Turbomolecular vacuum pump for ionized matter and plasma fields
10557471 ยท 2020-02-11
Inventors
Cpc classification
F04D13/026
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D19/042
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D27/0246
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/052
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D17/168
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D27/002
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/324
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
International classification
F04D27/00
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D17/16
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D29/32
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
F04D27/02
MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
Abstract
A turbomolecular pump is provided. In one arrangement, a stator stack and rotor stack have corresponding conical or frustum shapes that allow for adjusting the clearance between the stator vanes and rotor vanes of the pump to provide adjustable compression ratios and/or to adjust clearances. In another arrangement, the actuator or drive mechanism of the pump is formed from coils attached to the upper stage of rotor vanes which are controlled to interact with a plurality of stationary magnets attached to the housing of the pump to rotate the stator stack. In another arrangement, a control system of the pump utilizes the coils of the rotor drive to dynamically balance the pump during operation.
Claims
1. A turbomolecular pump comprising: a plurality of spaced rotor sets defining a rotor stack, each rotor set having a plurality of blades radially extending from a rotating hub, wherein, in cross-sectional profile, tip surfaces of the rotor stack define a first conical surface; a plurality of spaced stator sets defining a stator stack, where the spaced stator sets are arranged alternately with the rotor sets, each stator set having a plurality of blades radially extending toward the rotating hub from an outer stator housing, wherein, in cross-sectional profile, root surfaces of the stator housing between the stator sets define a second conical surface; a pump housing disposed around the outer stator housing and connected to a rotor shaft that is rotatively coupled to the rotor stack, wherein the rotor shaft defines a vertical axis of the pump; at least a first adjustable connector connecting the stator stack to the pump housing, wherein adjustment of the adjustable connector adjusts a position of the rotor stack along the vertical axis, wherein an axial position of the second conical surface is moved relative to the first conical surface.
2. The pump of claim 1, wherein adjustment of the adjustable connector adjusts a distance between the tip surfaces of the rotor stack and root surfaces of the stator housing.
3. The pump of claim 2, wherein adjustment of the adjustable connector adjusts a distance between bottom edges of the blades of the stator stack and a top edges of the rotor stack.
4. The pump of claim 1, further comprising: a plurality of coils attached to the plurality of blades of one set of the rotor stack; and a plurality of magnets fixedly attached to the pump housing; and a control system configured to provide a plurality of individual drive signals to each of the plurality of coils, wherein the plurality of coils are electrified in response to the drive signals and interact with the magnets to rotate the rotor stack.
5. The pump of claim 4, further comprising: strain sensors radially disposed about a bearing that couples the rotor stack to the rotor shaft, wherein outputs of the strain sensors are output to the control system.
6. The pump of claim 5, wherein the control system is configured to utilize the outputs of the strain sensor to identify an imbalance in the rotor stack during rotation.
7. The pump of claim 6, wherein the control system alters one or more of the plurality of individual drive signals to counteract the imbalance.
8. The pump of claim 5, wherein said stain sensors comprise optical strain sensors and wherein outputs of the optical strain sensors are provided to the control system via optical connections.
9. A turbomolecular pump comprising: a plurality of spaced rotor sets defining a rotor stack, each rotor set having a plurality of blades radially extending from a rotating hub; a plurality of spaced stator sets defining a stator stack, where the spaced stator sets are arranged alternately with the rotor sets, each stator set having a plurality of blades radially extending toward the rotating hub from an outer stator housing; a pump housing disposed around the outer stator housing and connected to a rotor shaft that is rotatively coupled to the rotor stack by at least a first bearing; a plurality of coils attached to the plurality of blades of one set of the rotor stack; and a plurality of magnets fixedly attached to the pump housing; and a control system configured to provide a plurality of individual drive signals to each of the plurality of coils, wherein the plurality of coils are electrified in response to the drive signals and interact with the magnets to rotate the rotor stack.
10. The pump of claim 9, further comprising: strain sensors radially disposed about the at least one bearing that couples the rotor stack to the rotor shaft, wherein outputs of the strain sensors are output to the control system.
11. The pump of claim 10, wherein the control system is configured to: utilize the outputs of the strain sensor to identify an imbalance in the rotor stack during rotation; and alter one or more of the plurality of individual drive signals to counteract the imbalance.
12. The pump of claim 10, wherein said stain sensors comprise optical strain sensors and wherein outputs of the optical strain sensors are provided to the control system via optical connections.
13. The pump of claim 9, further comprising a plurality of optically actuated insulated-gate bipolar transistors (IGBTs) connected to the rotor stack, wherein each IGBT is electrically connected to one of the coils.
14. The pump of claim 13, wherein each IGBT is electrically coupled to a metal bearing associated with the rotor shaft, wherein the metal bearing is connected to a power source.
15. The pump of claim 14, further comprising: a plurality of optical actuators connected to the rotor shaft, wherein the optical actuators are disposed adjacent to the IGBTs of the rotor stack and are connected to the control system via optical connections.
16. The pump of claim 15, wherein each optical actuator is configured to receive the drive signals from the control system via and generate an optical output in response to a received drive signal.
17. The pump of claim 16, wherein the optical output of each optical actuator is received by one IGBT, wherein the IGBT opens for a duration an magnitude corresponding to the drive signal, wherein power from the bearing is provided to a coil associated with the IGBT.
18. The pump of claim 9, further comprising: at least one position sensor configured to identify an angular orientation of the rotor stack, wherein an output of the position sensor is output to the control system.
19. The pump of claim 18, wherein the position sensor is an optical sensor mounted to the housing.
20. The pump of claim 19, wherein the position sensor is connected to the control system via an optical connection.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION
(13) Reference will now be made to the accompanying drawings, which at least assist in illustrating the various pertinent features of the presented inventions. The following description is presented for purposes of illustration and description and is not intended to limit the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the following teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described herein are further intended to explain the best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions.
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(15) As shown in
(16) Adjustable Stator Stack
(17) As noted above, one unique feature of the pump 10 is the ability to adjust the stator stack 20 relative to the rotor stack 30 to adjust the clearance between the stator vanes and the rotor vanes. The conical or frustum shape allows the stator vanes to effectively move in two directions relative to the rotor vanes to adjust the clearances there between. Adjusting the clearance between the stator vanes and the rotor vanes allows for adjusting the compression of the pump 10 as well as adjusting clearance to account for build up or condensation of PVD materials on the rotor vanes.
(18) As shown in
(19) As shown
(20) Stator Vane Drive
(21) As noted above, a unique feature of the presently disclosed pump is that the rotor stack 30 forms a portion of the actuator mechanism for the pump 10. Previously, turbo pumps have utilized a separate electric motor to rotate the rotor stack of the pump. In the present pump 10, the actuator for the pump is formed from coils attached to the upper set of rotor vanes which are controlled to interact with a plurality of stationary magnets attached to the housing of the pump. In this feature, the rotor stack in addition to providing compression and movement of gas molecules also forms an electromagnetic stator of a drive motor for the pump.
(22) As best shown in
(23) The coils 34 are selectively actuated to impart rotation to the rotor stack 30. More specifically, plurality of coils 34 attached to the plurality of rotor vanes 32A interact with a corresponding plurality of permanent magnets 40, which are fixedly attached to the housing 12. See
(24) In order to control the rotation of the rotor stack, a control system of the pump 10 must know the angular orientation of the rotor blades 32A and their supported coils 34. In the present embodiment, a plurality of optical sensors 42 are disposed radially around the outer periphery of the first row/set of rotor blades 32A. In the illustrated embodiment, each of these optical sensors 42 is disposed within a recess in a casing of the stator stack 20. Further, in the present embodiment, each optical sensor 42 is connected to the control system of the pump via a fiber optic filament 44. In operation, the optical sensors 42 output information that is utilized by the control system to determine the orientation of an adjacent stator vane 32 such the control system may controllably operate the coils 34 to control the rotation of the rotor stack 30.
(25) The present embodiment utilizes fiber optic filaments 44 to connect the optical sensors to the control system. Other embodiments may utilize non-optical sensors to provide such sensing and may utilize different connections. However, the utilization of fiber optic sensors and fiber optic filaments provides a benefit for the presented pump. Particularly, the pump 10 is often utilized in PVD processes where ionized matter and/or plasma fields exist. Such ionized matter in plasma fields often result in considerable electronic noise. Additional electronic noise is generated by the high speed operation of the pump itself. Along these lines, the use of optical sensors and optical signal transmission significantly reduces or eliminates potential interference that may arise from electronic noise.
(26) Dynamic Balancing
(27) As noted above, another feature of the pump is the ability to dynamically balance the pump during operation. During a PVD process, which generates chemical vapors or metals, turbo pump vanes can be subject to condensation of any process materials which can create an unbalanced condition for the turbo pump rotor. To minimize the vapor deposition on the vanes, turbo pumps are often externally heated. However, heating of turbo pumps is time-limited in extreme conditions (e.g., high temperatures). Such high temperature operation can result in premature bearing failure. The presented turbo pump 10 provides a mechanism for dynamically balancing the rotor during operation to offset imbalances that may occur due to condensation of process materials on the rotor vanes. More specifically, the use of the stator vane drive, described above, allows applying the non-uniform drive forces to the rotor stack, which can counteract imbalances that occur during operation.
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(29) As previously noted, the rotor stack 30 is rotatably coupled to the rotor shaft 26 by upper and lower bearing assemblies 28A, 28B. Each of these bearing assemblies 28A, 28B further incorporates an optical strain sensor 50A, 50B, respectively. These optical strains sensors 50A, 50B (hereafter 50 unless specifically referenced) are annular elements that surround their respective bearing assembly and which are connected to the control system by their respective optical filament sets 46A or 46B.
(30) To counteract the effects of an imbalance in the rotor stack 30, the processor 64 generates individual drive signals (e.g., drive pulses) for each of the coils 34 attached to each of the rotor blades 32A. That is, in the illustrated embodiment, the processor 64 generates thirty-six individual drive signals for each of the coils 34.sub.1-36 attached to each of the thirty-six individual stator vanes 32A.sub.1-36, respectively.
(31) A system for applying individual signals to individual coils 34 of the rotating rotor stack and powering each of the individual coils 34 is further illustrated in
(32) In order to provide individual drive signals to individual coils, individual filaments 68.sub.1 and 19 (only two shown) of the filament bundle 68 enter the pump 10 alongside the stationary rotor shaft 26. These filaments 68 each terminate at a fiber optic actuator 54, which is disposed adjacent to an optically actuated insulated-gate bipolar transistor (IGBT) 90. The IGBT is in electrical connection with the electrified seal 80. Upon a filament (e.g., filament 68.sub.19) providing an optical signal (e.g., drive signal) to the optical actuator 54, the optical actuator 54 outputs a light pulse corresponding to the drive signal to the optical IGBT 90. The IGBT 90 opens for a duration and magnitude corresponding to the drive signal provided by the processor via the filament 68.sub.19. That is, the IGBT passes electrical power to the coil 34.sub.19 via the electrical connector 38. The power is provided to the coil 34.sub.19 with a corresponding duration and magnitude to the drive signal provided for that coil. The energized coil interacts with an adjacent permanent magnet 40 as described above to rotate the rotor stack.
(33) As may be appreciated, each individual coil 34 is connected to an individual IGBT 90 via an individual connector 38. Along these lines, the IBGTs are connected to the hub 36 of the rotor stack and rotate with the rotor stack. In this regard, the drive signals provided to the IGBTs by the optical actuators 50 must be provided when the optical IGBT is aligned with the optical actuator 50. This information is known by the processor via the optical position sensors 42. Again, due to the processing speeds of modern computers, delivery of the drive signals to individual coils is possible even at high rotational speeds.
(34) Though a number of features have been discussed, the pump 10 includes a number of additional features that are novel alone and/or in various combination with the features discussed above. For example, the pump is configured to facilitate field maintenance. As best show in
(35) The foregoing description has been presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventions and/or aspects of the inventions to the forms disclosed herein. Consequently, variations and modifications commensurate with the above teachings, and skill and knowledge of the relevant art, are within the scope of the presented inventions. The embodiments described hereinabove are further intended to explain best modes known of practicing the inventions and to enable others skilled in the art to utilize the inventions in such, or other embodiments and with various modifications required by the particular application(s) or use(s) of the presented inventions. It is intended that the appended claims be construed to include alternative embodiments to the extent permitted by the prior art.