P13371

Task Time

Project Introduction 10 min

Mechanical System 45 min

Electrical System 35 min

Project Plan and Finances 20 min

Discussion Remaining Time

Customer Dr. Schrlau

Team Jacob Bertani

Bridget Lally

Avash Joshi

Nick Matson

Keith Slusser

Guide Bill Nowak

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

• Ultra-high precision positioning instrument

• Maneuver objects under high magnification, at the micro and nano scales

• Primary customer uses: • Cell behavior for medical

diagnostics

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

Controls Interface Subsystem

Controls Subsystem

Drive Subsystem

Manipulator Subsystem

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

# 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

# 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

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

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

40mm range ◦ translates to ~20mm range on manipulator

◦ 20mm > 10 mm

40mm

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

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.

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

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

Max rated pressure = 430 psi = 2.96MPa

Radial Expansion

Thermal Expansion

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

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

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

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

Clock Line 600 Hz Enable Signal 60Hz

TB6564AHQ Data Sheet

TB6564AHQ Data Sheet

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

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

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

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

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

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

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

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

# 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

# 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

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

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

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

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