HARMONI is the first light visible and near-IR integral field spectrograph for the ELT. It covers a large spectral range from 450 nm to 2450 nm with resolving powers from 3500 to 18000 and spatial sampling from 60 mas to 4 mas. It can operate in two Adaptive Optics modes - SCAO (including a High Contrast capability) and LTAO - or with NOAO. The project is preparing for Final Design Reviews. HARMONI is a work-horse instrument that provides efficient, spatially resolved spectroscopy of extended objects or crowded fields of view. The gigantic leap in sensitivity and spatial resolution that HARMONI at the ELT will enable promises to transform the landscape in observational astrophysics in the coming decade. The project has undergone some key changes to the leadership and management structure over the last two years. We present the salient elements of the project restructuring, and modifications to the technical specifications. The instrument design is very mature in the lead up to the final design review. In this paper, we provide an overview of the instrument's capabilities, details of recent technical changes during the red flag period, and an update of sensitivities.
Lightweight optical manufacture is no longer confined to the conventional subtractive (mill and drill), formative (casting and forging) and fabricative (bonding and fixing) manufacturing methods. Additive manufacturing (AM; 3D printing), creating a part layer-by-layer, provides new opportunities to reduce mass and combine multiple parts into one structure. Frequently, modern astronomical telescopes and instruments, ground- and space-based, are limited in mass and volume, and are complex to assemble, which are limitations that can benefit from AM. However, there are challenges to overcome before AM is considered a conventional method of manufacture, for example, upskilling engineers, increasing the technology readiness level via AM case studies, and understanding the AM build process to deliver the required material properties. This paper describes current progress within a four-year research programme that has the goal to explore these challenges towards creating a strategy for AM adoption within astronomical hardware. Working with early-career engineers, case studies have been undertaken which focus on lightweight AM aluminium mirror manufacture and optical mountings. In parallel, the aluminium AM build parameters have been investigated to understand which combination of parameters results in AM parts with consistent material properties and low defects. Metrology results from two AM case studies will be summarised: the optical characteristics of a lightweighted aluminium mirror intended for in-orbit deployment from a nanosat; and the AM build quality of wire arc additive manufacture for use in an optomechanical housing. Finally, an analysis of how surface roughness from AM mirror samples and build parameters are linked will be discussed.
Ground-based astronomical instruments have mass limits to ensure they can operate safely and accurately. Reducing the mass of optomechanical structures relieves mass budget for other components, improving the instrument’s performance. Many industries have adopted generative design (GD) and additive manufacturing (AM; 3D printing) to produce lightweight components. This is yet to be implemented in ground-based astronomical instrumentation; this paper aims to provide insight into the advantages and limitations of this approach. The project studied the Extremely Large Telescope (ELT) Mid-infrared Imager and Spectrograph (METIS) threemirror anastigmat (TMA); comparing the conventional, subtractive machined design with GD-AM designs. The TMA was selected due to its bespoke geometry constrained by an optical path, a conventional design which did not consider mass reduction, the size of the part (615mm × 530mm × 525mm) that necessitated a study of different AM methods, and the operational environment (70K & 10−6 Pa). The study created mass-optimised designs of the TMA using topology optimisation and field-driven design. The performance of these designs was analysed using finite element analysis and optical ray tracing. It was found that GD-AM designs pass the required optical, structural and modal requirements, with a greater than 30% weight reduction when compared to the conventional design. The study investigated wire arc additive manufacturing (WAAM), a viable method of manufacturing components of the TMA’s size. To commence the validation of WAAM for cryogenic environments, samples of WAAM aluminium 5356 were created and studied. The internal and external dimensions of two samples were investigated using X-ray computed tomography and the outgassing rate of two sets of three samples were evaluated to quantify the difference between machined and as-built samples.
MOONS (Multi-Object Optical and Near-infrared Spectrograph) is a third-generation visible and near-infrared spectrograph for the ESO Very Large Telescope, currently nearing the end of the assembly phase. The three channel spectrograph is fed via a fibre positioning module (FPM) which configures the location of 1001 fibres. The robotic fibre positioning units (FPUs) have been jointly developed by the UK Astronomy Technology Centre (UKATC) and MPS Microsystems (MPS) and provide a high-performance multiplexed focal plane with excellent transmission characteristics. An overview of the as-built mechanisms and supporting infrastructure is presented, with details on the extensive calibration process carried out. The integration process to date will be described, including a discussion of key lessons learned.
HARMONI is the first light visible and near-IR integral field spectrograph for the ELT. It covers a large spectral range from 450nm to 2450nm with resolving powers from 3500 to 18000 and spatial sampling from 60mas to 40mas. It can operate in two Adaptive Optics modes - SCAO (including a High Contrast capability) and LTAO - or with NOAO. The project is preparing for Final Design Reviews. The Focal Plane Relay Sub-System (FPRS) relays the ELT's Nasymth A2 focal plane to the HARMONI IFS focal plane. The FPRS maintains a -15°C environment to reduce additional thermal noise and contains two Ø600 mm x 20 mm windows in a double-glazing arrangement at the entrance. The external window surface temperature will be below the ambient telescope temperature due to insulation limitations and could lead to condensation forming reducing optical throughput and increased scatter, in particular in the IR-bands. We present the design and testing of a window flushing solution utilizing air knife technology
The Multi Object Optical and Near-infrared Spectrograph (MOONS) instrument is the next generation multi-object spectrograph for the Very Large Telescope (VLT). The instrument combines the high multiplexing capability offered by 1000 optical fibres deployed by individual robotic positioners with a novel spectrograph able to provide both low- and high-resolution spectroscopy simultaneously across the wavelength range 0.64μm - 1.8μm. Powered by the collecting area of the 8-m VLT, MOONS will provide the astronomical community with a world-leading facility able to serve a wide range of Galactic, Extragalactic and Cosmological studies. This paper provides an updated overview of the instrument and its construction progress, reporting on the ongoing integration phase.
HARMONI is the first light, adaptive optics assisted, integral field spectrograph for the European Southern Observatory’s Extremely Large Telescope (ELT). A work-horse instrument, it provides the ELT’s diffraction limited spectroscopic capability across the near-infrared wavelength range. HARMONI will exploit the ELT’s unique combination of exquisite spatial resolution and enormous collecting area, enabling transformational science. The design of the instrument is being finalized, and the plans for assembly, integration and testing are being detailed. We present an overview of the instrument’s capabilities from a user perspective, and provide a summary of the instrument’s design. We also include recent changes to the project, both technical and programmatic, that have resulted from red-flag actions. Finally, we outline some of the simulated HARMONI observations currently being analyzed.
The Natural Guide Star Sensors (NGSS) system of HARMONI provides wavefront and image stabilisation sensing for each of the observing modes of the instrument. The Focal Plane Relay System (FPRS) relays and redirects the telescope beam from the ELT Prefocal Station (PFS) to the NGSS and spectrograph. To limit thermal background and to ensure the required stability, the sensors and optics are contained in a dry gas environment stabilized at -15 degrees Celsius. Achieving this cooled, dry environment requires an insulated enclosure, cooling system and dry air flushing system. These measures present certain novel challenges; the design solutions are described here.
MOONS (Multi-Object Optical and Near-infrared Spectrograph) is a third-generation visible and near-infrared spectrograph for the ESO Very Large Telescope currently under construction. The instrument’s spectroscopic capabilities are multiplexed via a fibre positioning module (FPM) which configures the location of 1001 fibres. The fibre positioning units (FPUs) have been jointly developed by the UK Astronomy Technology Centre (UKATC) and MPS Microsystems (MPS) to optimise instrument efficiency by providing excellent transmission and an open-loop positioning strategy, allowing a tightly packed focal plane to be rapidly reconfigured. The mechanism geometry enables all positions in the focal plane to be observed in conjunction with a companion sky fibre at close separation. A description of the as manufactured design and production process of the FPUs is presented, along with a discussion of the performance proven to date, including achievement of the critical pupil alignment and positional repeatability requirements. An overview of the custom testing rig built to automate the characterisation and calibration process is also presented.
HARMONI is the adaptive optics assisted, near-infrared and visible light integral field spectrograph for the Extremely Large Telescope (ELT). A first light instrument, it provides the work-horse spectroscopic capability for the ELT. As the project approaches its Final Design Review milestone, the design of the instrument is being finalized, and the plans for assembly, integration and testing are being detailed. We present an overview of the instrument’s capabilities from a user perspective, provide a summary of the instrument’s design, including plans for operations and calibrations, and provide a brief glimpse of the predicted performance for a specific observing scenario. The paper also provides some details of the consortium composition and its evolution since the project commenced in 2015.
The Multi Object Optical and Near-infrared Spectrograph (MOONS) instrument is the next generation multi-object spectrograph for the VLT. This powerful instrument will combine for the first time: the large collecting power of the VLT with a high multipexing capability offered by 1000 optical fibres moved with individual robotic positioners and a novel, very fast spectrograph able to provide both low- and high-resolution spectroscopy simultaneously across the wavelength range 0.64μm - 1.8μm. Such a facility will provide the astronomical community with a powerful, world-leading instrument able to serve a wide range of Galactic, Extragalactic and Cosmological studies. Th final assembly, integration and verification phase of the instrument is now about to start performance testing.
After completion of its final-design review last year, it is full steam ahead for the construction of the MOONS instrument - the next generation multi-object spectrograph for the VLT. This remarkable instrument will combine for the first time: the 8 m collecting power of the VLT, 1000 optical fibres with individual robotic positioners and both medium- and high-resolution spectral coverage acreoss the wavelength range 0.65μm - 1.8 μm. Such a facility will allow a veritable host of Galactic, Extragalactic and Cosmological questions to be addressed. In this paper we will report on the current status of the instrument, details of the early testing of key components and the major milestones towards its delivery to the telescope.
KEYWORDS: Mirrors, Polishing, Surface roughness, Additive manufacturing, Finite element methods, Space mirrors, Aluminum, Single point diamond turning, Lightweight mirrors, Error analysis, 3D printing
Additive manufacturing (AM), more commonly known as 3D printing, is a commercially established technology for rapid prototyping and fabrication of bespoke intricate parts. To date, research quality mirror prototypes are being trialled using additive manufacturing, where a high quality reflective surface is created in a post-processing step. One advantage of additive manufacturing for mirror fabrication is the ease to lightweight the structure: the design is no longer confined by traditional machining (mill, drill and lathe) and optimised/innovative structures can be used. The end applications of lightweight AM mirrors are broad; the motivation behind this research is low mass mirrors for space-based astronomical or Earth Observation imaging. An example of a potential application could be within nano-satellites, where volume and mass limits are critical. The research presented in this paper highlights the early stage experimental development in AM mirrors and the future innovative designs which could be applied using AM.
The surface roughness on a diamond-turned AM aluminium (AlSi10Mg) mirror is presented which demonstrates the ability to achieve an average roughness of ~3.6nm root mean square (RMS) measured over a 3 x 3 grid. A Fourier transform of the roughness data is shown which deconvolves the roughness into contributions from the diamond-turning tooling and the AM build layers. In addition, two nickel phosphorus (NiP) coated AlSi10Mg AM mirrors are compared in terms of surface form error; one mirror has a generic sandwich lightweight design at 44% the mass of a solid equivalent, prior to coating and the second mirror was lightweighted further using the finite element analysis tool topology optimisation. The surface form error indicates an improvement in peak-to-valley (PV) from 323nm to 204nm and in RMS from 83nm to 31nm for the generic and optimised lightweighting respectively while demonstrating a weight reduction between the samples of 18%. The paper concludes with a discussion of the breadth of AM design that could be applied to mirror lightweighting in the future, in particular, topology optimisation, tessellating polyhedrons and Voronoi cells are presented.
The construction of the next generation of 40 m-class astronomical telescopes poses an enormous challenge for the design of their instruments and the manufacture of their optics. Optical elements typically increase in both size and number, placing ever more demands on the system manufacturing and alignment tolerances. This challenge can be met by using the wider design space offered by freeform optics, by for instance allowing highly aspherical surfaces. Optical designs incorporating freeform optics can achieve a better performance with fewer components. This also leads to savings in volume and mass and, potentially, cost.
This paper describes the characterization of the FAME system (freeform active mirror experiment). The system consists of a thin hydroformed face sheet that is produced to be close to the required surface shape, a highly controllable active array that provides support and the ability to set local curvature of the optical surface and the actuator layout with control electronics that drives the active array.
A detailed characterisation of the fully-assembled freeform mirror was carried out with the physical and optical properties determined by coordinate measurements (CMM), laser scanning, spherometry and Fizeau interferometry. The numerical model of the mirror was refined to match the as-built features and to predict the performance more accurately.
Each of the 18 actuators was tested individually and the results allow the generation of look-up tables providing the force on the mirror for each actuator setting. The actuators were modelled with finite element analysis and compared to the detailed measurements to develop a closed-loop system simulation. After assembling the actuators in an array, the mirror surface was measured again using interferometry. The influence functions and Eigen-modes were also determined by interferometry and compared to the FEA results.
Future X-ray astronomy missions require light-weight thin shells to provide large collecting areas within the weight limits of launch vehicles, whilst still delivering angular resolutions close to that of Chandra (0.5 arc seconds). Additive manufacturing (AM), also known as 3D printing, is a well-established technology with the ability to construct or ‘print’ intricate support structures, which can be both integral and light-weight, and is therefore a candidate technique for producing shells for space-based X-ray telescopes. The work described here is a feasibility study into this technology for precision X-ray optics for astronomy and has been sponsored by the UK Space Agency’s National Space Technology Programme. The goal of the project is to use a series of test samples to trial different materials and processes with the aim of developing a viable path for the production of an X-ray reflecting prototype for astronomical applications. The initial design of an AM prototype X-ray shell is presented with ray-trace modelling and analysis of the X-ray performance. The polishing process may cause print-through from the light-weight support structure on to the reflecting surface. Investigations in to the effect of the print-through on the X-ray performance of the shell are also presented.
Additive manufacturing, more commonly known as 3D printing, has become a commercially established technology for rapid prototyping and the fabrication of bespoke intricate parts. Optical components, such as mirrors and lenses, are now being fabricated via additive manufacturing, where the printed substrate is polished in a post-processing step. One application of additively manufactured optics could be within the astronomical X-ray community, where there is a growing need to demonstrate thin, lightweight, high precision optics for a beyond Chandra style mission. This paper will follow a proof-of-concept investigation, sponsored by the UK Space Agency’s National Space Technology Programme, into the feasibility of applying additive manufacturing in the production of thin, lightweight, precision X-ray optics for astronomy. One of the benefits of additive manufacturing is the ability to construct intricate lightweighting, which can be optimised to minimise weight while ensuring rigidity. This concept of optimised lightweighting will be applied to a series of polished additively manufactured test samples and experimental data from these samples, including an assessment of the optical quality and the magnitude of any print-through, will be presented. In addition, the finite element analysis optimisations of the lightweighting development will be discussed.
The Multi-Object Optical and Near-Infrared Spectrograph (MOONS) will exploit the full 500 square arcmin field of view offered by the Nasmyth focus of the Very Large Telescope and will be equipped with two identical triple arm cryogenic spectrographs covering the wavelength range 0.64μm-1.8μm, with a multiplex capability of over 1000 fibres. This can be configured to produce spectra for chosen targets and have close proximity sky subtraction if required. The system will have both a medium resolution (R~4000-6000) mode and a high resolution (R~20000) mode. The fibre positioning units are used to position each fibre independently in order to pick off each sub field of 1.0” within a circular patrol area of ~85” on sky (50mm physical diameter). The nominal physical separation between FPUs is 25mm allowing a 100% overlap in coverage between adjacent units. The design of the fibre positioning units allows parallel and rapid reconfiguration between observations. The kinematic geometry is such that pupil alignment is maintained over the patrol area. This paper presents the design of the Fibre Positioning Units at the preliminary design review and the results of verification testing of the advanced prototypes.
A multiple pick off mirror positioning sub-system has been developed as a solution for the deployment of mirrors within
multi-object instrumentation such as the EAGLE instrument in the European Extremely Large Telescope (E-ELT). The
positioning sub-system is a two wheeled differential steered friction drive robot with a footprint of approximately 20 x
20 mm. Controlled by RF communications there are two versions of the robot that exist. One is powered by a single cell
lithium ion battery and the other utilises a power floor system. The robots use two brushless DC motors with 125:1
planetary gear heads for positioning in the coarse drive stages. A unique power floor allows the robots to be positioned at
any location in any orientation on the focal plane. The design, linear repeatability tests, metrology and power continuity
of the robot will be evaluated and presented in this paper. To gather photons from the objects of interest it is important to
position POMs within a sphere of confusion of less than 10 μm, with an angular alignment better than 1 mrad. The
robots potential of meeting these requirements will be described through the open-loop repeatability tests conducted with
a Faro laser beam tracker. Tests have involved sending the robot step commands and automatically taking continuous
measurements every three seconds. Currently the robot is capable of repeatedly travelling 233 mm within 0.307 mm at 5
mm/s. An analysis of the power floors reliability through the continuous monitoring of the voltage across the tracks with
a Pico logger will also be presented.
Most of the sky is black: picking off the interesting bits is the challenge. By placing pick-off mirrors in the focal plane of
an instrument, it is possible to select light from only the desired sub-fields. The Micro Autonomous Positioning System
(MAPS) is a method for maneuvering pick-off mirrors into position by giving each mirror its own set of wheels. This
paper details the metrology algorithms that are being developed to provide real-time feedback of the robots’ positions.
This will be achieved through imaging high-resolution targets on the robots and analysing the power floor on which they
move. Early tests show that the imaging system is capable of resolving linear motions of lμm and rotation of <1mrad, for
an operating area of 25 x 20 cm.
The complexity and size of instruments for next generation telescopes demands innovative approaches to existing
problems. Within this framework, we present MAPS; a Micro Autonomous Positioning System for mirror deployment in
an E-ELT instrument such as EAGLE. The micro-robots have a 25mmx25mm footprint and utilise RF communications
and small rechargeable batteries to be completely wireless. Coarse positioning and fine alignment is achieved through
the use of miniature gear motors and gearheads. Positional information is determined externally and corrective motions
relayed to the robots. This paper reports on the challenges which such a system presents, current developments, and areas
of expected future research.
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