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In this paper, we present the design and prototyping of the HARMONI Adaptive Optics Calibration Unit (AOCU). The AOCU consists of a set of on-axis sources (covering 0.5-2.4 μm) with a controllable wavefront shape. It will deploy into the instrument focal plane to inject calibration light into the rest of the system. The AOCU supports all-natural guide-star wavefront sensors for SCAO, HCAO, and LTAO.
The AOCU will be used to calibrate the WFSs, the internal interaction matrices of HARMONI, measure and compensate NCPAs between AO dichroics and the science detectors, and calibrate the pointing model zero position. The illumination assembly of the AOCU will consist of six diffraction-limited sources and a resolved source coupled into fibres. Because of the wide range of wavelengths and the spatial separations requirements, we use two endlessly single-mode fibres and a multimode fibre. In addition, several LED sources need to be coupled efficiently into the single-mode fibres. In this paper, we present the general AOCU design using off-the-shelf with a focus on the illumination and source module.
A 3D printed version of the actuator is currently being used at the ATC to deform a mirror but it has several advantages that may make it suitable to other applications. The actuator is cheap to produce whilst obtaining a high accuracy and repeatability. The actuator design would be suitable for applications requiring large numbers of actuators with high precision.
The FAME design consists of a pre-formed, deformable thin mirror sheet with an active support system. The thin face sheet provides a close to final surface shape with very high surface quality. The active array provides the support, and through actuation, the control to achieve final surface shape accuracy.
In this paper the development path, trade-offs and demonstrator design of the FAME active array is presented. The key step in the development process of the active array is the design of the mechanical structure and especially the optimization of the actuation node positions, where the actuator force is transmitted to the thin mirror sheet. This is crucial for the final performance of the mirror where the aim is to achieve an accurate surface shape, with low residual (high order) errors using the minimum number of actuators. These activities are based on the coupling of optical and mechanical engineering, using analytical and numerical methods, which results in an active array with optimized node positions and surface shape.
Due to the opening of a new parameter space in optical design, Freeform Optics are a revolution in imaging systems for a broad range of applications from high tech cameras to astronomy, via earth observation systems, drones and defense. Freeform mirrors are defined by a non-rotational symmetry of the surface shape, and the fact that the surface shape cannot be simply described by conicoids extensions, or off-axis conicoids. An extreme freeform surface is a significantly challenging optical surface, especially for UV/VIS/NIR diffraction limited instruments.
The aim of the FAME effort is to use an extreme freeform mirror with standard optics in order to propose an integrated system solution for use in future instruments. The work done so far concentrated on identification of compact, fast, widefield optical designs working in the visible, with diffraction limited performance; optimization of the number of required actuators and their layout; the design of an active array to manipulate the face sheet, as well as the actuator design.
In this paper we present the status of the demonstrator development, with focus on the different building blocks: an extreme freeform thin face sheet, the active array, a highly controllable thermal actuator array, and the metrology and control system.
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