli, AQ) • Custom optical coatings for military, space and industrial equipment & applications. • ISO / MIL standards qualified. • N. 8 Vacuum Chambers up 750 mm dia. in Clean Room of about 300 m2 • UV-Vis-Nir-Mir ranges • Antireflection Coatings • HR Dielectric & Metallic Mirrors • Dielectric & Metallic Beam Splitters • Dichroic Filters • Diamond Like Carbon A/R on Si & Ge

  28. Optical production: coating facilities • Special developments • Coating on plastics optics; • Low temperature PE-CVD deposition process for the realization of Cladding Layers (i.e.: super-polishable SiC layers for SiC mirrors )

  29. Optical production Diamond Machining Facility (mod. Pneumo-Nanoform-300) for I.R. & visible optics, metal mirrors, diffractive optics

  30. Optical production Aspherical figuringwith on-line interferometric setup

  31. Optical production Medium size ground telescope Primary Mirror

  32. Optical production Silicon Carbide Mirrors Foamed sandwich substrates in SiC ( < 10 Kg/m2 technology) 320 mm Monolithic SiC (CP) for high efficiency space optics (15 Kg/m2)

  33. Optical benches in Aluminium & Titanium Carbon fiber Structures Optical production: materials & structures 500 mm telescope Carbon fiber structure TMA Telescope, 150 mm aperture (Carbon fiber structure)

  34. Optical production Ion Beam Figuring(co-operation with INAF Brera - I) Max size : 500 mm 170 mm SiC mirror: Before correction: 22 nm After correction: 8 nm

  35. Assembly and integration Area: 300 m2 clean rooms (100 to 100.000 class)

  36. Assembly and integration: electrical assembly

  37. Assembly and integration: testing equipment • Optical-Metrological Lab.s • Cleanliness Control • Laboratory • 1000 m2 clean rooms(Class 100 -100.000)

  38. Assembly and integration: testing equipment • Interferometers:Wyko 6000, Zygo MarkIV, Kugler, Moeller Wedel, In-house developed) • Spectro-photometers • MTF control benches • CGH testing set-up • Microprofilometers(NewView 5000, WyKo Topo3D) • Collimators(up to 300 mm aperture)

  39. AIT/AIV: intermediate testing Space & E/O facilities: Intermediate Testing

  40. AIT/AIV: T/V Space & E/O facilities: Thermal Vacuum

  41. AIT/AIV: cryo testing CRYOTESTon SiC mirrors for NIRSpec

  42. AIT/AIV: EMC testing Space & E/O facilities:Anechoic Chamber(EMI Testing facility)

  43. AIT/AIV: vibration testing Space & E/O facilities: Vibration Test

  44. Test setup for attitude sensors • Final Test Facilities for Attitude Sensors • Galileo leadership in attitude sensors is based on solid expertise and capabilities for the Assembly, Integration and testing (calibration and characterisation) of electro-optical sensors, achieved through top class set-ups “validated” through the feedback of in-flight data.

  45. Test setup for attitude sensors Space & E/O facilities:A-STR EGSE and Simulated sky in dynamic conditions

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