SUCCESS STORY – Positioning Loads Accurately to the Micrometer-- Birgit Schulze --Positioning Loads Accurately to the Micrometer
Hexapod at PETRA III

Physik Instrumente (PI) GmbH & Co. KG, Auf der Roemerstrasse 1, 76228 Karlsruhe, Germany
Phone +49 721 4846-0, Fax +49 721 4846-1019, Email info@pi.ws, www.pi.ws

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SUCCESS STORY – Positioning Loads Accurately to the Micrometer-- Birgit Schulze --Since 2010, PETRA III (Fig. 1) is the most brilliant storage-ringbased X-ray light source in the world and it providesinternational scientists with excellent experimentation
facilities. In particular, this benefits researchers investigating
very small samples or those requiring tightly collimated andvery short-wavelength X-rays for their experiments.
The high-energy radiation of up to and above 100,000
electron volts with high light intensity offers versatilecapabilities, for example in the broad field of materials
research for the inspection of welded seams, or for theexamination of fatigue symptoms in workpieces. In somecases, this involves accurately positioning really heavy loads
down to the micrometer. At the heart of the P07 beamline,
which delivers the high-energy X-ray radiation required formaterials research, is therefore a heavy-duty Hexapod.
Thanks to its accuracy, it facilitates in-situ measurements ofmaterial properties under realistic process conditions.

Fig. 1

In addition, the moved mass is lower, enabling better
dynamic performance, which is the same for all motion axes.
Moreover, cable management is no longer an issue, because
cables are not moved, and, last but not least, the system
features a much more compact design. Positioning takes
place with up to six degrees of freedom: Three linear andthree rotational motion axes. Depending on the geometry of
the Hexapod, rotations from a few degrees up to 60° andtranslations of a few millimeters to several centimeters are
possible.
The repeatability and minimum incremental motion achieves
values of below one micrometer. Due to the low mass of themoving platform, Hexapods have considerably shorter settling
times than conventional, stacked multi-axis systems. These
characteristics can be used in a wide range of applications.
Applications range from mechanical engineering and robotics
to medical technology, and, in particular, materials researchwith PETRA-III X-ray radiation which is more powerful andmore tightly collimated than the radiation of any otherstorage-ring-based system in the world. With 14 beamlines
and 30 experimental stations, the system therefore provides
optimum research capabilities.

PETRA III offers scientists from around the world superlative
experimentation facilities. In particular, this benefits researchersinvestigating very small samples or those requiring tightly
collimated and very short-wavelength X-rays for theirexperiments, e.g. in the field of materials research (image:DESY/Reimo Schaaf)

Hexapods are parallel kinematic positioning systems (Fig. 2),
now available in many versions with actuation travel lengthsof up to a few hundred millimeters. With micrometer
precision, they can position loads weighing from a few
kilograms to a few hundred kilograms, or even several tons.
They can also do this in any spatial orientation, i.e.
independently of the direction of installation. Theiradvantages compared with serial, i.e. stacked systems, arethat they have much better path accuracy, repeatability andflatness.

Fig. 2

Physik Instrumente (PI) GmbH & Co. KG, Auf der Roemerstrasse 1, 76228 Karlsruhe, Germany
Phone +49 721 4846-0, Fax +49 721 4846-1019, Email info@pi.ws, www.pi.ws

Basic design: In parallel-kinematic systems, all actuators act
directly on the same platform (image: PI)

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SUCCESS STORY – Positioning Loads Accurately to the Micrometer-- Birgit Schulze --Short-Wave X-Ray Radiation forMaterials Research
The X-rays generated are up to 5000 times finer than human
hair, enabling very tiny samples to be examined, e.g. minutecrystals from proteins or nano-crystals for the storage mediaof the future. Furthermore, PETRA III also provides very
'hard', i.e., short-wave X-ray radiation that penetrates very
deeply into the material and thus is also capable of passing
through material of greater thickness.
This enables welded seams to be inspected and fatigue
symptoms in workpieces to be measured as an aid toquantifying the anticipated durability and service lives, or toanalyze new metal alloys. Here effects can be proven down tothe level of domain or crystal structures.
The opportunities that proceed from this in respect ofmaterials research are leveraged by Helmholtz-Zentrum
Geesthacht (HZG), for example when conducting in-situ
measurements of the material properties that occur duringreshaping processes such as welding, pressing, rolling orstamping.
The application of a mechanical load causes tensile andelongation stresses to occur inside the material. The
investigation involving X-ray radiation then indicates thechronological sequence of effects occurring within a material
at a crystalline level in micrometer-sized domain areas (Fig. 3and Fig. 4.

Fig. 3Fig. 4The stress values are measured comparatively at thecorresponding location of the metal chip against the processparameters employed and applied in a simulated manner.
Details of the microstructural characterization itself, and of themodeling improvements required, can be obtained from theoriginal publications: [1] K. Brömmelhoff et al., Space resolved
microstructural characteristics in the chip formation zone oforthogonally cut C45E steel samples characterized by diffraction
experiments, Journal of Materials Processing Technology 213(2013) 2211-2216 und [2] E. Uhlmann et al., An extended shear
angle model derived from in-situ strain measurements duringorthogonal cutting, Production Engineering: Research andDevelopment 7 (2013) 401-408

The microstructure of C45E steel were investigated duringmachining (chip-cutting) operations. For this, a cutting edge waspressed against the workpiece with a 100 kN press (Instron8800) mounted on the Hexapod (image: PI/HZG)

Physik Instrumente (PI) GmbH & Co. KG, Auf der Roemerstrasse 1, 76228 Karlsruhe, Germany
Phone +49 721 4846-0, Fax +49 721 4846-1019, Email info@pi.ws, www.pi.ws

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SUCCESS STORY – Positioning Loads Accurately to the Micrometer-- Birgit Schulze --Powerful Positioning System for
the Experimentation Chamber
At the heart of the described experimentation chamber is anHexapod, developed by Physik Instrumente (PI) (Fig. 5).
Fig. 6Dr. Norbert Schell, the scientist responsible for the HEMS
beamline: "Only the in-situ investigations enabled the discoveryof 'transient' phases, i.e. of states that only occur within theprocess for a transitory period. Simply investigating the startingand finished products leaves far too much to the imagination tofacilitate any true understanding." (image: PI / HZG)

The parallel-kinematic custom model, the M-850K (Fig. 7),
delivers micrometer-precision positioning for loads of up to
one ton in every orientation. It stands approx. 700 mm highand has a diameter of 800 mm (top platform with largeaperture) and/or 900 mm (bottom). The lower platform is
installed on a 360° rotation table and the cabling was
designed to be dragchain compatible.

Fig. 5The parallel-kinematic custom model, the M-850K, delivers
positioning down to the micrometer for loads of up to one ton in
every orientation (image: PI)

Dr. Norbert Schell (Fig. 6), the scientist in charge of the HEMS
Beamline, illustrates the context: "For an increasingly large
range of in-situ investigations of 'real' processes, that isprocesses that actually occur in industry (but of course notonly there) – associated with the cutting of workpieces, thecoating of surfaces for the hardening or improvement oftribological properties, reshaping, welding, heat treatment aswell as combinations of these techniques – it is our ultra-rigid
Hexapod with its tremendous load-bearing capability andmicrometer precision positioning that makes it possible forthe first time for us to conduct scientifically rigorous
examinations of the structural changes that occur at an
atomic level.
This is highly interesting, and is also important in helping us tounderstand the processes that are occurring and that,ultimately, enable customized materials to be optimized."

Fig. 7

Hexapod in the experimentation station EH3 on the P07 beam
guidance unit on PETRA III: With its high load capacity, it can
carry the entire measuring setup including the structure wheremechanical forces are applied – in this figure a chamber for thelaser-welding of titanium aluminides (image: PI / HZG)

With its high load capacity of up to one ton, the Hexapod cancarry the entire measurement setup including the equipment
where mechanical forces are applied.
The Hexapod positions even these large masses overdistances of 400 mm to a precision of ±1 micron, andperforms rotational motions of ±20° with a resolution to0.5 µrad.

Physik Instrumente (PI) GmbH & Co. KG, Auf der Roemerstrasse 1, 76228 Karlsruhe, Germany
Phone +49 721 4846-0, Fax +49 721 4846-1019, Email info@pi.ws, www.pi.ws

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SUCCESS STORY – Positioning Loads Accurately to the Micrometer-- Birgit Schulze --Inside the experimental hutch, this enables complete engine
blocks, turbine components, sinter furnaces and cryogenic
chambers as well as welding fixtures or other machining units
to be aligned precisely for the planned investigations and tobe moved accordingly during the analysis. Despite the highforces, the position reached is held in a stable manner; thebrushless DC motors integrated in the Hexapod struts areequipped with brakes.

Comfortable Motion Control
For adequate motion control of the Hexapod system, theHexapod controller communicates with the primary controller
used in the experimental setup. Positions are commanded in
Cartesian coordinates, while all kinematic transformations tothe single drives are effected by the controller. Virtually any
desired point in space can be set as center of rotation via
software commands. This freely definable pivot point ismaintained independently of the motion, thus allowing themotion of the Hexapod platform to be tuned precisely to eachpositioning task.
Similar properties are applicable to many other areas ofapplication. There are in fact many different variants of theHexapod design, and they can be equipped with different
drive concepts. Depending on the application requirements,
they are driven by high-precision drive screws and precisely
controlled DC motors or directly by linear motors, e.g. basedon piezo-ceramic actuators. They have now proven theircapabilities in a diverse range of sectors, starting withmechanical engineering and tool machining, extending tosemi-conductor production, astronomy, biotechnology or lifesciences.

About P07 / HEMS
P07 or HEMS (High Energy Materials Science Beamline) is oneof the first operational lines on the PETRA III light source.
Since 2010, P07 facilitates diffraction and imaging
experiments such as tomography in the high-energy X-ray
range of 30 to 200 keV. In-house and development activities
are shared by DESY and Helmholtz-Zentrum Geesthacht(HZG).
HZG has specialized here in materials research associatedwith engineering science, with two experimentation stations(EH3 and EH4), while DESY has been in charge of one
experimentation station (EH2) that deals with the 'more
general' field of high-energy scattering experiments.

All of this scientific work comprises basic research into
metallurgy, physics, chemistry and biology, disciplines thatare converging to an ever greater extent.
Previous research work tackled the interaction of themacroscopic and microstructural properties of polycrystalline
materials,
grain-grainreciprocalinteractions,
thedevelopment of new and 'intelligent' materials or process
technologies and in-situ catalysis. The experimental
equipment makes it possible to investigate all types ofmaterials to high standards of precision and stability and low
substrate, including surfaces, buried layers, single-crystals,
powders or amorphous solids as well as fluids.
The applied research into the optimization of manufacturing
and reshaping processes on P07 benefits in particular fromthe high level of photon flux in combination with the highspeed 2D detectors that enable complex and dynamic in-situ
studies to be conducted into the transformation changes tomicrostructure that occur during processes such as welding,cutting or heat treatment.
The infrastructure enables large and heavy sample
environments to be created, as well as process chambers,
also for external users. The heavy-duty Hexapod has a majorrole to play here.

About Helmholtz-Zentrum
Geesthacht – Center for Materials
and Coastal Research
The Helmholtz-Zentrum Geesthacht – Center for Materials
and Coastal Research – is part of the Helmholtz Association ofGerman Research Centers, the largest German Scientific
Organization, in charge of the development and operation ofGerman and international large-scale research installations.
This interdisciplinary research center was established in 1956.
Until October 2010, it operated under the name of GKSSForschungszentrum Geesthacht GmbH.
The research and development work at the HelmholtzZentrum Geesthacht is organized in the research divisions ofthe Helmholtz Association in different programs, one of which
is materials research. Synchrotron radiation and neutrons
allow researchers to carry out non-destructive investigations
on materials and biological systems and to produce threedimensional images in high quality.
To this end, the Helmholtz-Zentrum Geesthacht operates test
installations both at DESY in Hamburg at the PETRA III storage
ring and at the FRM-II research reactor in Garching nearMunich.

Physik Instrumente (PI) GmbH & Co. KG, Auf der Roemerstrasse 1, 76228 Karlsruhe, Germany
Phone +49 721 4846-0, Fax +49 721 4846-1019, Email info@pi.ws, www.pi.ws

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SUCCESS STORY – Positioning Loads Accurately to the Micrometer-- Birgit Schulze --Author

Dipl.-Phys. Birgit Schulze, Market & Products at PI (PhysikInstrumente)

About PI
In the past four decades, PI (Physik Instrumente) with
headquarters in Karlsruhe, Germany has become the leading
manufacturer of nanopositioning systems with accuracies in
the nanometer range. With four company sites in Germanyand fifteen sales and service offices abroad, the privately
managed company operates globally. Over 850 highly
qualified employees around the world enable the PI Group to
meet almost any requirement in the field of innovative
precision positioning technology. All key technologies aredeveloped in-house. This allows the company to control every
step of the process, from design right down to shipment:
precision mechanics and electronics as well as positionsensors.
The required piezoceramic elements are manufactured by its
subsidiary PI Ceramic in Lederhose, Germany, one of the
global leaders for piezo actuator and sensor products.
PI miCos GmbH in Eschbach near Freiburg, Germany, is a
specialist for positioning systems for ultrahigh vacuum
applications as well as parallel-kinematic positioning systems
with six degrees of freedom and custom-made designs.

Physik Instrumente (PI) GmbH & Co. KG, Auf der Roemerstrasse 1, 76228 Karlsruhe, Germany
Phone +49 721 4846-0, Fax +49 721 4846-1019, Email info@pi.ws, www.pi.ws

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