Stephen J. Furst

Practical Implementation of Resistance Feedback Measurement for Position Control of a Flexible Smart Inhaler Nozzle

Many “smart materials” have the capacity to be used simultaneously as both an actuator and sensor. For example, SMA actuator wires can be heated by Joule heating to induce contraction; at the same time, the resistance across the SMA wire can be measured to give the user some indication of the strain in the wire. This multi-functional capability enables the design of applications requiring extremely light-weight and streamlined embedded sensors and actuators. One such “smart structure” application is the flexible nozzle used in the Smart Inhaler system under development at North Carolina State University. The Smart Inhaler allows a doctor to control the locations within the pulmonary system that are medicated by controlling the location at which medication is injected into an inhaled airflow. This can reduce the amount of healthy tissue that is exposed to potentially toxic medications, such as those used to treat lung cancer. However, the practical challenge of injecting medication into a flow without disturbing the flow requires a highly controllable yet non-obstructive nozzle. This paper presents a scheme that correlates the resistance measurement across an SMA actuator wire to the wire strain and the resulting deformation of the flexible nozzle. The relationship between resistance and nozzle deformation is nonlinear and hysteretic; however, the repeatability of the relationship allows the user to calibrate the feedback measurement. This enables the wire to be used as both position sensor and positioning actuator. The results represent the first experiments that exploit the multi-functional capabilities of SMA wires in the context of a practical embedded sensor and actuator application.Copyright

Development, assembly, and validation of an SMA-actuated two-joint nozzle and six-channel power supply for use in a smart inhaler system

The Smart Inhaler design concept recently developed at NC State University has the potential to target the delivery of inhaled aerosol medication to specified locations within the lung system. This targeted delivery could help patients with pulmonary ailments by reducing the exposure of healthy lung tissue to potentially harmful medications. However, controlled delivery can only be accomplished if medication is injected at a precise location in an inhaled stream of properly conditioned laminar flow. In particular, the medication must be injected into the inhaled flow using a small nozzle that can be positioned without disturbing the flow. This paper outlines the procedure used to assemble and control a key component of the smart inhaler: a shape memory alloy (SMA) based dual-joint flexible nozzle that exploits the sensing and actuating capabilities of thermally activated SMA wires. A novel 6-channel power-supply is used to control input power and measure the resistance across the SMA. Since a practical fabrication process may result in SMA wires with different contact resistances, the power supply employs an initialization procedure to self-calibrate and provide normalized power distribution 6 SMA wires simultaneously. Furthermore, a robust control scheme is used to ensure that a constant current is provided to the wires. In validation tests, a LabVIEW-based video positioning system was used to measure the deflection of the nozzle tip and joint rotation. Results show that the carefully controlled assembly of a stream-lined nozzle can produce a practical smart structure, and joint rotation is predictable and repeatable when power input is also controlled. Future work will assess the use of the SMA-resistance measurement as position feedback and PID position control power as a measurement of the convective cooling that results from the moving airflow.

Automated Part Centering With Impulse Actuation

Centering a part on a spindle for precision machining is a tedious, time-consuming task. Currently, a skilled operator must measure the run-out of a part using a displacement gauge, then tap the part into place using a plastic or rubber hammer. This paper describes a method to automatically center a part on a vacuum chuck with initial run-out as large as 2.5 mm. The method involves measuring the magnitude and direction of the radial run-out and then actuating the part until the part and spindle centerlines are within 5 μm of each other. The run-out can be measured with either a touch probe mounted to a machine axis or an electronic gauge. The part is tapped into place with a linear actuator driven by a voice coil motor This paper includes an analysis of run-out measurement uncertainty as well as the design, performance modeling, and testing of the alignment actuator. This actuator was employed for part realignment and successfully positioned a hemispherical part with an initial run-out of 1-2.5 mm to within 5 μm of the spindle centerline. This capability shows that the run-out of a part manually placed on flat vacuum chuck can be automatically corrected.

Electro-mechanical behavior of a shape memory alloy actuator

This paper presents experimental study and numerical simulation of the electro-thermo-mechanical behavior of a commercially available Flexinol shape memory alloy (SMA) wire [1]. Recently, a novel driver device has been presented [2], which simultaneously controls electric power and measures resistance of an SMA wire actuator. This application of a single wire as both actuator and sensor will fully exploit the multifunctional nature of SMA materials and minimize system complexity by avoiding extra sensors. Though the subject is not new [3-6], comprehensive resistance data under controlled conditions for time-resolved and hysteresis-based experiments is not readily available from the literature. A simple experimental setup consisting of a Flexinol wire mounted in series with the tip of a compliant cantilever beam is used to systematically study the SMA behavior. A Labview-based data acquisition system measures actuator displacement and SMA wire stress and resistance and controls the power passed through the SMA actuator wire. The experimental setup is carefully insulated from ambient conditions, as the thermal response of a 50-micron diameter Flexinol wire is extremely sensitive to temperature fluctuation due to convective heat transfer. Actuator performance is reported for a range of actuation frequencies and input power levels. The effect of varying actuator pre-stress is reported as well. All of the experimental data is compared with simulated behavior that is derived from a numerical model for SMA material [7-10].

Direct analysis of textile dyes from trace fibers by automated microfluidics extraction system coupled with Q-TOF mass spectrometer for forensic applications

Textile fiber is a common form of transferable trace evidence at the crime scene. Different techniques such as microscopy or spectroscopy are currently being used for trace fiber analysis. Dye characterization in trace fiber adds an important molecular specificity during the analysis. In this study, we performed a direct trace fiber analysis method via dye characterization by a novel automated microfluidics device (MFD) dye extraction system coupled with a quadrupole-time-of-flight (Q-TOF) mass spectrometer (MS). The MFD system used an in-house made automated procedure which requires only 10μL of organic solvent for the extraction. The total extraction and identification time by the system is under 12min. A variety of sulfonated azo and anthraquinone dyes were analyzed from ∼1mm length nylon fiber samples. This methodology successfully characterized multiple dyes (≥3 dyes) from a single fiber thread. Additionally, it was possible to do dye characterization from single fibers with a diameter of ∼10μm. The MFD-MS system was used for elemental composition and isotopic distribution analysis where MFD-MS/MS was used for structural characterization of dyes on fibers.

Design and validation of the mounting structure for BETTII balloon-based telescope with thin-walled optics

Abstract. The NASA Balloon Experimental Twin Telescope for Infrared Interferometry (BETTII) system is designed to study the infrared emissions from star formation and active galactic nuclei through a double-Fourier Michelson interferometer located on a balloon at an altitude of 37 km. The BETTII external optics include a pair of identical beam-reducing, four-mirror telescopes, each with a 522-mm aperture, nonrotationally symmetric primary mirror. These telescopes were designed and assembled at the North Carolina State University Precision Engineering Consortium and are composed entirely of thin-walled aluminum components. The mounting structure is designed to be light weight and stiff to reduce thermal equilibration time in the rarified air at the edge of space and to maintain robust alignment of the optical elements. The mounts also prevent deformation of the large optical elements via custom-built kinematic Kelvin couplings and fixed-load clamps; the maximum form error of the optical surfaces are 300 nm RMS. This work details the design of the thin mirrors and mounting structure as well as validation of the mount assembly process, mount stiffness, and the kinematic couplings.

Quantification of the Effectiveness of Various Adhesives in Holding an SMA Actuator Wire During Joule Heating

Shape memory alloy (SMA) actuator wires undergo a large contraction (∼4%) and resistance change (∼7%) in response to a material phase change induced by heating. However, a major impediment to using SMA wires as embedded actuators or sensors in practical applications is the challenge of attaching the small wires to the surrounding structure without adding significant bulk to the system. This work systematically determines the bond strength of different adhesives that could be used to attach small (<100-µm diameter) SMA wires to a structure by exposing the adhesive bond to the thermal and mechanical loading expected during typical embedded SMA applications. Results show that for all adhesives tested, bonding strength is reduced as heating current is increased; however, some two-part epoxies and contact adhesives are still able to maintain 6 MPa of bonding strength to a heated SMA wire. This number can be used to determine how much adhesive is needed to hold different diameter wires for a range of applications.

Characterization and Modeling of Opposing SMA-Wire System for Multifunctional, Resistance-Based Controls Applications

Shape Memory Alloy (SMA) actuator wires are often discussed in the context of multi-functional materials. This is because the temperature-induced phase transformation causes a significant (∼4%) contraction and a corresponding change in resistance. When a restoring force such as a pre-stretched spring is placed in series with an SMA wire, the contraction creates a repeatable actuation force, and the resistance provides measurement of the strain the wire, or structural (spring) deflection. Work has already been presented to demonstrate the stress, strain, and resistance characteristics of a single SMA actuator wire in series with a spring flexure under different pre-stresses and heating power input frequencies. Also, a method has been presented to linearly approximate the resistance vs strain characteristic, thus providing a direct mapping from SMA wire resistance to flexure deflection. This mapping method has been tested in the context of a simple PID controller used to position a flexure in series with a single SMA. This paper expands previous work by characterizing a system consisting of a spring flexure in series with two opposing SMA wires. Such an opposing SMA configuration is relevant to embedded SMA applications and gives the potential to increase cycling frequency by providing an active restoring force. The characterization results show that coupling SMA wires introduces alters the resistance vs strain characteristics of both wires because the second SMA wire essentially becomes a non-linear, hysteretic spring in series with the first. However, knowledge of the physics behind the complicated behavior enables sensible calibration schemes to be developed to accurately map resistance to strain for simultaneous sensing and actuating applications.Copyright

Optics of Balloon Experimental Twin Telescope for Infrared Interferometry (BETTII): delay lines and alignment

We present the optics of Balloon Experimental Twin Telescope for Infrared Interferometry (BETTII) as it gets ready for launch. BETTII is an 8-meter baseline far-infrared (30-90 μm) interferometer mission with capabilities of spatially resolved spectroscopy aimed at studying star formation and galaxy evolution. The instrument collects light from its two arms, makes them interfere, divides them into two science channels (30-50 μm and 60-90 μm), and focuses them onto the detectors. It also separates out the NIR light (1-2.5 μm) and uses it for tip-tilt corrections of the telescope pointing. Currently, all the optical elements have been fabricated, heat treated, coated appropriately and are mounted on their respective assemblies. We are presenting the optical design challenges for such a balloon borne spatio- spectral interferometer, and discuss how they have been mitigated. The warm and cold delay lines are an important part of this optics train. The warm delay line corrects for path length differences between the left and the right arm due to balloon pendulation, while the cold delay line is aimed at introducing a systematic path length difference, thereby generating our interferograms from where we can derive information about the spectra. The details of their design and the results of the testing of these opto-mechanical parts are also discussed. The sensitivities of different optical elements on the interferograms produced have been determined with the help of simulations using FRED software package. Accordingly, an alignment plan is drawn up which makes use of a laser tracker, a CMM, theodolites and a LUPI interferometer.

Development of a 6-Channel Power Controller for Simultaneous Actuation and Resistance Measurement of SMA Wires

The use of ‘multifunctional’ Shape Memory Alloy wires as embedded actuators and sensors has been proposed for numerous novel applications. The SMA wires are actuated as a result of the Joule heating induced by passing electric current through it. The resistance of the SMA wire can simultaneously be measured during its actuation enabling it to be used as sensor data that relates to the strain and temperature of the wire. In order to control actuation stroke from the SMA wire, the Joule heating (electric power supplied to the SMA wire) of the wire needs to be controlled. Therefore, a 6-channel power controller device has been developed that simultaneously controls the power supplied to six different SMA wires and measures the resistance of these wires during excitation. This paper continues from the previously presented concept of a multi-channel power controller implementation. The focus of this paper is to discuss the operation, calibration methods and optimization techniques to improve the performance and robustness of the device and to eliminate the issues in multi-channel implementation. Further, this device is implemented in a test setup to study the position control of SMA wire using resistance feedback. Results of these tests can be utilized in practical applications involving SMA wires as embedded actuators and sensors, such as Smart Inhaler system being developed at North Carolina State University.Copyright