Multi-Scale System Design

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Multi-Scale System Design posted by member150_php on 2/17/2009

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Abstract/Syllabus

Courseware/Lectures

Test/Tutorials

Multi-Scale System Design

Fall 2004

A photograph of the macro-scale hexflex nanomanipulator device.

The Macro-Scale Hexflex Nanomanipulator is an example of a Multi-Scale System (MuSS) considered in this class. (Photo courtesy of Prof. Martin Culpepper.)

Course Highlights

This course features a complete set of lecture slides and extensive documentation on tools.

Course Description

Multi-scale systems (MuSS) consist of components from two or more length scales (nano, micro, meso, or macro-scales). In MuSS, the engineering modeling, design principles, and fabrication processes of the components are fundamentally different. The challenge is to make these components so they are conceptually and model-wise compatible with other-scale components with which they interface. This course covers the fundamental properties of scales, design theories, modeling methods and manufacturing issues which must be addressed in these systems. Examples of MuSS include precision instruments, nanomanipulators, fiber optics, micro/nano-photonics, nanorobotics, MEMS (piezoelectric driven manipulators and optics), X-Ray telescopes and carbon nano-tube assemblies. Students master the materials through problem sets and a project literature critique.

Syllabus

Course Goals

Macro, micro and nano-scale technologies rely on scale-specific performance models, design methods and fabrication processes which may be used to engineer machines within a limited range of size. The inherent incompatibility between engineering processes at different size scales leads to machines whose interactions with larger/smaller machines may be limited or impractical. This is troublesome as mechanical systems are often required to perform functions which are best achieved via combinations of different-scale machines. This course has been developed to teach students how to engineer multi-scale mechanical systems to ensure compatibility of macro, micro and nano-scale machines/components. This is a key to enabling broad utility of emerging nano and micro-scale machines in the "macro-scale world." Examples of MuSS include precision instruments, Nanomanipulators, fiber optics, Nanorobotics, MEMS, X-Ray telescopes and carbon nano-tube assemblies.

Term Project

Materials are studied and mastered via a project in which students design and fabricate a Scanning Tunneling Microscope (STM). A series of problem sets at the beginning of the term will lead students through key design decisions and modeling steps.

Tools

Students will receive a Tablet PC which contains the modeling, design and fabrication software required to complete the course project.

Paper Critique and Presentation

Students will read, critique and present findings on a paper which addresses MuSS research or covers important advances/implications for MuSS.

Grading

ACTIVITIES	PERCENTAGES
Assignments	35%
Project	35%
Participation	10%
Paper Critique	20%

Calendar

Title for Table Goes Here
SES #	TOPICS	SESSION CATEGORIES	INSTRUCTORS	KEY DATES
1	Introduction to MuSS and SPM Case Study Course Goals, Logistics and Expectations Comparison of MuSS and MoSS Fundamentals MuSS Example: Overview of SPM Technology	Fundamental Principles	Prof. Martin L. Culpepper	Assessment test
2	MuSS Design Fundamentals and Methods MuSS Design Fundamentals and Methods Design Principles and Systems Design MuSS Manufacturing Issues	Fundamental Principles	Prof. Sang-Gook Kim
3	Macro/Meso-scales Components and Characteristics Principles, Metrics and Types of Cross-scale Incompatibilities Incompatibilities of Macro/Meso Parts with Micro/Nano Parts Integrating Constraints on Macro/Meso-scale Parts	Fundamental Principles	Prof. Martin L. Culpepper
4	Micro-scale Components and Characteristics Principles of Macro/Meso-scale and Micro-scale Part Integration Incompatibilities of Micro Parts with Nano Parts Micro-scale Part Errors and Implications for Integration	Fundamental Principles	Prof. Martin L. Culpepper	Problem set 1 due
5	Nano-scale Components and Characteristics Principles of nm-scale Physics which govern Integration Incompatibility Nano-scale Actuators, Structures and Sensors Trasmissability of Nano-scale Errors to Other Scales	Fundamental Principles	Prof. Martin L. Culpepper
6	Scanning Probe Microscopy Project Introduction Project Goals and Expectations Demonstration of 2.76 SPM Questions, Team Selection and Planning	Case Study/Application	Soohyung Kim, Course TA	Problem set 2 due
7	Piezo MEMS: Materials Piezoelectricity Materials Processing	Fundamental Principles	Prof. Sang-Gook Kim	Problem set 3 due
8	Piezoelectric MEMS: Applications Piezoelectric Transducers Micro-actuators Sensors and Generators	Case Study/Application	Prof. Sang-Gook Kim
9	Optical MEMS Functionality Devices Materials	Fundamental Principles	Prof. Sang-Gook Kim
10	Nominal and Statistical Error Budgets Principles of Determinism, Accuracy, Repeatability Kinematic Error Modeling of Rigid-flexible Systems Nominal and Probabilitic System Error Modeling	Design and Manufacturing	Prof. Martin L. Culpepper	Literature critiques due
11	Presentations on Paper Critiques		Students	Problem set 4 due
12	Mechanical Interfaces for Cross-scale Alignment Principles of Mechanical Constraint Design of Rigid, Flexible and Rigid-flexible Constraint Manufacturing and Assembly of Cross-scale Interfaces	Design and Manufacturing	Prof. Martin L. Culpepper
13	Mechanisms for Inter-scale Motion Principles of Mass, Momentum and Energy Incompatibility Momentum Incompatibilities Energy Incompatibilities	Design and Manufacturing	Prof. Martin L. Culpepper	Problem set 5 due
14	Carbon Nanotubes Synthesis Properties and Applications Issues of Manufacturing	Design and Manufacturing	Prof. Sang-Gook Kim	Problem set 6 due
15	Complexity of MuSS Uncertainty and Difficulty Complexity Functional Periodicity	Design and Manufacturing	Prof. Sang-Gook Kim
16	Metrology System Requirements Components and Selection Process Metrology-Machine Integration	Design and Manufacturing	Guest Lecturer
17	Telescopes and the Oil Industry X-Ray Telescopes Oil-well MEMS Sensors Questions and Discussion	Case Study/Application	Guest Lecturer
18	Data Acquisition, Sensors and Control Programming in Simulink® Introduction to dSPACE Control System Demonstration of Acquisition and Control System	Design and Manufacturing	Guest Lecturer
19	Pre-amplifier Electronics Assemble Amplifier Interface with Data Acquisition and Controls Characterize and Optimize Signal-to-Noise Ratio	Integration and Assembly Lab	Staff
20	Probe and 3 Axis Flexure Stage Fabricate Probes and Characterize Geometry Fabricate and Assemble 3-axis Flexure Characterize Six-axis Stiffness and Parasitic Errors	Integration and Assembly Lab	Staff
21	Actuators Fabricate Actuation Flexure Mounts Characterize Flexure Mount Stiffness Characterize Actuator-flexure Errors, Range, Resolution	Integration and Assembly Lab	Staff
22	Metrology Integrate Metrology, Actuators and Stage Characterize/Compensate Errors, Resolution and Range Repeatability and Stability Characterization	Integration and Assembly Lab	Staff
23	Mapping Map and Navigate Test Maze I, II, III	Integration and Assembly Lab	Staff
24	Contest Contest Introduction, Round I, Round II	Demonstration Lab	Staff
25	Course Wrap up Course Wrap up and Awards Tau Beta Pi Evaluation Post-class Assessment			Assessment test

Readings

SES #	TOPICS	READINGS
1	Introduction to MuSS and SPM Case Study Course Goals, Logistics and Expectations Comparison of MuSS and MoSS Fundamentals MuSS Example: Overview of SPM Technology	Suh, Nam P. "Complexity Theory Based on Axiomatic Design." Chapter 3 in Complexity: Theory and Applications. New York: Oxford University Press, 2005. ISBN: 9780195178760.
3	Macro/Meso-scales Components and Characteristics Principles, Metrics and Types of Cross-scale Incompatibilities Incompatibilities of Macro/Meso Parts with Micro/Nano Parts Integrating Constraints on Macro/Meso-scale Parts	Hale, Layton C. "Principles and Techniques for Desiging Precision Machines." MIT PhD Thesis. 1999, pp. 67-82, and 174-204.
6	Scanning Probe Microscopy Project Introduction Project Goals and Expectations Demonstration of 2.76 SPM Questions, Team Selection and Planning	Pohl, Dieter W. "Some Design Criteria in Scanning Tunneling Microscopy." IBM Journal of Research and Development 30, no. 4 (July 1986): 417. Lewis, R. A., et al. "Student Scanning Tunneling Microscope." Am. J. Phys. 59, no. 1 (January 1991): 38. Binning, G., et al. "Surface Studies by Scanning Tunneling Microscopy." Physical Review Letters 49, no. 1 (5 July 1982): 57. Golovchenko, J. A. "The Tunneling Microscope: A New Look at the Atomic World." Science (New Series) 232, no. 48-53 (4 April 1986): 4746.
10	Nominal and Statistical Error Budgets Principles of Determinism, Accuracy, Repeatability Kinematic Error Modeling of Rigid-flexible Systems Nominal and Probabilitic System Error Modeling	Prepost, R. "Scanning Tunneling Microscope." Notes for Physics 407 Advanced Laboratory, University of Wisconsin, April 26 2000, pp. 1-14
12	Mechanical Interfaces for Cross-scale Alignment Principles of Mechanical Constraint Design of Rigid, Flexible and Rigid-flexible Constraint Manufacturing and Assembly of Cross-scale Interfaces	Hale, Layton C. Appendix C: Contact Mechanics, in "Principles and Techniques for Desiging Precision Machines." MIT PhD Thesis. 1999, pp. 417-426. Slocum, A. "Kinematic Couplings for Precision Fixturing - Part 1: Formulation of Design Parameters." Precision Engineering 10, no. 2 (April 1988): 86. Slocum, A. "Kinematic Couplings for Precision Fixturing - Part 2: Experimental Determination of Repeatability and Stiffness." Precision Engineering 10, no. 3 (July 1988): 115. Slocum, A. "Design of Three-groove Kinematic Couplings." Precision Engineering 14, no. 2 (April 1992): 67. Optional Readings Culpepper, M. L., et al. "Design of Integrated Eccentric Mechanisms and Exact Constraint Fixtures for Micron-level Repeatability and Accuracy." Paper accepted for publication in Precision Engineering. Mangudi, K., and M. L. Culpepper. "Active, Compliant Fixtures for Nanomanufacturing." 2004 Annual Meeting of the American Society for Precision Engineering, Orlando, FL., October 2004, pp. 113 -116. Slocum, et al. "Flexural Mount Kinematic Couplings and Method." U. S. Patent 5, 678, 944. Granted October 21, 1997. Culpepper, M. L., et al. "Quasi-kinematic Couplings for Low-cost Precision Alignment of High-volume Assemblies." Transactions of the ASME 126 (May 2004): 456-463. Culpepper, M. L. "Design of Quasi-kinematic Couplings." Precision Engineering 28 (2004): 338–357.