p13371. customer dr. schrlau team jacob bertani bridget lally avash joshi nick matson keith...

Hydraulic Nanomanipulator

P13371

CustomerDr. Schrlau

TeamJacob BertaniBridget LallyAvash JoshiNick MatsonKeith Slusser

GuideBill Nowak

Introductions

Task Time

Live demo of manipulation via remote desktop 3 min

Project background and motivation 2 min

Specs:: pass or fail 15 min

Lessons learned and recommendations 10 min

Questions and comments remaining

Table of Contents & Agenda

Jacob Bertani – Lead Hydraulic Subsystem Engineer

Avash Joshi – Lead Driver / Hydraulic Interface Subsystem Engineer

Keith Slusser – Lead Manipulator Subsystem Engineer

Bridget Lally – Lead Controls Engineer

Nick Matson – Project Manager & Controls Engineer

Team Roles

• Ultra-high precision positioning instrument

• Maneuver objects under high magnification, at the micro and nano scales

• Primary customer uses:• Cell behavior for medical

diagnostics

What Is a Nanomanipulator?

Improve 12371 prototype and redesign where applicable

Improve overall nanomanipulator function to meet competitive operational specifications

Reduce price of nanomanipulator with respect to commercial devices

Broaden participation in nanoscience

Project Objectives & Goals

Customer Needs

# Description Importance

CN1 High Resolution 9

CN2 Low Cost 9

CN3 Reliable Movement 9

CN4 Easy to Operate 9

CN5 Visual Feedback 3

CN6 Adequate Range of Motion 3

CN7 Reliable Control of Speed 3

CN8 Keep Hardware Safe 3

CN9 Easy to Maintain 1

CN10 Easy to Setup 1

CN11 Portable 1

CN12 Remote Access 1

System Specs HOQ

movement r

esolution

Position re

peatabilit

y

Manufactu

re Cost

joystick

contro

l

system bac

klash

; dire

ction ch

ange

Development C

ost

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se

GUI contro

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spee

d of trave

l

Limits

of trave

l; xyz

ease of a

ssembly

Safe operation

system m

ounts sta

ndard pipett

e holder

Size M

anipulator Syste

m

weight of M

anipulator

remote inter

net acce

ss0

50

100

150

200

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

P13371 Pareto of SpecsCo

unt

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System Architecture

Final System Assembly

Spec: 8x8x8 (cm) Theory: 10x10x10 (cm) Actual: 13x13x13 (cm)

Fail◦ 1% of relative customer needs

CAD model smaller than actual cylinder Did not account for fittings

Size of Manipulator

Spec: 550 (grams) Theory: 570 (grams) Actual: 689 (grams)

Fail◦ 1% of relative customer needs

Inaccurate CAD model Weight of water 8% improvement from phase 1 (750 grams)

Weight of Manipulator

Spec: <$2,500 Theory: $900 Actual: $2,128

Pass◦ 8% of relative customer needs

Development Cost

Spec: $1,500 Theory: $1,400 Actual: $1,471

Pass◦ 11% of relative customer needs

$179 cost reduction from phase 1 Assuming $270 for labor costs

Manufacturing Cost

Spec: 1 (cm) Theoretical: 1.1 (cm) Actual:1.1 (cm)

Pass◦ 5% of relative customer needs

X: 1.2 cm Y: 1.1 cm Z: 1.1 cm

Limits of Travel in Each Direction

Spec: 0.5 mm/sec Theory: 0.104 mm/sec Actual: 0.04 mm/sec

Fail◦ 6% of relative customer needs

Stepper motor gear ratio Stepper motor max rpm

Speed of Travel

Spec: 100 nm/step Theory: 66 nm/step Actual: X: 56 nm/step

Y: 51 nm/step Z: 56 nm/step

Pass◦ 12% of relative customer needs

Resolution

Spec: <1 rev Theory: 0 rev Actual: X: 1.1

Y: 2.9 Z: 2.8

Fail◦ 9% of relative customer needs

80% improvement phase 1 (14 rev)

Backlash

Spec: <0.02 um Theory: 0 um Actual: 0 um

Pass◦ Part of position repeatability◦ 4% of relative customer needs

Manipulator does not change position when left for hours in lab

System Drift Over Time

Spec: undefined Theory: undefined Actual: X: 2.0um

Y: 3.8um Z: 6.2um

Pass/ Fail ?◦ Part of position repeatability◦ 8% of relative customer needs

System Drift During Manipulation

System is easily assembled / disassembled◦ Yes◦ Pass

3% of relative customer needs◦ See operators manual for instructions

System is easy to use◦ Yes◦ Pass

7% of relative customer needs◦ See users experience survey

Additional Specs

System is controlled by GUI◦ Yes◦ Pass

7% of relative customer needs

System is controlled by Joystick◦ Yes◦ Pass

11% of relative customer needs

System mounts standard pipette holder◦ Yes◦ Pass

3% of relative customer needs

Additional Specs

System can be operated safely through range of motion◦ Yes◦ Pass

3% of relative customer needs

System can be controlled remotely ◦ Remote desktop only◦ Fail

0% of relative customer needs

Additional Specs

83% of customer needs passed

Major Failures:◦ Backlash (9%)◦ Speed of travel (6%)

Significant improvements on backlash, position repeatability and cost for manufacturing

Maximum travel speed is still functional and practical when working in field of vision under microscope

Summary of Specs

# Specification (metric)Unit of

MeasureTarget Value

Actual Value

S1 Size of manipulator (h x w x l) cm 8 x 8 x 8 13 x 13 x 13

S2 Weight of manipulator Grams 550 689

S3 Development cost $ < 2,500 $2,128

S4 Cost to manufacture after development $

1000 -1500

$1,471

S5 Limits of travel in each direction cm >1 1.1

S6 Speed of travel mm/sec 0.5 0.04

S7 Resolution μm < 0.1 .056

S8 System backlash#

Revolutions < 1 2.9

S9 System drift μm < .02 0

# Specification (metric)Unit of

MeasureTarget Value

Theoretical Value

S10 System is easily assembled/disassembled Survey Yes Yes

S11 Easy to use Survey Yes Yes

S12 Joystick Control Binary Yes Yes

S13 Systems can be operated safely Binary Yes Yes

S14 System mounts standard pipette holder Binary Yes Yes

S15 GUI Control Survey Yes Yes

S16 Remote internet access Binary Yes No

Controls◦ Stepper motor control board

◦ Implementation of limit switches

◦ Limited computer engineering experience

◦ Outdated serial communication

Lessons Learned – System

Pump Assembly◦ Reevaluate stepper motor gear ratio to get best

resolution vs. speed

◦ Improper manufacturing on reused parts

Manipulator Assembly◦ Implement bearing sliders

◦ Cylinders

◦ Implement hard mount for correct orientation

Lessons Learned – System

Hydraulics Assembly◦ Cylinders

◦ Protection of hydraulic lines

◦ Hose length

Manufacturing◦ Uniform parts for all axes

◦ Multiple bolted fasteners can cause alignment issues

Lessons Learned – System

Purchasing ◦ Use reliable suppliers

◦ Ample amount of spares when testing

Refer to subject mater experts

Scheduling

Communication and organization

Lessons Learned – Team

Dr. Schrlau – Customer

Bill Nowak - Guide

Mr. Wellin -RIT ME Department

Dr. Patru - RIT EE Department

Sabine Loebner & Brad Olan - P12371

Ken Snyder – RIT EE Department

Rick Tolleson– RIT CE Department

Rob Kranynik & Jan Maneti - ME Machine Shop

Acknowledgments

Questions and Comments