Mr. Jeffrey Grayczyk Profile

Jeffrey Grayczyk

Mechanical Engineer at Collins Aerospace

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Publications (2)

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Proceedings Article | 29 August 2022 Poster + Paper

Wide field of view optical assemblies for severe environments in space

Ryan S. Bronson, Charles W. Micka, Donna Groth, Jeffrey Grayczyk, Ryan Kaufman, John Fitzpatrick

Proceedings Volume 12188, 121882N (2022) https://doi.org/10.1117/12.2629447

KEYWORDS: Cryogenics, Optical fabrication, Modulation transfer functions, Glasses, Temperature metrology, Inspection, Adhesives, Optical components, Metals, Image quality

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Wide field-of-view (WFOV) lenses covering a full field of view of <120° have been designed and analyzed for spaceborne applications for use in severe environments. The optical designs have been passively athermalized and achromatized over the visible waveband for use during operating conditions and the opto-mechanical designs have been ruggedized for survivability in severe environmental conditions with random vibration levels exceeding 2000 Grms and cryogenic temperature conditions reaching -175°C. To characterize the performance and survivability of the lens assembly for such environments, image quality and random vibration testing was performed on representative optical assemblies, with previous flight experience, before and after exposure to cryogenic liquid nitrogen temperatures. The dynamic test environment consists of low-level random vibration testing in each of the three orthogonal axes (X, Y & Z) and the image quality testing performed includes resolution (MTF), distortion, and effective focal (EFL). Finite element analysis (FEA) was performed to verify survivability to full random vibration spectrums and shock levels; external testing was performed with flight hardware and results were validated. High correlation of characterization measurements before and after cryogenic exposure indicate the optical assemblies' ability to withstand severe temperature environments without any impact to functionality or performance. This document provides an overview of the optical and opto-mechanical lens designs for severe space environments, a comprehensive look into component material characteristics over temperature for various space-grade adhesives used to mechanically retain lens elements, and detailed explanations of the cryogenic test methodology using a custom laboratory test setup to characterize the performance and survivability of lens assemblies and their various components.

Proceedings Article | 24 August 2021 Poster + Paper

Quantifying passive athermalization performance of high-resolution spaceborne optical assemblies

Ryan Bronson, Charles Micka, Jeffrey Grayczyk, Daniel Lombardo

Proceedings Volume 11820, 118200X (2021) https://doi.org/10.1117/12.2591663

KEYWORDS: Wavefronts, Temperature metrology, Glasses, Chemical elements, Interferometry, Optical fabrication, Monochromatic aberrations, Interferometers, Aluminum, Aerospace engineering

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Spaceborne optical lens assemblies serve a wide range of applications, including deep-space exploratory missions, earth weather imagery, satellite reconnaissance, and surveillance. These applications demand operation over a wide range of optical performance metrics and environmental conditions. Systems deployed in space cannot afford to use the limited battery or solar power to energize motors required for maintaining focus and diffraction-limited image quality. Therefore, it is vital to develop and characterize passively athermalized solutions for spaceborne optical assemblies that are isolated from direct human contact or have limited access to power. These multi-lens element systems of varying glass materials are susceptible to small optical property changes between glass melt lots and highly dependent on the opto-mechanical assembly method; this creates large sensitivities within the system design that can result in changes in system level performance parameters. Accurate quantification of the optical system performance over the specified operating temperature range prior to flight is critical for mission success. Collins Aerospace, Mission Systems Optronics has developed an environmental test setup and interferometric wavefront measurement approach capable of quantifying the optical performance over temperature of passively athermalized spaceborne optical assemblies. Interferometric wavefront measurements are performed across the operating temperature range; resulting interferograms are analyzed and decomposed in terms of thermal defocus, low-order aberrations, and RMS wavefront error to assess final system compliance. The laboratory prototype system consists of a 633nm common-path interferometer, nitrogen-purged environmental test chamber, and retro-null reflecting pin. We use an f/3 aerospace lens, intended for deep-space application, to demonstrate these measurement techniques.

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