hydraulic nanomanipulator
DESCRIPTION
Hydraulic Nanomanipulator. P13371. Table of Contents & Agenda. Introductions. Customer Dr. Schrlau Team Jacob Bertani Bridget Lally Avash Joshi Nick Matson Keith Slusser Guide Bill Nowak. Team Roles. Jacob Bertani – Lead Hydraulic Subsystem Engineer - PowerPoint PPT PresentationTRANSCRIPT
Hydraulic Nanomanipulator
P13371
Task TimeProject Introduction 10 minMechanical System 45 minElectrical System 35 minProject Plan and Finances 20 minDiscussion Remaining Time
Table of Contents & Agenda
CustomerDr. Schrlau
TeamJacob BertaniBridget LallyAvash JoshiNick MatsonKeith Slusser
GuideBill Nowak
Introductions
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
Existing System (P12371)
Existing System (P12371)
Controls Interface Subsystem
Existing System (P12371)
Controls Subsystem
Existing System (P12371)
Drive Subsystem
Existing System (P12371)
Manipulator Subsystem
Customer Needs# Description Importance
CN1 High Resolution 9CN2 Low Cost 9CN3 Reliable Movement 9CN4 Easy to Operate 9CN5 Visual Feedback 3CN6 Adequate Range of Motion 3CN7 Reliable Control of Speed 3CN8 Keep Hardware Safe 3CN9 Easy to Maintain 1CN10 Easy to Setup 1CN11 Portable 1CN12 Remote Access 1
# Specification (metric) Unit of Measure
Target Value
S1 Size of manipulator (h x w x l) cm 8 x 8 x 8
S2 Weight of manipulator Grams (oz) 550 (20)S3 Development cost $ < 2,500S4 Cost to manufacture after development $ 1000 -
1500S5 Limits of travel in each direction cm 1S6 Speed of travel mm/sec 0.5S7 Resolution μm < 0.1S8 System backlash # Revolutions < 1S9 System drift μm/min < .02
# Specification (metric) Unit of Measure
Target Value
S10 System is easily assembled/disassembled Survey Yes
S11 Ease of use Survey Yes
S12 Joystick Control Binary Yes
S13 Systems can be operated safely Binary Yes
S14 System mounts standard pipette holder Binary Yes
S15 GUI Control Survey Yes
S16 Remote internet access Binary Yes
Top Specifications◦ Movement resolution◦ Position Repeatability◦ Manufacturing Cost◦ Joystick Control◦ Backlash reduction
If Top 8 of 16 Specs Met◦ 76% of customer needs satisfied
House of Quality Pareto Analysis
System Architecture
System Assembly
Stepper Motors
Gear ratio: 26 103/121 : 1 planetary Gear
Max holding torque: 7.55 N-m
Max sustainable torque: 2.94 N-m
Step angle: 0.067 degrees
Max Speed: 22.88 RPM
# Leads: 4 – Bipolar stepper
Electrical: 12V supply 1.6A/phase
Stepper Motors
Stepper Motors
Pump Subsystem
Assembly
Base Plate, Motor Bracket and Lead Screw Mount
Lead Screw and Lead Screw Nut
Track and Carriage
Lead=0.0125 in/rev = 0.3175mm/rev Gear Ratio = 26 103/121:1 Step Angle Before Gears = 1.8° Step Angle After Gears = 0.07°
With hydraulic advantage of 1.78◦ 33nm/step
If we quarter step, 8nm/quarter step
Resolution Feasibility Analysis
stepnmrevsteprev
mm /593601*07.*3175.0
Range of Motion Feasibility Analysis
40mm range◦ translates to ~20mm range on manipulator◦ 20mm > 10 mm
40mm
Motor rated at 22 RPM Lead = 0.3175 mm/rev
0.065 mm/s < 0.5 mm/s◦ Does not meet specification◦ 0.065 mm/s is comparable to commercial
manipulators
Speed Feasibility Analysis
Motor is rated for 2.96Nm◦ Loss due to micro-stepping
With 4 micro-steps per step, the max rated torque becomes .571Nm when micro stepping
Motor Torque Feasibility
stepstepsstep /#90sin*max
Motor will also need to overcome friction◦ Loss due to lead screw nut drag; property of lead
screw
◦ Loss to overcome system friction
With calculated Friction Force of 20.96NM, lead of .0003175m, and lead screw thread efficiency of 13%
Motor Torque Feasibility
Nmdrag 00706.
leadscrew
frictionfriction
lF
*2
*
Nmfriction 00788.
Motor will also have to overcome accelerating the lead screw.
◦ Assuming acceleration is only for .1second:
Motor Torque Feasibility
2
max
2643
4
2822
00071.
sec/30.2sec60min1*2*min2260/2*
556.1)00635)(.8000)(0762(.22
)(
352.5
0003175.1*296.20
)2(
1***1
NmJ
radrevradrevRPMw
NmEmm
kgmRLJ
NmE
mrev
rev
NpWJ
twJJJ
g
motor
LSLSLSleadscrew
Load
motorleadscrewloadaccel
Nm
NmENmENmsm
rad
accel
accel
0167.
)556.1352.500071(.*sec)1)(./81.9(
sec/3.2 262822
Torque required from the motor:
Motor Factor of Safety
Motor Torque Feasibility
Nmaccelfrictiondragrequired 03164.
18required
stepFS
Resolution◦ 20 revolutions = 6.35mm
Limits of travel◦ Operate full range of motion and measure distance
Speed of travel◦ Measure the time taken to complete 10 revolutions
System backlash◦ Number of steps taken to change direction
Safe in full range of motion◦ Make sure nothing is damaged
Test Plan
Hydraulic Subsystem
Hydraulic Line Assembly
Hydraulic Line Assembly
Hydraulic Mount
Hydraulic Mount
Max rated pressure = 430 psi = 2.96MPa
Radial Expansion
Thermal Expansion
Feasibility Analysis
Limits of travel◦ Operate full range of motion and measure
distance System Drift
◦ Compress and hold at a set displacement and measure drift after elapsed time
Test Plan
Manipulator Subsystem
Manipulator Assembly
Carriage, Track, and Cylinder Receiver
Piston Cylinder Mound and Piston
X-Axis
YZ-Bracket
Y-Axis
XY-Axis
Z-Axis
Manipulator Assembly
Weight Feasibility AnalysisDensity Plastic 0.035lbs/in3
Brass 0.3lbs/in3
Track 290g/mAluminum 0.098lbs/in3
1 pound 453.5grams
Item Volume Units QPA Mat'l Weight Weight (grams)Thread Receiver 0.0671 in3 2 Alum 0.0132 lbs 6.0Cylinder Mount 0.562 in3 3 Plastic 0.0590 lbs 26.8
ZY bracket 0.208 in3 1 Alum 0.0204 lbs 9.2M3 bolt 0.005 in3 17 Alum 0.0083 lbs 3.8
Item Weight Unit QPA Mat’l Weight Cylinder 136 g/cylinder 3 Brass 408 grams 408.0Track 270 mm 1 Alum 78.3 grams 78.3
carriage 13 g/carriage 3 Bronze-PTFE 39 grams 39.0Total 571.0
Weight◦ Predicted 570 grams
Static Coefficient of Friction◦ Force required to move each axis
Size Range of Motion
◦ Distance axis travels at full plunger depression
Test Plan
Controls Subsystem
Control System Overview
DB25 Male Breakout Board
TB6560 Driver Board Controller
Freescale HCS12 Microcontroller
Joystick
PC (Windows) Stepper Motors
USB
Serial (Comm)
USB(Power)
DB25 Cable
Plug In Headers
Power Supply
Limit Switch(x6)
Resolution setting will become speed setting
Implement Camera live feed into GUI◦ Actively learning JAVA language◦ Open source code available◦ Friends in the CE department
Front End JAVA Program
Control Implementation
Clock Line 600 Hz
Enable Signal 60Hz
Control Implementation
TB6564AHQData Sheet
Control Implementation
TB6564AHQData Sheet
Control Implementation
Time
0s 5s 10s 15s 20s 25s 30s 35s 40s 45s 50s 55s 60s 65s 70s 75s 80s 85s 90s 95s 100sV(R4:1) V(R3:1) V(V3:+) V(R1:1) V(R4:1) V(R3:1) V(V3:+) V(R1:1)
0V
1.0V
2.0V
3.0V
4.0V
5.0V
6.0V
7.0V
Speed Control Timing Diagram Single Step
Enable
Clk 1
Clk 2
Clk 3
Control Implementation
Time
0s 5s 10s 15s 20s 25s 30s 35s 40s 45s 50s 55s 60s 65s 70s 75s 80s 85s 90s 95s 100sV(R3:1) V(R2:1) V(R1:1) V(R4:1) V(R3:1) V(R2:1) V(R1:1)
0V
1.0V
2.0V
3.0V
4.0V
5.0V
6.0V
7.0V
Enable
Clk 1
Clk 2
Clk 3
Speed Control Timing Diagram Continuous Motion
C code Flow Chart
Micro Controller to Control Board Connection
Micro Controller to Control Board Connection
Freescale Microcontroller will plug into DB25 break out board connector◦ Improves testability◦ More reliable than a “home made” custom cable◦ Easy to reprogram
In production, DB25 break out board unnecessary◦ Custom cable◦ Direct connect to controls board
Micro Controller to Control Board Connection
3-Axis Control Board
Toshiba TB6560AHQ◦ 1 – 1/16 micro stepping setting◦ 12 – 36 VDC power ◦ Adjustable 0.5 – 2.5 A driver current / phase◦ PWM actuation output
3-axis of motion
Limit switch functionality
Parallel port connection
Overload, over-current, over-temp protection
3-Axis Control Board
http://drkfs.net/REVERSESTEPPERfullsize.htm
Control Board has been reverse-engineered by Dr. Kevin F. Scott and is presented on his website www.drkfs.net
Control Board Schematics
Control Board Schematics – Limit Switch
The microcontroller electrically connects to the controls board◦ Use ohmmeter to check resistivity between
connection points
The GUI and Joystick input function◦ Use oscilloscope to watch the outputs of the microcontroller when control signals are sent
Test Plan
Full System Assembly
Size, Weight◦ Manipulator test plan
Cost Limits of travel
◦ Step through entire range of motion Speed
◦ Time system run at max speed for 10 revs and see distance traveled
Resolution◦ Send known amount of steps to motor and see
step size under microscope
Full System Test Plan
Backlash◦ Count the amount of revolutions to change directions
at various speeds Drift
◦ Assembly system, leave it on with no input for a period of time, sample position
Ease of Assembly◦ Give new users a system manual and survey their
experience Ease of use
◦ Give new users a system manual and survey their experience
Full System Test Plan
# Specification (metric) Unit of Measure
Target Value
TheoreticalValue
S1 Size of manipulator (h x w x l) cm 8 x 8 x 8 10 x 10 x 10
S2 Weight of manipulator Grams 550 570
S3 Development cost $ < 2,500 $900
S4 Cost to manufacture after development $ 1000 -
1500 $1400
S5 Limits of travel in each direction cm >1 1.1
S6 Speed of travel mm/sec 0.5 .065
S7 Resolution μm < 0.1 .033
S8 System backlash # Revolutions < 1 0
S9 System drift μm/min < .02 0
# Specification (metric) Unit of Measure
Target 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
Cost of suggested improvements (Development Cost): ~$900.00◦ New sliders◦ Smaller diameter, thick walled tubing◦ New piston sleeves◦ Double compression fittings◦ Updated Controls◦ Motors
Estimated Manufacturing Cost: $1,460.00 Previous Manufacturing Cost: $1,650.00
◦ Cost reduction: $190.00
Development Cost
Risk ManagementID Risk Item Effect Cause
Likelihood
Severity
Importance Action to Minimize Risk Owner
Describe the risk briefly
What is the effect on any or all of the project deliverables if the cause actually happens?
What are the possible cause(s) of this risk?
L*S
What action(s) will you take (and by when) to prevent, reduce the impact of, or transfer the risk of this occurring?
Who is responsible for following through on mitigation?
23 Chips burn outCan’t control the system
Programming errors, wiring errors, feedback, unisolated contacts 2 3 6
Bought standalone control board that has over current/over temperature protection Nick M / Bridget L
14 Hydraulic leakNo manipulator movement
Rupture in pipe, improper seal 2 3 6
Compression fittings with ball valve Keith S
15
Hydraulic fluid compresses/unresponsive to mechanical input
Backlash and reduced manipulator movement
Air introduced into system and sealing issues 3 2 6
Compression fittings with ball valve Jacob B
22Controls have a delay or slow response time Backlash
Unoptimized control and system components unable to respond 2 3 6
Optimize control program to counter-act motor inductance Nick M / Bridget L
24 Bugs in UI CodeImproper control of system
Inexperience with programming language 3 2 6
Produced detailed flow chart to help develop program Nick M / Bridget L
25Parts don’t arrive on time Delays entire project Supplier problems 2 3 6
Long lead items identified and ordered early. Jacob B
30Part/equipment availability Delay entire project Back order 2 3 6
Identified parts with low availability and ordered early Jacob B
MSD I◦ Week 10/11
Get MSD II project green light Review BOM & order parts
MSD II◦ Week 1
All parts in house check Begin manufacturing Begin controls program debugging
◦ Week 3 Mechanical manufacturing complete Java and C-code working with no bugs Begin motor control testing / tuning
Project Planning
MSD II (cont.)◦ Week 5 (week after 2 week winter break)
System completely assembled and functioning ◦ Week 6-8
Evaluate, improve, redesign as able and necessary Start tech paper and poster (end of week 8)
◦ Week 9 Submit poster
◦ Week 10 Finish tech paper Evaluate lessons learned Complete project presentation
Project Planning (see Gantt Chart hand out)
*See Gantt Chart on P13371 website for more detail
Mr. Wellin -RIT ME Department
Dr. Patru - RIT EE Department
Sabine Loebner & Brad Olan - P12371
Hal Spang – RIT CE Student
Dr Kevin F. Scott – Board Schematics
Ken Snyder – RIT EE Department
Rick Tolleson– RIT CE Department
Acknowledgments
Questions?