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