DBQ support – motorization and performance upgrade

Mateusz SosinEN/MEF-SU

Agenda

• Initial requirements• Solution proposed• R&D summary • Perspectives of development • Needs• Future advantages

Initial requirementsNeeds vs. constraints

Tight space constraints 14.5mm for „hexapod” platform

integration Small distance to V-supports Small distance to cradle (rear

DBQ) Instalation on the girder

Needs +/- 1mm of stroke in X and Y µm resoultion of X-Y position

adjustment Rotations adjustment

within +/- 4 mrad ~20µrad resolution of

angular adjustment

Solution proposedModified Stewart platform configuration

Conceptual design - May 2013

R&D summaryStep 1: Validation of flexural parts and actuators

FLEXURES AND REGULATION UNITS TEST ADAPTER

Tests on the linear actuators test bench Additional adapters desighed to provide flexures

and regulation units tests Flexures bending by transversal linear slide LabView acquisition software software for data

logging written

September 2013

Step 1: Validation of flexural parts and actuators

R&D summary

Results – vertical actuators

1µm regulation resolution easily achievable

0.1µm regulation resolution feasible in ~10s

regulation time

Repeatability ~5..7µm

Linearity ~10µm

Backlash ~15µm Results – radial actuators

3µm regulation resolution

1µm regulation resolution feasible (~10s regulation

time)

Repeatability ~15..20µm

Non-Linearity ~10µm

Backlash ~45µm Longitudinal flexure – patented wire spring

September 2013

Step 2: Tests of prototype platform

R&D summary

-0.8 -0.6 -0.4 -0.2 0 0.2 0.4 0.6 0.8 1-1.5

-1

-0.5

0

0.5

1

of horizontal supports prismatic joints (D-D = E-E)

X [

mm

], R

OLL [

mra

d]

, P

ITC

H [

mra

d]

, Y

AW

[m

rad]

0

0.002

0.004

0.006

0.008

0.01

0.012

0.014

0.016

0.018

Y [

mm

]

Results – tests with ‚dummy’ DBQ (180kg) Long term stability of the support has been

confirmed, with no drift or material creeping observed Resolution: 1µm vertical, below 4 µm radial Rotations resolution between 20-40 µrad No backlash Manual regulation to obtain adjustment with

precision of 4µm, 20-40µrad is taking less than 10 minutes

April 2014

Step 3: Final series for manual adjustment of CLEX DBQ

R&D summary

2 platforms installed succesfully in CLEX

Updates according to the prototype and procurement of platforms for CLEX

Tolerances of components optimized

Manual adjustment of platforms position and orientation

Price of single platform ~5kEUR (Eastern Eurpe manufacturing)

May-October 2014

October 2014

Perspectives of developmentPrototyping and preliminary series

(1) Motorization of platform

(2) Improve theregulation range and performance

Design of motorizedadapter + sensors system, allowing automatic adjustment

x

z

MO

T

Change spchericalnotch joints to universal, allowing shifts stroke changeto +/- 2..3mm. Updatesto improve precision

(3) Cost optimization:to minimize the platform cost below3 kEUR

Replace platform with twoDBQ-side mounting blocks

Frame as welded structurewith minimized machining cycles

Additional budget for development

Needs

(1) Platform motorization R&D - tests on the old prototype (25kCHF)

Motorized adapter prototype (machanics)

DAC and controls – NI cRIO/cDAQ + modules

Needed platform modifications

In case of motors and sensors radiation tests – additional budget needed

(2) Improve regulation range and performance + (3) Optimization (25kCHF)

New platform prototype (with welded supporting frame)

Two versions of platform:

Platform as a single piece (similar to current design)

No platform, but two side blocks assembled to DBQ side surfaces EN/MEF-SU → 0.2 FTE

Additional budget for TBTM DBQ platforms tests

Needs

Costs depends on number of DB Quads supported by adjustable platform

4 platform estimated cost: 15..40kCHF (depends on optimization results and

manufacturer)

Mock-up tests of standard (platform) and side mounting block solution (2 +

2)

In case of platforms equipped in permanent motorized modules - estimated

cost of single positioning module

is estimated to be lower than 10kCHF

(including electronics)

Advantages of project

Remote alignment of components in 5DOF with µm

precison

Small amount of components, minimized volume

and reduced price/perormance ratio

Easy acces to all regulation components in case of

manual regulation version

Predictable kinematics of support during regulation

Project „know-how” will allow for easy design of same

platform types for other, complex alignmemt applications

Universal and cheap solution for future use