hydraulic nanomanipulatoredge.rit.edu/content/p13371/public/detailed design review...toshiba...
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P13371
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Task Time
Project Introduction 10 min
Mechanical System 45 min
Electrical System 35 min
Project Plan and Finances 20 min
Discussion Remaining Time
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Customer Dr. Schrlau
Team Jacob Bertani
Bridget Lally
Avash Joshi
Nick Matson
Keith Slusser
Guide Bill Nowak
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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
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• Ultra-high precision positioning instrument
• Maneuver objects under high magnification, at the micro and nano scales
• Primary customer uses: • Cell behavior for medical
diagnostics
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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
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Controls Interface Subsystem
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Controls Subsystem
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Drive Subsystem
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Manipulator Subsystem
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Customer Needs
# Description Importance
CN1 High Resolution 9
CN2 Low Cost 9
CN3 Reliable Movement 9
CN4 Easy to Operate 9
CN5 Visual Feedback 3
CN6 Adequate Range of Motion 3
CN7 Reliable Control of Speed 3
CN8 Keep Hardware Safe 3
CN9 Easy to Maintain 1
CN10 Easy to Setup 1
CN11 Portable 1
CN12 Remote Access 1
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# 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 $ < 2,500
S4 Cost to manufacture after development $ 1000 -1500
S5 Limits of travel in each direction cm 1
S6 Speed of travel mm/sec 0.5
S7 Resolution μm < 0.1
S8 System backlash # Revolutions < 1
S9 System drift μm/min < .02
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# 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
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Top Specifications ◦ Movement resolution
◦ Position Repeatability
◦ Manufacturing Cost
◦ Joystick Control
◦ Backlash reduction
If Top 8 of 16 Specs Met ◦ 76% of customer needs satisfied
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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
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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
stepnmrev
steprev
mm/59
360
1*07.*
3175.0
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40mm range ◦ translates to ~20mm range on manipulator
◦ 20mm > 10 mm
40mm
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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
stepstepsstep
/#
90sin*max
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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%
Nmdrag 00706.
leadscrew
friction
friction
lF
*2
*
Nmfriction 00788.
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Motor will also have to overcome accelerating the lead screw.
◦ Assuming acceleration is only for .1second:
2
max
2643
4
28
22
00071.
sec/30.2sec60
min1*2*min
2260/2*
556.1)00635)(.8000)(0762(.22
)(
352.5
0003175.1*2
96.20
)2(
1***
1
NmJ
radrev
radrevRPMw
NmEmm
kgm
RLJ
NmE
mrev
rev
N
p
WJ
twJJJ
g
motor
LSLSLSleadscrew
Load
motorleadscrewloadaccel
Nm
NmENmENmsm
rad
accel
accel
0167.
)556.1352.500071(.*sec)1)(./81.9(
sec/3.2 262822
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Torque required from the motor:
Motor Factor of Safety
Nmaccelfrictiondragrequired 03164.
18required
stepFS
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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
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Max rated pressure = 430 psi = 2.96MPa
Radial Expansion
Thermal Expansion
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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
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Density Plastic 0.035 lbs/in3 Brass 0.3 lbs/in3 Track 290 g/m Aluminum 0.098 lbs/in3
1 pound 453.5 grams
Item Volume Units QPA Mat'l Weight Weight (grams) Thread Receiver 0.0671 in3 2 Alum 0.0132 lbs 6.0 Cylinder Mount 0.562 in3 3 Plastic 0.0590 lbs 26.8
ZY bracket 0.208 in3 1 Alum 0.0204 lbs 9.2 M3 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 408.0
Track 270 mm 1 Alum 78.3 grams 78.3 carriage 13 g/carriage 3 Bronze-PTFE 39 grams 39.0
Total 571.0
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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
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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)
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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
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Clock Line 600 Hz Enable Signal 60Hz
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TB6564AHQ Data Sheet
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TB6564AHQ Data Sheet
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Time
0s 5s 10s 15s 20s 25s 30s 35s 40s 45s 50s 55s 60s 65s 70s 75s 80s 85s 90s 95s 100s
V(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
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Time
0s 5s 10s 15s 20s 25s 30s 35s 40s 45s 50s 55s 60s 65s 70s 75s 80s 85s 90s 95s 100s
V(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
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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
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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
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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
http://drkfs.net/REVERSESTEPPERfullsize.htm
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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
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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
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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
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# Specification (metric) Unit of
Measure Target Value
Theoretical Value
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
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# 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
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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
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ID Risk Item Effect Cause Like
liho
od
Seve
rity
Imp
ort
ance
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 out
Can’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 leak
No manipulator
movement
Rupture in pipe,
improper seal 2 3 6
Compression fittings with ball
valve Keith S
15
Hydraulic fluid
compresses/unrespon
sive 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
22
Controls 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 Code
Improper control of
system
Inexperience with
programming
language 3 2 6
Produced detailed flow chart to
help develop program Nick M / Bridget L
25
Parts don’t arrive on
time Delays entire project Supplier problems 2 3 6
Long lead items identified and
ordered early. Jacob B
30
Part/equipment
availability Delay entire project Back order 2 3 6
Identified parts with low
availability and ordered early Jacob B
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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
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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
*See Gantt Chart on P13371 website
for more detail
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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
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