Midterm Review 28-29/05/2015 David Tshilumba ESR3.3, WP3

Midterm Review 28-29/05/2015

David TshilumbaESR3.3, WP3

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Background /

MSc in Mechanical engineering from University of Brussels (André Jaumotte Award)

Master thesis: “Contrôle des électro-aimants finaux d’un collisionneur linéaire”

Member of LSC (LIGO Scientific Collaboration)

Main author of 1 article, Co-author of 2 articles published in refereed journals and 3 publications in conference proceedings

LIGO: www.ligo.org

SLAC: http://www.linearcollider.org/ILC

http://www.ligo.org/

http://www.linearcollider.org/ILC

http://www.ligo.org/index.php

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ESR3.3, WP3 /

Contract start date: 1st April 2014

PACMAN subject: Nano-Positioning of the main LINAC quadrupole as means of laboratory pre-alignment

PhD Institution: Delft University of Technology

Secondment: Delft University + TNO (6M )

David TSHILUMBA, ESR3.3PACMAN Mid-term review 28-29/05/2015

CERN Supervisors Kurt ARTOOS, Hélène MAINAUD DURAND

Academic supervisors Prof. Just HERDER, Prof. Jo SPRONCK

Industry supervisor Dr. Stefan KUIPER

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PhD thesis/

Starting date: 1st April 2014

Thesis title: Nano-Positioning of the main LINAC quadrupole as means of laboratory pre-alignment

Statuts: Admitted to the doctoral school (Go/No Go meeting)

Credits: 45 GS credits are required; 12.5 GS credits acquired.


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Project /

To upgrade the existing type 1 prototype for nanopositioning and vibration isolation

Cross check between different components

To study the possibility to increase the range of the nanopositioning stage

ObjectivesPiezo stack actuator:Stiffness: 480 N/µmStroke: 15 µmResolution: 0.15 nm

Flexural joints:Axial stiffness: 300 N/µmRotational stiffness: 220 Nm/rad


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State of the art

Typical applications

• Atomic force microscopy

• Semiconductor test equipment

• Scanning interferometry

Parameters ValueResolution 1nm

Travel 1m up to 300mStiffness ≤10N/μm

Admissible payload ≤10kgDynamic force

capacity≤100N

Typical specifications


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State of the art

Performances:

Range: 10mm x 10mmParasitic in-plane rotation: ≤ 100radResolution: ≤4nmLow stiffness


Courtesy of S.Awtar, G. Parmar

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Research gap /

Study of an integrated positioning system with high stiffness (>100N/m) capable of moving heavy loads (>100 kg) with high resolution (<1nm) over a large range (≥1mm)


Parameters ValueResolution <0.25nm

Stroke ± 3mm step displacement 0.25 up to 50nm

Roll angle < 100radSpeed 10μm/s

Settling time t1->t2 5ms≤ts≤10msStiffness

(vertical/lateral)1/0.55 kN/μm

Vertical force (dynamic)

50N

Horizontal force (dynamic)

30NFunctions :• Nanopositioning• Vibration isolation• Alignment

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Project /

Range increase concept

Possible monolithic design• No friction• No backlash• No wear

Avoid plastic deformation!

n<1 Stiffness amplification Resolution improvement

in

out

x

x

a

bn

out

in

F

Fn

out

in

k

kn 2


Range increase concept: inverted lever mechanism

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Project /

Method followed


Analytic simplified model (Matlab)

3D CAD modelling (CATIA-Smart Team)

Static and dynamic Finite Element simulations (ANSYS)

Finite Element simulation results + Full dynamic model Positioning control algorithms

Experimental validation of positioning performances

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Project /

Tasks description

Development of a long rangeactuator

Requirements definition: March 15

Design of concept 1DOF: Aug 15

Performance characterization: Oct 15

Extrapolation to 2 DOFs: Sept 16

System review and upgrade: Apr 15

Positioning strategies comparison

Positioning test in CMM


State of the art

Adaptation of the type 1 setup of the PACMAN bench: Aug 15

PACMAN nano-positioning system

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Project /

Results

Parasitic resonance modes

• Design target: 1st resonance ≥100Hz • Unexpected eigen modes detected by EMA between 30Hz and 50Hz

• Suspect root cause: connection stiffness between components

• Bolting: up to 40% drop in eigen frequency• Gluing: up to 8.5% drop in eigen frequency

Courtesy of M. Guinchard


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Project /

Results

Parasitic resonance modes

Further improvement:

• Monolithic base plate design

•Additional stiffeners

Old plate (EMA) Upgraded plate (FEA)

30Hz 52Hz45Hz 75Hz52Hz 114Hz

Other root cause: variable contact on a supporting point modify interface with cam stage


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Project /

Results

1. 48.135 Hz 2. 70.269 Hz3. 123.35 Hz 4. 195.11 Hz5. 236.4 Hz6. 256.81 Hz

2 side mode + bend

1 Longitudinal + plate bend

3 Torsion


• Adjustable jack for system equilibrium• Optimized finite element model (1 hour)• Bending of baseplate • Lowest modes lateral and vertical components

issue

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Project /

Results

1 Longitudinal mode

2 Side mode 3 Torsion

1. 91.6 Hz2. 117.2 Hz3.167.14 Hz4. 244 Hz5.270.39 Hz6. 278.4 Hz


• Larger flat contact surface with ground • Base plate reinforcement (longitudinal)• Lowest mode in longitudinal direction

Not an issue

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Improvement: first lateral mode at 100Hz

Project /

Results


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Project /

Results

Roll motion reduction: parallel kinematics • Permissible roll displacement: 100μrad

• Aluminum eccentric shear pins • 5.15μrad/μm coupling

• Alternative: rotational symmetry hinges• 0.47μrad/μm coupling

• Features:• Less components• Tunable translational stiffness

•Design optimization required (Space availability)


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Training /

• Training in CATIA-SmartTeam

• Basic principles of metrology

• Experimental modal analysis

• Making Presentations

• CERN guide training

• Team building


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Secondment in TUDelft and TNO

Training /• Thesis background

• High performance mechatronic system design

• Modal analysis measurement on support structure of large mirror of a large telescope


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Conferences & workshop:

• PACMAN workshop, 02-04.02.2015one presentation

MEDSI 2016 (Mechanical Engineering Design of Synchrotron Radiation Equipment and Instrumentation)

ICM 2016 (International Conference on Mechatronics)

ICMRE (International Conference on Mechatronics and Robotics Engineering)

ICMMR (International Conference on Mechanics and Mechatronics Research)

ICROM (International Conference on Robotics and Mechatronics )

Outreach & Dissemination /


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Networking Opportunities /

• ACTUATOR conference (May 2014)

• Precision Fair Eindhoven (November 2014)

• Secondment at TUDelft and TNO

• EUSPEN (European Society of Precision Engineering)


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Impact /

• Mechatronic system designer

• Modelling of complex mechanical assemblies

• Improve employability

• Networking


Midterm Review 28-29/05/2015

Thank you for your attention

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Current system overview /


Coarse stage (cams)• locked after pre-alignment• Resolution : 0.35µm• Stroke: 3mm

Fine stage (piezo stacks)• Resolution: 0.15nm • Stiffness : 480N/um (piezo)• Useful Stroke: 5µm

Limitations: • precision of coarse stage (>10µm)• insufficient stroke of fine stage

for thermal load in tunnel ( >100µm)

Increase of range of fine stage

Field gradients K for restoring force in quadrupole

K=dBy/dxK=dBx/dy

Beam trajectory technique Lorentz Force Control of beam oscillation Collision quality optimized

CLIC: NANO-POSITIONING

Courtesy of J. Pfingstner

D. Tshilumba, Delft, 15 April 2015

Beam steering /

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Nanopositioning /


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Type 1 magnet nano-positioning: Inter-pulse sequence

1 2 3 4 Stage

Time (ms)0 t1 t2 20

• Beam divided into trains• Calculation of new positions by global controller• Positioning step of magnet• check of actual new position (machine protection)

Documents

Midterm Review 28-29/05/2015 David Tshilumba ESR3.3, WP3