Johnson ARW2011 Thermal imaging platform

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Development of a Remotely
Controlled, Mobile, Thermal
Imaging Platform.
Adrian Johnson
Senior Operations Technician
Diamond Light Source
Adrian Johnson. ARW2011 10-15 April 2011
Overview of Diamond
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Opened for Users in 2007.
Currently 18 operational Beamlines.
4 Beamlines currently under construction.
Total of 32 Beamlines by 2017.
Adrian Johnson. ARW2011 10-15 April 2011
Overview of Diamond Accelerators
• 100MeV Linac.
• 3GeV Booster.
• 3GeV Storage Ring.
• Stored Beam currently at 200mA (running in Top up).
• Target of 300mA (running in Top up).
• Stable beam to provide steady conditions for Users.
• Beam position to be stable and reproducible.
• Beam profile to stable and reproducible.
• Minimise beam downtime.
Adrian Johnson. ARW2011 10-15 April 2011
The Need
• Assessment of beam induced heating.
• Assessed by calculation, but needs verifying.
• Entry with handheld camera after beam dropped not adequate.
• As we head towards 300mA beam, want to perform thermal
surveys of the Storage Ring with stored beam present.
• To do this needs a remote control thermal imaging camera.
Adrian Johnson. ARW2011 10-15 April 2011
The Working Environment
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Inside the ‘Locked up’ Vaults.
Stored Beam present.
Blue lighting.
Smooth Flooring.
Few obstacles.
Trenches.
Adrian Johnson. ARW2011 10-15 April 2011
The Working Environment
• Accelerator vaults divided into PSS
search Zones.
• Zone gates at either end and on
entrance.
• Zone gates are interlocked.
• Traps remote control camera in one
Zone.
• Access only during Machine
Development shifts.
Adrian Johnson. ARW2011 10-15 April 2011
Design Requirements
• Capable of capturing Thermal Images.
• Capable of being fielded in the Accelerator Vaults with beam present.
• Without affecting the machine operation.
• Remotely Controlled from the Control Room.
• Stable and Controllable.
• Able to recharge batteries to facilitate long term use.
• Locked in a zone for at least 1 week.
• Inexpensive.
• Height Adjustment on Thermal Camera.
Adrian Johnson. ARW2011 10-15 April 2011
Hardware
Thermal Camera
FLIR A320
Pan / Tilt Head
Visible light Camera
Motorised Lab Jack
CoroBot ‘Robotic’ Drive unit
Adrian Johnson. ARW2011 10-15 April 2011
Network set up
• Camera Platform controlled over a Wireless network.
• FLIR and Axis cameras connected to CoroBot LAN port
via a Network switch.
• CoroBot LAN and WiFi connected via ‘Network Bridge’
in Windows XP.
• Wireless access point connected to existing ‘secondary’
network in Vault.
Adrian Johnson. ARW2011 10-15 April 2011
Software
• Control Software.
• Microsoft Robotics Studio, written in C#.
• Modular Services running concurrently (i.e. each one on a separate
thread).
• Services read from sensors or sends commands to actuators or
read/write to other services.
• Control by communication between services.
• Used original CoroBot Drive, Motor Encoder control and Input / Output Board
Services.
• New Services written:
• Motor Control Board (to control Height adjustment motor).
• Robot Drive Control.
• Robot Power.
Adrian Johnson. ARW2011 10-15 April 2011
Battery charging
• Modifications for Battery Charging.
Adrian Johnson. ARW2011 10-15 April 2011
Height Adjustment
• Addition of Camera Height adjustment.
• Speed controlled to accelerate /
decelerate smoothly, to prevent tipping.
• 25cm (40cm full travel) of height
adjustment, to put Thermal Camera 1m
from floor level.
Adrian Johnson. ARW2011 10-15 April 2011
Control
• Controlled from the Main Control Room.
• Driven by the on duty Operator.
• Two Remote desktop sessions.
• 1st to the Robot PC.
• Control GUIs for Driving, Battery Charging and Pan/Tilt head.
• 2nd to another Windows PC.
• FLIR camera software.
• Axis Camera web page (used for Navigation).
• Can also be controlled from any PC/Laptop connected to the Network.
Adrian Johnson. ARW2011 10-15 April 2011
Control User Interfaces
Adrian Johnson. ARW2011 10-15 April 2011
Usage.
• Storage Ring Survey.
• Nov / Dec 2009 – started survey 250 & 275mA stored beam.
• High current running and surveys being carried out during Machine
Development shifts.
• Two Zones completed.
• High current running delayed due to RF cavity issues.
• 2010.
• Verification of correct water flow to Booster RF Cavity following
adjustment and manifold modifications.
• Confirmation that a set of Vacuum bellows was not damaged following
a Girder movement.
• Monitoring of new components installed, during a major lattice change.
Adrian Johnson. ARW2011 10-15 April 2011
Vacuum Vessel Bellows - Results
RF Off
RF On 50kW CW
150mA 600 bunches
200mA 900 bunches
Adrian Johnson. ARW2011 10-15 April 2011
New Installation - Results
RF Off
200mA 900 bunches
200mA hybrid fill
Adrian Johnson. ARW2011 10-15 April 2011
New Installation - Results
RF Off
200mA 900 bunches
200mA hybrid fill
Adrian Johnson. ARW2011 10-15 April 2011
Costs
Item
Cost (as of 2009)
FLIR A320 Thermal Camera
£7500
CoroBot
£3000
Axis 213 Camera
£1400
Pan / tilt head
£130
Motor Control Card
£100
Modified Lab Jack
£150
Networking Components
£50
Misc.
£200
Total
£12530
• Estimated ½ man year of effort from concept to use.
Adrian Johnson. ARW2011 10-15 April 2011
• Limitations.
Limitations
• The platform can only be used in one PSS zone at a time, due to the
Zone Gates.
• Viewing of components on the ‘far side’ of the Storage Ring is limited to
static placement.
• Battery life when roaming, approx. 1 hour.
• Radiation damage to the Axis camera.
• Battery life degradation.
Adrian Johnson. ARW2011 10-15 April 2011
Summary
• An inexpensive Remote Control, Mobile, Thermal imaging
camera platform has been developed.
• It has been in use in the Diamond accelerator vaults, with
beam present, for over a year.
• It has proved to be a useful tool.
Adrian Johnson. ARW2011 10-15 April 2011
End of Presentation
Adrian Johnson. ARW2011 10-15 April 2011
Hardware Details (appendix)
• FLIR A320 Thermal Camera.
• 320x240 pixel, uncooled microbolometer.
• -20ºC to +120ºC or 0ºC to +350ºC temperature range, ± 2ºC accuracy.
• TCP/IP communication.
• Hague Pan/tilt camera mount.
• USB controlled.
• CoroBot ‘robotic’ drive unit.
• 1.5GHz PC, 512MB RAM, 802.1g WiFi card, 80GB Hard drive, Windows XP.
• 4 wheel motorised drive, with differential speed steering controlled via a Lynx
motion SSC-23 servo control board.
• A Phidgets 8/8/8 Interface card to provide 8 Analogue and 8 Digital inputs
and 8 Digital Outputs.
• 10AHr 12V rechargeable batteries, ~2.5hours of run time.
• Axis 213 PTZ camera.
• TCP/IP camera.
• ±170º Pan, -10º to +90º tilt.
• Low Light mode, with built in Infra Red LED light.
Adrian Johnson. ARW2011 10-15 April 2011
Timescales (appendix)
• Oct 2008 - Project initiated.
• Dec 2008 – Specification issued.
• Jan 2009 – Orders placed.
• Apr 2009 – All Hardware delivered.
• June 2009 – First test fielding in Linac (no charging).
• Hardware and Software Modifications made to facilitate charging.
• Nov & Dec 2009 - Survey of Storage Ring started, 250 and 275mA
stored beam.
• High current running and surveys being carried out during Machine
Development shifts.
• High current running delayed due to RF cavity issues.
Adrian Johnson. ARW2011 10-15 April 2011
Timescales (appendix)
Jan to May 2010 – Modifying Robot to fit Height adjustment and write
software.
• Jun 2010 – Monitoring of Booster RF Cavity water temperatures after flow
adjustment.
– Monitoring suspect set of bellows in the Storage Ring (150mA
900 bunches).
• July 2010 – Monitoring Booster RF Cavity water temperatures with
increasing power.
• Aug 2010 – Monitoring suspect set of bellows in the Storage Ring (150mA
& 200mA 600 bunches).
• Sept to Nov 2010 – Monitoring of new ‘Mini Beta’ components in Storage
Ring (200mA, 900 & 600 bunches and hybrid fills)
• Apr 2011 - Monitoring of second installation of ‘Mini Beta’ components in
Storage Ring.
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Adrian Johnson. ARW2011 10-15 April 2011
Booster RF Cavity Cooling – Results (appendix)
RF Off
RF On 50kW CW
RF On normal ramp
Adrian Johnson. ARW2011 10-15 April 2011
Remote desktop set up (appendix)
Adrian Johnson. ARW2011 10-15 April 2011
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