David Tshilumba ESR3.3, WP3

MSc in Mechanical engineering from University of Brussels (André Jaumotte Award) Master thesis: “Contrôle des électro-aimamts finaux d’un collisionneur linéaire” Member of LSC (LIGO Scientific Collaboration) Main author of 1 article, Co-author of 2 articles published in refereed journals and 3 publications in conference proceedings LIGO: www.ligo.org SLAC: http://www.linearcollider.org/ILC Background /

ESR3.3, WP3 / Contract start date: 1st April 2014 PACMAN subject: Nano-Positioning of the main LINAC quadrupole as   means of laboratory pre-alignment PhD Institution: Delft University of Technology Secondment: Delft University + TNO (6M ) ESR3.3, WP3 / CERN Supervisors Kurt Artoos, Hélène MAINAUD DURAND, Michele MODENA Academic supervisors Prof. Just HERDER, Pr. Jo SPRONCK Industry supervisor Dr. Stefan KUIPER David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

To upgrade the existing type 1 prototype for nanopositioning and vibration isolation Cross check between different components To study the possibility to increase the range of the nanopositioning stage Project / Piezo stack actuator: Stiffness: 480 N/µm Stroke: 15 µm Resolution: 0.15 nm Flexural joints: Axial stiffness: 300 N/µm Rotational stiffness: 220 Nm/rad Objectives David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Dynamic force capacity Typical applications Atomic force microscopy Semiconductor test equipment Scanning interferometry State of the art Typical specifications Parameters Value Resolution 1nm Travel 1m up to 300m Stiffness ≤10N/μm Admissible payload ≤10kg Dynamic force capacity ≤100N David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

State of the art Performances: Range: 10mm x 10mm Parasitic in-plane rotation: ≤ 100rad Resolution: ≤4nm Low stiffness David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Research gap / Functions : Nanopositioning Vibration isolation Parameters Value Resolution <0.25nm Stroke ± 3mm step displacement 0.25 up to 50nm Roll angle < 100rad Speed 10μm/s Settling time t1->t2 5ms≤ts≤10ms Stiffness (vertical/lateral) 1/0.55 kN/μm Vertical force (dynamic) 50N Horizontal force (dynamic) 30N Research gap / Functions : Nanopositioning Vibration isolation Alignment Study of an integrated positioning system with high stiffness (>100N/m) capable of moving heavy loads (>100 kg) with high resolution (<1nm) over a large range (≥1mm) David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Place in PACMAN Project / David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Method followed Project / Range increase concept: inverted lever mechanism Possible monolithic design No friction No backlash No wear Avoid plastic deformation! Project / Method followed n<1 Stiffness amplification Resolution improvement David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Tasks description Project / State of the art PACMAN nano-positioning system Development of a long range actuator Project / System review and upgrade: Apr 15 Requirements definition: March 15 Design of concept 1DOF: Aug 15 Adaptation of the type 1 setup of the PACMAN bench: Aug 15 Performance characterization: Oct 15 Comparison of positioning strategies Tasks description Extrapolation to 2 DOFs: Sept 16 Positioning test in CMM David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / Parasitic resonance modes Unexpected eigen modes detected by EMA between 30Hz and 50Hz Suspect root cause: connection stiffness between components Bolting: up to 40% drop in eigen frequency Gluing: up to 8.5% drop in eigen frequency Project / Results Courtesy of M. Guinchard David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / 12 Parasitic resonance modes Further improvement: Monolithic base plate design Additional stiffeners Old plate (EMA) Upgraded plate (FEA) 30Hz 52Hz 45Hz 75Hz 114Hz Other root cause: variable contact on a supporting point modify interface with cam stage David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / 3 Torsion 1 Longitudinal + plate bend 1. 48.135 Hz 5 Rotation 2 side mode + bend 4 vertical + plate bend Results David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / 3 Torsion 1 Longitudinal mode 1. 91.6 Hz 2. 117.2 Hz 2 Side mode 4 vertical Results David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / Low modes caused by unsupported corner Putting the system on the ground will help a lot Rigidifying the plate will not help sufficiently when posed on three points on the alignment system Sideplates are very useful to increase the longitudinal stiffness thanks to their lower connection to the base plate through the longitudinal profiles on it =>logitudinal mode at 95Hz. Project / Results David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / Improvement: first lateral mode at 100Hz David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / Roll motion reduction: parallel kinematics Permissible roll displacement: 100μrad Aluminum eccentric shear pins 5.15μrad/μm coupling Alternative: rotational symmetry hinges 0.47μrad/μm coupling Features: Less components Tunable translational stiffness Design optimization required (Space availability) Project / Results David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Results Project / Roll motion reduction: parallel kinematics Permissible roll displacement: 100μrad Rotational symmetry hinges 0.47μrad/μm coupling Lost motion: 5% (vertical) High resonance frequencies Project / Results David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Network-wide activities Training in CATIA-SmartTeam Basic principles of metrology Experimental modal analysis ANSYS workbench advanced LABview Real-time Cern accelerator school Training / Network-wide activities David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Local training activities Secondment in Tudelft and TNO Training / Thesis background High performance mechatronic system design Modal analysis measurement on support structure of large mirror of a large telescope Local training activities David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Training / Transferable skills Making Presentations CERN guide training Effective article and report writing Project management Time management Negotiating effectively Transferable skills David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Outreach & Dissemination / Conferences & workshop: PACMAN workshop, 02-04.02.2015 one presentation MEDSI 2016 (Mechanical Engineering Design of Synchrotron Radiation Equipment and Instrumentation) ICM 2016 (International Conference on Mechatronics) ICMRE (International Conference on Mechatronics and Robotics Engineering) ICMMR (International Conference on Mechanics and Mechatronics Research) ICROM (International Conference on Robotics and Mechatronics ) Outreach & Dissemination / David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Networking Opportunities / ACTUATOR conference (May 2014) Precision Fair Eindhoven (November 2014) Secondment at TUDelft and TNO EUSPEN (European Society of Precision Engineering) David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Impact / Mechatronic system designer Modelling of complex mechanical assemblies Improve employability Networking David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015

Thank you for your attention