18,000 RPM Air Bearing Spindles for Image Scanning in Harsh Conditions

Project Background

A leading laser scanning manufacturer sought to enhance their rail inspection capabilities across Europe. Their existing system, using ball-bearing spindles, struggled with image clarity due to vibrations and poor synchronization. They turned to ABTech to develop a solution capable of delivering precise, high-quality imagery while enduring the harsh conditions of rail inspection.

train
custom-rail-air-bearing-imaging-spindle

The Challenge
Design an inspection system for a European high‐speed rail system – that must function accurately in harsh conditions while moving 75 mph.

 

The Design Solution

We designed a set of three high‐speed air bearing spindles that were synchronized for the 3‐dimensional image scanning and inline inspection.
To inspect the track, switches, tunnels and bridges for potential maintenance issues, the system was mounted on a dedicated rail car traveling at 75 mph allowing the spindles to create a 3‐D image of the rail every 10 cm (less than 4″).

 

To achieve the necessary rotational speeds of 18,000 rpm, the design incorporated individual direct drive brushless DC servo motors and encoders on each of the ultra‐ precision air bearing spindles. To simulate the most extreme conditions, each spindle was tested, including vibration testing to 10 G’s, after being stored in a freezer overnight and then run at 180°F continuously for over 8 hours.

System Feature Summary

  • Synchronized ultra‐precision air bearing spindles
    • Aluminum construction for low inertia
    • Individual direct drive brushless DC servo motors
    • High resolution rotary encoders
    • 50 mm clear apertures through the spindles
    • 45° fold mirrors
  • Vibration isolation platform
  • Multi‐axis controller
  • Capacitance probe monitoring system
Three Spindles

ABTech Custom Design Solutions

Lawrence Livermore National Lab NIF Target Assembly Station

2‐Axis Air Bearing Lathe and Metrology Precision Machining Work Cell

NASA NuSTAR Telescope Optics Assembly Stations

AT400, 2000LBS, Rotational Accuracies better than 5µ” (millionths of an inch)

18,000 RPM Air Bearing Spindles for Image Scanning in Harsh Conditions

Non‐Contact 3‐D Optical Metrology Platform

Custom 150” Setting Master for Large Diameter Beam Gages


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