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The numerical dynamic model of a ball-bearing with angular contact and oil lubricant, which allows to study movement of the bearing parts, having six degrees of freedom, is developed. The general parameters, characterizing loading of bearing retainer, are analyzed. The influence of general structural parameters of several ball-bearings on in-service operation conditions of their retainers is analyzed.
A method is proposed for calculating the load capacity of a radial ball bearing with increased radial clearance.
Purpose: To compare two different quality assurance tools for kV-MV isocenter coincidence check. Methods: Ball-Bearing device (BBD) (Elekta) provided along with a CBCT equipped LINAC and isocenter cube phantom (CP) (a commercial product of Modus Medical Devices) are utilized to check the coincidence between the MV and kV beam isocenters. The microstepping meter of the BBD allows precision adjustment to better than 0.01mm in three directions. The BBD is aligned to the MV-isocenter with the lasers and followed by taking MV-images of at two collimator angles at each cardinal gantry, then its position adjusted. This process takes in iterative steps until 0.25mm tolerance is achieved. Four planar kV-images are taken at cardinal angles and deviations of BBD position from kVisocenter are evaluated. CP is positioned on the couch with the lasers at known offset from the isocenter. CBCT is utilized to set the cube to its kV isocenter with the precision of linac’s couch (1mm). MV-images are taken at various gantry, collimator, and couch angles and evaluated with the CP manufacturer provided QA software to determine coincidence of the 6mm steel ball at cube center with MV-isocenter. Three sets of measurements, one after another, were performed on the same day for each phantom on the same linac. Results: Assuming little variation between kV and MV isocenters in a short time, BBD measurements are more reproducible than CP. With comparable conditions both methods agree within 0.5 mm in each direction, while for BBD average standard deviation was 0.07mm and for iso-cube 0.3mm. Conclusion: Since BBD is more reliable and its results are more reproducible, it should be used during the monthly QA. Since CP is a more efficient device, it should be used for daily QA. A comparison study between the two devices should be periodically performed.
The Gripper Test Assembly (GrTA) is an experimental test article designed for use at the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The GrTA will test mechanical components intended for use in compact in-vessel fuel handling machines (FHM) for sodium cooled fast reactors (SFR). The GrTA will test radial and thrust ball bearings, radial and thrust roller bearings, ball screws and nuts, spline shafts and ball nuts, radial spur gears, and universal joints submerged in liquid sodium at high temperatures (250°C-650°C). These components will be tested in a prototypic, full-scale gripper head and under prototypic SFR fuel handling loads. The design of the GrTA was completed in FY2022 and has progressed into fabrication and initial assembly. All custom manufactured components have been fabricated and delivered to ANL following inspection. All custom gears have been fabricated and delivered to ANL. Bearings, ball screws, and spline shafts have been purchased to allow for initial assembly in air, and sodium compatible versions have either been purchased or are in design at appropriate manufacturers. The drive motor systems that operate the various functions of the GrTA have been purchased and delivered to ANL. Instrumentation and control hardware has been purchased and delivered to ANL as well. All sodium facing components of the GrTA have been assembled and show proper fit. The three main functions of the GrTA are to raise or lower a gripper head under prototypic fuel handling loads, rotate the gripper head while carrying a fuel handling load, and extend or retract gripper jaws that lock a fuel assembly to the gripper head. All three functions have been demonstrated in air, while under no load. The GrTA project will move forward next fiscal year by completing the initial assembly, incorporating the drive system and I&C, and preparing the assembly for introduction to sodium.
Highlights: • Fly ash microsphere is collected from fly ash with electrostatic adsorption classification. • Fly ash microsphere acts as 'ball-bearings' in alkali-activated cements. • Fly ash microsphere works as inorganic dispersing agent to improve workability. • Fly ash microsphere exhibits a good compatibility in alkali-activated cements. - Abstract: The highly viscous property of alkali silicate-activated cements is one of the critical challenges that hinder their wide application. The present study focuses on ameliorating the rheological performance of sodium silicate-activated fly ash/slag pastes by using fly ash microsphere (FAM), which are highly spherical particles collected from fly ash with electrostatic adsorption classification technology. The FAM particles work as 'ball-bearings' in the pastes to reduce the internal friction between fly ash and slag grains, and meanwhile mitigate the agglomeration of flocs and fragmentation to release the locked water. The interrelationship between the FAM particle geometry and plastic viscosity of the paste is well described by the Krieger-Dougherty equation, which supports the proposed mechanisms of 'ball-bearings' effects. FAM can work as an inorganic dispersing agent to improve the workability of alkali-activated cement products for a variety of application aspects.
The high-precision ball bearing is fundamental to the performance of complex mechanical systems. As the speed increases, the cage behavior becomes a key factor in influencing the bearing performance, especially life and reliability. This paper develops a high-precision instrument for analyzing nonlinear dynamic behavior of the bearing cage. The trajectory of the rotational center and non-repetitive run-out (NRRO) of the cage are used to evaluate the instability of cage motion. This instrument applied an aerostatic spindle to support and spin test the bearing to decrease the influence of system error. Then, a high-speed camera is used to capture images when the bearing works at high speeds. A 3D trajectory tracking software TEMA Motion is used to track the spot which marked the cage surface. Finally, by developing the MATLAB program, a Lissajous’ figure was used to evaluate the nonlinear dynamic behavior of the cage with different speeds. The trajectory of rotational center and NRRO of the cage with various speeds are analyzed. The results can be used to predict the initial failure and optimize cage structural parameters. In addition, the repeatability precision of instrument is also validated. In the future, the motorized spindle will be applied to increase testing speed and image processing algorithms will be developed to analyze the trajectory of the cage.
Purpose: The isocenter accuracy of a linear accelerator is often assessed with star-shot films. This approach is limited in its ability to quantify three dimensional wobble of radiation field centers (RFCs). The authors report a Winston-Lutz based method to measure the 3D wobble of RFCs during gantry rotation, collimator rotation, and collimator field size change. Methods: A stationary ball-bearing phantom was imaged using multileaf collimator-shaped radiation fields at various gantry angles, collimator angles, and field sizes. The center of the ball-bearing served as a reference point, to which all RFCs were localized using a computer algorithm with subpixel accuracy. Then, the gantry rotation isocenter and the collimator rotation axis were derived from the coordinates of these RFCs. Finally, the deviation or wobble of the individual RFC from the derived isocenter or rotation axis was quantified. Results: The results showed that the RFCs were stable as the field size of the multileaf collimator was varied. The wobble of RFCs depended on the gantry angle and the collimator angle and was reproducible, indicating that the mechanical imperfections of the linac were mostly systematic and quantifiable. It was found that the 3D wobble of RFCs during gantry rotation was reduced after compensating for a constant misalignment of the multileaf collimator. Conclusions: The 3D wobble of RFCs can be measured with submillimeter precision using the proposed method. This method provides a useful tool for checking and adjusting the radiation isocenter tightness of a linac.
The Gear Test Assembly (GTA) is an experimental test apparatus built and installed in the Mechanisms Engineering Test Loop (METL) at Argonne National Laboratory (ANL). The focus of GTA has been to test larger radial spur gears sets machined from Inconel 718 along with a variety of bearing components that are to be used in the fuel handling machines built for use in pool-type sodium fast reactors. The testing in GTA also informs the design and material choices for the full-scale Gripper Test Assembly (GrTA) being developed by Argonne. To date, the Inconel 718 gears used in all six GTA experimental campaigns have completed over 23.2 million revolutions under various loads equivalent to approximately 37,156 simulated fuel assembly maneuvers (removal from and reinsertion to core) using a conventional height of a core assembly. While the heat treated and untreated tapered roller bearings and cylindrical pin thrust bearings used in the first five experimental campaigns have experienced mechanical or material failure after completing a range of fuel assembly maneuvers ranging from as early as 575 operations in Campaign #5 to 9800 operations in Campaign #1, Campaign #6 was the most successful campaign, achieving 22,563 maneuvers and was concluded before any catastrophic failure occurred. In this report we will present the results from the most recent campaigns, #5 and #6. The longevity of Campaign #6 was likely aided by a variety of adjustments made to the materials and components used and to the experimental testing procedures employed. In terms of materials and components, new gearboxes were fabricated, as opposed to using the old gear boxes which had been impacted by the previous bearing failures, and ball bearings were replaced with tapered roller bearings. The adjustments to the experimental procedure focused on a lowering of the maximum torque applied to the gears and bearings and the increase of the duration of each simulated fuel assembly maneuver conducted. This report will present and discuss the changes made to the materials, components, and procedures and the subsequent results for Campaign #5 and Campaign #6.
In this paper, we present a connection between argon ion flux, element-mixing, and rolling contact fatigue (RCF) life of a thin film nickel-copper-silver lubricant on ball bearings. The film is deposited on the balls using an ion plating process and tested for RCF in high vacuum. The ion flux is measured using a Langmuir probe and the plane stress within the film during deposition is calculated using a thin film model. Experiments reveal that there is an inverse relationship between ion flux and RCF life for most deposition voltage and pressure combinations tested, specifically, 15.5-18.5 mTorr and 1.5-3.5 kV. For voltages up to 2.5 kV, RCF life decreases as ion flux increases due to increased compressive stress within the film, reaching as high as 2.6 GPa. For voltages between 2.5 and 3.5 kV, interlayer mixing of nickel and copper with the silver layer reduces RCF life due to contamination, even as ion flux and corresponding film compressive stress are reduced. A Monte Carlo-based simulation tool, SRIM is used to track collision cascades of the argon ions and metal atoms within the coating layers. At process voltages above 2.5 kV we observe elemental mixing of copper and nickel with the silver layer using Auger electron spectroscopy of coated steel and Si{sub 3}N{sub 4} balls. The authors conclude that an ion flux greater than 5.0 x 10{sup 14} cm{sup -2} s{sup -1} leads to reduced RCF life due to high film stress. In addition, process voltages greater than 2.5 kV also reduce RCF life due to contamination and interlayer mixing of nickel and copper within the silver layer.
Purpose: To develop and demonstrate application of a method that characterizes deviation of linac x-ray beams from the centroid of the volumetric radiation isocenter as a function of gantry, collimator, and table variables. Methods: A set of Winston-Lutz ball-bearing images was used to determine the gantry radiation isocenter as the midrange of deviation values resulting from gantry and collimator rotation. Also determined were displacement of table axis from gantry isocenter and recommended table axis adjustment. The method, previously reported, has been extended to include the effect of collimator walkout by obtaining measurements with 0 and 180 degree collimator rotation for each gantry angle. Twelve images were used to characterize the volumetric isocenter for the full range of available gantry, collimator, and table rotations. Results: Three Varian True Beam, two Elekta Infinity and four Versa HD linacs at five institutions were tested using identical methodology. Varian linacs exhibited substantially less deviation due to head sag than Elekta linacs (0.4 mm vs. 1.2 mm on average). One linac from each manufacturer had additional isocenter deviation of 0.3 to 0.4 mm due to jaw instability with gantry and collimator rotation. For all linacs, the achievable isocenter tolerance was dependent on adjustment of collimator position offset, transverse position steering, and alignment of the table axis with gantry isocenter, facilitated by these test results. The pattern and magnitude of table axis wobble vs. table angle was reproducible and unique to each machine. Conclusion: This new method provides a comprehensive set of isocenter deviation values including all variables. It effectively facilitates minimization of deviation between beam center and target (ball-bearing) position. This method was used to quantify the effect of jaw instability on isocenter deviation and to identify the offending jaw. The test is suitable for incorporation into a routine machine QA program. Software development was performed by Radiological Imaging Technology, Inc.
We use molecular simulations to study the nonadhesive and adhesive atomic-scale contact of rough spheres with radii ranging from nanometers to micrometers over more than ten orders of magnitude in applied normal load. At the lowest loads, the interfacial mechanics is governed by the contact mechanics of the first asperity that touches. The dependence of contact area on normal force becomes linear at intermediate loads and crosses over to Hertzian at the largest loads. By combining theories for the limiting cases of nominally flat rough surfaces and smooth spheres, we provide parameter-free analytical expressions for contact area over the whole range of loads. Our results establish a range of validity for common approximations that neglect curvature or roughness in modeling objects on scales from atomic force microscope tips to ball bearings.
Purpose:Verification of the mechanical isocenter position is required as part of comprehensive quality assurance programs for stereotactic radiosurgery/radiotherapy (SRS/SRT) treatments. Several techniques have been proposed for this purpose but each of them has certain drawbacks. In this paper, a new efficient and more comprehensive method using cine-EPID images has been introduced for automatic verification of the isocenter with sufficient accuracy for stereotactic applications. Methods: Using a circular collimator fixed to the gantry head to define the field, EPID images of a Winston-Lutz phantom were acquired in cine-imaging mode during 360 deg. gantry rotations. A robust matlab code was developed to analyze the data by finding the center of the field and the center of the ball bearing shadow in each image with sub-pixel accuracy. The distance between these two centers was determined for every image. The method was evaluated by comparison to results of a mechanical pointer and also by detection of a manual shift applied to the phantom position. The repeatability and reproducibility of the method were tested and it was also applied to detect couch and collimator wobble during rotation. Results:The accuracy of the algorithm was 0.03 {+-} 0.02 mm. The repeatability was less than 3 {mu}m and the reproducibility was less than 86 {mu}m. The time elapsed for the analysis of more than 100 cine images of Varian aS1000 and aS500 EPIDs were {approx}65 and 20 s, respectively. Processing of images taken in integrated mode took 0.1 s. The output of the analysis software is printable and shows the isocenter shifts as a function of angle in both in-plane and cross-plane directions. It gives warning messages where the shifts exceed the criteria for SRS/SRT and provides useful data for the necessary adjustments in the system including bearing system and/or room lasers. Conclusions: The comprehensive method introduced in this study uses cine-images, is highly accurate, fast, and independent of the observer. It tests all gantry angles and is suitable for pretreatment QA of the isocenter for stereotactic treatments.
Purpose: To develop a system that can define the radiation isocenter and correlate this information with couch coordinates, laser alignment, optical distance indicator (ODI) settings, optical tracking system (OTS) calibrations, and mechanical isocenter walkout. Methods: Our team developed a multi-adapter, multi-purpose quality assurance (QA) and calibration device that uses an electronic portal imaging device (EPID) and in-house image-processing software to define the radiation isocenter, thereby allowing linear accelerator (Linac) components to be verified and calibrated. Motivated by the concept that each Linac component related to patient setup for image-guided radiotherapy based on cone-beam CT should be calibrated with respect to the radiation isocenter, we designed multiple concentric adapters of various materials and shapes to meet the needs of MV and KV radiation isocenter definition, laser alignment, and OTS calibration. The phantom's ability to accurately define the radiation isocenter was validated on 4 Elekta Linacs using a commercial ball bearing (BB) phantom as a reference. Radiation isocenter walkout and the accuracy of couch coordinates, ODI, and OTS were then quantified with the device. Results: The device was able to define the radiation isocenter within 0.3 mm. Radiation isocenter walkout was within ±1 mm at 4 cardinal angles. By switching adapters, we identified that the accuracy of the couch position digital readout, ODI, OTS, and mechanical isocenter walkout was within sub-mm. Conclusion: This multi-adapter, multi-purpose isocenter phantom can be used to accurately define the radiation isocenter and represents a potential paradigm shift in Linac QA. Moreover, multiple concentric adapters allowed for sub-mm accuracy for the other relevant components. This intuitive and user-friendly design is currently patent pending.
Purpose: The purpose of this work is to improve the repeatability of the measurement of the slice-sensitivity profile (SSP) in reconstructed breast tomosynthesis volumes. Methods: A grid of aluminum ball-bearings (BBs) within a PMMA phantom was imaged on breast tomosynthesis systems from three different manufacturers. The full-width half-maximum (FWHM) values were measured for the SSPs of the BBs in the reconstructed volumes. The effect of transforming the volumes from a Cartesian coordinate system (CCS) to a cone-beam coordinate system (CBCS) on the variability in the FWHM values was assessed. Results: Transforming the volumes from a CCS to a CBCS before measuring the SSPs reduced the coefficient of variation (COV) in the measurements of FWHM in repeated measurements by 56% and reduced the dependence of the FWHM values on the location of the BBs within the reconstructed volume by 76%. Conclusions: Measuring the SSP in the volumes in a CBCS improves the robustness of the measurement.
In this work we report the design and performance of a novel compact in-vacuum actuator, designed to be compatible with all the motions required for the scissor-type ESRF mirror bender. These mirror benders include several linear actuators, which drive the mirror bending torques, as well as the main alignment motions such as pitch and translation along the normal to the mirror surface. The motions are provided by compact linear actuators, which consist of motor, reduction, spindle and nut, encapsulated on a closed air volume to provide vacuum compatibility. The actuator includes a hydroformed bellows to transmit the force to the actuator tip, and an electrical feedthrough for the motor cables. The design boundaries for these actuators are quite tight, as they must be integrated in a narrow volume, must be UHV compatible and must provide high resolution, for a relatively high load. As a result, they have limited mechanical performance, and in some cases poor reliability. To overcome these problems, we designed and implemented a different concept. In the proposed concept, the motor rotation is converted onto a linear motion by means of a cam instead of a spindle and a nut. This allows for much shorter and stiffer transmission system, with similar dimensions. The vacuum compatibility is intrinsic for this solution, since the whole mechanism of the actuator is UHV compatible. All motions are preloaded and guided by vacuum compatible (hybrid metal-ceramics) ball bearings. This allows the system reaching a repeatability and backlash well within the micron. The absence of friction allows for a high reliability and releases the maintenance needs of the system. The transmission is intrinsically irreversible, and the system can hold a load of 250 N within a few nanometers without any holding current on the motors. This allows the system to move reliably also in micro-stepping mode, providing a resolution well below the half-step nominal resolution of 100 nm. Performances have been tested on a prototype. We report the results of the tests obtained in air and in vacuum after bake-out. Two units of the new actuator have been installed at the photoemission beamline of ALBA (CIRCE) and are routinely used to align the 3 µm spot on the field of view of the Photoemission Electron Microscope. The absence of any noticeable backlash, or any friction effect and the reliability of the micro-stepping motion has simplified very much the alignment of the photon beam, reducing the alignment process to few minutes. The excellent performances and relatively high load capacity of this new compact actuator make of it a versatile element to be integrated in other systems requiring reliable in-vacuum positioning.
Purpose: Gantry sag is one of the well-known sources of mechanical imperfections that compromise the spatial accuracy of radiation dose delivery. The objectives of this study were to quantify the gantry sag on multiple linear accelerators (linacs), to investigate a multileaf collimator (MLC)-based strategy to compensate for gantry sag, and to verify the gantry sag and its compensation with film measurements. Methods: The authors used the Winston-Lutz method to measure gantry sag on three Varian linacs. A ball bearing phantom was imaged with megavolt radiation fields at 10 deg. gantry angle intervals. The images recorded with an electronic portal imaging device were analyzed to derive the radiation isocenter and the gantry sag, that is, the superior-inferior wobble of the radiation field center, as a function of the gantry angle. The authors then attempted to compensate for the gantry sag by applying a gantry angle-specific correction to the MLC leaf positions. The gantry sag and its compensation were independently verified using film measurements. Results: Gantry sag was reproducible over a six-month measurement period. The maximum gantry sag was found to vary from 0.7 to 1.0 mm, depending on the linac and the collimator angle. The radiation field center moved inferiorly (i.e., away from the gantry) when the gantry was rotated from 0 deg. to 180 deg. After the MLC leaf position compensation was applied at 90 deg. collimator angle, the maximum gantry sag was reduced to <0.2 mm. The film measurements at gantry angles of 0 deg. and 180 deg. verified the inferior shift of the radiation fields and the effectiveness of MLC compensation. Conclusions: The results indicate that gantry sag on a linac can be quantitatively measured using a simple phantom and an electronic portal imaging device. Reduction of gantry sag is feasible by applying a gantry angle-specific correction to MLC leaf positions at 90 deg. collimator angle.
Purpose: The purpose of this study was to define an independent verification method based on on-board orthogonal fluoroscopy to determine the geometric accuracy of synchronized gantry–ring (G/R) rotations during dynamic wave arc (DWA) delivery available on the Vero system. Methods and Materials: A verification method for DWA was developed to calculate O-ring-gantry (G/R) positional information from ball-bearing positions retrieved from fluoroscopic images of a cubic phantom acquired during DWA delivery. Different noncoplanar trajectories were generated in order to investigate the influence of path complexity on delivery accuracy. The G/R positions detected from the fluoroscopy images (DetPositions) were benchmarked against the G/R angulations retrieved from the control points (CP) of the DWA RT plan and the DWA log files recorded by the treatment console during DWA delivery (LogActed). The G/R rotational accuracy was quantified as the mean absolute deviation ± standard deviation. The maximum G/R absolute deviation was calculated as the maximum 3-dimensional distance between the CP and the closest DetPositions. Results: In the CP versus DetPositions comparison, an overall mean G/R deviation of 0.13°/0.16° ± 0.16°/0.16° was obtained, with a maximum G/R deviation of 0.6°/0.2°. For the LogActed versus DetPositions evaluation, the overall mean deviation was 0.08°/0.15° ± 0.10°/0.10° with a maximum G/R of 0.3°/0.4°. The largest decoupled deviations registered for gantry and ring were 0.6° and 0.4° respectively. No directional dependence was observed between clockwise and counterclockwise rotations. Doubling the dose resulted in a double number of detected points around each CP, and an angular deviation reduction in all cases. Conclusions: An independent geometric quality assurance approach was developed for DWA delivery verification and was successfully applied on diverse trajectories. Results showed that the Vero system is capable of following complex G/R trajectories with maximum deviations during DWA below 0.6°.