merlin epu support and drive system design review steve marks mark coleman 4/26/06
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Merlin EPU Support and Drive System Design Review
Steve Marks
Mark Coleman
4/26/06
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Scope of Review- Mechanical System
• Frame – Deflection
• Bearings and Mounts– Deflection– Load Rating
• Drive Screws – Load Rating
• Backing Beams
• Motor Torques
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Other Reviews
• Magnetic structure – 2/2/06
• Motor Control System – TBD?
• Sector 4 EPBI – TBD
• APRP– Scope– Installation Readiness
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EPU90 vs. EPU50
EPU50 (old) EPU90 (new)
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EPU90 vs. EPU50
EPU50 (old) EPU90 (new)
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What is New?
• 90mm Period (three previous EPUs are50mm)• Separate mounting of block/keepers
– Avoid correlated motion causing shift dependent skew quad• Modified backing beam
– Bearings closer to load– Horizontal drive closer to load– Steel backing beam
• Stiffer Frame– To accommodate ~ 2.3 vertical load
• Mount encoder directly to backing beams• Harmonic drive coupling on vertical screws for taper
adjustment• Modified gear ratio for horizontal drive
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EPU90
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EPU90
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EPU90
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EPU90
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Vertical Drive
• Drive Screws:– Max. load per screw = 17 kN– Static load rating = 107 kN (static), – Mean load ~ 10 kN– Dynamic load rating = 27 kN (dynamic)
• Linear Roller Bearings– Moment load = 2.7 kN-m– Rating = 7.2 kN-m
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Vertical Drive
• Torque/speed– Max torque = 1.2 N-m– Max speed = 1500 RPM
• Motor rating (with EPU50 motor)– Cont. Stall Torque = 3.9 N-m– Rated speed = 1500 RPM
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Deformation due to Vertical Load
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Vertical Drive
• Drive screw mounting is over constrained -affected by deflection of frame and bearing mounts.
• EPU90 vs. EPU50 Scaling Comparison:– Vertical columns:
• Vertical load: F90/F50 = 2.3• Frame column stiffness: I90/I50 = 6.5• Deflection: 90/ 50 = 0.35
– Duplex bearing mounts• Moment: M90/M50 = 1.9• Stiffness: I90/I50 = 2.0• Length: L90/L50 = 0.8• Deflection: 90/ 50 = 0.67
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Backing Beam Deflection
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Backing Beam / Horizontal Drive
Deflection Test Setup
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Backing Beam / Horizontal Drive
• Cross Roller Bearings:– Load per roller = 1.0 kN
– Bearing load rating = 3.9 kN
• Torque/Speed with 5/1 gear ratio (3/1 on EPU50):– Max. torque = 2.1 N-m
– Motor rating (using same motor as EPU50):• Cont. Stall Torque = 3.9 N-m
• Speed limit = 900 RPM vmax = 10 mm/sec (~10 secs. to switch polarization)
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Procurement/Fabrication Plan
• Proceed with procurement of drive screws (long lead – critical path on schedule)
• Initiate fabrication of backing beams, frame, etc.
• Proceed with control system procurement after control system discussion/review