MARS 2 Design Review-Optomechanical Review

MARS 2

Mechanical Design
Review

07 Nov 2002 GLW 1

 MARS 2 Design Review-Optomechanical Review

Topics
• Drive axes • Optical mounts
– Orientation, location, & – Manual adjustments
travel range of axes • Beam splitter
– Typical axis drive • Collimator
configuration • Lenslet/camera
– Axis loads, drives, • Knife edge
encoders, & bearings • CCAS mounting
• Current design status

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Drive Axes

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MARS 2 Remote Axes

Top to bottom

• Wavescope camera
• SenSys camera focus
• Focus (Z)
• X
• Yaw (rotation about an axis parallel to Y)
• Pitch (rotation about an axis parallel to X)
• Y’ (combined with Focus to get Y)

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Axis Travel Ranges

Required Axis Desired Limits,
Axis Range Range source Axis Travel Motor/Actuator Encoding Resolution Home 2X each
Remote operation
estimate based on
current system,
thermal calculations,
1 focus (z) +/- 25 mm and comments 50 mm IMS rotary/absolute 0.001 mm x x
estimate, thermal
2 y' (used w/focus to get y) +/- 25 mm calcs 50 mm IMS rotary/absolute 0.001 mm x x
3 x +/- 25 mm estimate/discussion 50 mm IMS rotary/absolute 0.001 mm x x
4 pitch (about x or x') +/- 2 deg estimate/discussion +/- 20 mm IMS rotary/absolute 1 mRad x x
5 yaw (about y) +/- 2 deg estimate/discussion +/- 16 mm IMS rotary/absolute 1 mRad x x
6 camera 50 mm M Wolf doc, Dec 2001 50 mm IMS rotary/absolute 0.001 mm x x
visual via camera,
7 knife edge voice coil range 0.30 in BEI switch x
8 knife edge position (in/out) stage range 1.00 in Bimba in/out switches x
9 HET shutter Bimba in/out switches x
10 reference mirror shutter Bimba in/out switches x
11 sensys camera focus estimate/discussion 1.0 in TS Products 0.001 mm x x

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MARS 2 Axes from Model

Camera
Focus

Yaw

Pitch

Y’
SenSys
X

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Common Axis Drive

Components

• For all BUT the SenSys axis

– Stepper motor
– Ball screw with preloaded drive nut
– Limit and home switches
– Encoder (absolute, rotary)
– Fail-safe brake (not on camera axis)
• SenSys camera axis
– TS Products motor with internal encoder

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Axis Drive Resolution

• Stepper motor
– 200 full steps per revolution
– 10 steps per full step
2,000 steps per revolution
• Lead Screw
– 2-mm per revolution lead screw
– With stepping results in 1 m per step resolution
• will need ~1/2 m per step for yaw and pitch resolution
• Absolute encoder
– Parallel interface
– Minimum encoder resolution of 2,000 counts per
revolution will count each step
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Axis Drive Loads

• Worst case is “uphill” motion
• Loads consist of:
– Inertia load
– Gravity component along axis
– Friction
• Encoder
• Bearings
• Drive screw
• Others

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Axis Loads
Load Torque
Axis [lbf] [oz-in]
Camera 5.4 6.9
Focus 182 42.9
X 14.1 3.3
Yaw 38.8 9.2
Pitch 38.8 9.2
Y’ 19.0 4.5

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Linear Axis Mounting

• THK preloaded rails & bearings
– Multiple rails with one block per rail
– Slides mounted perpendicular to travel on one side will
prevent binding due to misalignment & thermally
induced dimensional changes
• similar to bearing arrangement on the tracker carriage

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Yaw/Pitch Axis Mounting

• Yaw axis
– THK radial cross roller bearing for the pivot
– THK curved bearing rail for additional support
• similar to rho bearing on the carriage
• Pitch axis will use flex pivots for the pivot
• Yaw and Pitch axes will use flex pivots and small
slides to accommodate  (±2°) & L (~0.3 mm)
at the drive nut
L

Stage

Lead screw

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Optical Mounts
and Adjustments

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Optical Mounts

• Manual adjustments made with opposed

adjusting screws where possible
– Locks stage in position, does not rely on springs to
hold stage against adjustment screw
• Combination of flex pivots, pins, adjusting and
clamping screws for yaw/pitch adjustments
• X-Y-Z and X-Z cross roller stages for translation

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Manual Adjustments
Part 1
• Lenslet
– x, y, yaw, pitch: aligns lenslet to optical axis
• Lenslet/camera stage
– focus: positions lenslet/camera wrt collimator
• Collimator
– x, y, yaw, pitch: aligns collimator to optical axis
– focus: positions collimator wrt beam splitter cube
• Beam splitter cube
– x, y, focus, yaw, pitch: aligns cube to laser beam

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Manual Adjustments
Part 2
• Reference mirror
– x, y, yaw, pitch: aligns mirror to optical axis
– focus: positions mirror wrt HET focus
• SenSys camera
– x, y: positions camera wrt optical axis
• Light source
– x, y, focus: positions fiber wrt pin hole
• Knife edge
– focus: positions knife edge wrt beam splitter cube

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Isometric View of MARS2

Collimator Lenslet
Reference
Mirror

Beam splitter
Cube

Knife Edge

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Mounting in CCAS Tower

• Remove everything down to 12-inch I-beams
• Install stiffeners to forward cross beams
• Install a layer of dampening material (plywood)
• Install base plate
– Incorporates gross translation & tip/tilt adjustments
• Install base wedge with y’-axis
• Install pitch, yaw, & x-axis assembly
• Install assembled optical bench with focus axis
• Install electronics rack

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CCAS Components
Electronics
rack

Base plate

Dampening
material
12-inch
I-beam
members
Frame
stiffener
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Current Design Status

• Most purchased components are identified

• Final layout work & mounting details need to be
completed
• Drive configuration needs to be finalized
• Laser for component alignment needs to be
added
• Drawing generation is the next big task

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Unknowns

• Tolerance analysis
• Metal finishing-is it needed?

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Top View of MARS2

Light SenSys
Knife Edge
Source Camera

Camera Lenslet

Collimator Pellicle

Reference
Mirror Beam splitter
Cube

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Relative Axis Locations

Side View
Camera

Focus
Y
Yaw

X
Pitch

SenSys

Y’

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Axis Drive Loads

in pictures and equations
Fdrive + F = ma
a Fdrive-Ffr-W*cos() = m*a

and with m = W/gc

Ffr
Fdrive-Ffr-W*cos() = W*a/gc

rearranging
W cos()
W

Note that:
 = 35° >> cos(35°) = 0.82
gc = 386.4 in/sec2 >> for small a’s, cos() dominates
Fdrive = Ffr + W*[cos() + a/gc]
used a = 10 in/sec2 in calculations
Not all axes have a W cos() component
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Torque to Load
Ball screw with xx Drive coupling
lead (pitch)

Motor
Drive nut
produces torque
converts torque to force

Force * Lead
Torque =
2 * * 

 = efficiency of ball screw, ~ 0.85-0.90

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Axis Drive Specifics

• IMS stepper motor
– two sizes to cover six axes
– dual shaft
• Schneeberger ball screw
– 12-mm diameter for all but camera axis
• 3,400 N (770 lbf) static load  s. f. min = 4.2
• 2,500 N (565 lbf) dynamic load (L10)  s. f. min = 3.1
– preloaded drive nut
– special order for length and end configuration
• Absolute rotary encoder
– parallel output
– multi turn (25 turns needed)
– 4,096 steps per revolution
• 2 encoder steps/1 m
• 1 encoder step /0.5 m
• Electroid fail-safe brake
– engages with power off
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Beam Splitter Mount

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Collimator Mount

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Lenslet/Camera Mount

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Knife Edge Mount

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