1. David Tshilumba
ESR3.3, WP3

2. 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:
SLAC:
Background /

3. 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

4. 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

5. 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

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

7. 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

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

9. 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< Stiffness amplification
Resolution improvement
David TSHILUMBA, ESR3.3
PACMAN Mid-term review 28-29/05/2015

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

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

17. 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

18. 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

19. 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

20. 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

21. 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

22. Outreach & Dissemination /
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 28-29/05/2015

23. 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

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

25. Thank you for your attention