hydraulic nanomanipulator

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)


Controls Interface Subsystem


Controls Subsystem


Drive Subsystem


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


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%


Nmdrag 00706.

leadscrew

frictionfriction

lF

*2

*

Nmfriction 00788.

Motor will also have to overcome accelerating the lead screw.

◦ Assuming acceleration is only for .1second:


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


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 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


TB6564AHQData Sheet


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


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

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


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


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?

hydraulic nanomanipulator

Documents

lead screw mount lead

1s8 system backlash

step angle

lead screw nut track

hydraulic advantage

price of nanomanipulator

maintain1cn10 easy

high magnification