Robot drive with magnetic spindle bearings

• US 9,024,488 B2
• Filed: 10/05/2012
• Issued: 05/05/2015
• Est. Priority Date: 06/27/2007
• Status: Active Grant

• Current Assignee: Brooks Automation Ltd. (United Kingdom) (Azenta, Inc.)
• Original Assignee: Brooks Automation Incorporated (Azenta, Inc.)
• Inventors: Gilchrist, Ulysses, Hosek, Martin, Moura, Jairo Terra, Krishnasamy, Jay, Hofmeister, Christopher
• Primary Examiner(s): Leung, Quyen
• Assistant Examiner(s): Truong, Thomas
• Application Number:
  US13/646,282
• Publication Number:
  US 20130028700A1
• Time in Patent Office: 942 Days
• Field of Search: 310/67.R, 310/90, 310/90.5, 310/114, 310/154.01, 310/154.03, 310/254.1, 310/12.14, 310/12.15, 310/12.19, 414/744.5, 414/749.2, 901/15, 901/23, 744/900.1, 744/900.3
• US Class Current: 310/12.14
• CPC Class Codes: H02K 29/03 with a magnetic circuit specially adapted for avoiding torque ripples or self-starting problems
• CPC Class Codes: H02K 7/09 with magnetic bearings
• CPC Class Codes: Y10S 901/15 Jointed arm
• CPC Class Codes: Y10S 901/23 Electric motor
• CPC Class Codes: Y10T 74/20305 Robotic arm
• CPC Class Codes: Y10T 74/20317 including electric motor
• CPC Class Codes: Y10T 74/20329 Joint between elements

Abstract

A drive section for a substrate transport arm including a frame, at least one stator mounted within the frame, the stator including a first motor section and at least one stator bearing section and a coaxial spindle magnetically supported substantially without contact by the at least one stator bearing section, where each drive shaft of the coaxial spindle includes a rotor, the rotor including a second motor section and at least one rotor bearing section configured to interface with the at least one stator bearing section, wherein the first motor section is configured to interface with the second motor section to effect rotation of the spindle about a predetermined axis and the at least one stator bearing section is configured to effect at least leveling of a substrate transport arm end effector connected to the coaxial spindle through an interaction with the at least one rotor bearing section.

Claims

1. A substrate transport for transporting substrates to and from at least one substrate seating surface, the substrate transport comprising:

a substrate transport arm;

a drive section located within a frame and connected to the substrate transport arm through a coaxial spindle, the drive section being configured to operate the substrate transport arm through a spindle rotation or spindle displacement; and

at least one substrate support coupled to the substrate transport arm;

wherein the drive section has a solid state actuator that includes at least one stator attached to the frame that interfaces with and is configured to magnetically support the coaxial spindle substantially without contact and to effect a substantially solid state change, free of stator movement, in an orientation of a predetermined axis of rotation of the coaxial spindle relative to the at least one stator of the solid state actuator to spatially orient the at least one substrate support with respect to one of the at least one substrate seating surface.

2. The substrate transport of claim 1, further comprising a linear drive coupled to the drive section and configured to linearly translate the drive section within the frame.

3. The substrate transport of claim 1, wherein the drive section further comprises at least one rotor attached to the coaxial spindle, the at least one stator being configured to change at least an angular orientation of the predetermined axis of rotation of the coaxial spindle with respect to a centerline of the at least one stator through an interaction with the at least one rotor.

4. The substrate transport of claim 3, wherein the at least one stator and the at least one rotor are isolated from one another where the at least one stator operates in a first environment and the at least one rotor operates in a second environment.

5. The substrate transport of claim 1, further comprising a drive section feedback system comprising at least one sensor located within the drive section and configured to measure a planar position of a spindle centerline and an angular orientation of the spindle centerline with respect to a centerline of at least one stator of the drive section.

6. The substrate transport of claim 1, wherein the coaxial spindle comprises at least two drive shafts each having a rotor configured to interface with a respective stator of the drive section where each of the respective stators interacts with a respective one of the rotors to effect a change in spatial orientation of a predetermined axis of rotation of the spindle.

7. The substrate transport of claim 6, wherein the respective stators are configured to interact with a respective rotor of the at least two drive shafts to axially offset the predetermined axis of rotation of the spindle from a centerline of the respective stators.

8. The substrate transport of claim 7, wherein axially offsetting the predetermined axis of rotation of the spindle effects planar positional adjustment of the at least one substrate support.

9. The substrate transport of claim 1, wherein the drive section comprises two motors configured to provide the substrate transport with six degrees of freedom.

10. The substrate transport arm of claim 1, wherein the drive section comprises two motors configured to provide the substrate transport with seven degrees of freedom.

11. A method of operating a substrate transport drive section comprising:

magnetically supporting axial and radial moment loads applied to a coaxial spindle of the drive section substantially without contact;

measuring a longitudinal orientation of the coaxial spindle about a first predetermined axis of rotation of the coaxial spindle; and

energizing windings of the drive section to effect a substantially solid state repositioning of the longitudinal orientation of the coaxial spindle about a second predetermined axis of rotation;

wherein repositioning of the coaxial spindle effects at least a spatial orientation of a substrate transport arm end effector connected to the coaxial spindle with respect to a substrate support surface.

12. The method of claim 11, wherein the first predetermined axis of rotation and the second predetermined axis of rotation are at different longitudinal angles with respect to each other.

13. The method of claim 11, wherein the repositioning of the coaxial spindle effects a planar positional adjustment of the end effector.

14. The method of claim 11, wherein the first predetermined axis of rotation and the second predetermined axis of rotation are substantially longitudinally parallel with respect to each other.

15. A substrate transport for transporting substrates to and from at least one substrate seating surface, the substrate transport comprising:

a frame;

a transport arm having at least one substrate support coupled to the transport arm;

a drive section located within the frame and having a coaxial spindle connected to the transport arm, the drive section having no more than two motors configured to provide the substrate transport with six degrees of freedom and being configured to operate the transport arm through a coaxial spindle rotation or coaxial spindle displacement, wherein each motor includes a stator.

16. The substrate transport of claim 15, wherein each stator is configured to passively magnetically levitate the coaxial spindle substantially without contact, and to effect substantially solid state generation of propulsion forces in an axial direction for axially displacing the coaxial spindle and to effect substantially solid state generation of radial forces for displacing the coaxial spindle in a direction perpendicular to the axial direction.

17. The substrate transport of claim 15, wherein an edge of each stator is axially offset from an edge of a respective rotor coupled to the coaxial spindle, wherein the axial offset is configured to provide passive levitation of the rotor.

18. The substrate transport of claim 15, wherein each stator is configured to tilt the coaxial spindle.

19. The substrate transport of claim 15, wherein each stator is atmospherically isolated from the coaxial spindle, the substrate transport further comprising non-invasive sensors for sensing a displacement of the coaxial spindle.

20. The substrate transport of claim 19, wherein the non-invasive sensors include one or more of an absolute sensor, a gap sensor and an incremental sensor.

21. A substrate transport for transporting substrates to and from at least one substrate seating surface, the substrate transport comprising:

a substrate transport arm;

a drive section located within a frame and connected to the substrate transport arm through a coaxial spindle, the drive section being configured to operate the substrate transport arm through a spindle rotation or spindle displacement; and

at least one substrate support coupled to the substrate transport arm;

wherein the drive section is configured to magnetically support the coaxial spindle substantially without contact and to effect a substantially solid state change in an orientation of the coaxial spindle to spatially orient the at least one substrate support with respect to one of the at least one substrate seating surface, and

wherein the drive section comprises at least one stator attached to the frame and at least one rotor attached to the coaxial spindle, the at least one stator being configured to change at least an angular orientation of a predetermined axis of rotation of the coaxial spindle with respect to a centerline of the at least one stator through an interaction with the at least one rotor.