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Status of the DB Quad adjustable support design – flexures and regulation units tests

Mateusz Sosin. Status of the DB Quad adjustable support design – flexures and regulation units tests. CLIC Module WG Meeting, 18-September-2013. DB Quad adjustable support – short review. 5DOF regulation thanks to flexure based supports 3 adjustable in vertical

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Status of the DB Quad adjustable support design – flexures and regulation units tests

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  1. Mateusz Sosin Status of the DB Quad adjustable support design – flexures and regulation units tests CLIC Module WG Meeting, 18-September-2013

  2. DB Quad adjustable support – short review • 5DOF regulation thanks to flexure based supports • 3 adjustable in vertical • 2 adjustable in horizontal + 1 support with constant length Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  3. DB Quad adjustable support – vertical regulation unit • Wedge based regulation • 30mm of wedge move = 2mm of ‚leg’ stroke • Expected resolution ~2µm • Expected precision (considering thread backlash) ~5µm Threaded wedge Belleville spring stack Regulation screw Wedge sliding bearing Flexural vertical support sliding bearing Regulation screw bearing unit (2 flat needle bearings + tightening screw) Flexural vertical support with wedge-profiled head Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  4. DB Quad adjustable support – radial regulation unit • Differential thread based regulation • 20 revolution of screw = 2mm of horiz.support stroke • Expected resolution ~2µm • Expected precision (considering thread backlash) ~10µm Flexural horizontal support. One end threaded (as a part of regulation screw) DB Quad platform clamping block Differential thread regulation screw Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  5. DB Quad adjustable support – longitudinal joint • Flexure based joint • Blocks longitudinal displacements of the DBQ platform • Allows vertical and horizontal displacements + rotations (within assumed range) Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  6. DB Quad adjustable support – flexures and regulation units tests • Development STEP 1: • Adjustable - vertical regulation unit tests • Adjustable – radial regulation unit tests • Longitudinal „blocking” flexure tests • Development STEP 2: • Final design and of 5DOF platform prototype • Tests with ‚dummy’ DB Quad • Development STEP 3: • Update of design according to the STEP1,2 tests results • Final DBQ series for CLEX Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  7. Test bench desscription FLEXURES AND REGULATION UNITS TEST ADAPTER • Existing ZTS linear actuators test bench used • Additional adapters desighed to provide flexures and regulation units tests • Flexures bending by transversal table • Suited LabView acquisition data logging software written Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  8. Vertical regulation unit tests Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  9. Vertical regulation unit tests - stiffness • Measurement conditions • Load up to 55kg (20% more than max flexure load) • 4 series with step ~10kg • Elongation measured by 50nm resolution RENISHAW linear scale • Stiffness of test bench components considered as negligible • Stiffness → ~5kg/µm Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  10. Vertical regulation unit tests - resolution • Measurement conditions • Manual adjustment using imbus key • Measurements in the middle and 25% wedge position • Load ~47kg • Observation of regulation ergonomy wrt. resulting position change • Results • 1µm regulation resolution achieved without any problems. Fine position adjustment within 2..5 seconds • 0.1µm regulation resolution feasible with longer regulation time Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  11. Vertical regulation unit tests – linearity, backlash repeatability • Measurement conditions • 3 iterations FW-BW • Load ~47kg • Wegde pos. Measured directly by SYLVAC (1µm resolution) probe FW REPEATABILITY Theoretical position BW • Results • Repeatability ~5..7µm • Non-linearity ~10µm • Backlash ~15µm Note: Observed „dead-zone” of SYLVAC proble at the level of ~3µm, so real repeataility should be better than mentioned above Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  12. Vertical regulation unit tests – impact of wegde bending for unit adjustment Δl +/-1mm (deflection) • Measurement conditions • 2 deflection iterations FW-BW • Load ~47kg • deflection measured directly by SYLVAC (1µm resolution) probe, regulated by hand • Results • +/- 1mm perpendicular deflection of flexure gives max. 8µm of longitudinal displacement. It is coherent with theoretical calculation for flexure geometry Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  13. Vertical regulation unit tests - summary • Results • Parameters of vertical regulation unit much better than expected (especially resolution and regulation ergonomy) • Position stable in the time • Assumed components tolerances and sliding bearings tolerances (H6/h5, minimal or no sliding bering perpendicular backlash)are correct. • Actions foreseen • Add grease grooves in V_FLEXURE_BEARING • Integrate wedge absolute position indicators/sensors – needed for ergonomic regulation. Potentiometric sensors forseen Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  14. Radial regulation unit tests Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  15. Radial regulation unit tests - stiffness • Measurement conditions • Load up to 55kg (20% more than max flexure load assumed) • 4 series with step ~10kg • Elongation measured by 50nm resolution RENISHAW linear scale • Stiffness of test bench components considered as negligible • Stiffness → ~2.5kg/µm Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  16. Radial regulation unit tests - resolution • Measurement conditions • Manual adjustment using imbus key • Measurements in the middle and 25% wedge position • Load ~39kg • Observation of regulation ergonomy wrt. resulting position change • Results • 3µm regulation resolution easily achieved. Fine position adjustment within 2..5 seconds • 1µm regulation resolution feasible with longer regulation time Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  17. Radial regulation unit tests – linearity, backlash repeatability • Measurement conditions • 3 iterations FW-BW • Load ~39kg • Rotation measured by encoder adapted to the regulation key: FW REPEATABILITY Theoretical position BW • Results • Repeatability ~15..20µm • Non-Linearity ~10µm • Backlash ~45µm Note: ENCODER-REGULATION SCREW connection had a big backlash and wasn’t stiff – what could be the source of analysis error. Real performance shall be better than measured. Will be checked during DBQ support platform tests, using integrated sensors Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  18. Aadial regulation unit tests – impact of wegde bending for unit adjustment Δl +/-1mm (deflection) • Measurement conditions • 2 deflection iterations FW-BW • Load ~39kg • deflection measured directly by SYLVAC (1µm resolution) probe, regulated by hand • Results • +/- 1mm perpendicular deflection of flexure gives max. 5µm of longitudinal displacement. It is coherent with theoretical calculation for flexure geometry Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  19. Radial regulation unit tests - summary • Results • Resolution satisfactory. Repeatability and linearity to be confirmed with additional sensors • Regulated position stable in the time • Actions foreseen • Need to increase the threads tolerances. More tight thread fitting. Smaller Ra needed to avoid thread seizure. Grinding of threads on steel components. Threads sets fitting during manufacturing • Prestress of the flexures to suppress thread backlash • Integrate differential screw absolute position indicators/sensors – needed for ergonomic regulation. Potentiometric sensors forseen Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  20. Longitudinal flexure tests Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  21. Longitudinal flexure tests – stiffness, buckling • Measurement conditions • Load up to 85kg (stress in flexure ‚thin’ section ~270MPa) • 4 series with step ~10kg • Elongation measured by 50nm resolution RENISHAW linear scale • Stiffness of test bench components considered as negligible • Stiffness → ~1.4kg/µm • No buckling appear during flexure pressing (even when exciting flexure center with perpendicular force ~10N) Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  22. Longitudinal regulation unit tests - summary • Results • Position given by flexure stable in the time • Observed position drift, when deforming flexure from extreme to extereme transversal position (-1mm...+1mm) at load of 50kg. Possible linked with plastic deformation in bending area. Simulated max. stress ~1100MPa (close to elasticity limit of spring steel defined as flexure material 1.0909 Re=1400MPa) • Actions foreseen • Optimize shape to decrease stress in bending areas (higher stress safety margin) • Check possibility of better material use • Confirm if delivered flexures material correspond to specified Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  23. Actions foreseen – STEP2/STEP3 Increase the threads tolerances. More tight thread fitting. Smaller thread surface Ra Integrate differential screw absolute position sensors/indicators Integrate wedges position sensors within vertical regulation units Optimize flexure shape to minimize stress in bended areas Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

  24. CLEX integration – remarks • Single actuator rotation (90 or 180˚) needed • According to the collision between one flexure support and actuator connector box – the rotation of actuator is needed • Considered as non conflicting with other installations (to confirm) Mateusz Sosin Status of the DB Quad adjustable support design – flexres nad regulation units tests

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