Project
| # | Title | Team Members | TA | Documents | Sponsor |
|---|---|---|---|---|---|
| 5 | Four-axis vacuum stage for advanced nano-manufacturing |
Songyuan Lyu Xingjian Kang Yanghonghui Chen Yanjie Li |
design_document1.pdf final_paper1.pdf final_paper2.pdf proposal1.pdf |
Olesksiy Penkov | |
| Four-axis vacuum stage for advanced nano-manufacturing Request for Approval # Team Members - Songyuan Lyu [slv4] - Xingjian Kang [xk9] - Yanjie Li [yanjiel2] - Yanghonghui Chen [yc47] # Problem In recent years, nanocoating technology has been developed at a rapid speed. The advancements in this area include better surface performance, prolonged lifespan of materials,higher corrosion resistance. For example, the market of ceramic-based nanocoating is expected to boost at a CAGR of 7.6% from 2022 to 2032 and finally reach a value of US$ 21.82 billion. The market has earned 10.49 billion dollars. However, most PVD coating machine can only deal with 2D or 2.5D component, and they cannot solve the problem of coating complicated surfaces, which is very unfavorable for meeting the coating requirements of industries such as aerospace for complex components. When it involves coating for complicated and irregular objects, it creates some obstacles to create high quality coating films. For an instance, if the company plans to coat with an artifical tooth, they need to deposit films for multiple times and manually change the tooth posture to achieve comprehensive coating. However, this will not only reduce the uniformity of the coating and affect its lifetime. Also, it will increase the coating time. # Solution Overview We decided to build a 4 DOF robotic arm(4 aixs vacuum stage) that allows components to move freely within 3 demensional space and realize 3D magnetron sputtering.The traditional nanocoating tachnology applies magnetron sputtering PVD method to form thin films. Dealing with irregularly shaped specimens often leads to non-uniform coating membranes. The aim is to design and construct a robotic manipulator to address these issues. This device will control the specimen's posture, enhancing the coating films' uniformity and mechanical properties. # Solution Components ## Mechanical System - Aluminum Industrial Profile - Aluminium Castings - Belt ## Control System - STM32F407 MCU - ZDT Emm42_V5.0 stepper motor controller ## Actuator - stepper motors for moving (42*48, 0.6Nm; 28*30, 0.07Nm) - reduction gear for enlargeing the torque (1:10; 1:50) ## Interface - 7 inch TFT touch screen, seiral TTL protocol - USB port for computer accessing ## Communication protocal - RS485 between MCU and stepper controller ## Integration - Design PCB board to integrate power supply, microcontroller, stepper motor controller and wires in one single board # Criteria for Success - The actuator must move correctly in response to the controller's commands, to the right angle and position without losing steps. - The system work correctly in the Magnetron Sputtering Coating Machine, unaffected by strong magnetism and high heat vacuum environments. - Coating layer achieve uniformity error less than 20%. - The system can work for objects with different shapes and sizes. |
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