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Universal Adjustment Platform

History and overview of UAP ProjectM. Sosin

Outline

2

Issues of position adjustment in accelerator environment

Alignment system requirements

CLIC DBQ support – reminder

Universal Alignment Platform (UAP)

Results:

UAP PHASE1 tests status and main conclusions

Platform components upgrade

UAP PHASE2 tests

UAP Project and documentation introduction

UAP development schedule

Conclusions

HL-LHC residual doses estimation

Typical issues with position adjustment

Crowded neighbourhood of aligned components Difficult access to regulation mechanisms/screws – (circus

skills needed for some of components regulation)

Fragile equipment around workspace – slow an careful

manipulation

Ergonomics of adjustment Mechanisms not always intuitive

Simple mechanisms => big backlash => multiple measurement andadjustment iterationsneeded =>

Long adjustment time

Alignment system requirements

Limit the presence of personnel in high radiation areas:

Easy access from transport zone

Intuitive kinematics of adjustment system

Possibility of position measurements from bigger distances

Option of remote (distance) adjustment using portable motorized

adapters

5 (6) DOF position adjustment preferred

Accuracy, resolution, stiffness – application dependent

Simple robust and cheap solution

A bit of history – CLIC DBQ adjustment platform

2012-2014

A bit of history – CLIC DBQ adjustment platform

Modified Stewart platform configuration

DBQ Support enabled to reduce pre-alignment

time from one day to 20 minutes

New solution design – adjustable platform concept

Stewart platform adaptation – 3 vertical and 2 horizontal supports

Simplified structure – reduced number of parts

Ergonomic – easy access

With DBQ support, time was reduced to 20 minutes

Second possible use → option for the tunnel

fast re-adjustment

The idea:

Motors

Gears

Trans-missions

Position

feedback

Controller

Portable motorised adapter needed

Position and orientation feedback coming from the absolute

tracker

Option of permanent installation (remote

adjustment) Pos. feedback sensors as eg. WPS needed

Motorized adapter functional prototype designed

and preliminarily tested

Mechanical design

Light and compact

Mobility – fast auto-lock

mechanism

Build-in sensors

Control algorithms adopted to

automated and semi-manual use

Feedback tunel measurements (eg. Laser

tracker or position sensors)

Adapter was designed to match the project needs

Mechanical design

Light and compact

Mobility – fast instalation

Build-in sensors

Ergonomic – simple installation and operation

The adjustment time is about one minute

11

Gearbox and

auto - lock

interface

integrated in

small space

To adjust the DBQ, precise position measurement

are used as an input for the algorithm

INVERSE

KINEMATIC

MODEL

Model created in

SimMechanics and

implemented in

LabVIEW code

Relative sensors

target positions

Temporarly installed

displacement sensors

for precise feedback -

> platform backlash

independent

LASER

SENSORS

*K

Feedback

(MEASURED

DISTANCES)

+

-

Adapter

+

Platform

https://www.micro-epsilon.com

Motors

speed Absolute Tracker

measurements

ALIGNMENT

ERROR

Alignment error

calculation based on the

external, precise

measurements from

Absolute Tracker (AT)

Motorized adapter functional prototype designed

and preliminarily tested

Measurement of the difference between desired and

achieved position showed very good performance

Z Y

X

DBQ reference frame-15

-10

-5

0

5

10

15

20

25

Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7

Linear displacement error[µm] [µrad]

X position Y position

AT measurement error ~10µm for translations

and ~40µrad for X and Y rotations

14

-250

-200

-150

-100

-50

0

50

100

150

200

250

Test 1 Test 2 Test 3 Test 4 Test 5 Test 6 Test 7

Angular displacement error[µrad]

X rotation Y rotation Z rotation

Universal Adjustment PlatformDefinition of set of design rules and development of standardized and modular components to:

increase safety of surveyors

unify small (<2T) accelerator components adjustment systems

15

Universal adjustment platform –

manual operation concept

Universal adjustment solution – concept of use plug-in motors:a) Platform measurement from distance using a laser tracker;b) Installation of plug-in motors in less than one minute;c) Remote adjustment from distance.

Universal adjustment solution - permanent motors version concept. Platform equipped with WPS sensors

Allows for various operation use cases



Y

ROLL

YAW

PITCH

spherical joint

spherical joint

Joints link (length dependant on platform dimensions)

- longitudinal adjustment jig, constant length->5DOF (Z blocked), variable length->6DOF (impact on Z),

X,Y, Roll, Pitch, Yaw - permitted

- vertical adjustment jig, variable length, the main impact on: Y, Pith, Roll

- radial adjustment jig, variable length, the main impact on: X, Yaw

Standardized equipment

Vertical adjustment jig

Radial adjustment jig

Joints

UAP R&D tests summary Preliminary radiation tests of prototype jigs – 8.2018 – 6.2010

Small UAP functional prototype preliminary tests 10.2018 – 1.2019

(PHASE1):

Verification of jigs and different joints types parameters

Measurements of platform directional stiffness and backlash

Behaviour of platform under different load

Check of the adjustment torques

Adjustment stability

Ergonomics tests

Impact of vacuum longitudinal force

Small UAP tests after joints upgrade - April 2019 (PHASE2):

Same set of tests as for PHASE1

Manual UAP

Small UAP jigs, joints design Jigs (vertical, radial) first batch assembled in 9.2019

LHCGUPS_0001 (radial), LHCGUPS_0007 (vertical)

Spherical joints – Inox-Bronze rotules from Michaud-

Chailly catalogue

Small UAP jigs radiation tests Preliminary 3MGy radiation tests in Fraunhofer Institute 8-10.2018

Report: EDMS 2138404

No operational issues observed, no grease problems (Molykote

BR2 plus)

UAP tests – PHASE 1

21

Small platform functional prototype preliminary tests

performed 10.2018 – 1.2019:

Verification of actuators and different joints types parameters




T. Błaszczyk, K. Widuch

22

Small platform functional prototype preliminary tests performed 10.2018 – 1.2019:

Verification of overall platform operation, adjustment

ergonomics and resolution



23

Small platform functional prototype preliminary tests performed 10.2018 – 1.2019:

Stability test after lateral various force

Vacuum – longitudinal force load


T. Błaszczyk, R. Pedersen

24

Batch of actuator prototypes irradiated in Fraunhofer institute (3MGy step done,

10MGy test ongoing) – no issues detected

Jigs adjustment resolution at µm level

Jigs works well, however small design tuning needed to decrease backlash – to be

solved in next jigs series. Discussion on commercialization of jigs production started

with POWERJACKS

Platform adjustment accuracy typically below +/- 50 µm for 2 iterations approach

(impact of backlash, pre-loading improves situation)

Adjustment ergonomics OK (15 .. 20 minutes adjustment time for big platform

misalignments), gear ratio of vertical jigs to be smaller to decrease resolution

Issues with top plate stiffness and joints backlash detected

– upgrades necessary

Michaud-Chailly joints backlash 20 .. 40 µm

20 mm thick Top plate deforming to much at big lateral load (vacuum test)

Flexible joints (Nitinol, flex-rope) considered as perspective,

however too big resources needed for validation

UAP tests – PHASE 1 -

conclusions

UAP prototype changes after PHASE 1

25

Upgrade of joints design

Upgrade of TOP plate thickness/stiffness (previous one deformed with - vacuum test - lateral forces)

Upgrade of joints assembly plates

Vertical jigs backlash adjusted using

shimming rings

PHASE 2 test 15 – 30 April 2019

UAP zero-backlash joints

26

Zero backlash, self lubricating (sintered bronze SELFOIL) based joints


27

Tests of Small platform functional prototype with zero-backlash

joints and updated Top plate structure (15.04.2019 –

30.04.2019):

Verification of actuators and different joints types parameters





28

Verification of platform stiffness, operational aspects (adjustment ergonomics, resolution,

accuracy)



29

Stability test

Vacuum – longitudinal force load


30

Platform adjustment accuracy below +/- 20 µm for 2 iteration approach

Stability of platform after random lateral load: +/- 30 µm

Ergonomics OK (~15 minutes adjustment time)

Longitudinal (vacuum) force test showed deflections of 2.5 mm at the

height of the Beam tube, what exceeds the requirement +/-0.5mm, given by

vacuum team – temporary fastening mechanism can be added to solve this

issue

Lateral stiffness of platform increased 3x (4.1 µm /kg to 1.3 µm/kg)

Platform behaviour assessed as satisfactory

UAP tests – PHASE 2 - conclusions

UAP Project

31

Objectives:

Propose standardized methods and technical solutions to unify of small (<2T) accelerator

components adjustment systems integration

To involve all potential UAP users to elaborate „in loop” the final versions of standardized

adjustment components and design procedures

UAP Project technical meetings

Agreement on final form of UAP by all stakeholders

Involve potential users in tests and validation of UAP

EDMS 2112762

CONCEPTUAL SPECIFICATIONUNIVERSAL ADJUSTMENT PLATFORM (UAP)

AND DESIGN METHODOLOGY

EDMS 2112762

TECHNICAL NOTEUNIVERSAL ADJUSTMENT PLATFORM (UAP)

Small UAP DESIGN GUIDELINES FOR

ENGINEERS (Version 1)

Revision 0

EDMS 2113940

ENGINEERING SPECIFICATIONSTANDARDIZED JOINTS AND ACTUATORS

FOR SMALL UAPRevision 0 (FIRST PROTOTYPE)

EDMS 2143881

ENGINEERING REPORTSMALL UAP ACTUATORS AND JOINTS

PRELIMINARY PROTOTYPES(Report summarizing design, design

approach and solutions introduced in preliminary prototypes of standardized

joints and actuators, targeted to be used in SMALL UAP preliminary prototype)

UAP Project - baseline documentation

32

Drafts of UAP specifications, engineering notes created for future

user consultations purposes

UAP Project - baseline documentation

33

i.e. UAP DESIGN GUIDELINES (EDMS 2112762) – manual for the engineers how to design the UAP

adopted for user equipment

Step 1: Adapt platform dimensions to supported component dimensions

Step 2: Arrange jigs pattern within Bottom plate volume (top); Step 3: Adjust thickness of the plate and position of radial jigs (bottom)

Step 4: Prepare the space for the UAP functional sub-components

Step 5: Prepare the Top plate initial model and adjust the joints length Step 6: Prepare the Top plate initial

model and adjust the joints length

Step 7: Integrate all user specific features and vertical jig assembly plates

Small UAP prototype document „folder”

34

EDMS 2112762

CONCEPTUAL SPECIFICATIONUNIVERSAL ADJUSTMENT PLATFORM (UAP)

AND DESIGN METHODOLOGY

EDMS 2112762

TECHNICAL NOTEUNIVERSAL ADJUSTMENT PLATFORM (UAP)

Small UAP DESIGN GUIDELINES FOR

ENGINEERS (Version 1)

Revision 0

EDMS 2113940


FOR SMALL UAPRevision 0 (FIRST PROTOTYPE)

EDMS 2143976

ENGINEERING REPORTSMALL UAP PRELININARY PROTOTYPE

(Report summarizing design of preliminary prototype of small Universal Adjustment

Platform. The small UAP prototype will be used for initial tests of platform

performance, to estabilish final solutions for SMALL and BIG UAPs designs)

EDMS 2143881

ENGINEERING REPORTSMALL UAP ACTUATORS AND JOINTS

PRELIMINARY PROTOTYPES(Report summarizing design, design

approach and solutions introduced in preliminary prototypes of standardized

joints and actuators, targeted to be used in SMALL UAP preliminary prototype)

EDMS 2112762

TEST NOTESMALL UAP PRELIMINARY PROTOTYPE

(SUPP) - TESTS PHASE 1 OVERVIEW

EDMS 2138404

TEST REPORTSMALL UAP ACTUATORS PRELIMINARY

PROTOTYPES – RADIATION TEST REPORT

EDMS 2138361

TEST REPORTSUPP - ACTUATORS AND JOINTS

BACKLASH (PHASE 1)

EDMS 2144482

TEST REPORTSUPP – DIRECTIONAL STIFFNESS OF

PLATFORM (PHASE 1)

EDMS 2144483

TEST REPORTSUPP – STABILITY TEST AFTER

ADJUSTMENT (PHASE 1)

EDMS 2144484

TEST REPORTSUPP – ALIGNMENT ERGONOMICS

OF PLATFORM (PHASE 1)

EDMS 2112762

ENGINEERING REPORTSMALL UAP PRELININARY PROTOTYPE

UPGRADES AFTER TESTS PHASE 1

EDMS ...

TEST REPORTSUPP – DIRECTIONAL STIFFNESS OF

PLATFORM (PHASE 2)

EDMS ...

TEST REPORTSUPP – STABILITY TEST AFTER

ADJUSTMENT (PHASE 2)

EDMS ...

TEST REPORT ???SUPP – ALIGNMENT ERGONOMICS

OF PLATFORM (PHASE 2)

EDMS ...

TEST REPORTSUPP - ACTUATORS AND JOINTS

BACKLASH (PHASE 2)

EDMS ...

TEST REPORTSMALL UAP PRELIMINARY PROTOTYPE

(SUPP) - TESTS PHASE 2 SUMMARY

EDMS ...

TECHNICAL NOTEDESIGN METHODOLOGY OF UNIVERSAL

ADJUSTMENT PLATFORM (UAP) REVISION 1

EDMS ...


FOR SMALL UAPREVISION 1

IN PREPARATION/VALIDATION AVAILABLENOT READY

UAP PROJECT BASELINE DOCUMENT

ENGINEERING/TEST REPORT

UAP Collaboration workspace

35

https://espace.cern.ch/universal-alignment-platform/

Collaboration workspace created to group important information about the project:

Current status of R&D and tests

Links to important documents and tests

UAP Meetings schedule

universal adjustment platform history and overview of uap ... · uap r&d tests summary...

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