1. DBQ support – motorization and performance upgrade Mateusz Sosin EN/MEF-SU

2. Agenda Initial requirements Solution proposed R&D summary Perspectives of development Needs Future advantages

3. Initial requirements Needs vs. constraints Tight space constraints 14.5mm for „hexapod” platform integration Small distance to V-supports Small distance to cradle (rear DBQ) Instalation on the girder Needs +/- 1mm of stroke in X and Y µm resoultion of X-Y position adjustment Rotations adjustment within +/- 4 mrad ~20µrad resolution of angular adjustment

4. Solution proposed Modified Stewart platform configuration Conceptual design - May 2013

5. R&D summary Step 1: Validation of flexural parts and actuators FLEXURES AND REGULATION UNITS TEST ADAPTER Tests on the linear actuators test bench Additional adapters desighed to provide flexures and regulation units tests Flexures bending by transversal linear slide LabView acquisition software software for data logging written September 2013

6. Step 1: Validation of flexural parts and actuators R&D summary Results – vertical actuators 1µm regulation resolution easily achievable 0.1µm regulation resolution feasible in ~10s regulation time Repeatability ~5..7µm Linearity ~10µm Backlash ~15µm Results – radial actuators 3µm regulation resolution 1µm regulation resolution feasible (~10s regulation time) Repeatability ~15..20µm Non-Linearity ~10µm Backlash ~45µm Longitudinal flexure – patented wire spring September 2013

7. Step 2: Tests of prototype platform R&D summary Results – tests with ‚dummy’ DBQ (180kg) Long term stability of the support has been confirmed, with no drift or material creeping observed Resolution: 1µm vertical, below 4 µm radial Rotations resolution between 20-40 µrad No backlash Manual regulation to obtain adjustment with precision of 4µm, 20-40µrad is taking less than 10 minutes April 2014

8. Step 3: Final series for manual adjustment of CLEX DBQ R&D summary 2 platforms installed succesfully in CLEX Updates according to the prototype and procurement of platforms for CLEX Tolerances of components optimized Manual adjustment of platforms position and orientation Price of single platform ~5kEUR (Eastern Eurpe manufacturing) May-October 2014 October 2014

9. Perspectives of development Prototyping and preliminary series (1) Motorization of platform (2) Improve the regulation range and performance Design of motorized adapter + sensors system, allowing automatic adjustment MOT Change spcherical notch joints to universal, allowing shifts stroke change to +/- 2..3mm. Updates to improve precision (3) Cost optimization: to minimize the platform cost below 3 kEUR Replace platform with two DBQ-side mounting blocks Frame as welded structure with minimized machining cycles

10. Additional budget for development Needs (1) Platform motorization R&D - tests on the old prototype (25kCHF) Motorized adapter prototype (machanics) DAC and controls – NI cRIO/cDAQ + modules Needed platform modifications In case of motors and sensors radiation tests – additional budget needed (2) Improve regulation range and performance + (3) Optimization (25kCHF) New platform prototype (with welded supporting frame) Two versions of platform: Platform as a single piece (similar to current design) No platform, but two side blocks assembled to DBQ side surfaces EN/MEF-SU → 0.2 FTE

11. Additional budget for TBTM DBQ platforms tests Needs Costs depends on number of DB Quads supported by adjustable platform 4 platform estimated cost: 15..40kCHF (depends on optimization results and manufacturer) Mock-up tests of standard (platform) and side mounting block solution (2 + 2) In case of platforms equipped in permanent motorized modules - estimated cost of single positioning module is estimated to be lower than 10kCHF (including electronics)

12. Advantages of project Remote alignment of components in 5DOF with µm precison Small amount of components, minimized volume and reduced price/perormance ratio Easy acces to all regulation components in case of manual regulation version Predictable kinematics of support during regulation Project „know-how” will allow for easy design of same platform types for other, complex alignmemt applications Universal and cheap solution for future use