Leonardo SpA is leading an Italian Space Industry Team, funded by ASI, collaborating to the ESA mission PLATO program for the realization of the 26 telescopes, which will fly on a single platform, aimed to discover, observe and analyze the exoplanets. The mission is based on a challenging telescope design with peculiar optical performance to be assured at very low operative temperature (-80°C). The “large” number of telescopes, produced in high rate (up to 3 telescopes every 2 months), is quite unusual for the production of scientific payloads. It has imposed a change with respect the prototypical manufacturing and test approach, generally a few flight units for space equipment, addressing the implementation of smart and fast methodologies for aligning and focusing each telescope, based on simulation of the peculiar “as-built” data. The opto-mechanical design of the telescope has been optimized to implement an industrial approach for all the manufacturing, assembly, integration and test (MAIT) phases. The number, production rate and the performance results of the flight units so far delivered by Leonardo to the PLATO Consortium, are validating the selected design solutions and all the selected MAIT processes. All the units already delivered present very similar performance, full specs and very close to the theoretical design.
Within the ESA PLATO M3 mission, the Telescope Optical Unit (TOU), i.e. the opto-mechanical unit, is a fully refractive optical system. The 26 TOU Flight Models (FM) to be delivered to the upper level, the PLATO Camera, make it a series production. The first Flight Models production faced many initial challenges from a Product Assurance point of view, mostly related to MAIT activities, while moving forward these challenges decreased. Discrepancies and nonconformities associated with, mainly, but not only, materials and processes, cleanliness and contamination control, safety, qualifications and validations, are the object of this proceeding. Thus, showing that serial production adds one more variable to possible failures, but at the same time, when root causes are corrected and solved, yields less difficulties in subsequent FMs MAIT and final production. Product Assurance, in monitoring the product in failure-proofing aspects, aims at mitigating criticalities and arranging for corrective and preventive actions that allow improving the likelihood of success of the mission.
KEYWORDS: Contamination, Manufacturing, Cameras, Space operations, Picture Archiving and Communication System, Optics manufacturing, Materials processing, Telescopes, Inspection, Contamination control
The TOU is the Telescope Optical Unit for the PLATO ESA mission, consisting of the opto-mechanical unit for each of the 26 Cameras of which PLATO is composed. The TOU is currently in the manufacturing, assembly, integration and testing (MAIT) phase for the Proto Flight Model (PFM) and for Flight Models (FMs). We present the design processes as seen from the Product Assurance (PA) point of view: PA aims at monitoring the design and addresses specific issues related to, among others, materials and processes (these shall be suitable for the purpose and for the life-time of the mission), cleanliness and contamination control (to limit the loss of optical performance), safety, monitoring of qualifications/validations. PA supports the project in failure-proofing aspects to mitigate criticalities, e.g. in the elaboration of non-conformances and deviations that can arise during the design and MAIT process, and/or are highlighted during the reviews for manufacturing, test, and delivery of the related hardware. PA ensures early detection of potential problems and risks for the TOU and arranges for corrective actions that aim at improving the likelihood of success of the mission.
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