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phd-thesis.org
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phd-thesis.org
@@ -13642,8 +13642,146 @@ The system performed exceptionally well during vertical scans, though some limit
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With the implementation of an accurate online metrology system, the NASS will be ready for integration into the beamline environment, significantly enhancing the capabilities of high-precision X-ray experimentation on the ID31 beamline.
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* TODO Conclusion and Future Work
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* Conclusion and Future Work
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<<chap:conclusion>>
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#+LATEX: \begingroup
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#+LATEX: \def\clearpage{\par}
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** Summary of Findings
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#+LATEX: \endgroup
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The primary objective of this research was to enhance the positioning accuracy of the ID31 micro-station by approximately two orders of magnitude, enabling full exploitation of the new $4^{\text{th}}$ generation light source, without compromising the system's mobility or its capacity to handle payloads up to $50\,\text{kg}$.
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To meet this demanding objective, the concept of a Nano Active Stabilization System (NASS) was proposed and developed.
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This system comprises an active stabilization platform positioned between the existing micro-station and the sample.
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Integrated with an external online metrology system and an custom control architecture, the NASS was designed to actively measure and compensate for positioning errors originating from various sources, including micro-station imperfections, thermal drift, and vibrations.
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The conceptual design phase rigorously evaluated the feasibility of the NASS concept.
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Through progressive modeling, from simplified uniaxial representations to complex multi-body dynamic simulations, key design insights were obtained.
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It was determined that an active platform with moderate stiffness offered an optimal compromise, decoupling the system from micro-station dynamics while mitigating gyroscopic effects from continuous rotation.
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The multi-body modeling approach, informed by experimental modal analysis of the micro-station, was essential for capturing the system's complex dynamics.
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The Stewart platform architecture was selected for the active stage, and its viability was confirmed through closed-loop simulations employing a High-Authority Control / Low-Authority Control (HAC-LAC) strategy.
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This strategy incorporated a modified form of Integral Force Feedback (IFF), adapted to provide robust active damping despite the platform rotation and varying payloads.
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These simulations demonstrated the NASS concept could meet the nanometer-level stability requirements under realistic operating conditions.
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Following the conceptual validation, the detailed design phase focused on translating the NASS concept into an optimized, physically realizable system.
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Geometric optimization studies refined the Stewart platform configuration.
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A hybrid modeling technique combining Finite Element Analysis (FEA) with multi-body dynamics simulation was applied and experimentally validated.
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This approach enabled detailed optimization of components, such as amplified piezoelectric actuators and flexible joints, while efficiently simulating the complete system dynamics.
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Work was also undertaken on the optimization of the control strategy for the active platform.
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Instrumentation selection (sensors, actuators, control hardware) was guided by dynamic error budgeting to ensure component noise levels met the overall nanometer-level performance target.
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The final phase of the project was dedicated to the experimental validation of the developed NASS.
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Component tests confirmed the performance of the selected actuators and flexible joints, validated their respective models.
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Dynamic testing of the assembled nano-hexapod on an isolated test bench provided essential experimental data that correlated well with the predictions of the multi-body model.
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The final validation was performed on the ID31 beamline, utilizing a short-stroke metrology system to assess performance under realistic experimental conditions.
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These tests demonstrated that the NASS, operating with the implemented HAC-LAC control architecture, successfully achieved the target positioning stability – maintaining residual errors below $30\,\text{nm RMS}$ laterally, $15\,\text{nm RMS}$ vertically, and $250\,\text{nrad RMS}$ in tilt – during various experiments, including tomography scans with significant payloads.
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Crucially, the system's robustness to variations in payload mass and operational modes was confirmed.
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** Perspectives
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Although this research successfully validated the NASS concept, it concurrently highlighted specific areas where the system could be enhanced, alongside related topics that merit further investigation.
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***** Automatic tuning of a multi-body model from an experimental modal analysis
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The manual tuning process employed to match the multi-body model dynamics with experimental measurements was found to be laborious.
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Systems like the micro-station can be conceptually modeled as interconnected solid bodies, springs, and dampers, with component inertia readily obtainable from CAD models.
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An interesting perspective is the development of methods for the automatic tuning of the multi-body model's stiffness matrix (representing the interconnecting spring stiffnesses) directly from experimental modal analysis data.
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Such a capability would enable the rapid generation of accurate dynamic models for existing end-stations, which could subsequently be utilized for detailed system analysis and simulation studies.
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***** Better addressing plant uncertainty coming from a change of payload
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For most high-performance mechatronic systems like lithography machines or atomic force microscopes, payloads inertia are often known and fixed, allowing controllers to be precisely optimized.
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However, synchrotron end-stations frequently handle samples with widely varying masses and inertias – ID31 being an extreme example, but many require nanometer positioning for samples from very light masses up to 5kg.
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The conventional strategy involves implementing controllers with relatively small bandwidth to accommodate various payloads.
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When controllers are optimized for a specific payload, changing payloads may destabilize the feedback loops that needs to be re-tuned.
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In this thesis, the HAC-IFF robust control approach was employed to maintain stability despite payload variations, though this resulted in relatively modest bandwidth.
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Therefore, a key objective for future work is to enhance the management of payload-induced plant uncertainty, aiming for improved performance without sacrificing robustness.
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Potential strategies to be explored include adaptive control (involving automatic plant identification and controller tuning after a change of payload) and robust control techniques such as $\mu\text{-synthesis}$ (allowing the controller to be synthesized while explicitly considering a specified range of payload masses).
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***** Control based on Complementary Filters
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The control architecture based on complementary filters (detailed in Section ref:sec:detail_control_cf) has been successfully implemented in several instruments at the ESRF.
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This approach has proven straightforward to implement and offers the valuable capability of modifying closed-loop behavior in real time, which proves advantageous for many applications.
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For instance, the controller can be optimized according to the scan type: constant velocity scans benefit from a $+2$ slope for the sensitivity transfer function, while ptychography may be better served by a $+1$ slope with slightly higher bandwidth to minimize point-to-point transition times.
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Nevertheless, a more rigorous analysis of this control architecture and its comparison with similar approaches documented in the literature is necessary to fully understand its capabilities and limitations.
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***** Sensor Fusion
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While the HAC-LAC approach demonstrated a simple and comprehensive methodology for controlling the NASS, sensor fusion represents an interesting alternative that is worth investigating.
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While the synthesis method developed for complementary filters facilitates their design (Section ref:sec:detail_control_sensor), their application specifically for sensor fusion within the NASS context was not examined in detail.
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One potential approach involves fusing external metrology (utilized at low frequencies) with force sensors (employed at high frequencies).
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This configuration could enhance robustness through the collocation of force sensors with actuators.
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The integration of encoder feedback into the control architecture could also be explored.
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***** Development of multi-DoF metrology systems
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Although experimental validation using the short-stroke metrology prototype was achieved, the NASS remains unsuitable for beamline applications due to the lack of a long stroke metrology system.
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Efforts were initiated during this project to develop such a metrology system, though these were not presented herein as the focus was directed toward the active platform, instrumentation, and controllers.
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The development process revealed that the metrology system constitutes a complex mechatronic system, which could benefit significantly from the design approach employed throughout this thesis.
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This challenge is particularly complex when continuous rotation is combined with long stroke movements.
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Yet, the development of such metrology systems is considered critical for future end-stations, especially for future tomography end stations where nano-meter accuracy is desired across larger strokes.
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Promising approaches have been presented in the literature.
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A ball lens retroreflector is used in [[cite:&schropp20_ptynam]], providing a $\approx 1\,\text{mm}^3$ measuring volume, but does not fully accommodate complete rotation.
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In [[cite:&geraldes23_sapot_carnaub_sirius_lnls]], an interesting metrology approach is presented, utilizing interferometers for long stroke/non-rotated movements and capacitive sensors for short stroke/rotated positioning.
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***** Alternative Architecture for the NASS
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The original micro-station design was driven by optimizing positioning accuracy, utilizing dedicated actuators for different DoFs (leading to simple kinematics and a stacked configuration), and maximizing stiffness.
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This design philosophy ensured that the micro-station would remain functional for micro-focusing applications even if the NASS project did not meet expectations.
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Analyzing the NASS as an complete system reveals that the positioning accuracy is primarily determined by the metrology system and the feedback control.
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Consequently, the underlying micro-station's own positioning accuracy has minimal influence on the final performances (it does however impact the required mobility of the active platform).
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Nevertheless, it remains crucial that the micro-station itself does not generate detrimental high-frequency vibrations, particularly during movements, as evidenced by issues previously encountered with stepper motors.
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Designing a future end-station with the understanding that a functional NASS will ensure final positioning accuracy could allow for a significantly simplified long-stroke stage architecture, perhaps chosen primarily to facilitate the integration of the online metrology.
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One possible configuration, illustrated in Figure ref:fig:conclusion_nass_architecture, would comprise a long-stroke Stewart platform providing the required mobility without generating high-frequency vibrations; a spindle that need not deliver exceptional performance but should be stiff and avoid inducing high-frequency vibrations (an air-bearing spindle might not be essential); and a short-stroke Stewart platform for correcting errors from the long-stroke stage and spindle.
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#+name: fig:conclusion_nass_architecture
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#+caption: Proposed alternative configuration for an end-station including the Nano Active Stabilization System
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#+attr_latex: :options [h!tbp]
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[[file:figs/conclusion_nass_architecture.png]]
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With this architecture, the online metrology could be divided into two systems, as proposed by [[cite:&geraldes23_sapot_carnaub_sirius_lnls]]: a long-stroke metrology system potentially using interferometers, and a short-stroke metrology system using capacitive sensors, as successfully demonstrated by [[cite:&villar18_nanop_esrf_id16a_nano_imagin_beaml]].
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***** Development of long stroke high performance stage
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As an alternative to the short-stroke/long-stroke architecture, the development of a high-performance long-stroke stage seems worth investigating.
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Stages based on voice coils, offering nano-positioning capabilities with $3\,mm$ stroke, have recently been reported in the literature [[cite:&schropp20_ptynam;&kelly22_delta_robot_long_travel_nano]].
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Magnetic levitation also emerges as a particularly interesting technology to be explored, especially for microscopy [[cite:&fahmy22_magnet_xy_theta_x;&heyman23_levcub]] and tomography [[cite:&dyck15_magnet_levit_six_degree_freed_rotar_table;&fahmy22_magnet_xy_theta_x]] end-stations.
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Two notable designs illustrating these capabilities are shown in Figure ref:fig:conclusion_maglev.
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Specifically, a compact 6DoF stage known as LevCube, providing a mobility of approximately $1\,\text{cm}^3$, is depicted in Figure ref:fig:conclusion_maglev_heyman23, while a 6DoF stage featuring infinite rotation, is shown in Figure ref:fig:conclusion_maglev_dyck15.
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However, implementations of such magnetic levitation stages on synchrotron beamlines have yet to be documented in the literature.
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#+name: fig:conclusion_maglev
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#+caption: Example of magnetic levitation stages. LevCube allowing for 6DoF control of the position with $\approx 1\,\text{cm}^3$ mobility (\subref{fig:conclusion_maglev_heyman23}). Magnetic levitation stage with infinite $R_z$ rotation mobility (\subref{fig:conclusion_maglev_dyck15})
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#+attr_latex: :options [htbp]
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#+begin_figure
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#+attr_latex: :caption \subcaption{\label{fig:conclusion_maglev_heyman23}LevCube with $\approx 1\,\text{cm}^3$ mobility \cite{heyman23_levcub}}
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#+attr_latex: :options {0.49\textwidth}
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#+begin_subfigure
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#+attr_latex: :width 0.9\linewidth
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[[file:figs/conclusion_maglev_heyman23.jpg]]
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#+end_subfigure
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#+attr_latex: :caption \subcaption{\label{fig:conclusion_maglev_dyck15}Stage with infinite $R_z$ rotation \cite{dyck15_magnet_levit_six_degree_freed_rotar_table}}
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#+attr_latex: :options {0.49\textwidth}
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#+begin_subfigure
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#+attr_latex: :width 0.9\linewidth
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[[file:figs/conclusion_maglev_dyck15.jpg]]
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#+end_subfigure
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#+end_figure
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***** Extending the design methodology to complete beamlines
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The application of dynamic error budgeting and the mechatronic design approach to an entire beamline represents an interesting direction for future work.
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During the early design phases of a beamline, performance metrics are typically expressed as integrated values (usually RMS values) rather than as functions of frequency.
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However, the frequency content of these performance metrics (such as beam stability, energy stability, and sample stability) is crucial, as factors like detector integration time can filter out high-frequency components.
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Therefore, adopting a design approach utilizing dynamic error budgets, cascading from overall beamline requirements down to individual component specifications, is considered a potentially valuable direction for future investigation.
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* Bibliography :ignore:
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#+latex: \printbibliography[heading=bibintoc,title={Bibliography}]
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