Midterm Review 28-29/05/2015 David Tshilumba ESR3.3, WP3

Background /  MSc in Mechanical engineering from University of Brussels (André Jaumotte Award)  Master thesis: “Contrôle des électro-aimants 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:  SLAC: 2

ESR3.3, WP3 /  Contract start date: 1 st 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 ) David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015 CERN SupervisorsKurt ARTOOS, Hélène MAINAUD DURAND Academic supervisorsProf. Just HERDER, Prof. Jo SPRONCK Industry supervisorDr. Stefan KUIPER 3

PhD thesis/  Starting date: 1 st April 2014  Thesis title: Nano-Positioning of the main LINAC quadrupole as means of laboratory pre-alignment  Statuts: Admitted to the doctoral school (Go/No Go meeting)  Credits: 45 GS credits are required; 12.5 GS credits acquired. David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015 4

Project /  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 Objectives 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 David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015 5

State of the art Typical applications Atomic force microscopy Semiconductor test equipment Scanning interferometry ParametersValue Resolution  1nm Travel 1  m up to 300  m Stiffness≤10N/μm Admissible payload≤10kg Dynamic force capacity ≤100N Typical specifications David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015 6

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 Courtesy of S.Awtar, G. Parmar 7

Research gap / 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 ParametersValue Resolution<0.25nm Stroke± 3mm step displacement0.25 up to 50nm Roll angle < 100  rad Speed10μm/s Settling time t1->t25ms≤ts≤10ms Stiffness (vertical/lateral) 1/0.55 kN/μm Vertical force (dynamic) 50N Horizontal force (dynamic) 30N Functions : Nanopositioning Vibration isolation Alignment 8

Project / Range increase concept Possible monolithic design No friction No backlash No wear Avoid plastic deformation! n<1 Stiffness amplification Resolution improvement David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015 Range increase concept: inverted lever mechanism 9

Project / Method followed David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/ Analytic simplified model (Matlab) 3D CAD modelling (CATIA-Smart Team) Static and dynamic Finite Element simulations (ANSYS) Finite Element simulation results + Full dynamic model Positioning control algorithms Experimental validation of positioning performances

Project / Tasks description Development of a long range actuator Requirements definition: March 15 Design of concept 1DOF: Aug 15 Performance characterization: Oct 15 Extrapolation to 2 DOFs: Sept 16 System review and upgrade: Apr 15 Positioning strategies comparison Positioning test in CMM David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015 State of the art Adaptation of the type 1 setup of the PACMAN bench: Aug 15 PACMAN nano-positioning system 11

Project / Results Parasitic resonance modes Design target: 1st resonance ≥100Hz 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 Courtesy of M. Guinchard David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/

Project / Results Parasitic resonance modes Further improvement: Monolithic base plate design Additional stiffeners Old plate (EMA) Upgraded plate (FEA) 30Hz52Hz 45Hz75Hz 52Hz114Hz 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/

Project / Results Hz Hz Hz Hz Hz Hz 2 side mode + bend 1 Longitudinal + plate bend 3 Torsion David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/ Adjustable jack for system equilibrium Optimized finite element model (  1 hour) Bending of baseplate Lowest modes lateral and vertical components issue

Project / Results 1 Longitudinal mode 2 Side mode 3 Torsion Hz Hz Hz Hz Hz Hz David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/2015 Larger flat contact surface with ground Base plate reinforcement (longitudinal) Lowest mode in longitudinal direction Not an issue 15

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

Project / Results 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) David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/

Training / Training in CATIA-SmartTeam Basic principles of metrology Experimental modal analysis Making Presentations CERN guide training Team building David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/

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 David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/

Conferences & workshop: PACMAN workshop, 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/

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/

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

Midterm Review 28-29/05/2015 Thank you for your attention

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

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/

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

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

Current system overview / David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/ Coarse stage (cams) locked after pre-alignment Resolution : 0.35µm Stroke: 3mm Fine stage (piezo stacks) Resolution: 0.15nm Stiffness : 480N/um (piezo) Useful Stroke: 5µm Limitations: precision of coarse stage (>10µm) insufficient stroke of fine stage for thermal load in tunnel ( >100µm) Increase of range of fine stage

Field gradients K for restoring force in quadrupole K=dBy/dx K=dBx/dy Beam trajectory technique Lorentz Force Control of beam oscillation Collision quality optimized CLIC: N ANO - POSITIONING Courtesy of J. Pfingstner D. Tshilumba, Delft, 15 April 2015 Beam steering /

Nanopositioning / David TSHILUMBA, ESR3.3 PACMAN Mid-term review 28-29/05/ Type 1 magnet nano-positioning: Inter-pulse sequence 1234 Stage Time (ms) 0 t1 t2 20 Beam divided into trains Calculation of new positions by global controller Positioning step of magnet check of actual new position (machine protection)