Patent Application
20180261490
The present invention relates to an apparatus for transporting an object from one location to another in a manufacturing environment.
The industry has developed a variety of robot mounted and controlled end effectors for the purpose of handling and transporting objects such as rigid disks (e.g., media, substrates, wafers and other round flat objects) in the various parts of the manufacturing process. End effector weight and paddle arrangement affect the precise control, speed, cost and overall processing efficiency. In a majority of manufacturing process steps, the disks are presented to process equipment in a cassette or carrier in which the disks are oriented in the vertical plane. Often times, the end effector must extract each disk from a cassette and orient it in the horizontal direction (plane) for placement into a process machine. At the end of the process, the end effector must retrieve the disk from the process machine, re-orient the disk in a vertical direction (plane) and insert it back into a cassette for transport to the next process step or stage.
For these processing steps, the industry has relied generally upon an end effector that incorporates either dual grippers or vacuum paddles. However, these end effectors are cumbersome to move. For some, large vertical and/or horizontal travel is required that must be carefully managed to ensure that the end effector does not collide with any obstacles or mechanical constraints within the process equipment. For other end effectors, they must move two grippers together to process a disk and incorporate two linear actuators to independently control the two grippers during a process sequence. These additional actuators significantly increase the number of moving parts, cost, and weight.
It would therefore be desirable to provide an end effector that overcomes the disadvantages above.
Embodiments of an apparatus for transporting objects such as disks from one location to another in a manufacturing environment are disclosed.
In accordance with an embodiment of the disclosure, an apparatus is disclosed for transporting an object from one location to another location within a manufacturing environment, the apparatus comprising: a rotary union extending along a first longitudinal axis and configured to rotate axially about the first longitudinal axis and translate longitudinally along the longitudinal axis; and a first drive extending along a second longitudinal axis and configured to support a first paddle assembly that is adapted to hold the object, the first drive supported for movement by the rotary union; wherein the first drive is configured to move the paddle assembly in a first direction or a second direction opposite to the first direction with respect to the second longitudinal axis.
In accordance with another embodiment of the disclosure, a system is disclosed for processing disks during manufacture, the system comprising: an apparatus for transporting a disk from one location to another location; and a paddle assembly coupled to the apparatus, the paddle assembly configured to hold a disk for transportation of the disk; wherein the apparatus comprising: a rotary union extending along a first longitudinal axis and configured to rotate axially about the first longitudinal axis and translate longitudinally along the first longitudinal axis; a first drive extending along a second longitudinal axis and configured to support a first paddle assembly that is adapted to hold an object, the first drive supported for movement by the rotary union; and a first arm extending along the second longitudinal axis and supported for movement by the rotary union, the arm having a first end mounted to the rotary union and a second end mounted to the first drive, wherein the first drive is configured to move the paddle assembly in one of a first direction and a second direction opposite to the first direction with respect to the second longitudinal axis.
In accordance with yet another embodiment of the disclosure, a system is disclosed for processing disks during manufacture, the system comprising: an apparatus for transporting one or more disks from one location to another location; and first and second paddle assemblies coupled to the apparatus, the first and second paddle assemblies configured to hold the one or more disks for transporting the one or more disks; wherein the apparatus comprising: a rotary union extending along a first longitudinal axis and configured to rotate axially about the first longitudinal axis and translate longitudinally along the first longitudinal axis; first and second drives extending along second and third longitudinal axes and configured to support a first and second paddle assemblies for movement by the rotary union, respectively; and a first arm and second arm extending along the second and third longitudinal axes, respectfully and supported for movement by the rotary union, the first and second arms each having a first end mounted to the rotary union and a second end mounted to the respective first and second drives, wherein the first and second drives include first and second shafts extending along first and second lateral axes with respect the second and third longitudinal axes, respectively, the first and second drives configured to selectively move the first and second paddle assemblies up or down with respect to the second and third longitudinal axes, respectively.
In yet another embodiment of the disclosure, a system is disclosed for processing disks during manufacture, the system comprising: an apparatus for transporting one or more disks from one location to another location; and first and second paddle assemblies coupled to the apparatus, the first and second paddle assemblies configured to hold the one or more disks for transporting the one or more disks; wherein the apparatus comprising: a rotary union extending along a first longitudinal axis and configured to rotate axially about the first longitudinal axis and translate longitudinally along the first longitudinal axis; and first and second drives extending along second and third longitudinal axes that form a reflex angle, the first and second drives configured to support the first and second paddle assemblies for movement by the rotary union, respectively.
Embodiments of the present disclosure are described herein with reference to the drawing figures.
Embodiments of the present disclosure are described herein with reference to the drawing figures.
Apparatus 102 is an end effector 102 that comprises rotary union 110 (may also be referred to as rotary unit 110), ported arms 112, 114 (may also be referred to as arms 112,114), motor wrist drives 116, 118, off axis compliance, paddle mounting and adjustment blocks 120, 122 (may also be referred to as blocks 120,122) and motor drive controllers 124,126. (Motor wrist drives 116,118 may also be referred to as motor drives, drives or motor and sensor assemblies 116,118.)
Rotary union 110 attaches to robot unit 108 and they have a longitudinal axis B, i.e., they extend along a longitudinal axis B. Rotary union 110 is configured to rotate axially around the longitudinal axis and/or translate longitudinally along the longitudinal axis B in response to robot unit 108 as known to those skilled in the art. Rotary union 110 includes a main frame 110-10 integral to rotary union 110 that is attached to robot unit 108. Ported arms 112,114 are mounted to the base of main frame 110-10 and motor drive controllers 124,126 are also mounted to main frame 110-10. Ported arms 112,114 and motor drive controllers 124,126 are bolted to main frame 110-10. Main frame 110-10 is intended to deliver the vacuum and electrical services to the other parts of end effector 102. In this embodiment, rotary union 110 (including main frame 110-10) is integral to the overall structure of end effector 102. Importantly, rotary union 110 provides structural support to ported arms 112,114, motor wrist drives 116,118 and paddle assemblies 104,106, while at the same time serving as the direct mechanical interface to robot unit 108. Rotary union 110 is described in more detail below.
Ported arms 112, 114 are attached to rotary union 110 and provide the mounts for the motor wrist drives 116,118 and paddle assemblies 104,106, respectively. Ported arms 112, 114 each have a longitudinal axis (C, D), i.e., extends along a longitudinal axis and both are located in the same (horizontal) plane with respect to the longitudinal axis B of rotary union 110. Those skilled in the art know however that this plane may be oriented at a different angle with the respect to rotary union 110 to achieve desired results. Drives 116, 118 and ported arms 112, 114 are oriented to form an angle with respect to each other. That is, the longitudinal axes C and D of the ported arms 112, 114 intersect at the rotary union to form such angle. This angle is preferably an acute angle between 30 to 60 degrees or a reflex angle (i.e., angle greater than 180 degrees but less than 360 degrees), but those skilled in the art know that any angle may be used to achieve desired results. Arm 114 incorporates a vacuum channel to provide scavenging vacuum (not shown). Arm 114 also incorporates vacuum porting 114-1 and vacuum pipe 114-2 to provide process vacuum to paddle assemblies 104,106 as known to those skilled in the art. Arm 112 similarly includes a vacuum channel, vacuum porting and vacuum tubing 112-1 but they are not shown in
Motor wrist drives 116,118 each include a pitch axis electrical motor (described below) intended to rotate a motor output shaft (described below) axially (around axis A), thereby causing a respective attached paddle assembly to pitch or pivot (move) up or down with respect to an arm and/or drive as shown (i.e., with respect to the longitudinal axis thereof). In the event that the arm and/or drive are oriented in a vertical direction for example, however, the paddle assembly may be pitched or moved side to side with respect to the arm. In sum, a drive may pitch or move a paddle assembly in one of two opposing directions depending on the position of the drive and/or the arm with respect to the rotary union). Motor wrist drives 116, 118 have first ends that are attached to first ends of ported arms 112,114, respectively. In this embodiment, motor wrist drives 116,118 are bolted directly to facing surfaces of ported arms 112,114, respectively. However, those skilled in the art know that assemblies 116,118 may be attached or mounted to ported arms 112,114 by other means. Alternatively, a motor wrist drive and arm may be one integral component (i.e., the motor wrist drive and arm may be one component).
Motor wrist drives 116,118 have second distal ends that are attached directly to off axis compliance, paddle mounting and adjustment blocks 120,122 respectively. In this embodiment, assemblies 116,118 are bolted directly to off axis compliance, paddle mounting and adjustment blocks 120,122, at different points (screw holes describe below) along vertical edge of pitch axis interfaces (described below) of the motor wrist drives 116,118, as shown to enable a user to adjust the pitch of paddle assemblies 104,106 with respect to the horizontal planes of motor wrist drives 116,118 (and ported arms 112,114), respectively. As described in more detail below, the horizontal plane of each motor wrist drive is positioned above the horizontal plane of each respective (attached) paddle assembly to enable a continuous position sensor (described below) of a motor wrist drive to sense (i.e., detect) forces or torques on the paddle assembly and thereby to adjust the programmed positions of paddle assembly during disk processing.
Each motor wrist drive 116,118 is configured to pitch a paddle assembly (104,106) in a precise, programmable motion within a 180 degree rotation (+/−90 degrees). Specifically, each motor wrist drive 116, 118 is capable of rotating from 90 degrees pitch up position as shown in dotted lines in
Off axis compliance, paddle mounting and adjustment blocks 120,122 are constructed as off axis compliant paddle mount and adjustment blocks that mount (attach) paddle assemblies 104,106 to motor wrist drives 116,118, respectively. Off axis compliance, paddle mounting and adjustment blocks 120,122 are each bolted directly to the top of a universal mount (described below) of a paddle assembly. Each block includes two opposing L-shaped edges, each with one or more holes. Each block 120,122 is intended to bolt to various points (holes) along vertical edge of pitch axis interfaces (discussed below) of the motor wrist drives 116,118. The pitch of a paddle assembly is therefore adjusted (below motor wrist drive) by attaching a block to different points along the pitch axis interface of a motor wrist drive).
Motor drives controllers 124,126, one for each motor wrist drive 116,118, are mounted to the base of rotary union 110. (Motor drive controllers may also be referred to as drive controllers or controllers.) Motor drive controllers 124,126 are each typically a commercially available programmable single axis motion controller that incorporates a processor, memory and other components as known to those skilled in the art. Each controller 124,126 is initially programmed (coded) for each deployment to teach robot unit 108 and the motor inside respective motor wrist drive (116,118) the exact points where a respective paddle assembly (104,106) is meant to be located during the manufacturing process (for holding and transporting the disks). That is, controllers 124, 126 are programmed to move these respective assemblies to the proper locations to hold and transport the disks during the manufacturing process. (Redeployment may require reprogramming.) In operation, a continuous position sensor (118-4 of a motor wrist drive—
Reference is now made to
In particular, motor wrist drive 118 includes motor output shaft 118-1, pitch axis electric motor 118-2, gear reducer 118-3, continuous position sensor 118-4, motor housing 118-5, motor coupler 118-6, pitch axis interface 118-7, bearing set 118-8, inner race clamp plate 118-9, outer race clamp plate 118-10 and cover 118-11.
Pitch axis electric motor 118-2 is intended to rotate motor output shaft 118-1 via gear reducer 118-3. Pitch axis electric motor 118-2 may be a servo, stepper or other motor as known to those skilled in the art.
Gear reducer 118-3 functions to reduce the rotation of motor 118-2 into a usable rotation of motor output shaft 118-1 as known to those skilled in the art. (The shaft has an axis A (i.e., extends along an axis A) that is lateral to a longitudinal axis of an arm.)
Motor housing 118-5 functions to house the portion of the motor 118-2 and motor output shaft 118-1. Scavenging vacuum is applied to the motor housing via the ported arm to minimize contamination.
As described above, continuous position sensor 118-4 functions to sense (i.e., detect) the precise position of the motor output shaft and any deviation from a commanded position resulting from any force or torque on motor output shaft 118-1 transmitted from pitch axis interface 118-7 via motor coupler 118-6.
Pitch axis interface 118-7 is configured to rotate in response to rotation of drive shaft 118-1 through motor coupler 118-6, thereby causing attached paddle assembly 106 to pivot up or down as required for disk processing. Pitch axis interface 118-7 accommodates bearing set 118-8. Pitch axis interface 118-7 is attached to paddle assembly 106 as described in detail below.
Bearing set 118-8 enables the pitch axis interface 118-7 to rotate freely. Preloading bearing set 118-8 removes any lateral motion of the motor wrist assembly 118. Inner race clamp plate 118-9 preloads the inner race of bearing set 118-8 and outer race clamp plate 118-10 preloads the outer race of bearing set 118-8. Cover 118-11 attaches motor coupler 118-6 to the pitch axis interface 118-7 and encloses the bearing set to eliminate contamination. Bearing set 118-8 may be a commercially available component.
As indicated above, motor wrist drive 116 includes the same components and functions similarly as the motor wrist drive of assembly 118. While motor wrist drives 116,118 are shown in the figures and described herein, those skilled in the art know that any drive/mechanism may be used to pitch or move paddle assemblies 104,106 up or down (or other opposing directions) with respect to arms 112,114 (i.e., an axis defined by the arms 114,116). In addition, while dual arms 112,114, drives 116,118 and paddle assemblies 104,106 are described herein above and shown in
End effector 102 as described above is designed to work with any paddle assembly known to those skilled in the art. Paddle assemblies 104,106 are example assembles that may be used with end effector 102. The operation of end effector 102 is now described with respect to paddle assemblies 104,106 but those skilled in the art know that other paddle assemblies may be employed. In operation, robot unit 108 moves to an input cassette housing one or more disks. End effector 102 pitches paddle assembly 104 to a vertical down position and a paddle assembly 106 to the horizontal position. Paddle assembly 104 extracts a first (unprocessed) disk from the input cassette. Robot unit 108 moves to a process machine. End effector 102 pitches paddle assembly 104 to a vertical up position. Paddle assembly 106 removes the finished disk from the process machine. In a coordinated sequence, robot unit 108 moves up vertically, paddle assembly 106 pitches to a vertically up position, paddle assembly 104 pitches to a horizontal position, end effector 102 rotates through an acute angle of typically 30 to 60 degrees as described above and robot unit 108 moves down to deposit (place) the unprocessed disk on the process machine. Robot unit 108 moves to an output cassette. Paddle assembly 106 pitches to a vertically down position and inserts the finished disk into the output cassette. Robot 108 moves to the input cassette and repeats this sequence.
In summary, end effector 102 described above has several advantages. First, the overall mass and size of end effector 102 is significantly small, thereby allowing robot 108 to move it its optimal speed and affording high system throughput. Second, motor wrist drives of end effector 102 each have a mass at the end thereof that is very low, allowing a small, lightweight and low power motor to be used. Third, the distance from each motor wrist drive 116,118 to the end of each paddle assembly 104,106 is short, with very few tolerance stack-ups. This ensures that paddle assembly (disk) position uncertainty is minimized. Fourth, the combination of continuous position sensor 118-4, electric motor 118-2 and controller 126 (or 124) allow for the precise control of the position/speed profile of the pitch motion of each paddle assembly throughout its range, thereby optimizing both speed and accuracy and minimize settling times of each pitch motion. Fifth, the combination of the continuous position sensor 118-4, electric motor 118-2, controller 126 (or 124) allow for the coordination and synchronization of pitch operations and robot unit 108 motion, thereby minimizing the disk exchange time at each process machine and increasing system throughput. Sixth, the integration of controllers 126,124 into the rotary union 110 minimizes the number of electrical wires that must be routed through robot unit 108 to end effector 102, thereby minimizing contamination, potential cable failures and system downtime. Seventh, the electrical connections between controllers 126 (or 124) and electric motors (e.g., 118-2) are fixed and stationary, thereby eliminating the possibility of cable failures and system downtime. Eighth, the rigid, stationary mechanical mounting of motor wrist drives 116,118 to ported arms 112,114 and the mounting of ported arms 112,114 to rotary union 110 minimize the mechanical tolerance build-ups of the end effector (assembly), thus assuring uniformity from one end effector 102 to another. Ninth, the particular arrangement of off axis compliance, paddle mounting and adjustment blocks 120,122 (off axis compliant paddle mount and adjustment blocks) allows continuous position sensor 118-4 to detect any resistance forces and torques that may be produced when placing or retrieving a disk from a process machine or cassette. Such built-in detection allows real-time, continuous and automatic adjustment of the precise coordinates of each location to which it moves with little or no human intervention. Lastly, off axis compliance, paddle mounting and adjustment blocks 120,122 allows for direct detecting (sensing) of many types of obstacles directly by continuous position sensor 118-4 therefore avoiding equipment damage and product loss.
Embodiments of example paddle assemblies 104,106 are now described with respect to
Specifically, paddle assembly 104 comprises universal paddle mount 104-1, paddle clamps 104-2, 104-3, stub paddles or plates 104-4, 104-5, disk post pins 104-6, 104-7, lateral alignment pin (not shown), washer plates 104-8, 104-10, nut plates 104-9 and 104-11 and vacuum ports 104-12,104-13.
Universal paddle mount 104-1 (or paddle mount or mount) is used to mount paddle assembly 104 to motor wrist drive 116 by way of block 120. Paddle clamps 104-2,104-3 are used to attach and align two stub paddles or plates 104-4,104-5 to paddle mount 104-1. Paddle mount 104-1 and paddle clamps 104-2,104-3 are configured to be independent of disk form factor dimensions.
Plates 104-4,104-5, in an assembled configuration, together form a paddle that is configured to receive and hold (grasp) disk 200 for subsequent transportation. Specifically, plates 104-4, 104-5 include chamfer edges (walls) 104-4a, 104-5a that define groove 104-14 wherein disk 200 is seated. Groove 104-14 extends inwardly from curved peripheral edges or borders 104-4b, 104-5b (of plates 104-4 and 104-5) toward the rear of groove 104-14 as shown. This is best shown in
In practice, groove 104-14 is configured having a width slightly larger at the rear than the width of the disk. The rim of the disk typically makes contact with the top chamfer edge 104-4a only, as a result of gravity and vacuum application, thereby leaving a small space between the rim of the disk and chamfer edge 104-5a (adjacent the bottom rim of disk 200) as known to those skilled in the art. Registration is essentially one or more points of contact between disk 200 and chamfer edge 104-4a. It is this contact registration that controls the vertical position of disk 200 during transportation.
Disk post pins 104-6, 104-7 are positioned within the opposing triangular ends or tips of the paddle assembly between plates 104-4, 104-5 and adjacent groove 104-14.
Disk post pins 104-6,104-7 are configured to ensure precise and repeatable horizontal alignment of disk 200 within the groove defined by chamfer edges 104-4a, 104-5a of plates 104-4,104-5. That is, disk post pins 104-6,104-7 guide disk 200 so that it engages and seats with groove 104-14 properly. In short, pins 104-6, 1-4-7 control the horizontal position of disk 200 within the groove. Disk post pins 104-6, 104-7 also ensure the precise and repeatable horizontal alignment of the two plates 104-5, 104-6 when assembled and mounted to the universal paddle mount 104-1.
In sum, it is this contact registration described above (i.e., contact with pins 14-6, 104-7 and one or more points on edge 104-4a of groove 104-14) that controls both the vertical and horizontal position of disk 200 during transportation. In this respect, disk 200 is not damaged or contaminated by the contact registration.
Lateral alignment pin 104-16, washer plates 104-8, 104-10 and nut plates 104-9,104-11 are configured to assist in proper assembly and alignment of paddles 104-4,104-5. Three pins are described herein and shown in the figures, but those skilled in the art know that any number of pins may be used to achieve desired results.
Vacuum ports (pipes) 104-12,104-13 provide vacuum services from vacuum pipes on ported arms 112,114 (e.g., vacuum pipe 114-2). The vacuum services or suction maintain disk 200 in place within the groove described above.
The components of the paddle assemblies 104,106 may be constructed with a variety of materials such as various conductive and static dissipative plastic compounds, aluminum and stainless steel.
As described above, the same components and functionality of paddle assembly 104 are part of paddle assembly 106.
Paddle assemblies 104,106 have several advantages. First, these paddle assemblies reduce disk contamination by decreasing sliding contact and/or reducing airborne particles. Second, the plates can be removed, disassembled, cleaned and inspected in great detail. Worn and damaged parts can be easily replaced without incurring excessive production down time for adjusting programmed positions and end effector alignment and calibration. Further, individual components are less expensive to replace. Third, disk outer diameter damage is reduced. Fourth, dividing a vacuum paddle into two plates exposes all inner surfaces, thereby making machining and deburring easier with the ability to hold very tight tolerances as compared to current designs. Fifth, all critical dimensions of the paddle assembly and especially its interior are precisely controlled and are readily measured to determine compliance with design specifications. Sixth, the dimensions and contours of the groove (defined by the stub paddles) and the interior of the assembled paddle are varied along the circumference of the groove to minimize the contact area between the paddle and the disk. Seventh, the width of the groove is precisely controlled to maximize the paddle's holding power of the disks during high dynamic loads. Eighth, abrasion between the surface of the disk and the paddle is minimized and as a result contamination is reduced. And finally, surface contact between the body of the paddle and the surfaces of the disk is significantly reduced or eliminated.
While the embodiments of apparatus 102 and assemblies 104,106 described above involve disks, apparatus 102 and paddle assemblies 104,106 may also be used holding and transporting objects that are circular and flat that require fast, efficient and low cost and/or low contamination handling.
It is to be understood that the disclosure teaches examples of the illustrative embodiments and that many variations of the invention can easily be devised by those skilled in the art after reading this disclosure and that the scope of the present invention is to be determined by the claim(s) below.
The application claims priority to U.S. provisional application No. 62/163,602, filed May 19, 2015 entitled “Apparatus For Transporting Disks and Paddle Assemblies For Holding Disks” which is incorporated by reference herein.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US16/32570 | 5/14/2016 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62163602 | May 2015 | US |
