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NASA NTRS2011

Cryogenic Thermal Vacuum Testing with Remote Optical Metrology

Flexure Engineering was awarded an SBIR to research and develop technology needed to build a thermal vacuum chamber made to take laser radar metrology through a window. The XATF test is proof of concept for this, and demonstrated the need for such a chamber. XATF refers to two pieces of critical ground support equipment for NASA's JWST (James Webb Space Telescope) Integrated Science Instrument Module (ISIM), the ISIM Alignment Target Fixture (IATF) and the Master Alignment Target Fixture (MATF). These optical alignment assemblies require characterization while under cryogenic temperature. A thermal vacuum chamber equipped with a shroud cooled with gaseous and liquid nitrogen was used. An inner shroud was cooled with liquid helium to approximately 30K. The XATF assemblies were kinematically mounted and oriented inside the inner shroud such that the optical targets were visible from outside an optical window on one of the chamber ports. Laser radar and theodolite mounted outside the window took measurements of various optical targets. Two cold cycles were completed. A third cycle was aborted. Metrology was successfully taken. There were some problems with the helium system. The cryo pumps were turned off to reduce vibrations during metrology. Many new technologies and testing methods must be developed for JWST and future programs that will require precision measurements. These technologies will be applicable to other cold temperature applications, such as lunar missions and superconductors. Remote metrology technologies can also be applicable to testing in harsh environments. Facilities with remote metrology capability will be valuable.

Boyd, Guinevere↗

NASA NTRS2010

Status of the James Webb Space Telescope Integrated Science Instrument Module System

The Integrated Science Instrument Module (ISIM) of the James Webb Space Telescope (JWST) is discussed from a systems perspective with emphasis on development status and advanced technology aspects. The ISIM is one of three elements that comprise the JWST space vehicle and is the science instrument payload of the JWST. The major subsystems of this flight element and their build status are described.

Greenhouse, Matthew A.↗

NASA NTRS2011

NIRCam: Development and Testing of the JWST Near-Infrared Camera

The Near Infrared Camera (NIRCam) is one of the four science instruments of the James Webb Space Telescope (JWST). Its high sensitivity, high spatial resolution images over the 0.6 - 5 microns wavelength region will be essential for making significant findings in many science areas as well as for aligning the JWST primary mirror segments and telescope. The NIRCam engineering test unit was recently assembled and has undergone successful cryogenic testing. The NIRCam collimator and camera optics and their mountings are also progressing, with a brass-board system demonstrating relatively low wavefront error across a wide field of view. The flight model?s long-wavelength Si grisms have been fabricated, and its coronagraph masks are now being made. Both the short (0.6 - 2.3 microns) and long (2.4 - 5.0 microns) wavelength flight detectors show good performance and are undergoing final assembly and testing. The flight model subsystems should all be completed later this year through early 2011, and NIRCam will be cryogenically tested in the first half of 2011 before delivery to the JWST integrated science instrument module (ISIM).

Greene, Thomas↗

NASA NTRS2011

Measuring the Cryogenic Optical Alignment Between the Telescope Element and the Instruments Module of the James Webb Space Telescope

The alignment between the Aft Optical Subsystem (AOS) and the Integrated Science Instruments Module (ISIM) is non-adjustable in orbit, so the alignment must be carefully verified in a cryogenic vacuum environment prior to launch. Optical point source locations calibrated by optical metrology instruments are imaged through the AOS onto the Science Instruments to determine focal, lateral, and clock angle alignment. The pupil image of the AOS is overlaid onto the pupil image of the NIRCam to determine the tip and tilt alignment. In addition, an image from fiducial lights at the Primary Mirror checks the pupil alignment between the telescope entrance pupil, the telescope pupil mask, and the NIRCam aperture stop. The image positions are combined to determine the relative alignment between the Optical Telescope Element (OTE) and the ISIM in all six degrees of freedom with corresponding alignment uncertainties. Uncertainties in the position of focused images of the test sources and images from the pupils are derived from sensitivities of an optical model of the system and the Science Instrument sensing capability. Additional uncertainty in the pupil alignment measurement is due to uncertainty in the analytical removal of gravity effects that simulate the on-orbit alignment environment.

Whitman, Tony↗

NASA NTRS2012

James Webb Space Telescope Integrated Science Instrument Module Calibration and Verification of High-Accuracy Instrumentation to Measure Heat Flow in Cryogenic Testing

The James Webb Space Telescope (JWST) is an upcoming flagship observatory mission scheduled to be launched in 2018, Three of the four science instruments are passively cooled to their operational temperature range of 36K to 40K, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. The requirement for multiple thermal zones results in the instruments being thermally connected to five external radiators via individual high purity aluminum heat straps. Thermal-vacuum and thermal balance testing of the flight instruments at the Integrated Science Instrument Module (ISIM) element level will take place within a newly constructed shroud cooled by gaseous helium inside Goddard Space Flight Center's (GSFC) Space Environment Simulator (SES). The flight external radiators are not available during ISIM-Ievel thermal vacuum/thermal testing, so they will be replaced in test with stable and adjustable thermal boundaries with identical physical interfaces to the flight radiators. Those boundaries are provided on specially designed test hardware which measures the heat flow within each of the five heat straps to an accuracy of less than 2 m W, which is less than 5% of the minimum predicted heat flow values. This is essential to ISIM thermal model correlation, since thermal models are more accurately correlated when temperature data is supplemented by accurate knowledge of heat flows. Devices that measure heat flow in this manner have historically been referred to as "Q-meters". Perhaps the most important feature of the design of the Q-meters is that it does not depend on the absolute accuracy of its temperature sensors, but rather on a difference in heater power, for which a table is empirically developed during a calibration campaign in a small chamber at GSFC. This paper discusses the Q-meter calibration procedure including calibration chamber modifications and accommodations, the handling of differing conditions between calibration and usage, the calibration process itself, and the results of the tests used to determine if the calibration is successful.

Comber, Brian↗

NASA NTRS2012

James Webb Space Telescope Integrated Science Instrument Module Calibration and Verification of High-Accuracy Instrumentation to Measure Heat Flow in Cryogenic Testing

The James Webb Space Telescope (JWST) is an upcoming flagship observatory mission scheduled to be launched in 2018. Three of the four science instruments are passively cooled to their operational temperature range of 36K to 40K, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. The requirement for multiple thermal zoned results in the instruments being thermally connected to five external radiators via individual high purity aluminum heat straps. Thermal-vacuum and thermal balance testing of the flight instruments at the Integrated Science Instrument Module (ISIM) element level will take place within a newly constructed shroud cooled by gaseous helium inside Goddard Space Flight Center's (GSFC) Space environment Simulator (SES). The flight external radiators are not available during ISIM-level thermal vacuum/thermal testing, so they will be replaced in test with stable and adjustable thermal boundaries with identical physical interfaces to the flight radiators. Those boundaries are provided by specially designed test hardware which also measures the heat flow within each of the five heat straps to an accuracy of less than 2 mW, which is less than 5% of the minimum predicted heat flow values. Measurement of the heat loads to this accuracy is essential to ISIM thermal model correlation, since thermal models are more accurately correlated when temperature data is supplemented by accurate knowledge of heat flows. It also provides direct verification by test of several high-level thermal requirements. Devices that measure heat flow in this manner have historically been referred to a "Q-meters". Perhaps the most important feature of the design of the JWST Q-meters is that it does not depend on the absolute accuracy of its temperature sensors, but rather on knowledge of precise heater power required to maintain a constant temperature difference between sensors on two stages, for which a table is empirically developed during a calibration campaign in a small chamber at GSFC. This paper provides a brief review of Q-meter design, and discusses the Q-meter calibration procedure including calibration chamber modifications and accommodations, handling of differing conditions between calibration and usage, the calibration process itself, and the results of the tests used to determine if the calibration is successful.

Comber, Brian↗

NASA NTRS2012

Measuring Segmented Primary Mirror WFE in the Presence of Vibration and Thermal Drift on the Light-Weighted JWST

The light-weighted design of the Optical Telescope Element (OTE) of the James Webb Telescope (JWST) leads to additional sensitivity to vibration from the ground - an important consideration to the measurement uncertainty of the wavefront error (WFE) in the primary mirror. Furthermore, segmentation of the primary mirror leads to rigid-body movements of segment areas in the WFE. The ground vibrations are minimized with modifications to the test facility, and by the architecture of the equipment supporting the load. Additional special test equipment (including strategically placed isolators, tunable mass dampers, and cryogenic magnetic dampers) mitigates the vibration and the response sensitivity before reaching the telescope. A multi-wavelength interferometer is designed and operated to accommodate the predicted residual vibration. Thermal drift also adds to the measurement variation. Test results of test equipment components, measurement theory, and finite element analysis combine to predict the test uncertainty in the future measurement of the primary mirror. The vibration input to the finite element model comes from accelerometer measurements of the facility with the environmental control pumps operating. One of the isolators have been built and tested to validate the dynamic performance. A preliminary model of the load support equipment and the OTE with the Integrated Science Instrument Module (ISIM) is complete. The performance of the add-on dampers have been established in previous applications. And operation of the multi-wavelength interferometer was demonstrated on a scaled hardware version of the JWST in an environment with vibration and thermal drift.

Whitman, Tony L.↗

NASA NTRS2005

Thermal Conductivity and Specific Heat Measurements of Candidate Structural Materials for the JWST Optical Bench

The James Webb Space Telescope will include an optical bench known as the integrated science instrument module (ISIM). Candidate structural materials for the ISIM must have low density, high stiffness, high thermal conductivity, and low thermal expansion coefficient at the operating temperature of 30 Kelvin. The specific heat is also important in modeling the on-orbit cooldown. We built two different systems for measuring the thermal conductivity and specific heat of samples between 4 Kelvin and 290 Kelvin. Both experiments were carefully designed to minimize potential errors due to radiative heat transfer. We chose the cooling system and instrumentation to allow long-term unattended operation. Software was developed to automate each experiment. It used an algorithm designed to ensure that each system was in thermal equilibrium before a measurement was taken. We describe the two experiments and present the data.

Canavan, E. R.↗

NASA NTRS2013

JWST Integrated Science Instrument Module Alignment Optimization Tool

During cryogenic vacuum testing of the James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM), the global alignment of the ISIM with respect to the designed interface of the JWST optical telescope element (OTE) will be measured through a series of optical characterization tests. These tests will determine the locations and orientations of the JWST science instrument projected focal surfaces and entrance pupils with respect to their corresponding OTE optical interfaces. If any optical performance non-compliances are identified, the ISIM will be adjusted to improve its performance. In order to understand how to manipulate the ISIM's degrees of freedom properly and to prepare for the ISIM flight model testing, a series of optical-mechanical analyses have been completed to develop and identify the best approaches for bringing a non-compliant ISIM element into compliance. In order for JWST to meet its observatory-level optical requirements and ambitious science goals, the ISIM element has to meet approximately 150 separate optical requirements. Successfully achieving many of those optical requirements depends on the proper alignment of the ISIM element with respect to the OTE. To verify that the ISIM element will meet its optical requirements, a series of cryogenic vacuum tests will be conducted with an OTE Simulator (OSIM). An optical Ray Trace and Geometry Model tool was developed to help solve the multi-dimensional alignment problem. The tool allows the user to determine how best to adjust the alignment of the JWST ISIM with respect to the ideal telescope interfaces so that the approximately 150 ISIM optical performance requirements can be satisfied. This capability has not existed previously.

Bos, Brent↗

NASA NTRS2014

Design and Lessons Learned on the Development of a Cryogenic Pupil Select Mechanism (PSM)

Calibration and testing of the instruments on the Integrated Science Instrument Module (ISIM) of the James Webb Space Telescope (JWST) is being performed by the use of a cryogenic, full-field, optical simulator that was constructed for this purpose. The Pupil Select Mechanism (PSM) assembly is one of several mechanisms and optical elements that compose the Optical Telescope Element SIMulator, or OSIM. The PSM allows for several optical elements to be inserted into the optical plane of OSIM, introducing a variety of aberrations, distortions, obscurations, and other calibration states into the pupil plane. The following discussion focuses on the details of the design evolution, analysis, build, and test of this mechanism along with the challenges associated with creating a sub arc-minute positioning mechanism operating in an extreme cryogenic environment. In addition, difficult challenges in the control system design will be discussed including the incorporation of closed-loop feedback control into a system that was designed to operate in an open-loop fashion.

PSM Design↗

NASA NTRS2014

A New Large Vibration Test Facility Concept for the James Webb Space Telescope

The James Webb Space Telescope consists of three main components, the Integrated Science Instrument Module (ISIM) Element, the Optical Telescope Element (OTE), and the Spacecraft Element. The ISIM and OTE are being assembled at the National Aeronautics and Space Administration's Goddard Spaceflight Center (GSFC). The combined OTE and ISIM Elements, called OTIS, will undergo sine vibration testing before leaving Goddard. OTIS is the largest payload ever tested at Goddard and the existing GSFC vibration facilities are incapable of performing a sine vibration test of the OTIS payload. As a result, a new large vibration test facility is being designed. The new facility will consist of a vertical system with a guided head expander and a horizontal system with a hydrostatic slip table. The project is currently in the final design phase with installation to begin in early 2015 and the facility is expected to be operational by late 2015. This paper will describe the unique requirements for a new large vibration test facility and present the selected final design concepts.

test facilities↗

NASA NTRS2014

A New Large Vibration Test Facility Concept for the James Webb Space Telescope

vibration↗

NASA NTRS2016

Relative Throughput of the Near-IR Science Instruments for the James Webb Space Telescope as Measured During Ground Testing the Integrated Science Instrument Module

Data were obtained for the purpose of measuring the relative throughput of the Near-IR Science Instruments (SIs) of the James Webb Space Telescope (JWST) as part of the second and third cryogenic-vacuum tests (CV2CV3) of the Integrated Science Instrument Module (ISIM) conducted at the Goddard Space Flight Center (GSFC) in 2014 and 20152016, at the beginning and end of the environmental test program, respectively. This Poster focuses on data obtained as part of the Initial Optical Baseline and as part of the Final Performance test -- two epochs that roughly bracket the CV3 test. The purpose of the test is to trend relative throughput to monitor for any potential changes from gross problems such as contamination or degradation of an optical element. Point source data were taken at a variety of wavelengths for NIRCam Module A and Module B, NIRSpec, NIRISS, Guider 1 and Guider 2 using the Laser Diode (LD) 1.06 micron, LD 1.55 micron, 2.1 micron LED and 3.5 micron LED, as well as for NIRCam Mod A and B and NIRISS using a tungsten source and the F277W, and F480M filters. Spectra were taken using the G140M, G235M, and G395M gratings for NIRSpec, the GRISMR grism for NIRCam Mod A and B and the GR150C grism for NIRISS. The results of these measurements are compared to what would be expected given the efficiency of each of the optical elements in each SI. Although these data were taken as a check against gross problems, they can also be used to provide the first relative throughput estimate for each SI through the various filters source wavelengths measured in their flight-like configurations.

technology development↗

NASA NTRS2016

Alignment Test Results of the JWST Pathfinder Telescope Mirrors in the Cryogenic Environment

After integration of the Optical Telescope Element (OTE) to the Integrated Science Instrument Module (ISIM) to become the OTIS, the James Webb Space Telescope OTIS is tested at NASAs Johnson Space Center (JSC) in the cryogenic vacuum Chamber A for alignment and optical performance. The alignment of the mirrors comprises a sequence of steps as follows: The mirrors are coarsely aligned using photogrammetry cameras with reflective targets attached to the sides of the mirrors. Then a multi-wavelength interferometer is aligned to the 18-segment primary mirror using cameras at the center of curvature to align reflected light from the segments and using fiducials at the edge of the primary mirror. Once the interferometer is aligned, the 18 primary mirror segments are then adjusted to optimize wavefront error of the aggregate mirror. This process phases the piston and tilt positions of all the mirror segments. An optical fiber placed at the Cassegrain focus of the telescope then emits light towards the secondary mirror to create a collimated beam emitting from the primary mirror. Portions of the collimated beam are retro-reflected from flat mirrors at the top of the chamber to pass through the telescope to the SI detector. The image on the detector is used for fine alignment of the secondary mirror and a check of the primary mirror alignment using many of the same analysis techniques used in the on-orbit alignment. The entire process was practiced and evaluated in 2015 at cryogenic temperature with the Pathfinder telescope.

Interferometer↗

NASA NTRS2016

Status of the JWST Science Instrument Payload

The James Webb Space Telescope (JWST) Integrated Science Instrument Module (ISIM) system consists of five sensors (4 science): Mid-Infrared Instrument (MIRI), Near Infrared Imager and Slitless Spectrograph (NIRISS), Fine Guidance Sensor (FGS), Near InfraRed Camera (NIRCam), Near InfraRed Spectrograph (NIRSpec); and nine instrument support systems: Optical metering structure system, Electrical Harness System; Harness Radiator System, ISIM Electronics Compartment, ISIM Remote Services Unit, Cryogenic Thermal Control System, Command and Data Handling System, Flight Software System, Operations Scripts System.

JWST Payload↗

NASA NTRS2014

Thermal Vacuum Chamber Repressurization with Instrument Purging

At the conclusion of cryogenic vacuum testing of the James Webb Space Telescope Optical Telescope Element Integrated Science Instrument Module (JWST-OTIS) in NASA Johnson Space Center’s (JSCs) thermal vacuum (TV) Chamber A, contamination control (CC) engineers are postulating that chamber particulate material stirred up by the repressurization process may be kept from falling into the Integrated Science Instrument Module (ISIM) interior to some degree by activating instrument purge flows over some initial period before opening the chamber valves. This manuscript describes development of a series of models designed to describe this process. The models are strung together in tandem with a fictitious set of conditions to estimate overpressure evolution from which net outflow velocity behavior may be obtained. Creeping flow assumptions are then used to determine the maximum particle size that may be kept suspended above the ISIM aperture, keeping smaller particles from settling within the instrument module.

Repressurization↗

NASA NTRS2016

James Webb Space Telescope Integrated Science Instrument Module Thermal Vacuum Thermal Balance Test Campaign at NASA's Goddard Space Flight Center

The James Webb Space Telescope is a large infrared telescope with a 6.5-meter primary mirror, designed as a successor to the Hubble Space Telescope when launched in 2018. Three of the four science instruments contained within the Integrated Science Instrument Module (ISIM) are passively cooled to their operational temperature range of 36K to 40K with radiators, and the fourth instrument is actively cooled to its operational temperature of approximately 6K. Thermal-vacuum testing of the flight science instruments at the ISIM element level has taken place in three separate highly challenging and extremely complex thermal tests within a gaseous helium-cooled shroud inside Goddard Space Flight Centers Space Environment Simulator. Special data acquisition software was developed for these tests to monitor over 1700 flight and test sensor measurements, track over 50 gradients, component rates, and temperature limits in real time against defined constraints and limitations, and guide the complex transition from ambient to final cryogenic temperatures and back. This extremely flexible system has proven highly successful in safeguarding the nearly $2B science payload during the 3.5-month-long thermal tests. Heat flow measurement instrumentation, or Q-meters, were also specially developed for these tests. These devices provide thermal boundaries o the flight hardware while measuring instrument heat loads up to 600 mW with an estimated uncertainty of 2 mW in test, enabling accurate thermal model correlation, hardware design validation, and workmanship verification. The high accuracy heat load measurements provided first evidence of a potentially serious hardware design issue that was subsequently corrected. This paper provides an overview of the ISIM-level thermal-vacuum tests and thermal objectives; explains the thermal test configuration and thermal balances; describes special measurement instrumentation and monitoring and control software; presents key test thermal results; lists problems encountered during testing and lessons learned.

JWST ISIM Thermal↗

NASA NTRS2016

Structural, Thermal, and Optical Performance (STOP) Modeling and Results for the James Webb Space Telescope Integrated Science Instrument Module

The James Webb Space Telescope includes the Integrated Science Instrument Module (ISIM) element that contains four science instruments (SI) including a Guider. We performed extensive structural, thermal, and optical performance(STOP) modeling in support of all phases of ISIM development. In this paper, we focus on modeling and results associated with test and verification. ISIMs test program is bound by ground environments, mostly notably the 1g and test chamber thermal environments. This paper describes STOP modeling used to predict ISIM system performance in 0g and at various on-orbit temperature environments. The predictions are used to project results obtained during testing to on-orbit performance.

structural↗