1. Feed horn array sub-system for QUBIC
For Technological Demonstrator (T.D.)
And
For Final Instrument (F.I.)
QUBIC Collaboration Meeting, January 18/19, Milano

2. QUBIC Collaboration Meeting, January 18/19, Milano
People involved (UniMi)
Francesco Cavaliere (head of machine shop, mechanical supervision)
Federico Pezzotta (mechanical assembly, top and bottom flange production, metrological measurements, interface with manufacturer)
Daniele Viganò (mechanical support)
Paola Battaglia (metrological measurements, support to electromagnetic tests, electromagnetic simulations)
Elenia Manzan (MSc student, metrological measurements and analysis, electromagnetic simulations)
Aniello Mennella (scientific supervision, responsible for UniMi)
QUBIC Collaboration Meeting, January 18/19, Milano

3. QUBIC Collaboration Meeting, January 18/19, Milano
8x8 module for T.D.
8x8 module for T.D.
QUBIC Collaboration Meeting, January 18/19, Milano

4. QUBIC Collaboration Meeting, January 18/19, Milano
8x8 Horn Arrays: Status
Design: Completed
Manufacturing: Completed
Assembly: Almost completed
Modules A and B already assembled, but using different strategies. Final decision to be taken based on EM test results.
Test: In progress
UNIMI Metrology report on platelets available (16/02/2016, P.Battaglia et al.)
Metrological tests also performed on assembled modules (flatness). Should be repeated upon final assembly.
EM tests: on-going in Milano-Bicocca
QUBIC Collaboration Meeting, January 18/19, Milano

5. QUBIC Collaboration Meeting, January 18/19, Milano
Horn mechanical development
QUBIC Collaboration Meeting, January 18/19, Milano

6. QUBIC Collaboration Meeting, January 18/19, Milano
Horn mechanical development
QUBIC Collaboration Meeting, January 18/19, Milano

7. QUBIC Collaboration Meeting, January 18/19, Milano
Horn mechanical development
QUBIC Collaboration Meeting, January 18/19, Milano

8. QUBIC Collaboration Meeting, January 18/19, Milano
Horn mechanical development
QUBIC Collaboration Meeting, January 18/19, Milano

9. QUBIC Collaboration Meeting, January 18/19, Milano
Horn mechanical development
QUBIC Collaboration Meeting, January 18/19, Milano

10. QUBIC Collaboration Meeting, January 18/19, Milano
Horn mechanical development
QUBIC Collaboration Meeting, January 18/19, Milano

11. QUBIC Collaboration Meeting, January 18/19, Milano
Horn mechanical development
QUBIC Collaboration Meeting, January 18/19, Milano

12. QUBIC Collaboration Meeting, January 18/19, Milano
Metrological inspections: Platelets
Mechanical measurements performed at UniMi with WERTH Scopecheck metrological machine
Verify that platelets are produced within required tolerance
Problem identified with 8x8 module due to etching time – will be corrected for final module
QUBIC Collaboration Meeting, January 18/19, Milano

13. QUBIC Collaboration Meeting, January 18/19, Milano
Metrological inspections: Platelets
Module n. 1
QUBIC Collaboration Meeting, January 18/19, Milano

14. QUBIC Collaboration Meeting, January 18/19, Milano
Metrological inspections: Platelets
Module n. 2
QUBIC Collaboration Meeting, January 18/19, Milano

15. QUBIC Collaboration Meeting, January 18/19, Milano
Effect on return loss - simulations
Return loss at 150 GHz for three selected horns compared to nominal and requirement (module 1)
QUBIC Collaboration Meeting, January 18/19, Milano

16. QUBIC Collaboration Meeting, January 18/19, Milano
Effect on return loss - simulations
Return loss at 150 GHz for three selected horns compared to nominal and requirement (module 2)
QUBIC Collaboration Meeting, January 18/19, Milano

17. QUBIC Collaboration Meeting, January 18/19, Milano
Effect on return loss – simulations and meas.
Return loss at 150 GHz – comparison between simulations and measurements
QUBIC Collaboration Meeting, January 18/19, Milano

18. QUBIC Collaboration Meeting, January 18/19, Milano
Effect on beam pattern - simulations
QUBIC Collaboration Meeting, January 18/19, Milano

19. QUBIC Collaboration Meeting, January 18/19, Milano
Effect on beam pattern - simulations
H plane 150 GHz
QUBIC Collaboration Meeting, January 18/19, Milano

20. QUBIC Collaboration Meeting, January 18/19, Milano
Effect on beam pattern - simulations
QUBIC Collaboration Meeting, January 18/19, Milano

21. QUBIC Collaboration Meeting, January 18/19, Milano
Effect on beam pattern - simulations
QUBIC Collaboration Meeting, January 18/19, Milano

22. QUBIC Collaboration Meeting, January 18/19, Milano
Tolerance problem on 8x8
8x8 prototype shows an out-of-spec problem on platelet diameters
This was not present on previous 2x2 prototypes
Discussions with manufacturer point to a possible problem in the chemical etching process (QUBIC platelets were etched typically at the end of the day, when the acid was somewhat exausted)
Problem not expected in final instrument horns: manufacturer will deliver platelets only after internal assessment of tolerance
Main effect on return loss, minor effect on beam pattern
Should not be an issue for technological demonstrator, will not be an issue for final instrument
QUBIC Collaboration Meeting, January 18/19, Milano

23. QUBIC Collaboration Meeting, January 18/19, Milano
Metrological inspections: Flatness
Horn modules A and B have been assembled using different strategies:
Module A: Torque on screws recursively adjusted to improve flatness of top surface.
Flatness achieved: mm
Module B: All screws fixed once at nominal torque value (0.8Nm)
Flatness achieved: mm
QUBIC Collaboration Meeting, January 18/19, Milano

24. QUBIC Collaboration Meeting, January 18/19, Milano
module for F.I.
module for F.I.
QUBIC Collaboration Meeting, January 18/19, Milano

25. QUBIC Collaboration Meeting, January 18/19, Milano
Horn Arrays: Status
Design: Almost completed
Platelets: design is already fixed
Top and bottom flanges: discussion on-going with Switches team to finalize the design (Horns-Switches interfaces, alignment options). Few candidates left, could be fixed by the end of this meeting.
Manufacturing: In progress
Platelets are currently being manufactured by chemical etching. Delivery expected by the end of February 2017
CAD-CAM conversion and manufacturing of top and bottom flanges could start upon final design choice
M3 Ergal screws have already been delivered.
QUBIC Collaboration Meeting, January 18/19, Milano

26. QUBIC Collaboration Meeting, January 18/19, Milano
Horn Arrays: Status
Assembly: To follow
Critical steps of the assembling procedure were assessed with 8x8 horn array
20x20 will be larger, heavier, with many more screws: the task will be more difficult and will require more time
An optimized assembling strategy should be planned in advance based on current experience. Custom equipment may be required.
Test: To follow
Metrological inspection on 8x8 included all horns and all platelets
Preparing and performing all the measurements required more than one month
A more efficient strategy could be considered for the 20x20 (e.g. a subset of complete horns in relevant positions of the array).
QUBIC Collaboration Meeting, January 18/19, Milano

27. QUBIC Collaboration Meeting, January 18/19, Milano
Design: Platelets
Each sheet can hold 4 platelets. Total amount of metal sheets: 352
QUBIC Collaboration Meeting, January 18/19, Milano

28. QUBIC Collaboration Meeting, January 18/19, Milano
Manufacturing: Platelets
First samples available (4 sheets): spot checks on horn holes dimensions revealed compliance with expected tolerances.
QUBIC Collaboration Meeting, January 18/19, Milano

29. QUBIC Collaboration Meeting, January 18/19, Milano
Design: Flanges
Top flange (right): design is already fixed
Bottom flange (left): design in almost completed. Interfaces and alignment choices with the switches block will drive the final solution (discussion is on-going on theese topics among Milano, Milano-Bicocca and APC).
QUBIC Collaboration Meeting, January 18/19, Milano

30. QUBIC Collaboration Meeting, January 18/19, Milano
Delivery dates: for Technological Demonstrator
Project Number
Resp.
Item
Task
Start after task #
Can start at
Completion of fab / test and delivery at
112
Milano-B
Horns
Tests at Ghz of 8x8 -
Started
20/01/17
119
Milano / Milano-B
B2B H+S
assembly
112 / 118
03/04/17
07/04/17
QUBIC Collaboration Meeting, January 18/19, Milano

31. QUBIC Collaboration Meeting, January 18/19, Milano
Delivery dates: for Full Instrument
Project Number
Resp.
Item
Task
Start after task #
Can start at
Completion of fab / test and delivery at
162
Milano
horns
Fabrication and assembly
Started
08/03/17
163
Milano-B
Test
09/03/17
04/10/17
167
Milano / Milano-B
H+S B2B
Assembly
163 / 166
02/11/17
15/11/17
QUBIC Collaboration Meeting, January 18/19, Milano