cad model-based visual control system for the national ignition facility target area positioners*
DESCRIPTION
CAD Model-Based Visual Control System for the National Ignition Facility Target Area Positioners* Ephraim Tekle. 2007 International Conference on Accelerators and Large Experimental Physics Control Systems, Knoxville, TN October 14, 2007 Lawrence Livermore National Laboratory, USA. - PowerPoint PPT PresentationTRANSCRIPT
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CAD Model-Based Visual Control System for the National Ignition Facility Target Area Positioners*Ephraim Tekle
* This work performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344.
2007 International Conference on Accelerators and Large Experimental Physics Control Systems, Knoxville, TN October 14, 2007Lawrence Livermore National Laboratory, USA
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NIF concentrates all the energy in a football stadium-sized facility into a mm3NIF is 94% complete, on schedule and budget
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Symmetry & nomenclatureNational Ignition Facility
Laser Ports
Target Chamber
NIF is a 192 beam laser organized into quads, bundles and clusters with a 10m diameter chamber
Quads are the basic building blocks of a NIF experiment, 4 beams with same pulse shape and time delay. Each quad enters the chamber through the final optic assemble.
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The Integrated Computer Control System (ICCS) orchestrates complex automated shots
Shots fired every few hours culminate in a nanosecond laser pulse in lock-step with diagnostics timed to 30 picoseconds
• 60,000 control points are installed in over 6,000 line replaceable units
• ICCS is deployed on 850 front-end processors, servers, and workstations
• A CORBA-based software framework was developed to deliver 1.8M SLOC
• 192 beams precisely aligned on target to 10 microns over a 300-meter optical path
Main Control Room
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Streak X-ray imager (SXI)
SXIDIM
Alignment sensor positionerTarget positioner
Cryo-Target positioner
Cross-chamber referencesystem (CCRS)
Optics damager inspection positioner
DIM
CCRS
Diagnostics insertion manipulator (DIM)
Future DIM
Ten target and diagnostic positioners are precision aligned for each shot
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The target positioner (TARPOS) inserts the mm-scale fuel capsule with five degrees-of-freedom
10 meters
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The alignment sensor views the target for precision alignment
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Diagnostic instruments manipulators (DIM) position physics packages at chamber center
Four DIMs precision align a diverse suite of diagnostic instruments
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The seven-floor target bay contains the vacuum chamber, final optics system, and target diagnostics
Upper Beam Ports
Target Chamber
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Each experiment requires careful coordination of the motion control system
• Limited chamber access requires remote control and sensing
• Positions maintained to accuracies of 10 microns
• Varied 3D geometries and alignment scenarios
• Complex motion sequences involving multiple devices
• Absolute encoder and video feedback
• Potential collisions must be avoided
A CAD model-based control system with integrated video feedback meets these requirements
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Collision avoidance protects positioners that reach 6 meters into the chamber
Target
Alignment Sensor
Cryo Target 2
Diagnostics 1
X-ray Imager 2
Optics Inspection
X-ray Imager 1
Diagnostics 2
Cryo Target 1
Positioner Interference Matrix
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Situational awareness provided by the surveillance cameras is less than ideal
Wide Field-of-View
Narrow Field-of-View
High viewer magnification limits the field-of-view to a small central region
Chamber Wall
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Camera views of the chamber interior
Wide FOV Narrow FOV
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Collision-free positioner routes are calculated using model-based analysis and tracking tools
• Pro/ENGINEER* — CAD tool used to design NIF’s mechanical hardware— Leveraged to derive the control system model
• DIVISION MockUp* — 3D simulation of the chamber and all positioners
– Based on experimental set up– Used for real-time controls during operations
— Live visualization of positioner operation– Delivers sub-millimeter accuracy– High-precision servo motors with encoders provide hardware
feedback — Determines distances between points or/and positioners— Calculates collision free routes
* Pro/ENGINEER and DIVISION MockUp are a registered trademark of Parametric Technology Corporation (PTC)
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The 3D model “sees” the chamber mechanical arrangement at all times
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3D simulation and analysis tool coded in Java proved the model-based concept
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Simulation integrity is verified in real-time by comparison to the view generated by MockUp
Live-video
Semi-transparent overlay from MockUp
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Visual assisted control
• Calibrated video— Virtual 3D axes are defined using cross-coupling matrices— Video views are calibrated to these axes
• Video integrated control— Calibrated videos provide a live-video integrated control by
dragging movement commands on the screen
• Operator aids— Live-video overlays— Alignment markers— Zoom, etc.
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Movement commands are “dragged” across the live video display using calibrated views
865 mm
750 mm
880 mm
(x,y) x
• Reference point and transformation matrix
• Maps any point (x,y) in the camera coordinate system to (x,y,z) in chamber coordinate system
• Scale and rotation factors• Maps video pixels (x,y)
to positioner coordinate system
• 3D virtual-axes• Defined along camera
field-of-view using cross-coupling matrices
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Routing is analogous to driving directions given by Google Maps
GoogleTM Map
Positioner route finding
x
x
x
x x x
Pause points
Segment (3D axis)
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The offline test lab integrates special hardware simulators and cameras
• Hardware-based testing• Multi-axis encoded hardware simulators on an optics table• Calibrated cameras• PLC motor end-of-travel monitoring and shut-down system• Configured to mimic the NIF target chamber
• Software-based testing• Emulated virtual positioners• Provides for multiple concurrent tests
The test lab ensures software quality, assesses usability, and helps train operators
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Hardware-based testing is supported by five-axis positioner simulators that have the same range of motion as the real positioners
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Calibrated video cameras
Simulator undergoing acceptance tests
Test Lab
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Conclusion
• Enhanced real-time video feedback provides operators with metrology and controls in real physical dimensions
• Model-based visualizations provide a complete control environment in support of complex operations in the limited access chamber
• Model validation assures the system accurately represents reality
• Automated controls ensure interference-free and repeatable coordinated motion sequences
• Status
• Video-assisted controls are deployed to NIF
• CAD model-based system is on schedule for delivery next year
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