Conveying device for conveying at least one wafer
11430683 · 2022-08-30
Assignee
Inventors
Cpc classification
B65G54/02
PERFORMING OPERATIONS; TRANSPORTING
B65G2811/0668
PERFORMING OPERATIONS; TRANSPORTING
International classification
Abstract
A conveying device includes a transport body configured to carry or hold a wafer, and a stator relative to which the conveying device is designed to move the transport body at least two-dimensionally on a conveying surface. The stator includes several movably arranged actuating magnets, each of which is connected to the stator via an actuating element, and the actuating element is configured to change a position and/or an orientation of the connected actuating magnets relative to the stator. The transport body includes at least two stationary magnets which are connected to the transport body such that the stationary magnets are immovable relative to the transport body, and the stator and the transport body are magnetically coupled by the stationary magnets and the actuating magnets. The device conveys the transport body relative to the stator by controlled positioning and/or orientation of the actuating magnets via the actuating elements.
Claims
1. A conveying device for conveying at least one wafer, comprising: at least one transport body configured at least to carry or hold the at least one wafer; and a stator, relative to which the conveying device is configured to convey the at least one transport body at least two-dimensionally on a conveying surface in controlled fashion, wherein: the stator comprises several movably arranged actuating magnets, each of which is connected to the stator via an actuating element, wherein the actuating element is configured to change a position and/or an orientation of the connected actuating magnets relative to the stator in controlled fashion; the at least one transport body comprises at least two stationary magnets which are connected to the transport body such that the at least two stationary magnets are immovable relative to the transport body; the stator and the at least one transport body are magnetically coupled by means of the at least two stationary magnets and the several actuating magnets; and the conveying device is configured to convey the at least one transport body relative to the stator by controlled positioning and/or orientation of the several actuating magnets via the actuating elements.
2. The conveying device according to claim 1, wherein the conveying device is configured to convey the at least one transport body in a controlled floating fashion.
3. The conveying device according to claim 1, wherein the conveying device is configured to levitate the at least one transport body relative to the stator via the several actuating magnets and the at least two stationary magnets.
4. The conveying device according to claim 1, further comprising: at least one slit valve fixedly positioned relative to the conveying surface, and configured to allow at least a portion of the wafer carried or held by the at least one transport body therethrough while precluding at least a portion of the at least one transport body from passing therethrough.
5. The conveying device according to claim 1, wherein the several actuating magnets and/or the at least two stationary magnets are arranged facing the conveying surface, wherein the conveying device is configured to convey the at least one transport body relative to the stator along the conveying surface in controlled fashion.
6. The conveying device according to claim 1, wherein the at least one transport body include at least two transport bodies, and the conveying device is configured to convey the at least two transport bodies along different conveying paths on the conveying surface such that one transport body of the at least two transport bodies can overtake another transport body of the at least two transport bodies.
7. The conveying device according to claim 1, wherein the at least one transport body include at least two transport bodies, and the conveying device is configured to convey the at least two transport bodies along a conveying path having at least two tracks on the conveying surface.
8. The conveying device according to claim 1, wherein the conveying device is configured to convey the at least one transport body at least up to a processing station, or to at least position or align the at least one wafer transported by the at least one transport body in the processing station.
9. A conveying device for conveying at least one wafer, comprising: at least one transport body configured at least to carry or hold the at least one wafer; and a stator, relative to which the conveying device is configured to convey the at least one transport body at least two-dimensionally on a conveying surface in controlled fashion, wherein: the at least one transport body comprises several movably arranged actuating magnets, each of which is connected to the transport body via an actuating element, wherein the actuating element is configured to change a position and/or an orientation of the connected actuating magnet relative to the transport body in controlled fashion; the stator comprises at least two stationary magnets which are connected to the stator such that the at least two stationary magnets are immovable relative to the stator; the at least one transport body and the stator are magnetically coupled by means of the at least two stationary magnets and the several actuating magnets; and the conveying device is configured to convey the at least one transport body relative to the stator by controlled positioning and/or orientation of the several actuating magnets by means of the actuating elements.
10. The conveying device according to claim 9, further comprising: at least one slit valve fixedly positioned relative to the conveying surface, and configured to allow at least a portion of the wafer carried or held by the at least one transport body therethrough while precluding at least a portion of the at least one transport body from passing therethrough.
11. The conveying device according to claim 9, wherein the several actuating magnets and/or the at least two stationary magnets are arranged facing the conveying surface, wherein the conveying device is configured to convey the at least one transport body relative to the stator along the conveying surface in controlled fashion.
12. The conveying device according to claim 9, wherein the conveying device is configured to levitate the at least one transport body relative to the stator via the several actuating magnets and the at least two stationary magnets.
13. A method for operating a conveying device, comprising: freely moving at least one transport body, which is configured to carry or hold at least one wafer, on a conveying surface into a desired position and/or orientation with the conveying device, which is configured to move the at least one transport body at least two-dimensionally on the conveying surface using a stator, relative to which the conveying device is configured to convey the at least one transport body in controlled fashion, wherein: one of the at least one transport body and the stator comprises several movably arranged actuating magnets, each of which is connected to the one of the at least one transport body and the stator via an actuating element, wherein the actuating element is configured to change a position and/or an orientation of the connected actuating magnet relative to the at least one transport body and the stator in controlled fashion; the other of the at least one transport body and the stator comprises at least two stationary magnets which are connected to the other of the at least one transport body and the stator such that the at least two stationary magnets are immovable relative to the other of the at least one transport body and the stator; the at least one transport body and the stator are magnetically coupled by means of the at least two stationary magnets and the several actuating magnets; and the conveying device is configured to freely move the at least one transport body relative to the stator by controlled positioning and/or orientation of the several actuating magnets by means of the actuating elements.
14. The method of claim 13, further comprising: moving at least a portion of the wafer carried or held by the at least one transport body through a slit valve; and precluding, with the slit valve, at least a portion of the at least one transport body from passing through the slit valve after moving the at least a portion of the wafer through the slit valve.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE DRAWINGS
(17)
(18) The transport bodies 200 may move substantially freely on the conveying surface 35 and thus deliver wafers 36 to processing station 37, and in some cases hold them in the processing stations 37 or position and/or align them therein. In order nonetheless to be able to guarantee an optimal separation of the interior of the processing stations 37 from the environment, slit valves 39 for example may be provided, through which at least the part of the transport body 200 holding the wafer or wafers 36 may protrude (when the valve is open).
(19)
(20) The position and orientation of the transport body relative to the stator may be described in a stator coordinate system 900 which is spanned by an X direction 902, a Y direction 904 and a Z direction 906. The transport body has its own transport body coordinate system 920 which is spanned by an X1 direction 922, a Y1 direction 926 and Z1 direction 926, and comprises a roll angle 932, a pitch angle 934 and a yaw angle 936.
(21) The conveying device 10 is preferably controlled such that the transport body 200 is levitated in stable fashion and guided on a predefined nominal curve with respect to translation and rotation.
(22) Whereas
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(24)
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(26) The transport body 200 may serve as a mechanical link between a transport product 20, e.g. a holder for holding a wafer 36, on one side and the stator 100 on the other. Preferably, the transport body 200 is formed as a mechanically rigid element and configured to support or transport a transport product 200 on a top side of the top cover element 202. Preferably, the transport product 20 may be fixed to the transport body 200 and then, together with the transport body 200, guided on a nominal curve over the stator 100 and/or held stable at a nominal position. The transport body 200 according to the embodiment shown is electrically passive, i.e. to perform its function, it requires no electrical energy or connections and in particular comprises no actuating magnets.
(27) According to the embodiment shown, the transport body 200 comprises a plurality of stationary magnets 22 in a superficial arrangement in the X1/Y1 plane, arranged as a magnet group 24 in a geometric arrangement, wherein the geometric arrangement of the stationary magnets 22 is fixed relative to the transport body 200, and the stationary magnets 22 do not therefore move relative to the transport body 200. For example, the top cover element 202 and/or the bottom cover element 204 and/or the edge element 206 may be configured to at least partially fix the stationary magnets 22 in their position or geometric arrangement. Alternatively or additionally, the transport body 200 may comprise one or more further components for fixing the stationary magnets 22. Preferably, the stationary magnets 22 comprise a permanent magnet and/or are configured as permanent magnets. Particularly preferably, the stationary magnets 22 comprise permanent magnets of rare earth alloys.
(28) The position of a magnet or stationary magnet 22 preferably means the position of its centroid. A magnetisation direction of the respective stationary magnet is described by a dipole vector, which is depicted symbolically as a corresponding arrow. It is evident from
(29) The arrangement of the stationary magnets 22 in the transport body 200 is preferably adapted or matched to an arrangement of actuating magnets 26 (see for example
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(31)
(32) Arrangements in which the stationary magnets 22 are all arranged in one arrangement plane are particularly suitable for applications in which primarily translational movements must be executed parallel to the arrangement plane, and/or rotations about the Z-axis of the stator 100 or the Z1 axis of the respective transport body 200.
(33) The magnet groups 24 comprise preferably stationary magnets 22 which are arranged as at least one Halbach array. The Halbach array or arrays are preferably oriented or arranged such that the magnetic field or magnetic field intensity is increased in the direction of the stator 100, and/or reduced in the direction of the transport product 20 and/or in the direction of possible adjacent transport bodies 200 which may also be conveyed on the same stator 100. Exemplary arrangements of stationary magnets 22 which form Halbach arrays amongst others are depicted in
(34)
(35)
(36) The arrangement of the stationary magnets 22 on a curved plane may offer an increased pivot angle range at least in one direction of the transport body 200. For example, a cylindrical transport body 200, the curved casing surface of which as an action surface levitates on a stator 100, may in some cases perform an endless rotation about its cylinder axis. In addition, an endless rotation about the Z-axis of the stator 100 may be possible.
(37) A surface which is curved in two spatial directions may for example enlarge the pivot angle range in two spatial directions of the transport body 200. For example, in some cases a spherical transport body 200 equipped with stationary magnets 22 may execute endless rotations in all spatial directions.
(38) The transport body 200 may also be designed as a segment of a cylinder or ball, as shown for example in
(39)
(40) A structural component or housing or frame of a transport body 200, which for example holds together the individual components of the transport body 200 such as the stationary magnets 22, is preferably made of non-ferromagnetic material, for example of plastic and/or ceramic and/or non-ferrous metals. Optionally, it has an edge element 206 not equipped with magnets, which serves for example as a spacer from other transport bodies 200, so that preferably mutual contact forces between two touching transport bodies 200 are limited and a free positionability of both transport bodies 200 is not obstructed, preferably also when they are touching.
(41) On the side facing the stator 100, the transport bodies 200 may be provided with a bottom cover element 204, which for example has a cover layer which preferably acts as a spacer from possible objects in the environment of the transport body 200, and preferably can safely limit the distance and hence the maximal action forces of the stationary magnets 22. In this way for example, it is possible to reduce the risk of injury in handling transport bodies 200, such as the risk of crushing fingers on incorrect approach of a ferromagnetic object. Furthermore, preferably an overload limitation may be achieved for drives or actuating magnets in the stator 100, since the forces and moments which the transport body 200 exerts on the actuating magnets in the stator 100 can preferably be limited. In addition, preferably, a better cleaning of the transport body 200 from adhering ferromagnetic particles can be achieved, since the holding forces are lower. Also, an optional integration of additional functions in the bottom cover element may be advantageous, such as for example a coil for inductive energy transmission or a data carrier for identification of the transport body 200.
(42) Several transport bodies 200 may be coupled together mechanically and/or for control purposes in order for example to perform a common function. For example, a passive mechanical parallel kinematic, the bars of which are actively driven and positioned by separate transport bodies 200, may execute handling tasks. In another example, by being moved and conveyed preferably in synchrony, several transport bodies 200 together may transport loads which are too heavy for example for a single transport body 200.
(43) According to a further preferred embodiment, a transport body 200 may also have internal degrees of freedom and for example consist of several components movable relative to each other, so that preferably in total it has more than six degrees of freedom. By providing stationary magnets 22 in several of the components, preferably the more than six degrees of freedom of the transport body 200 can be actively controlled. As
(44) In addition, according to a preferred embodiment, a transport body 200 may be equipped with function groups for further additional functions. For example, a mechanical energy transmission may take place in that a disc, preferably mounted rotatably in the transport body 200 and equipped with magnets, is actively driven by the stator 100. For the drive, the disc is treated by the stator 100 for example as a seventh degree of freedom. Also, optionally, an electric contactless energy transmission may be implemented, in that for example coils for inductive energy transmission are integrated in the stator 100 and in the transport body 200. Alternatively or additionally, for example, a permanently rotating magnet in the stator 100 may induce an alternating voltage in a coil in the transport body 200 which can preferably be used to generate power on the transport body 200. On translational movement of the transport body 200, the task of exciting the additional function is continuously transferred to other magnet groups or actuating magnets of the stator 100 which lie for example in an action region of the induction coil. Also for example, a contactless data transmission can be achieved between the stator 100 and the transport body 200, for example with inductive and/or optical transmitters and receivers. Furthermore, optionally a facility for location and/or identification of the transport body 200 may be provided. For example, an optical camera-based sensor in the stator 100 may read a position or identification code provided on the side of the transport body 200 facing the stator 100. For example, at least part of the transport body 200 may be equipped with an identification element such as for example a barcode, using which the conveying device 10 or stator 100 can identify the respective transport body 200.
(45)
(46) The actuating magnets 26 or magnet groups 24 are connected to actuating elements 114, by means of which their position and/or orientation can be changed. An actuating element 114 here has at least one drive, such as an electric motor, which is preferably connected to the magnet group 24 via a drive shaft and/or a gear mechanism and/or a linkage.
(47) The magnetic fields required to guide the at least one transport body 200 are generated by a controlled e.g. regulated movement of the magnet groups 24 or actuating magnets 26 in the stator 100. The magnetic field generated by the magnet groups 24 emerges at least partially from the action surface 102 of the stator 100 and exerts forces and/or moments on the stationary magnets 22 in the transport body 200. The direction and intensity of the forces and/or moments in the transport body 200 are influenced by the position or orientation of the actuating magnets 26 or magnet groups 24 in the stator 100. The position of the actuating magnets 26 or magnet groups 24 in the stator 100 is here, preferably, controlled such that the transport body 200 floats and is guided along a predefined nominal curve in all six dimensions or held in stable fashion at a predefined nominal position with a predefined nominal orientation.
(48) As
(49) Furthermore, according to the preferred embodiment shown, the stator 100 comprises a magnet position determination element 118, by means of which the actual position and/or orientation of the magnet groups 24 or actuating magnets 26 can be determined. For example, the magnet position determination element 118 may have a sensor layer.
(50) The arrangement of the magnet groups 24 in the stator 100 is preferably flat, i.e. preferably all magnet groups 24 are arranged in one plane.
(51)
(52) The coil layer 128 may for example be configured as a multilayer circuit board with internal coils.
(53) The surface of the cover 112a facing the at least one transport body 200 preferably forms the action surface 102 of the stator 100. Optionally, a mechanical retraction device may be provided (not shown) which increases the distance of all magnet groups 24 of actuating magnets 26 from the action surface 102. This retraction device may for example be activated automatically on stoppage of the conveying device 10, so that the magnetic fields emerging from the action surface 102 at a standstill are safely limited. Thus for example, safe handling in front of the action surface 102 is possible, and it is easier to remove adhering ferromagnetic particles.
(54) The stator 100 can preferably be operated in any direction relative to gravity, for example in table mode (transport body 200 floating over the action surface 102), in wall mode (transport body 200 floating next to the action surface 102), or in ceiling mode (transport body 200 floating below the action surface 102). Also, in principle, the entire system may be operated in an accelerated reference system or in weightless conditions.
(55) Preferably, the stator 100 is modular in construction so that several identical and/or different stator modules can easily be arranged next to each other, preferably seamlessly (see
(56) The transport bodies 200 may preferably slide freely across from one stator module to another stator module. Thus, preferably, a working range of the transport bodies 200 can be extended as required. Each module furthermore preferably has an interface for energy supply 126 and mechanical interfaces for coupling to further stator modules and for simple integration in a system.
(57) The magnetic field of the stator 100 is preferably produced by a primarily superficial or flat arrangement of the magnet groups 24. The arrangement of the magnet groups 24 preferably forms a regular square pattern of magnet groups 24, but other regular or irregular arrangements are however possible.
(58)
(59) According to a preferred embodiment, an actuating magnet 26 is formed by a single magnet, as shown in
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(62) The magnet groups 24 are preferably individually adjustable in the stator 100, i.e. their position and/or orientation may be varied. Preferably, they can execute a linear movement and/or a rotation and/or a superposed movement. Preferably, a rotation is performed about a structurally fixedly predefined rotation axis of the drive shaft 28. In order to achieve an effective change in the magnetic field by rotation, the dominant dipole vector of the magnet group 24 is oriented preferably perpendicularly to the rotation axis of the drive shaft 28.
(63) The rotation axes of the magnet groups 24 may be oriented differently relative to the action surface 102. Preferably, they are oriented perpendicularly and/or parallel to the action surface 102. The distance between adjacent magnet groups 24 is selected such that the torques on the magnet groups 24 caused by their magnetic interaction are low in comparison with typical torques caused by the transport bodies 200.
(64) For the positioning and orientation of the magnet groups 24, actuating elements 114 are used which can preferably execute linear movements and/or rotations and/or superposed movements. An actuating element 114 preferably moves at least one magnet group 24. Preferably, actuating elements 114 are used which can cover an angular range of 360° and are preferably able to execute endless rotations. This may be advantageous for many movements of the transport body 200.
(65)
(66) For example, an actuating element 114 has an electric motor, with at least one magnet group 24 mounted on its shaft. The sensor 30 measures the rotation angle a of the drive shaft, a PID controller with optional downstream drive amplifier preferably actuates the motor 34. To increase the torque or rotation speed, a gear mechanism 32 may be provided between the motor 34 and the drive shaft 28. The gear mechanism 32 may for example be self-inhibiting so that the motor 34 need not be supplied with power for maintaining a torque in a constant angular position.
(67) The exemplary flat arrangements, shown in
(68)
(69) An actuating element 114 with several drives can preferably influence several degrees of freedom of a magnet group 24. For example, a magnet group 24 mounted universally rotatably in two spatial directions may be rotated by two actuating elements 114 in two different spatial directions.
(70) Instead of electric motors, other drive systems may also be used, for example a lift magnet or a piezo drive.
(71) To achieve a high dynamic, it may be advantageous to rotate the magnet groups 24 about one of their main inertia axes with low inertia moment. The rotation axis preferably runs through the centroid of the respective magnet group 24 in order to avoid vibrations of the stator 100 because of imbalance. In order to compensate for the inertia of the mechanical drives, for example additional coils (see
(72) Since the drives and the drive amplifiers may heat up in operation, a cooling device may be provided which for example cools the drives and/or drive amplifiers by heat dissipation via a cooling body, or a ventilation system and suitable ventilation channels in the stator 100 (see for example
(73)
(74) According to a further preferred embodiment, the conveying device comprises a position determination unit. This is preferably configured such that the position and/or orientation of the at least one transport body 200 relative to the action surface of the stator 100 can be detected, preferably in cyclic fashion, particularly preferably with high frequency and low latency time. Preferably, all degrees of freedom of the transport body 200 are detected. A measurement may for example constitute the basis for controlling the position of the transport body.
(75) The position determination unit may be at least partially integrated in the stator 100 or be installed physically separately from the stator 100 and transmit the position data to a stator controller. Preferably, the position determination unit is however integrated in the stator 100, whereby preferably a constant dimensional reference to the stator 100 can be guaranteed, and/or handling of the entire system can be simplified. Integration in the stator 100 may for example make efficient use of the existing installation space, since the position determination takes place on the side of the transport body 200 which faces the stator 100, and thus preferably the position determination is not obstructed or falsified by the transport product.
(76) Preferably, magnetic field sensors and/or capacitive sensors and/or optical sensors are used as sensors 132. The sensors are preferably arranged in a regular pattern below the action surface 102. For example, Hall sensors may detect the magnetic field in the transport body 200 at several places and/or in different spatial directions. Preferably, all sensor signals are transmitted to a computer system for evaluation. There, for example by means of an algorithm, the actual position of the transport body 200 can be determined from the sensor signals and a modelled description of the magnet arrangements in the transport body 200 and stator 100.
(77) In order to reduce or eliminate the influence of the magnetic fields in the stator 100 on the position determination of the transport body 200, the sensors 132 are preferably mounted as far as possible away from the magnet groups 24 of the stator 100. In addition, magnetic screening devices may be provided which weaken the influence of the magnet groups on the sensors 132 configured as magnetic field sensors. For example, in a single automatic calibration process without the presence of the transport body, the sensor signal from all sensors 132 can be measured as a function of the position of each individual magnet group 24, wherein the measurement values can be permanently stored in a memory of the computer system as a correction table. In operation, for example the raw sensor values may be corrected after each measurement by the error amounts of all magnet groups stored in the correction table, depending on their current position.
(78) According to a further preferred embodiment, an operating interface in the stator 100 provides basic operating and display elements for the device and/or for operation and/or service and/or maintenance. For example, an on/off switch, a reset button and signal lamps for displaying the operating or fault state of the stator 100 may be present. More complex set-up functions are preferably accessible from a higher-level computer system, which for example is connected to the stator 100 via a communication interface.
(79) Preferably, an electronic control system with at least one computer system detects the sensor signals, communicates with the higher-level system, the user interface and in some cases with further stators and system components, and actuates the actuating elements.
(80) Preferably, a computer system is integrated in each stator 100 or in each stator module. When several stators 100 or stator modules are used, their computer systems may be networked for example with bus systems, the topology of which may be extended in flexible fashion.
(81) The bus systems are able to transmit large data quantities in a short time without latency. The bus systems can transmit the data electrically, optically and/or inductively. For example, adjacent stators 100 or stator modules may have optical transmitters and receivers via which they exchange status information. Further computer systems may be integrated in the bus systems.
(82) According to a preferred embodiment, the method for operating the conveying device 10 may be implemented in the form of algorithms on the at least one computer system. A group of several stators 100 may be treated as a functional unit, so that a transport body 200 is controlled irrespectively of whether it is situated in the influence zone of just one stator 100 or of several stators 100. For this, the computer systems are preferably synchronised on a common time basis.
(83) The at least one computer system preferably provides all functions necessary for set-up and/or safe operation and/or service and maintenance of each stator 100 and a group of several stators 100. For example, integrated self-diagnosis functions permanently monitor correct function, so that a malfunction can be detected and reported immediately and/or substitution measures taken, and the system can if necessary automatically transfer to safe emergency holding.
(84) The conveying device 10 here comprises at least one stator 100 or at least one stator module and at least one transport body 200. Preferably, there are many configuration parameters which can be influenced for adaptation to a target application, e.g. dimensions of the stator 100 for scaling to the size or weight of the transport product, a maximal torque and/or rotation speed and/or inertia moment of the drives, an intensity and/or arrangement of actuating magnets and stationary magnets in the stator 100 or transport body 200, and control parameters.
(85) The arrangement of the magnet groups 24 in the stator 100 is preferably matched to the arrangement of the magnet groups 24 in the transport body 200 such that a transport body 200 with f degrees of freedom can, at every point of its working space, be influenced by the forces and moments of at least f magnet groups 24. In particular, the magnet arrangements are designed such that there are no singularities, i.e. no singular regions in the working space at which this condition is not fulfilled. Exemplary pairings of magnet arrangements in stator and transport body are as follows: stator as
(86) Whereas λ designates the period length of a Halbach array of stationary magnets 22 or magnet groups 24 of stationary magnets 22, γ designates a period length of a regular arrangement of actuating magnets 26 or magnet groups 24 (see for example
(87) Preferably, the transport bodies 200 are overdetermined, i.e. they may be influenced by more than f magnet groups 24 simultaneously. The resulting redundancy has advantages such as an improved security against failure. If one magnet group 24 can no longer be effectively controlled, preferably other magnet groups 24 at least partially compensate for the failure so that the position of the transport body 200 can be maintained, albeit possibly with restrictions. The position change necessary for a force/moment change can preferably be divided over several magnet groups 24. This preferably reduces the position change for each individual magnet group 24. Therefore preferably the position change as a whole can be carried out more quickly so that the dynamic of the conveying device 10 increases. Preferably, the forces and moments to be applied for guiding a transport body 200 are divided over several magnet groups 24, so that smaller magnet groups 24 with weaker actuating elements 114 can be used to achieve the same effect. This may bring advantages for energy consumption and the costs of the conveying device 10.
(88) The conveying device can preferably be combined with conventional transfer systems. For example, the transport bodies 200 may be transported over great distances by a conveyor belt in that for example they leave a stator 100, are moved by a conveyor belt to a new position and there transferred to or placed on a stator. As part of a modular overall system, stators 100 with different capacities may be combined. For example, stator modules may be used which are optimised for high speed and/or high precision and/or high forces. These modules are preferably used in zones, wherever they are required.
(89) Stators with curved surfaces as shown in
(90) To save energy, preferably the actuating elements 114 may be operated temporarily with reduced power or switched off when no transport body 200 is in the inclusion zone of the respective magnet group 24. On approach of a transport body 200, they are preferably reactivated briefly.
(91) The outer surfaces of the stator 100 and transport body 200 may preferably be configured such that they are adapted to the respective environmental conditions, for example extreme temperature requirements, high cleanliness requirements, absence of particles, absence of germs, ease of cleaning, resistance to aggressive materials, use in hazardous areas, use under liquid or gaseous atmosphere etc. For this, for example, a wide range of non-ferromagnetic materials is available, such as non-ferrous metals, plastic, Teflon, ceramic, glass, rubber, wood and many more.
(92) A group of transport bodies 200 may preferably perform a task together. For example, several transport bodies moved in synchrony may carry a large load which is too heavy for one transport body 200. Or several transport bodies 200 are connected together for example via a passive parallel kinematic and joints, so that the kinematic can be used as a handling device.
(93) Not all degrees of freedom need necessarily be executed in levitating fashion, but instead individual degrees of freedom may be implemented by a mechanical guide.
(94) For economic implementation of a levitation system with a large transport zone, the stator 100 may preferably be combined with conventional axis systems or vehicles as movement devices. For example, an axis system or vehicle with wheels transports a stator 100 in a large working zone, while the stator 100 itself may position a transport body 200 in a precise and floating fashion in a small working zone.
(95) Optionally, an intermediate level (particle barrier) is present between the stator 100 and transport body 200. The transport body 200 may preferably be situated in the clean zone, while the vehicle is outside. The translational movement function is performed primarily by the vehicle with its classic wheeled drive, and the levitation function and precise positioning by the stator 100 with transport body 200.
(96) The action principles of the stator 100 and transport body 200 may be exchanged in other preferred embodiments, so that the stator 100 for example contains an arrangement of stationary magnets 22, and the transport body 200 contains actively movable actuating magnets 26. In this variant for example, the transport body 200 may carry its own energy supply 38 (e.g. accumulator, fuel cell, solar cell) or have an external energy supply (e.g. via a cable). In this way for example, a wafer holder for holding a wafer 36 may be moved by active drive without wheels, in that it comprises a drive 42 with actuating magnets 26 in order for example to travel on a rail or plane attached to the floor 40 and equipped with stationary magnets 22 (see
(97) On the basis of the conveying device 10 described above, a method according to a preferred embodiment is described below with which the stable magnetic levitation of at least one transport body 200 is achieved, without the disclosure however being restricted to the explained method.
(98) The at least one transport body 200 experiences forces and moments in a dynamically variable magnetic field which is produced by the controlled movement of actuating magnets 26 and at least one stator 100.
(99) To describe the position of the at least one transport body 200, the Cartesian coordinate systems 900 and 920 are used:
(100) Each transport body i has a coordinate system 920i with the axes (x.sub.i, y.sub.i, z.sub.i) and a stationary reference to the transport body; its origin lies for example in the theoretical centre of mass of the magnet arrangement of the transport body.
(101) The stator coordinate system 900 with axes (X, Y, Z) has a stationary reference to the stator. Its X and Y axes lie in the action surface of the stator, while the Z-axis stands perpendicularly on the action surface and points in the direction of the transport body. The position of the transport body with index i is described in the stator coordinate system by the spatial vector {right arrow over (r)}.sub.i which indicates the origin of the transport body coordinate system. The angular position of the transport body i is expressed by the vector {right arrow over (φ)}.sub.i, the three components of which give the angles enclosed respectively by the X, Y and Z axes of the coordinate systems of the stator and transport body.
(102) Furthermore, the stator comprises an arrangement of magnet groups which are individually movable relative to the stator in at least one dimension, and the position of which can be changed by actuating elements. It is assumed below that the rotary position or angular position of the magnet group is variable, while the rotation axis in the stator coordinate system is constant and runs through the centre of mass of the magnet group. The actual rotary position of the magnet group k is α.sub.k. The control system predefines the nominal angle α.sub.k, nom which is implemented rapidly and precisely by the controller of the actuating element so that after a short time α.sub.k=α.sub.k, nom.
(103) According to the preferred embodiment, the method is implemented as a program in the control unit and is run in cyclic fashion with a frequency of 100-10,000 Hz. The function steps of the exemplary loop run-through as depicted as an example in
(104) 3000a) Determination of the Actual Position and Actual Speed of the Transport Body
(105) Magnetic field sensors, capacitive sensors and/or optical sensors are arranged in a regular pattern below the action surface of the stator. The following description is based as an example on Hall sensors. Each Hall sensor measures three magnetic field components in orthogonal directions. The raw sensor values are read by a computer together with the angular position of all magnet groups in the stator. If further stators are adjacent, the measurement values determined there at the same time are transmitted to the stator via a data bus. The entire read process typically takes 0.1 ms-1 ms.
(106) Firstly, measurement values from each sensor are corrected for the influence of the adjacent magnet groups. The field contributions of the adjacent magnet groups were determined once for each sensor in an initialisation run and are stored in correction tables as a function of rotary angle. The correction tables are accessed using the actual read rotary angle of the adjacent magnetic groups. The field contributions of the adjacent magnet groups are subtracted from all raw sensor values. The resulting corrected sensor values represent the flux density of the transport body magnet arrangement over the action surface.
(107) Then the position of the at least one transport body is determined. For this, a description of the magnet arrangement of the transport body is stored as a list in the computer memory. The list contains the positions and dipole vectors of all actuating magnets and/or magnet groups 24 indicated in the transport body coordinate system. Using this list, the field equation for each magnetic dipole and the superposition principle, a computer model of the flux density distribution of the transport body is produced. Using the models, the flux density vectors to be expected at the location of the stator sensors for a predefined transport body position can be calculated. A scalar error function determines a dimension for the error adaptation of the measured and modelled flux densities of all transport bodies and magnet groups. By iterative optimisation of the position and angular position of the transport bodies in the model, the error function is minimised i.e. adapted to the real measurement data. The iteration process ends as soon is no further improvement is achieved and/or the error falls below a predefined error threshold.
(108) The resulting 6D position of the at least one transport body i is interpreted in the context of the accuracy of the model as a real position of the transport body i with spatial vector {right arrow over (r)}.sub.i and angular vector {right arrow over (φ)}.sub.i. By numerical differentiation of the cyclic sequence of position values, the actual speed is calculated with the speed vector {right arrow over (ν)}.sub.i,nom for translation and the angular speed vector {right arrow over (ω)}.sub.i,nom for rotation.
(109) 3000b) Determination of Nominal Position and Nominal Speed of the Transport Body
(110) The control system of a higher-level system can determine the desired movement track of the at least one transport body as a result of the 6D nominal positions, nominal times and/or nominal speeds. The track may consist of straight lines, circle portions or other geometric base elements.
(111) The control system interpolates the movement track spatially and temporally. For spatial interpolation, various interpolation methods are considered which are usually applied in robotics: for example linear, spline or polynomial interpolation. For temporal interpolation, the control system breaks down the spatially interpolated track into support points. In each cycle, for each transport body i, it provides the nominal position with spatial vector {right arrow over (r)}.sub.i,nom and angular vector {right arrow over (φ)}.sub.i,nom, and optionally the nominal speed with the speed vector {right arrow over (ν)}.sub.i,nom for translation and the angular speed vector {right arrow over (ω)}.sub.i,nom for rotation, and transmits these to the track controller.
(112) 3000c) Track Control
(113) The track controller ensures that the actual position of the transport body rapidly and precisely follows the nominal position. For this, the track controller calculates the control deviation, i.e. the difference between the nominal and actual position, and/or the nominal and actual speed, in all 6 dimensions. It uses these as input variables for a control algorithm, for example the PID algorithm, which is calculated separately for each dimension to be controlled. As an output variable, for each transport body i, the track controller supplies the nominal force vector {right arrow over (F)}.sub.i,nom and the nominal moment vector {right arrow over (M)}.sub.i,nom which is necessary for correction of the track. The control parameters such as amplification (P), adjustment time (I) and holding time (D), are either determined once and fixedly stored in the control system, or are adapted dynamically to the movement and load state of the transport bodies, such as for example to their total mass or the mass distribution, which can be determined by an observer or by an observation device (see 3000f)).
(114) 3000d) Force/Moment Control
(115) For all transport bodies, this program part determines, from the nominal force vectors and nominal moment vectors, the nominal position for all magnet groups which lead to production of the nominal forces and moments. All magnet groups are taken into account which have an influence on the transport bodies to be controlled. For this, the force/moment controller uses a spatial model of the magnet arrangement in the stator and in the at least one transport body. The model is able to calculate approximately the forces and moments which result at a predefined position of the magnet groups. The model contains the magnet arrangement of the transport bodies as a list of positions and dipole vectors of all transport body magnets. It also contains a list of the magnets of each magnet group. The model is used firstly to calculate the partial forces and moments between all magnet pairs, and from this the total force and total moment acting on each transport body are determined. All influences are taken into account as well as possible, for example also the forces and moments mutually exerted between two transport bodies.
(116) Substantially the following equations are used for calculation.
(117) Magnetic field {right arrow over (B)} of a magnetic dipole {right arrow over (μ)} at site {right arrow over (r)}:
(118)
(119) with r=|{right arrow over (r)}|, wherein μ.sub.0 is the magnetic field constant.
(120) Magnetic field {right arrow over (B)}.sub.ges as superposition of the fields {right arrow over (B)}.sub.i (superposition principle)
(121)
(122) wherein n represents the number of fields to be superposed.
(123) Force {right arrow over (F)} on a magnetic dipole {right arrow over (μ)} in field {right arrow over (B)}:
{right arrow over (F)}={right arrow over (∇)}({right arrow over (μ)}{right arrow over (B)}).
(124) The torque {right arrow over (M)} which acts on a magnetic dipole {right arrow over (μ)} in field {right arrow over (B)}:
{right arrow over (M)}={right arrow over (μ)}×{right arrow over (B)}
(125) The additional torque {right arrow over (M)}.sub.F from forces {right arrow over (F)}.sub.i which act at a distance {right arrow over (r)}.sub.i from the centroid, wherein n represents a number of forces:
(126)
(127) By including the actual position of all actuating elements and transport bodies, the model is used to calculate the actual force vector {right arrow over (F)}.sub.i and the actual moment vector {right arrow over (M)}.sub.i which currently act on each transport body i. The error adjustment between the actual and nominal forces and the actual and nominal moments of all transport bodies is evaluated by a scalar error function E:
(128)
wherein m represents a number of transport bodies, {right arrow over (F)}.sub.i and {right arrow over (M)}.sub.i the actual force and actual moment respectively, {right arrow over (F)}.sub.i,nom and {right arrow over (M)}.sub.i,nom the nominal force and nominal moment, and F.sub.0 and M.sub.0 the reference force and reference moment.
(129) The lower E is, the better the correlation between the actual and nominal forces and moments of all transport bodies. The error function may be modified or extended by additional terms so that energetically favourable constellations are promoted. Thus the behaviour of the entire system can be optimised for example for minimal power consumption, minimal position change of magnet groups, or minimal number of magnet groups involved in a position change.
(130) In an iterative optimisation process, the positions of the magnet groups in the model are changed in stages. After each step, the forces and moments are recalculated in the model and evaluated with the error function. Steps which lead to a reduction in the error E are retained and form the basis for the next iteration step. As soon as the error cannot be reduced further and/or falls below a predefined threshold, and/or a predefined number of iteration steps as been performed, the optimisation loop is ended.
(131) 3000e) Output of Nominal Positions to Actuating Elements
(132) The positions of the magnet groups which have been optimised in the model are output to the actuating elements as nominal specifications.
(133) 3000f) Observer for Determining the Movement Parameters (Optional)
(134) An algorithm described as an “observer” detects the temporal development of the actual position of the magnet groups and transport bodies as a reaction to this. It uses the information to determine the movement parameters of the transport bodies using an extended model. The extended model is based on the force/moment model described above and is supplemented by further physical variables which describe the movement state of the transport body, for example mass, damping, centre of gravity, gravity vector, inertia sensor or inertial acceleration. In addition, the model calculates the movement equations of the transport bodies both in translation and rotation.
(135) Since the movement parameters are not known a priori, their value is initially estimated and then optimised by targeted parameter variation in an iterative calculation of the model. For evaluation of the error adaptation, a scalar error function is applied which evaluates the deviation of the modelled track curve from the measured track curve over the period of the last measurements.
(136) This results in approximate values for the above-mentioned movement parameters. These may be used e.g. within the control system to optimise the control parameters such as P, I, D. For example, the total weight m of the transport body with load may be determined and used in the track controller as a factor in the calculation of the nominal forces and moments, so that for double the weight, the doubled forces and moments are output to the transport body, and hence the acceleration a=F/m is independent of mass. The movement parameters may also be output as status information to the higher-level system (
(137) One or more of the following advantageous embodiments may also contribute to refining the conveying device (10) proposed here, according to which in particular: the at least two stationary magnets (22) comprise two stationary magnets (22) which are arranged on a straight line, wherein a dipole moment of at least one of the stationary magnets is not oriented parallel to this straight line, or three or more stationary magnets (22); the at least two stationary magnets (22) and/or the several actuating magnets (26) each comprise at least one permanent magnet; the at least one permanent magnet has a magnetic flux density of at least 0.05 T, preferably at least 0.1 T, further preferably at least 0.25 T, even further preferably at least 0.5 T, particularly preferably at least 0.75 T, most preferably at least 1 T; the several actuating magnets (26) each comprise a magnet group (24), and/or the at least two stationary magnets (22) are arranged in a magnet group (24), wherein preferably each actuating magnet (26) comprises a magnet group (24), and/or wherein preferably each actuating magnet (26) comprises a magnet group (24), and wherein each magnet group comprises a plurality of permanent magnets and/or magnetic coils; the plurality of permanent magnets and/or magnetic coils of the at least one magnet group (24) are arranged according to at least one Halbach array such that a magnetic field of the magnet group (24) preferably extends towards the conveying surface; the actuating element (114) comprises a drive element which is configured to change the position and/or orientation of the connected actuating magnet (26) in controlled fashion; and/or wherein the actuating element (114) comprises a sensor element which is configured to determine the position and/or orientation of the actuating magnet (26) connected to the actuating element (114); and/or wherein the actuating element (114) comprises a control element which is configured to adjust the position and/or orientation of the actuating magnet (26) connected to the actuating element (114) to a predefined value by means of the drive; the conveying device (10) furthermore comprises a position determination unit which is configured to determine a relative position and/or orientation of the at least one transport body (200) relative to the stator (100); the conveying device (10) furthermore comprises a movement device which is configured to move the stator relative to an environment; the transport body (200) or the stator comprises an energy store; the at least one transport body (200) has at least one internal degree of freedom, and preferably in total more than six degrees of freedom; the stator (100) and/or the transport body (200) furthermore comprise a cover (112a) which is configured to limit the forces acting between the stator (100) and the transport body (200); the stationary magnets (22) are arranged as two-dimensional Halbach arrays and in particular have a rectangular and/or square and/or hexagonal and/or circular arrangement; the stationary magnets (22) in the transport body (200) are arranged at least partially in the form of a cylinder and/or ball, such that they have a greater pivot range than transport bodies (200) with a flat arrangement of stationary magnets (22); the at least one transport body (200) has an identification element, and the conveying device (10) is configured to identify the transport body (200) from the identification element; the stator comprises several stator modules which are preferably arranged adjacent to each other; the actuating elements (114) are configured as rotary actuators which in particular have a rotation axis perpendicular to an action surface (102) of the stator (100); the stator (100) has a curved action surface (102); a number of degrees of freedom of the actuating magnets (26) is at least as great as a number of degrees of freedom along which the at least one transport body (200) is to be conveyed and/or positioned in controlled fashion; the conveying device (10) is configured as a contactless mechanical bearing; the conveying device is configured to fix the at least one transport body to the at least one stator in the event of an interruption in the power supply; the conveying device (10) furthermore comprises a load detection device which is configured to determine a load state of the transport body; the conveying device (10) furthermore contains an observation device which is configured to determine a mass and/or a centre of gravity of the transport body (200) relative to the stator (100).
(138) One or more of the following advantageous embodiments may contribute to refining the method proposed here, according to which in particular: the actuating elements (114) are actuated such that the at least one transport body (200) assumes a desired position and/or orientation relative to the stator (100); the desired position and/or orientation has six degrees of freedom; the step of actuating the actuating elements (114) such that the at least one transport body (200) assumes a desired position and/or orientation relative to the stator (100) comprises: determining an actual position and/or actual speed of the transport body (200) relative to the stator (100); determining a nominal position and/or a nominal speed of the transport body (200) relative to the stator (100); establishing a deviation of the actual position and/or actual speed from the nominal position and/or nominal speed; calculating nominal settings of at least some of the actuating magnets (26) such that the respective actuating magnets (26) act towards a reduction of the deviation of the nominal position and/or nominal speed from the actual position and/or actual speed of the transport body; arranging the respective actuating magnets (26) by means of the actuating elements (114) such that the respective actuating magnets assume the nominal settings.