About ADC
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ABOUT US » Overview

Overview

ADC USA, located near Cornell University in Ithaca, New York, is a leading developer and supplier of complex scientific components and instruments for large government laboratories and corporations around the world. Founded as a privately held company in 1995, ADC has grown into one of world’s leading technology companies and has enjoyed 18 straight years of business growth and profitability with more than 500 customers located in over 26 countries. ADC’s vision is to be a global leader in the development and manufacturing of innovative products for scientific and research markets. 

 

 

History

ADC was founded in 1995 starting in a small modest office at Cornell Business and Technology Park. ADC established itself as a custom design manufacturing system prime contractor. In 1995, ADC won its first contract for $10,700 working with Crouse-Hinds-Cooper Industries (Syracuse, NY), a humble beginning from which the company continues to grow. All of the early awards were competitive.

 

By 1998, ADC occupied its first building of 3,000-sq. ft. The company did grow steadily throughout the late 2000s, always reinvesting in the people and new engineering design, assembly and manufacturing equipment to provide the most cost-effective solutions to our customers.

 

Today ADC occupies over 22,000 square feet of space and consists of different departments to make up the framework of our operations. This includes; Engineering Design and Analysis, Manufacturing and Planning, Temperature Control/Clean Room Assembly/Testing Facility, Ultra-High Vacuum (UHV) Facility, Metrology Laboratory, Magnetic Measurement Facility (Undulator Testing Facility), and Electronics and Instrumentation. Each department plays an important role in the capabilities we offer our customers. It is rare to find this myriad of capabilities in one company.  

 

Capabilities which differentiate ADC from competitors include the investment in test equipment (both CNS machining and QC room, as well as the comprehensive UHV and magnetic measurement facility), which permits qualification and first article testing to be performed in-house. As a technology company, support staff is very heavy in engineering personnel that can provide top quality troubleshooting, thorough sophisticated engineering tools, and technical recommendations to the customer just as their own engineering staff would offer.

 


 

We have developed designs and processes, employed qualified personnel and systems that have allowed us to build complex cutting-edge instruments. From State-of-the-art high-resolution extreme-ultraviolet-light (EUV) microscope making measurements in Nano range for Lawrence Berkeley National Laboratory (LBNL), to 26 tone, 20 meter long, 2.3 meter in diameter complex Time-of-Flight Small Angle Neutron Scattering (ToF SANS) instrument for ANSTO, Australia. ADC has also completed a number of large manufacturing jobs including the Jefferson Lab 12 GeV Upgrade Cavity Parts Project.

 

Engineering Design and Analysis

The Engineering Design and Analysis group is a multi-disciplinary team of engineers with unique training and creativity, and dedication to meeting the needs of our customers.  ADC uses the latest computational and graphics software and hardware to approach the most challenging problems in the Aerospace, Automotive, Nuclear, Turbomachinery, Automated Machinery, Electro-Optical Products, synchrotron, high energy physics, and neutron diffraction communities.  Parametric solid models are created for all mechanical designs, using Autodesk Inventor 2014 Professional.  Drawing on our extensive experience, we present practical, economical and safe designs. We stand apart by providing a multidisciplinary approach - in materials, modelling and manufacturing to the design process. We review design and fabrication requirements, scoping and detailed stress analysis, determining specification and regulatory constraints, and working to practical cost limitations.

 

These models are the basis for procurement, manufacturing and assembly, ensuring accurate and timely execution of the designs.  Autodesk Inventor 2014 comes with a finite element package capable of many different types of simulations including stress analysis, modal analysis and thermal analysis.  These simulations as well as ANSYS are used for providing numerical results that cannot be efficiently calculated by hand.  With a dedication to customer satisfaction backed by over 18 years of experience in developing innovative designs, we are confident we can tackle and solve the most challenging problems; examples below.

 

Top left: Finished product and solid model; Top right: solid model; bottom right: finite elemental analysis.

 

Finite Element Analysis 

ADC Engineers perform structural design and analysis for the manufacturing, aerospace, Electro-Optical Products, synchrotron, high energy physics, and neutron diffraction communities. We perform finite element analysis (FEA) to accurately model products and processes to determine structural integrity, performance and reliability, as well as predict structural failures. ADC uses FEA for decreasing design cycles, keeping production costs low through design optimization, and uncovering potential sources of field failures.  Analysis includes:

 

•           Structural Integrity

•           Component Life Prediction

•           Fatigue, Buckling, and Code Compliance

•           Design Optimization

•           Fabrication Process Evaluation

•           Heat Transfer

•           Thermal Cycling

•           Creep Response & Ratcheting

•           Shock, Vibration & Impact

•           Flow-Induced Vibrations

•           Fluid Flow Analyses

•           Computational Fluid Mechanics                      

•           2D & 3D Finite Element Analysis

•           Linear & Nonlinear

•           Seismic & Vibration

•           Thermal Analysis

•           Elevated Temperature Applications

 

ADC uses Finite Element Analysis (FEA) to predict the deflections of complex and critical structures and to solve the most challenging product engineering problems. For example, when ADC’s engineers design insertion devices, the magnet support structure behavior can be simulated in ANSYS by applying the anticipated magnetic forces, which are determined from a RADIA calculation.  Solid models generated using Autodesk Inventor can be imported into ANSYS, greatly simplifying the interactive design process.  Many aspects of the design, such as material selection, girder geometry, bearing size and preload, and magnet clamping are optimized using FEA. Below is a typical example of what you would expect to see from ADC, including a solid model, finished product and installed product.

 

 

 

Design process and project completion

 

Magnetic Design 

The Engineering Design and Analysis group at ADC also perform magnetic designs.  These are typically performed for an insertion device. ADC’s scientists use B2E, SRW and RADIA (developed at the ESRF), along with Mathematica and ANSYS FEA in the design of insertion devices.  An initial, parametric magnetic design is completed as part of each proposal to ensure that the customer’s specifications can be met.  From these specifications the magnetic materials are chosen to produce either a pure permanent magnet (PPM) or hybrid design (both SmCo and NdFeB magnets have been used in our designs). 

 

Using a model of the device, and a preliminary magnet design, the specifications are checked to ensure that the period, length, gap and flux density are sufficient to meet the desired range of photon energy. 

 

Optics Design

ADC uses SHADOW a widely used program for the simulation of optical systems, more geared to the synchrotron radiation research.  It is based on a geometrical ray-tracing approach, but also traces field amplitude with phase difference. This design tool is used by ADC in combination with ADC’s High Accuracy Optical Mirror Metrology Profilometer.

 

 
 

 

Electronics and Instrumentation

ADC has several electrical/software engineers and techs capable of providing custom circuit design and complete turn-key control systems.  Some of our skills include integrated PLC design and programming, analog and digital circuit design, logic design (including PLA and FPGA programming), stepper and servo motor applications, microprocessor, RFID, serial and RF communications, and system controllers.

 

We have a suite of instrumentation tools for test and measurement of temperature, position, angular displacement, tolerance, acceleration, vacuum, magnetic fields, and motor controls with extensive stock components for prototyping and breadboard.  Our electrical lab includes various precision DVMs, oscilloscopes, power supplies, and other tools.

 

Our design tool set includes National Instruments (NI) MultiSim for schematic capture and NI UltiBoard for circuit board design, Xilinx ISE for FPGA design, ModelSim for simulation, and StateCad.  Non-circuit board Schematics are drawn on various platforms with output to DXF. Microprocessor experience is broad but recent projects focus on the PIC Micro Family from MicroChip.  ICE units and code simulation for the PIC microprocessors are in-house.  Software skills and development platforms include Microsoft Visual C++, PERL, LabView, Visual Basic, CNC, and generic PLC (AB, NAIS, GE-Fanuc, Schneider, etc.) and Parker 6K and 9K (Accroloop).

 

Our standard motor controls and driver that we offer is Galil as described in this document. However, many of our customers have requirements for custom integration of these components into a functioning system, fully debugged, documented, and ready for operation.

 

ADC’s Standard Motor Controls and Driver 

The DMC-40x0 motion controller is Galil's highest performance, stand-alone motion controller, at right. It belongs to Galil's latest generation motion controller family: the Accelera Series, which accepts encoder inputs up to 22 MHz, provides servo update rates as high as 32 kHz, and processes commands as fast as 40 microseconds-10 times the speed of prior generation controllers.

 

 

ADC Standard Motor Controls and Driver

 

 

Ensemble Series of Controllers by Aerotech

 

 

The Ensemble® motion controller is a next-generation, multi-axis, stand-alone controller for moderate- to high-performance applications with high-speed communication through 10/100 Base T Ethernet or USB interfaces. The Ensemble™ can control brushless, brush or stepper motors or stages in any combination, and both PWM and linear drives are available. It offers easy to use, affordable multi-axis (1-10 axes) motion programming for laboratory experimentation, production testing or advanced OEM automated manufacturing systems.

 

Like all Galil controllers, programming the DMC-40x0 is simplified with two-letter, intuitive commands and a full set of software tools such as GalilTools for servo tuning and analysis.

 

Computer Hardware 

Dell- Personal Computer

  • Intel® Core™ i3-2100 processor (3MB Cache, 3.10GHz)
  • 2GB Dual Channel DDR3 SDRAM at 1333MHz - 2 DIMMs
  • 250GB Serial ATA Hard Drive (7200RPM) w/DataBurst Cache™
  • Genuine Windows® 7 Professional SP1, 64bit
  • Dell E Series E2011H 20"W Monitor, 20.0 Inch VIS, Widescreen, VGA/DVI
 

User / Software Interface

National Instruments- LabView 

 

LabVIEW is a graphical programming environment used by millions of engineers and scientists to develop sophisticated measurement, test, and control systems using intuitive graphical icons and wires that resemble a flowchart. It offers unrivaled integration with thousands of hardware devices and provides hundreds of built-in libraries for advanced analysis and data visualization – all for creating virtual instrumentation. The LabVIEW platform is scalable across multiple targets and OSs, and, since its introduction in 1986, it has become an industry leader.

Graphical User interface for the motion control include:

  • Data Display;
  • Ability to move individual axis;
  • Absolute move of axis;
  • Relative move of axis;
  • Home individual axis;
  • Encoder feedback;
  • Limit switch detection, and;
  • Easy install on a Windows OS platform.

 

Hardware Schematic

DMC-40x0 controller, Motor, limits, & encoders 

 

 

 

EPICS Interface 

The Gallil DMC-40x0 controller/driver is already supported by EPICS Ethernet drivers. This means the DMC-40x0 controller will communicate with the local IOC. ADC will provide the EPICS database for incorporation into the local IOC EPICS program. This will consist of a list of input and output variables with their units and range of value. Each blade can be controlled independently.

 

CAM SOFTWARE

We have also set up a computer station with the appropriate program packages so that we can feed our CAD drawings directly into our machining centers.  We have recently switched to new powerful CAM software called Fusion 360 from Autodesk. Fusion 360 is built off of the same kernel as HSMWorks and Inventor HSM giving it years of proven experience. Fusion 360 is the next generation of CAM software allowing the machinist to create a CNC program faster and more accurately than ever before. Using adaptive clearing strategies that maintain load on the tool cutting time is decreased by as much as 50% while also increasing tool life. Fusion 360 also includes extensive finishing strategies to allow machining of fine details. The part shown below was programmed and run in the CNC machine in less than 90 minutes while maintaining a small tolerance of one thousandth of an inch!!

 

 
 

 

Our Mission:

ADC provides systems engineering, integration and collaboration with first class manufacturing facilities all over the world that enable us to provide a full range of products to our diverse customers; from structural metal fabrication to turn key design products with complex control systems. In our After Sales Service department, we have our own skilled team of assembly supervisors who work all over the world, with appropriate personnel, to integrate our high-tech equipment reliably into your facilities and laboratories.

 

ADC takes new approaches to shorten assembly and commissioning times. We create modular construction units which can be installed cost-effectively and extended easily when needed. You can count-on ADC’s continued service support after the commissioning stage.

 

Through intensive technical training sessions and our policy of involving customer personnel at an early stage, we are able to assure seamless and rapid familiarization with our new technologies. This approach has meant that, in many major projects, our customers have been able to operate their equipment independently and to their satisfaction within a very short period of time. At ADC, our After Sales Service is staffed by experienced specialists who can deliver fast support using leading-edge document management systems, assuring our customers a quick-delivery of spare parts and wear components.

 

ADC Customer Service team provides installation, installation supervision, after sales support and service, troubleshooting and remote diagnostics. We believe that success is in the details and this philosophy delivers high customer satisfaction and instills a strong sense of loyalty. Our friendly and courteous customer service staff is always available for questions and order placement for the key replacement parts to keep your ADC system running at peak efficiency. Whether it is a small replacement part or a new component, we are committed to the fastest resolution to your needs.

 

ADC is uniquely positioned and invested in providing exceptional after-sales support.    Available support and services including:

 

•Installation and start-up

•Service and repair – factory / service center / or onboard

•Service contracts

•Troubleshooting assistance over the phone

•Engineering and technical sales assistance

•Upgrade and retrofit parts and programs

•Spare and replacement parts

•Tailored factory and on-board training

•On-board system and spares analysis

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