Square One Systems Design Supports the World’s Most Powerful X-ray Laser at SLAC Using PC-based Control, EtherCAT, and Robotics
- Shane Novacek
- Jun 30
- 5 min read
Tri-Sphere Robotic Positioning System speeds up research at SLAC National Accelerator Laboratory by reducing equipment changeovers from two days to just 12 hours
At SLAC National Accelerator Laboratory, an advanced robotic system by Square One Systems Design and Beckhoff USA helps with maximizing access for researchers, streamlining operations to fully utilize “beam time”, and improving research outcomes. Developed by the Jackson, Wyoming-based Square One, the Tri-Sphere Robotic Positioning System offers unparalleled capabilities.
Square One’s patented Tri-Sphere robot is a state-of-the-art parallel robot whose design was tailored to meet the rigorous demands of high-energy physics research. Like revolute jointed industrial robots, the Tri-Sphere offers six degrees of freedom in movement. However, unlike traditional robots, the Tri-Sphere robot delivers huge payload capacity, ultra-high precision, and a compact design that fits seamlessly into tight spaces. The Tri-Sphere also conforms to the EPICS standard (Experimental Physics Integrated Control System) which is widely adopted in the physics community. EPICS provides researchers and technicians with a standardized control system architecture and software toolkit to interface with and control high-end equipment. EPICS’ many toolkits improve process tracking performance and optimizes analysis of the metadata gathered during experiments.
SLAC's deployment of Tri-Sphere robots is part of larger upgrades to their Linac Coherent Light Source (LCLS), the world’s most powerful X-ray free-electron laser. A recent upgrade (LCLS-II) increased the capabilities of the original system from 120 pulses per second to 1 million pulses per second, and a future upgrade (LCLS-II-HE) will increase the X-ray energy. In simple terms, this opens up an entirely new realm for advanced research projects that were previously considered impossible by scientists, including a new generation of solar energy technologies, superconductors, advanced drug discovery, etc.
Breaking through the limits of physics research
The unique design of the Tri-Sphere robot offers several advantages to accommodate the rapid succession (removal and replacement) of complex research setups and operate in the demanding environment typical of facilities like LCLS. The Tri-Sphere robot’s compact geometry means it can fit into the tight confines of a mainstay in research facilities, the hutch, or the equipment used in research facilities where X-ray beams pass through test samples. The Tri-Sphere robot’s high-precision positioning system ensures that it can precisely move research equipment into beams as narrow as 100 nanometers.
The Tri-Sphere robot is not only accurate, it’s also very strong – supporting rapid movement and repositioning of heavy objects with the accuracy required to perform cutting-edge experiments. “The Tri-Sphere robot is designed with heavy payloads in mind and has the ability to handle up to 12,000 pounds – which is essential when positioning heavy objects in national labs like SLAC," explains Bob Viola, Director of Engineering at Square One Systems Design. "This performance far exceeds that of conventional robots that may be more suited to industrial use."
Maximizing beam time is essential to accommodate as many experiments as possible. "National labs like SLAC are literally priceless national resources, and every second of beam time counts," Viola emphasizes. "The ability to perform quick changeovers without compromising precision or reliability is a game-changer."
Jace Walsh, Chief Controls Engineer at Square One, explains further, "The Tri-Sphere's asymmetric work envelope and software-tunable rotation point provide unmatched versatility and precision, allowing it to adapt to a wide range of experiments. This flexibility is crucial for experiments, where the ability to quickly and accurately reposition experimental setups can significantly impact research outcomes."
The Tri-Sphere upgrade integrates automation and control technology from Beckhoff across multiple experimental hutches, allowing SLAC to conduct high-precision experiments with minimal downtime. The staff can set up a new center for the beam in the Tri-Sphere’s user-friendly front-end software, dial in new configuration settings, and enter new height parameters and rotation settings.
The SLAC Tri-Sphere systems are mounted on air casters. This enables the robots to be quickly moved in and out of different hutches. The Tri-Sphere can handle delicate samples with precision, another key advantage. "The robot features a vacuum transfer system to ensure that the system can handle a wide variety of container types without damage, including delicate products with soft-touch finishes," says Viola. "This is crucial for experiments using highly sensitive sample materials."
Automating what’s next in research and discovery
Instrumental to the success of the Tri-Sphere Robotic Positioning System has been the integration of PC- and EtherCAT-based control technology from Beckhoff. The implementation received extra assurances from Square One’s official membership in the Beckhoff Integrator Group (BIG). The Tri-Sphere currently relies on Beckhoff's CX2033 Embedded PCs with AMD Ryzen™ V1202B processors as the primary controller, leveraging real-time EtherCAT communication and high processing speeds to seamlessly handle all automation and control tasks. The CX2033 runs TwinCAT NC PTP software for motion control. “As a clean, all-in-one package, Beckhoff's advanced automation technologies have been instrumental in optimizing the Tri-Sphere system's performance,” says Walsh. "The real-time EtherCAT communication and fast processing speeds of the Beckhoff embedded PC made this possible. Unlike traditional PLC technologies, PC-based automation allows us to handle all automation and control functionality on one device, with seamless integration across the Beckhoff platform, the robot controller, and the machine vision system."
EtherCAT’s automatic addressing of its highly modular devices, numerous wiring topology options, and high device count – up to 65,535 devices in one network – ensure a robust and scalable network infrastructure. In addition, the compact size of the DIN-rail mounted EtherCAT Terminals easily fit in compact enclosures distributed throughout the Tri-Sphere robot.
Not just relegated only to data acquisition, EtherCAT Terminals can also incorporate Beckhoff’s compact drive technology. Square One integrated EL7041 and EL7047 stepper motor terminals to handle some of the Tri-Sphere’s motion requirements. The system also leverages EL5042 dual interface terminals for the required encoders. The EL5042 is a BiSS® C master and enables the direct connection of absolute encoders with BiSS® C or SSI interface.
Beckhoff’s TwinSAFE I/O terminals and Safety over EtherCAT (FSoE) technology provide robust machine safety functionality that integrates seamlessly with SLAC’s personnel protection system and equipment protection connections from the lab for sending safety status whenever personnel are in a hutch and initiating e-stops if they’re ever needed. "TwinSAFE supports these unique safety requirements, ensuring safe access to the hutches at all times and reliable control of these powerful positioners," emphasizes Viola.
The Tri-Sphere system is also compatible with the seismic anchoring requirements typical of installations in California. This ensures that the systems can withstand seismic activity and maintain their precise positioning. Through a kinematic base designed by Square One, the Tri-Sphere meets the demanding requirements to withstand extreme vibrations.
A high-energy future for the world’s leading research projects
“When SLAC can prepare an experimental work setup on a Tri-Sphere outside of the working hutch without shutting down the beamline, it speeds things up,” Viola says. “The system reduced the time required for SLAC experiment changeovers from two days to just 12 hours.”
Square One also sees a bright future for the Tri-Sphere system in all the research applications they support. "We are in the process of upgrading several older Mark IV systems around the country to Beckhoff controllers and exploring new applications for Tri-Sphere technology," says Viola. "The flexibility and scalability of Beckhoff's automation and control solutions are key to fueling our ongoing innovation."
Looking ahead, the potential applications for the Tri-Sphere Robotic Positioning System are vast. "The Beckhoff system's advanced diagnostics and modularity have been crucial in achieving new levels of safety and reliability," Walsh notes. “In addition, Beckhoff's responsiveness and commitment to application engineering and technical support have been critical to our success. Their field engineers, like Ryan Kirkland, have provided invaluable support throughout the project."
Mathew Garcia, Business Development Leader at Beckhoff USA, echoes this sentiment. "The Tri-Sphere project is a testament to the collaborative efforts of Square One and Beckhoff. It's exciting to see how our technology is helping improve research outcomes and efficiencies at SLAC and other facilities." The Tri-Sphere, as demonstrated by its successful deployment at SLAC, is helping overcome key challenges in many areas of scientific research. With proven flexibility and performance to adapt to a wide range of difficult testing spaces, the system has since been deployed at other world-renowned laboratories to help reach the next big discovery.
Ready to accelerate your research application right to your next big discovery?Contact your local Beckhoff sales engineer today.
Shane Novacek is the Marketing Communications Manager at Beckhoff Automation LLC
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