阅读说明：本技术 具有被动转子的机器人驱动器 (Robot drive with passive rotor ) 是由 M·霍塞克 T·哈 C·霍夫迈斯特 D·普尔 于 2012-09-14 设计创作，主要内容包括：一种基板传送装置,其包括驱动部分以及第一可移动臂组件。驱动部分包括第一电机。第一电机包括定子与被动转子。第一可移动臂组件连接到第一电机。基板传送装置配置为以便第一可移动臂组件可定位在真空室中,被动转子与真空室内部的环境连通。(A substrate transport apparatus includes a drive section and a first movable arm assembly. The driving portion includes a first motor. The first motor comprises a stator and a driven rotor. The first movable arm assembly is connected to a first motor. The substrate transport apparatus is configured such that the first movable arm assembly is positionable in a vacuum chamber, the passive rotor being in communication with an environment inside the vacuum chamber.)

1. A substrate transfer apparatus comprising:

a drive section comprising a first motor, wherein the first motor comprises a stator and a passive rotor; and

a first movable arm assembly connected to the first motor,

wherein the substrate transport apparatus is configured such that the first movable arm assembly is positionable in a vacuum chamber, the passive rotor being in communication with an environment inside the vacuum chamber.

Technical Field

The exemplary and non-limiting embodiments relate generally to robotic drives and, more particularly, to drives having passive rotors.

Background

Conventional fabrication techniques for semiconductor integrated circuits and flat panel displays typically include processing silicon wafers and glass panels, often referred to as substrates, by fully automated cluster tool. A typical cluster tool may include a vacuum chamber with a load lock and a processing unit. This tool is typically serviced by a robot manipulator (robot or substrate transport) that circulates the substrate from the load lock, through the processing unit, and back to the load lock. Another robot may be positioned in an atmospheric transfer unit that serves as an interface between the load locks of the vacuum chamber and a standard load port serviced by an external transfer system.

Disclosure of Invention

The following summary is intended to be exemplary only. This summary is not intended to limit the scope of the claims.

According to one aspect, there is provided an example substrate transfer apparatus, comprising: a drive section including a first motor, wherein the first motor includes a stator and a passive rotor; and a first movable arm assembly connected to the first motor. The substrate transport apparatus is configured such that the first movable arm assembly is positionable in a vacuum chamber, the passive rotor being in communication with an environment inside the vacuum chamber.

According to another aspect, an example method includes providing a substrate transport apparatus including a drive portion and a first movable arm assembly coupled to the drive portion, wherein the drive portion includes a motor including a stator and a passive rotor; and connecting the substrate transport apparatus to a vacuum chamber, wherein the first movable arm assembly is positioned in the vacuum chamber and the passive rotor is in communication with an environment inside the vacuum chamber.

According to another aspect, an example substrate transfer apparatus includes: a drive section including a first motor, wherein the first motor includes a stator and a passive rotor; a first movable arm assembly connected to a first motor; and a gas barrier positioned in the gap between the stator and the passive rotor to separate an environment at the passive rotor from an environment at the stator.

Drawings

The foregoing aspects and other features are explained in the following description, taken in connection with the accompanying drawings, wherein:

FIG. 1 is a schematic cross-sectional view of an example apparatus;

FIG. 2 is a schematic view of a feedthrough;

FIG. 3A is a schematic view of another feedthrough;

FIG. 3B is a schematic view of another feedthrough;

FIG. 3C is a schematic view of another feedthrough;

FIG. 3D is a schematic view of another feedthrough;

FIG. 4 is a schematic view of a read head connected to a housing;

FIG. 5 is a schematic view of another example of a read head coupled to a housing;

FIG. 6 is a schematic view of another example of a read head coupled to a housing;

FIG. 7 is a schematic view of another example of a read head coupled to a housing;

FIGS. 8 and 9 are schematic views of another example of a read head coupled to a housing;

FIGS. 10 and 11 are schematic views of another example of a read head coupled to a housing;

FIGS. 12-19 are schematic views of multiple divider wall configurations;

20-23 are schematic views of a plurality of stator and rotor combinations with stator packages;

figure 24 shows a motor with a radial field arrangement;

FIG. 25 shows a hybrid motor design with a toothed passive rotor, stator phase A separated from stator phase B by a ring permanent magnet;

FIG. 26 shows a motor with an axial field design;

figure 27 shows a motor with a brushless design with a passive rotor;

28-29 show a motor with a toothed passive rotor;

figures 30-31 show an electric machine with a toothed passive rotor;

fig. 32-33 show an electric machine with a toothed passive rotor;

figures 34-35 show an electric machine with a toothed passive rotor; and

fig. 36-37 show an electric machine with a toothed passive rotor.

Detailed Description

Referring to fig. 1, a schematic view of a robot driver 10 of a substrate transfer apparatus 2 is shown. Although the robot drive 10 is described with reference to a vacuum robot, any suitable robot drive (atmospheric or otherwise) may be provided having the features as disclosed. The drive 10 may include features as previously disclosed or disclosed herein. Aside from the preferred embodiment or embodiments disclosed, this invention is capable of other embodiments and of being practiced or being carried out in various ways. It is to be understood, therefore, that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the drawings. If only one embodiment is described herein, the claims hereof are not to be limited to that embodiment. Furthermore, the claims hereof are not to be read restrictively unless there is clear and convincing evidence manifesting a certain exclusion, restriction, or disclaimer.

An example robotic manipulator or device 2 including a vacuum compatible direct drive system of one or more embodiments of the present invention is shown in fig. 1. The robotic manipulator may be built around the frame 101, for example an aluminium projection suspended from a lug or mounting device 102. Alternatively, the mounting means may be on one side of the frame 101, on the bottom of the frame 101 or the frame 101 may be mounted in any other suitable manner. The frame 101 may include one or more vertical rails 103 with linear bearings 104 to provide guidance to a housing 105 driven by a motor 106 via a ball screw mechanism 107. Only one track 103 is shown for simplicity. Alternatively, the motor housing 105 may be driven by a linear motor attached directly to the frame 101 or coupled to the frame 101 in any other suitable movable or non-movable manner. As will be described in more detail below, the motor housing 105 may include one, two, three, four, or more direct drive units. The housing 105 may house motors 108, 109 equipped with position encoders 110 and 111. The housing 105 is shown as an exemplary structure, wherein the housing 105 may have portions configured relative to the motors 108, 109 and the position encoders 110 and 111, as will be described in more detail below. Bellows 120 may be used to accommodate movement of motor 105 along vertical track 103 to separate the environment in which the movable components of encoders 110, 111 operate, e.g., vacuum, from the external environment, e.g., atmosphere, for motors 108, 109.

In the example of fig. 1, two direct drive units each having one motor and one encoder are shown. However, any suitable number of direct drive units having any suitable number of motors and encoders may be used. As shown in fig. 1, a reverse service loop 222 may be used to supply energy to the direct drive unit and facilitate transmission of signals between the direct drive unit and other components of the robotic system, such as a controller 224. Alternatively, a conventional, non-inverting service loop 226 may be used. As shown in fig. 1, the upper motor 108 may drive a hollow outer shaft 112 connected to a first linkage 114 of the robotic arm. The lower motor 109 may be connected to a coaxial inner shaft 113 that may be coupled to a second link 116 via a belt drive 115. Another strap arrangement 117 may be used to maintain the radial orientation of the third link 118 regardless of the position of the first two links 114 and 116. This may be achieved due to a 1:2 ratio between the pulley comprised in the first link and the pulley connected to the third link. The third link 118 may form an end effector that may carry a payload 119 of, for example, a semiconductor substrate. It should be noted that the robotic arm of FIG. 1 is shown for exemplary purposes only. Any other suitable arm mechanism or drive mechanism may be used, alone or in combination. For example, multiple direct drive units according to one or more embodiments of the present invention may be used in a single mechanical manipulator or a mechanical manipulator having multiple manipulators, or in any suitable combination. Here, the units may be stacked in different planes along substantially the same rotational axis, concentrically positioned in substantially the same plane, arranged in a configuration that combines stacking with concentric arrangement, or included in the mechanical manipulator in any other suitable manner.

The vacuum compatible direct drive system of one or more embodiments of the present invention may include a housing and a radial field motor arrangement having a stator and a rotor disposed proximate to the stator such that it is rotatable relative to the stator and interacts with the stator through a magnetic field that is substantially radial relative to an axis of rotation of the rotor. Alternatively, an axial field motor or a combination of radial/axial field motors, or a combination thereof, may be provided. The stator may include a set of windings that are energized by a suitable controller based on the relative position of the rotor with respect to the stator. The rotor may comprise a set of permanent magnets of alternating polarity.

In the illustrated embodiment, the housing may separate an atmospheric-type environment on the exterior of the housing from a vacuum or other non-atmospheric environment inside the housing. As will be described, a movable component such as an encoder read head or stator may be secured to and/or interfaced with the housing, for example, the read head or stator may be pressed into or otherwise secured to the housing to eliminate conventional clamping components, and as will be described, may be encapsulated in a suitable material such as a vacuum compatible epoxy based potting to limit outgassing of the component to a vacuum or other non-atmospheric environment. Here, the components of the encapsulation may be in a vacuum, atmosphere, or any suitable environment in which the encapsulation protects the stator from the environment, e.g., prevents corrosion, and promotes efficient heat removal. The packaging may also bond the read head or stator to the housing or other component or sub-component to further secure the device relative to the housing. As will be described with reference to fig. 2, leads to the windings or other moving parts of the readhead or windings of the stator may pass through openings through the hermetically sealed housing, thereby eliminating the need for a separate vacuum feedthrough, for example. Alternatively, the readhead or stator may be clamped, bolted or attached to the housing in any other suitable manner, and leads leading from the atmosphere to the windings or other moving parts of the readhead or windings of the stator may be routed through the wall of the housing, through vacuum feedthroughs, or in any other suitable manner, for example as described with reference to fig. 3A-3D.

In fig. 2, feedthrough 202 is shown interfacing with housing 105, where housing 105 may separate first environment 204 from second environment 206. The feedthrough 202 may interface with a movable component 208, wherein the movable component 208 may have a movable core 210 and leads 214. As will be described, the movable core 208 may be encapsulated in an enclosure 212, wherein the enclosure 212 may be a coating, encapsulation, envelope, or a combination of all or part thereof. Alternatively, the closure 212 may not be provided. The leads 214 pass through holes 216 of the casing 105 and are isolated from the casing 105 by potting or isolating material 218. Here material 218 may be the same material as material 212 or may be separately potted or otherwise isolated, where material 218 may seal across pressure gradients between environments 204 and 206 or otherwise.

In fig. 3A, feedthrough 224 is shown interfacing with housing 105, where housing 105 may separate first environment 204 from second environment 206. The feedthrough 224 may interface with the movable component 208 ', where the movable component 208' may have a movable core 210 'and leads 214'. As will be described, the movable core 208 ' may be encapsulated in an enclosure 212 ', where the enclosure 212 ' may be a coating, encapsulation, envelope, or a combination thereof, in whole or in part. Alternatively, the closure 212' may not be provided. Lead 214' receives lead 226 which interfaces with feedthrough 228, passes through aperture 216 of casing 105 and is isolated from casing 105 by insulating core 230, wherein core 230 is sealed 232 to casing 105. Here the core 230 has a conductive insert 234 hermetically sealed therein, wherein the conductive insert receives the lead 226 on the first environmental side 204 and also receives the lead 236 on the second environmental side 206. Here, the core 230 in combination with the insert 234 may seal across the pressure gradient between the environments 204 and 206 or otherwise. In the disclosed embodiment, the movable components 208, 208' may be any suitable components such as a read head, windings, or any suitable movable components. Alternatively, the pin (insert 234) may be sealed with respect to the housing 105 and the insulating material (core 230) may provide the guiding and electrical insulation. Alternatively, the lead 226 and the insert 234 may be a single component, eliminating a connector. As will be described, an expandable feedthrough that can be mounted from the outside of the housing 105 can be provided, where this design can also accommodate misalignment due to tolerances between features in the housing and the features to which the feedthrough is connected in a vacuum.

In fig. 3B, feedthrough 240 is shown interfacing with enclosure 105, where enclosure 105 may separate first environment 204 from second environment 206. Here the feedthrough 240 has an insulating housing 242 and a pin 244. The socket 246 is provided as an electrical connection that couples into a moving component in the environment 204. Pin 244 is shown sealed to housing 105 by an O-ring seal, where pin 244 has a threaded end to allow coupling to a lug for electrical connection in environment 206. Socket 246 has a tapered portion 248 such that insertion of pin 244 into socket 246 expands socket 246 such that electrical contact is made between pin 244 and socket 246 when inserted and assembled.

In fig. 3C, feedthrough 240' is shown interfacing with enclosure 105, where enclosure 105 may separate first environment 204 from second environment 206. Here, the feedthrough 240 ' has an insulating housing 242 ' and a pin 244 '. The socket 246' is configured to couple to electrical connections in the active components in the environment 204. Pin 244 'is shown sealed to housing 105 by an O-ring seal, where pin 244' has a threaded end to allow coupling to a lug for electrical connection in environment 206. The pin 244 ' has a tapered portion 248 ' such that rotation of the set screw after inserting the pin 244 ' onto the socket 246 ' moves the inner pin of the pin 244 ' such that when assembled, electrical contact is made between the pin 244 ' and the socket 246 '.

In fig. 3D, feedthrough 240 "is shown interfacing with enclosure 105, where enclosure 105 may separate first environment 204 from second environment 206. Here, the feedthrough 240 "has an insulating housing 242" and a socket 244 ". The pin 246' is configured to couple to electrical connections in the moving components in the environment 204. Socket 244 "is shown sealed to housing 105 by an O-ring seal, where socket 244" has a threaded end to allow coupling to a lug for electrical connection in environment 206. The socket 244 "has a tapered portion 248" such that rotation of the screw after inserting the socket 244 "over the pin 246" moves the outer sleeve of the socket 244 "to compress the socket 244" such that when assembled, electrical contact is made between the socket 244 "and the pin 246".

In order to determine the angular position of the driven part of the direct drive unit, for example the angular position of the motor rotor relative to the housing, a position encoder may be included in the direct drive unit. 4-7, the position encoder track may be coupled to a driven portion of the direct drive unit, and the position encoder readhead may be attached to the housing 105 of the direct drive unit. Here, the read-head may be optical, conductive, or any suitable type of read-head for position determination or otherwise.

In one exemplary embodiment as seen in FIG. 4, the readhead may have a housing 252 that is sealed to the housing 105 with a seal 256, where a movable component 254 that may be located entirely in a vacuum or other non-atmospheric environment is inside the housing.

In another exemplary embodiment as seen in FIG. 5, the readhead may have a housing 252 ' that is sealed to the housing 105 with a seal 256, wherein a movable component 254 ', which may be isolated from a vacuum or other non-atmospheric environment, is located inside the housing by the housing 252 '.

In another exemplary embodiment as seen in FIG. 6, the readhead may have a housing 252 "sealed to the enclosure 105 by a seal 256, wherein the movable part 254" may be partially exposed 258 to a vacuum or other non-atmospheric environment, while another portion 260 of the movable part of the readhead may be present in the surrounding atmospheric environment. In this case, the read head may be positioned in an opening of the housing of the direct drive unit and sealed against a wall of the housing. The seal 256 may be compressible to allow adjustment of the readhead relative to the track. Alternatively, angular contact, axial or radial contact type sealing means may be utilized to provide a greater range of adjustment. As another alternative, a bellows, diaphragm or bellows may be utilized to allow adjustment of the readhead relative to the track.

In one exemplary embodiment as seen in fig. 7, the readhead may have a housing 252 "'sealed to the housing 105 by a seal 256, wherein the movable component 254"' utilizes a vacuum compatible packaging, including the described packaging replacements and reinforcements to minimize the risk of air bleed and protect the stator from the environment, e.g., to prevent corrosion, and to promote efficient heat removal, and may be used or, for example, may include two separating walls 262, 264 to isolate different portions 266, 268 of the readhead from one or more environments.

FIG. 8 illustrates an exemplary readhead mounting arrangement. As can be seen in fig. 9, the encoder has a disc 304 rotatably mounted on a shaft 306 and the read head 302 is movably mounted relative to the housing 105 and sealed to the housing 105 by a seal 256. Here the seal 256 may be an O-ring, crimp, or other suitable seal that provides sufficient radial, axial, and angular or other movement of the readhead relative to the disc 304 while maintaining a seal, such as a vacuum seal. The puck 304 here may be a solid construction made of metal with a pattern of lines or spaces for sensing by the read head 302 or other electrical conduction. The housing 105 has pins 308 corresponding to the mating holes and slots of the head 302 so that the head 302 is positively positioned relative to the housing 105 and the disc 304 rotatably mounted therein. Screws 310 secure the head 302 to the housing 105, with three sets of screws 312 allowing the head 302 to be adjusted radially relative to the disc 304 and horizontally or otherwise adjusted relative to the disc 304. In this manner, the position of the readhead 302 relative to the puck 304 may be adjusted without breaking the vacuum environment. In alternate aspects, any suitable orientation or level feature may be provided.

FIG. 11 illustrates an exemplary readhead mounting arrangement. The encoder has a disc 304 'rotatably mounted on a shaft 306 and a read head 302' is movably mounted relative to the housing 105 and sealed to the housing 105 by a seal 256. Here, seal 256 may be an O-ring, crimp, or other suitable seal that provides sufficient radial, axial, yet angular, or other movement of read head 302 relative to disk 304 while maintaining a seal, such as a vacuum seal. The puck 304 here may be a glass or other made opaque construction having a pattern of lines or spaces for optical sensing by the readhead 302' or otherwise. The housing 105 has pins 308 shown in fig. 10 that correspond to mating slots of the head 302 so that the head 302 'is positively positioned relative to the housing 105 and the disc 304' rotatably mounted therein. Screws 310 are fastened to the housing 105 through vertical slots of the head 302', with three sets of screws 312 allowing the head 302 to be adjusted radially relative to the disc 304 and horizontally or otherwise adjusted relative to the disc 304. The eccentric 314 is further configured to be rotationally coupled to the housing 105 and to engage a mating horizontal slot of the readhead 302 ' such that the position of the head 302 ' relative to the disc 304 ' may be axially adjusted. In this manner, the position of the read head 302 'relative to the puck 304' can be adjusted without breaking the vacuum environment. In alternate aspects, any suitable orientation or level feature may be provided.

Fig. 12-19 illustrate various combinations of dividing walls relative to the motor 108. Here, as will be described, for example, the separation wall may form an encapsulation, separation, vacuum, or gas barrier to separate two or more areas or environments. The motor 108 is shown here in partial cross-section and may be exemplary, wherein in alternative embodiments any suitable motor, combination of motors and/or combination of partition walls may be provided. In fig. 12, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The partition wall 356 may be a thin-walled tubular metal structure that separates the environment 204 from the environment 206 and separates the rotor 354 from the stator 352. Alternatively, the partition wall 356 may be a coating, plated, injection molded part, formed part and have any shape or any suitable partition wall or combination of partition walls and wall types. Further, the partition wall 356 may be integrally formed as part of the housing 105 or may be separate from the housing 105.

In fig. 13, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The partition wall 356 may be a thin-walled tubular metal structure that separates the environment 204 from the environment 206 and separates the rotor 354 from the stator 352. The separation wall 358 may also be a thin-walled tubular metal structure that separates the environment 204 from the environment 206. Alternatively, the partition walls 356, 358 may be any suitable shape, for example the partition walls 356, 358 may form an enclosure that surrounds part or all of the stator 352 such that the third environment 360 within the enclosure is formed to be isolated from the environment 204 and/or the environment 206. Alternatively, the walls 356, 358 may be coated, plated, injection molded, formed, of any shape or any suitable divider wall or combination of divider walls and wall types. Further, one or more of the partition walls 356, 358 may be integrally formed as part of the enclosure 105 or may be separate from the enclosure 105.

In fig. 14, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The dividing wall 356 may be a thin-walled tubular metal structure that separates the environment 204 from the environment 206. Alternatively, the partition wall 356 may be a coating, plated, injection molded part, formed part and have any shape or any suitable partition wall or combination of partition walls and wall types. Further, the partition wall 356 may be integrally formed as part of the housing 105 or may be separate from the housing 105.

In fig. 15, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The partition wall 356 may be a thin-walled tubular metal structure separating the environment 204 from the environment 206, with the stator 352 exposed to the environments 204 and 206 and forming a portion of the wall 356. Alternatively, the partition wall 356 may be a coating, plated, injection molded part, formed part and have any shape or any suitable partition wall or combination of partition walls and wall types. Further, the partition wall 356 may be integrally formed as part of the housing 105 or may be separate from the housing 105.

In fig. 16, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The partition wall 356 may be a thin-walled tubular metal structure separating the environment 204 from the environment 206 where the stator 352 is exposed to the environments 204 and 206, with a portion of the wall 356 separating a portion 362 of the stator 352 from another portion 364 of the stator 352. Alternatively, the partition wall 356 may be a coating, plated, injection molded part, formed part and have any shape or any suitable partition wall or combination of partition walls and wall types. Further, the partition wall 356 may be integrally formed as part of the housing 105 or may be separate from the housing 105.

In fig. 17, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The partition wall 356 may be a thin-walled tubular metal structure separating the environment 204 from the environment 206, with the stator 352 exposed to the environments 204 and 206, with a portion of the wall 356 separating a portion 366 of the stator 352 from another portion 368 of the stator 352. Alternatively, the partition wall 356 may be a coating, plated, injection molded part, formed part and have any shape or any suitable partition wall or combination of partition walls and wall types. Further, the partition wall 356 may be integrally formed as part of the housing 105 or may be separate from the housing 105.

In fig. 18, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The partition wall 356 may be a thin-walled tubular metal structure that separates the environment 204 from the environment 206 and separates the rotor 354 from a portion of the stator 352. The separation wall 358 may also be a thin-walled tubular metal structure that separates the environment 204 from the environment 206. Alternatively, the partition walls 356, 358 may be any suitable shape, for example the partition walls 356, 358 may form an enclosure that surrounds part or all of the stator 352 such that the third environment 360 within the enclosure is formed to be isolated from the environment 204 and/or the environment 206. Stator 352 is shown having a first portion 370 in environment 204, a second portion 372 in environment 360, and a third portion 374 in environment 206. Alternatively, the walls 356, 358 may be coated, plated, injection molded, formed, of any shape or any suitable divider wall or combination of divider walls and wall types. Further, one or more of the partition walls 356, 358 may be integrally formed as part of the enclosure 105 or may be separate from the enclosure 105.

In fig. 19, the motor 108 has a stator 352 and a rotor 354, each of which may have a core, magnets, windings, or any other suitable combination. The partition wall 356 may be a thin-walled tubular metal structure separating the environment 204 from the environment 206, with the stator 352 exposed to the environments 204 and 206 and forming a portion of the wall 356. The separation wall 358 may be a thin-walled tubular metal structure separating the environment 204 from a portion of the stator 352, wherein the stator 352 is exposed to the environments 204 and 206 and forms a portion of the wall 356. Alternatively, the partition wall 356 may be a coating, plated, injection molded part, formed part and have any shape or any suitable partition wall or combination of partition walls and wall types. Further, the partition wall 356 may be integrally formed as part of the housing 105 or may be separate from the housing 105. In alternative aspects, one or more features may be combined together, for example one or more of the features of the embodiments of fig. 12-23 may be combined in any suitable arrangement or combination.

Fig. 20 shows an example of a conventional stator 352 and rotor 354. The stator 352 may have a toothed (slotted) core that may provide a desired high torque that is constant and efficient. Alternatively, the stator 352 of the vacuum compatible drive unit may be a toothless (slot-less) design, which may provide a blunt tooth of a desired low height. Alternatively, the stator 352 of the vacuum compatible drive unit may be a ironless (coreless) design. Alternatively, the rotor 354 and stator 352 may be any suitable rotor or stator. The stator 352 may be encapsulated by an encapsulation 402, which may be a vacuum compatible epoxy with filler, or any suitable encapsulation. The encapsulation may completely or partially surround and encapsulate the stator 352. For example, the metal forming the ring 404 or any other suitable material, e.g., having good heat transfer or other desired properties, may be provided in contact with the casing 105 while a portion (or none) of the encapsulation 402 is or may also be in contact with the casing 105. Alternatively, package 402 may not be in contact with housing 105, for example, where stator 352, ring 404, and package 402 may form a discrete assembly and subsequently installed in housing 105. Here the stator 352 may have a ring 404 pressed or otherwise secured thereon and subsequently potted through the encapsulation 402. The outer envelope of package 402 may be formed by emptying the mold with stator 352 and/or ring 404 therein and introducing liquid resin therein. Here, a portion of the ring, stator, or other suitable component may or may not form part of the mold. Alternatively and as will be shown, the integral envelope may form all or part of a mould defining the volume of the package. When formed as a separate component from housing 105, components 352, 404, 402 may then be assembled to housing 105 by press-fitting or other suitable fastening. Here, heat may be transferred from the windings and laminations or core of the stator 352 and through the encapsulation and/or ring 404 for dissipation through the casing 105. Here, for example, the stator 352 may be compressed or otherwise secured by fasteners, adhesives, or other securing rings 404 in contact with the housing 105, wherein the rings are secured to the stator and/or housing in sufficient contact with the stator and/or housing to provide a sufficient heat transfer path from the stator to the rings and to the housing or other heat dissipation source. The package 402 may be integrally injection molded with the housing 105 and stator 352 or separately injection molded, for example as an assembly with the stator 352, with the ring 404 installed as an assembly in the housing 105 or otherwise. The ring 404 may also have an axial bore 424 and a trapezoidal cutout 420 formed to promote adhesion of the package 402 and resolution of internal stresses, such as due to thermal expansion of the potting material. Here, the function of the ring 404 may be to provide a path to remove heat from the stator 352 and transfer it to the casing 105, which may be cooled, e.g., externally or otherwise, while maintaining a continuous protective barrier around the stator, e.g., where the stator may be formed of laminated sheets, as opposed to a discontinuous lamination where the ring 404 forms a continuous protective barrier. Alternatively, package 402 and housing 105 may be made of the same material, such as where housing 105 and package 402 are injection molded as a unitary structure, with the stator being wholly or partially encapsulated in unitary material 105 and 402. Here, the encapsulation 402 may form a separation barrier and may provide protection from the environment, for example to prevent corrosion, and/or to facilitate heat removal as previously described. Although fig. 20 shows ring 404 for use in various combinations with stator 352, package 402, and housing 105, package 402 may alternatively be adapted for use with or without ring, housing 105, or other embodiments as a unitary structure with or without another component or otherwise. Accordingly, all such variations are included.

As shown in fig. 21, the exposed surfaces of the stator package 402 of the vacuum compatible direct drive unit may be completely or partially coated with a coating 406, such as with electroless nickel plating, to eliminate or minimize exposure of the potting material for the packaging of the stator to vacuum, atmospheric, sub-atmospheric, pressurized, or other non-atmospheric environment to further reduce the risk of outgassing. Here, the coating 406 may form a separation barrier as previously described. Alternatively, as seen in fig. 22, one or more sheets of protective material 408, 410, 412, e.g. made of stainless steel or another suitable material, may be bonded to the encapsulation of the stator in a potting process, e.g. as shown in fig. 22. This may limit exposure of the potting material to seams between sheets of protective material. Here, the potting material 402 may form a seal between the sheets 408, 412, 410 or the sheets may be additionally sealed by, for example, welding, brazing, soldering, or by any other suitable static seal such as an O-ring or other. Here, the tabs 408, 410, 412 and the ring 404 may form separate barriers as previously described. Here, the stator may be enclosed in a thin cage or incorporated into an envelope of potting material, for example in a potting process. The thin cage or envelope may be welded, for example, from a thin sheet of stainless steel.

In fig. 23, an envelope of, for example, machined or otherwise formed aluminum or stainless steel or other suitable material is provided having a sleeve 414, a lower housing 416 and an upper housing 418. Each may be additionally sealed by potting 402 or by, for example, welding, brazing, soldering, or by any suitable static seal such as an O-ring or others. Here, potting 402 may not be provided and wherein the interior space of the housing may form, for example, environment 360 or other intermediate environment. Alternatively, more or fewer or partial housings may be provided, for example, where the windings of the stator are potted and the teeth are not or in addition. Here, a small gap can be provided between the stator and rotor that preserves the torque output and efficiency of conventional motor designs. Here, with a radial field motor, the separation layer may be included in the stator, for example by coating, bonding or by any other suitable method. As another alternative, the stator may be injection molded or otherwise packaged in a material that is compatible and resistant to vacuum or any other environment to which the stator may be subjected. As a further alternative, the stator may be enclosed in a vacuum-tight container, as seen in fig. 23. Similarly, the rotor may be coated, carry a bonded protective layer, injection molded or encased in a protective material, enclosed in a vacuum-tight container, or protected from the environment in which it may operate.

The exposed surfaces of the stator encapsulation may be coated, for example, as shown in fig. 21, for example, with an electroless nickel coating to eliminate or minimize exposure of the potting material for the encapsulation of the stator to vacuum, or other non-atmospheric environment to further reduce the risk of outgassing. Alternatively, a sheet of protective material, for example made of stainless steel, as seen for example in fig. 22, may be bonded to the encapsulation of the stator, preferably in a potting process as shown in fig. 22. This limits the exposure of the potting material to the seams between sheets of protective material. As another alternative, as shown in fig. 23, the stator may be enclosed in a thin envelope bonded to the potting material, preferably during potting. The envelope may be welded, for example, from a thin sheet of stainless steel. As another alternative, a thin separation wall, for example in the form of a disc 412, may be present between the stator and the rotor of the axial field motor. As seen in fig. 20, the stator may be pressed, glued, clamped, bolted or attached in any other suitable manner to the housing of the direct drive unit.

The radial, axial, or radial-axial field combination motors described above may be coreless (coreless) designs. In another example embodiment with a motor arrangement, a coreless stator with windings and two rotors with magnets, each rotor on one side of the stator, may be used. Alternatively, the stator may comprise a core because the passive magnetic forces exerted on the core by the two rotors may be balanced. Yet another example embodiment with an electromechanical device may comprise two stators with windings and a single rotor with a magnet sandwiched between them. Vacuum compatible packaging including the packaging alternatives described above and stiffeners to minimize the risk of outgassing and/or enhance heat transfer may be used, or two or more divider walls may be included in the exemplary embodiments described.

In another embodiment of the vacuum compatible direct drive system of the present invention, the motor configuration used in the above example may be replaced by a different motor topology including, but not limited to, a mixed field (radial-axial) configuration. For example, the stator and rotor may have conical, convex v-shaped, concave v-shaped, convex semi-circular, or concave semi-circular profiles, any combination of conical, v-shaped, and semi-circular profiles, or any other suitable profile to form a substantially uniform gap or gaps between the stator and rotor. Vacuum compatible packaging including the packaging alternatives described above with stiffeners for minimizing the risk of outgassing may be used, or there may be a suitably shaped partition wall in the gap. An outer stator inner rotor and inner stator outer rotor configuration may be used. In an alternative embodiment, the entire housing 105 may be formed or otherwise injection molded wherein the stator may be directly included in the injection molded housing. As an alternative to injection moulding, casting or spray forming or any suitable manufacture of any suitable alternative material may be provided. In alternative embodiments, any suitable number of distributed or otherwise winding phases may be provided within the stator. In alternative embodiments, such as with the passive magnet-less rotor described or any suitable rotor, the rotor may not be solid, for example, where the rotor is laminated and vacuum compatible in some versions to reduce losses.

As seen in fig. 24, a vacuum compatible direct drive system may use a radial field motor arrangement 108 that includes a wound brushless stator 352 and a rotor 354 having magnets 452 disposed in proximity to the stator such that it may rotate relative to the stator and interact with the stator by a magnetic field that is substantially radial relative to the axis of rotation 306 of the rotor. The stator may have windings 454, a core 456, and a backing ring 404. Alternatively, the stator 352 may be coreless where the coreless stator may include a set of windings that are energized by a suitable controller based on the relative position of the rotor with respect to the stator. The rotor 354 may include a set of permanent magnets 452 having alternating polarities. As described, the stator may be encapsulated in a suitable material such as a vacuum compatible epoxy based potting to limit stator component outgassing to a vacuum or other non-atmospheric environment. As seen in fig. 20, the encapsulation may also bond the stator to the housing of the direct drive unit to further secure the stator relative to the housing. As seen in fig. 2, the leads to the windings of the stator may pass through openings of the housing sealed by the encapsulation, thereby eliminating the need for a separate vacuum feed-through as seen in fig. 3. Alternatively, the leads leading from the atmosphere to the windings of the stator of the radial field motor may be routed through the wall of the housing of the direct drive unit through vacuum feed-throughs or in any other suitable manner.

As seen in fig. 25, the electric machine 108 may be an electric machine 108' that may be a hybrid design having a toothed passive rotor 458, stator phases a460 and B462 separated by annular permanent magnets 464. A suitable example can be found in U.S. patent No.5,834,865 entitled "hybrid stepper motor," which is incorporated by reference herein in its entirety. Alternatively, the ring magnet may be disposed within the rotor 458. For example, as shown, a solid non-magnetic passive rotor, e.g. 400 series stainless steel without magnets, may be provided which does not include permanent magnets and which has a high magnetic permeability/saturation and a low coercivity to reduce air leakage, wherein the stator portion may be provided with one or more partition walls as previously described. This arrangement minimizes exposure of the material to the vacuum, e.g., where the magnet is not exposed to the vacuum. Such a non-magnetic passive rotor that similarly does not include permanent magnets may be used in conjunction with any suitable stator, such as the example embodiment stator or any of the additional disclosed embodiments.

As seen in fig. 26, the motor 108 may be an axial field designed motor 108 "that may have a rotor 470 with magnets 472 and a stator 474 with a core 476 and windings 478. Alternatively, the magnet may be disposed within the stator.

As seen in fig. 27, the motor 108 may be a motor 490 which may be a brushless design having a passive rotor 494 and a stator 492 as will be described in greater detail. Here the stator 492 may have a core 496 (solid or laminated), windings 498 and magnets 500. For example, as shown, a solid non-magnetic passive rotor such as 400 series stainless steel without magnets as described may be provided to reduce out-gassing, wherein the stator portion may be provided with one or more partition walls as previously described. This arrangement minimizes exposure of the material to the vacuum, e.g., where the magnet is not exposed to the vacuum. Similarly, this non-magnetic passive rotor, which does not include permanent magnets, may be used in conjunction with any suitable stator, such as the example embodiment stator or any of the additional disclosed embodiments.

As seen in fig. 28 and 29, a motor 502 is provided having similar features as shown in fig. 27. Liner variations can be found in U.S. patent No.7,800,256 entitled "motor," which is incorporated herein by reference in its entirety. The motor 502 has a stator 504 and a toothed passive rotor 506. The rotor 506 may be 400 series stainless steel or any suitable material capable of providing a path for magnetic flux from the stator 504 without permanent magnets. The stator 504 may be separated from the rotor 506 by one or more separation walls 508, 510 as previously described, wherein the walls 508, 510 may be 300 series stainless steel, aluminum, or other suitable material that allows field interaction between the rotor 506 and the stator 504. The stator 504 has a salient winding 512 on teeth 514 with two alternating magnets 516, 518 on each tooth, and with the magnets on adjacent teeth having matching polarities with respect to the teeth as shown. Alternatively, distributed windings may be provided. Flux is selectively directed by a given winding to one of the two magnets on the tooth depending on the polarity of the winding. Flux is directed from each tooth through a tooth on the rotor to and adjacent a tooth of the stator to selectively commutate the motor. In alternative aspects, any suitable electric machine having a non-magnetic passive rotor may be provided.

As seen in fig. 30 and 31, motor 552 is provided having similar features to those shown in fig. 27, 28 and 29. The motor 552 has a stator 554 and a toothed passive rotor 556. The rotor 556 may be 400 series stainless steel or any suitable material capable of providing a path for magnetic flux from the stator 554 without permanent magnets. The stator 554 may be separated from the rotor 556 by one or more separation walls 558, 560 as previously described, wherein the walls 558, 560 may be 300 series stainless steel, aluminum, or other suitable material that allows field interaction between the rotor 556 and the stator 554. The stator 554 has a salient tangentially wound winding 562 between teeth 564 with two alternating magnets 566, 568 on each tooth and with the magnets on adjacent teeth having matching polarity with respect to the teeth as shown. Alternatively, distributed windings may be provided. Flux is selectively directed by a given winding to one of the two magnets on the tooth depending on the polarity of the winding. Flux is directed from each tooth through a tooth on the rotor to and adjacent a tooth of the stator to selectively commutate the motor. In alternative aspects, any suitable electric machine having a non-magnetic passive rotor may be provided.

As seen in fig. 32 and 33, a motor 602 is provided having similar features to those shown in fig. 27. Similar arrangements can be found in U.S. patent No.7,898,135 entitled "hybrid permanent magnet motor" and U.S. patent publication No.2011/0089751a1 entitled "parallel magnetic circuit motor", both of which are incorporated herein by reference in their entirety. The motor 602 has a stator 604 and a toothed passive rotor 606. The rotor 606 may be 400 series stainless steel or any suitable material capable of providing a path for magnetic flux from the stator 604 without permanent magnets. The stator 564 may be separated from the rotor 606 by one or more separation walls 608, 610 as previously described, wherein the walls 608, 610 may be 300 series stainless steel, aluminum, or other suitable material that allows field interaction between the rotor 606 and the stator 604. Stator 604 has raised tangential windings 612 on cores 614, each core having two teeth and two alternating magnets 616, 618 on each core and wherein the magnets on adjacent cores have opposite polarity relative to the cores as shown. Alternatively, distributed windings may be provided. Flux is selectively directed through a given winding to one of two teeth on the core according to the polarity of the winding. Flux is directed from each tooth through a tooth on the rotor to and adjacent a tooth on the stator to selectively commutate the motor. In alternative aspects, any suitable electric machine having a non-magnetic passive rotor may be provided.

As seen in fig. 34 and 35, a motor 652 is provided having similar features to those shown in fig. 27. Liner variations can be found in U.S. patent No.7,800,256 entitled "motor," which is incorporated herein by reference in its entirety. The motor 652 has a stator 654 and a toothed passive rotor 656. The rotor 656 may be a 400 series stainless steel or any suitable material capable of providing a path for magnetic flux from the stator 504 without permanent magnets. The stator 654 may be separated from the rotor 656 by one or more separation walls 658, 660 as previously described, wherein the walls 658, 660 may be 300 series stainless steel, aluminum, or other suitable material that allows field interaction between the rotor 656 and the stator 654. The stator 654 has salient windings 662 on teeth 664 with two alternating magnets 666, 668 on opposite sides of the core of each tooth, and wherein the magnets on the cores of adjacent teeth have opposite polarity relative to the teeth as shown. Alternatively, distributed windings may be provided. Flux is selectively directed to the teeth by a given winding depending on the polarity of the winding. Flux is directed from each tooth through a tooth on the rotor to and adjacent a tooth of the stator to selectively commutate the motor. In alternative aspects, any suitable electric machine having a non-magnetic passive rotor may be provided.

As seen in fig. 36 and 37, an electric machine 702 is provided having similar features to those shown in fig. 27. Liner variations can be found in U.S. patent No.7,800,256 entitled "motor," which is incorporated herein by reference in its entirety. The electric machine 702 has a stator 704 and a toothed passive rotor 706. The rotor 706 may be 400 series stainless steel or any suitable material capable of providing a path for magnetic flux from the stator 504 without permanent magnets. The stator 704 may be separated from the rotor 706 by one or more separation walls 708, 710 as previously described, where the walls 708, 710 may be 300 series stainless steel, aluminum, or other suitable material that allows field interaction between the rotor 706 and the stator 704. The stator 704 has projecting windings 712 on split teeth 714, with magnets 716 splitting each tooth, and with the magnets on adjacent teeth having opposite polarity relative to the teeth as shown. Alternatively, distributed windings may be provided. Flux is selectively directed to one of the two split portions of the tooth by a given winding depending on the polarity of the winding. Flux is directed from each tooth through a tooth on the rotor to and adjacent a tooth of the stator to selectively commutate the motor. In alternative aspects, any suitable electric machine having a non-magnetic passive rotor may be provided.

An example substrate transfer apparatus may include: a drive section including a first motor, wherein the first motor includes a stator and a passive rotor; and a first movable arm assembly connected to the first motor. The substrate transport apparatus may be configured such that the first movable arm assembly is positionable in a vacuum chamber 4 (see fig. 1), the passive rotor being in communication with the environment inside the vacuum chamber.

The first motor may be a radial field motor arrangement. The stator may include a coil and a permanent magnet. The passive rotor may not include coils and does not include permanent magnets. The passive rotor may comprise a stainless steel one-piece member. The first motor may be a linear motor arrangement. The passive rotor may include a tooth surface facing the stator. The substrate transport apparatus may also include a gas barrier positioned between the stator and the passive rotor to separate the environment in which the passive rotor is located (the environment in the chamber 4 and extending into the motor area of the drive 10) from the environment in which the stator is located (such as the atmosphere 6). The gas barrier may comprise at least one separation wall. The partition wall may comprise stainless steel, or aluminum, or other material that allows magnetic field interaction between the passive rotor and the stator. The gas barrier may comprise a housing substantially completely surrounding the stator. The housing may include an encapsulation material surrounding the stator. The potting material may include an overmolded polymer material that is molded over the stator.

An example method may include providing a substrate transport apparatus including a drive portion and a first movable arm assembly coupled to the drive portion, wherein the drive portion includes a motor including a stator and a passive rotor; and connecting the substrate transport apparatus to a vacuum chamber, wherein the first movable arm assembly is positioned in the vacuum chamber and the passive rotor is in communication with an environment inside the vacuum chamber.

A substrate transport apparatus is provided that includes a stator that may include coils and permanent magnets, and a passive rotor that may not have coils and permanent magnets. The method may also include positioning a gas barrier between the stator and the passive rotor to separate an environment at the passive rotor from an environment at the stator. The gas barrier may comprise at least one separation wall positioned between the stator and the passive rotor. The gas barrier may include encapsulating the stator with an encapsulating material. The gas barrier may include enclosing the stator inside an envelope, wherein a wall of the envelope is positioned in a gap between the stator and the passive rotor.

An example substrate transfer apparatus may include: a drive section including a first motor, wherein the first motor includes a stator and a passive rotor; a first movable arm assembly connected to a first motor; and a gas barrier positioned in the gap between the stator and the passive rotor to separate an environment at the passive rotor from an environment at the stator.

It should be understood that the above description is illustrative only. Many alternatives and modifications can be devised by those skilled in the art. For example, features recited in a number of dependent claims may be combined with each other in any appropriate combination. Furthermore, features from different embodiments described above may be selectively combined in new embodiments. Accordingly, the specification is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.