Air Bearing Stage With Spherical Chuck for Precise Planar Alignment
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Solution Overview
Problem
Existing manufacturing equipment lacks the precision and flexibility to achieve highly refined, particularly planar alignment and placement of components, especially for irregularly shaped devices, in automated or semi-automated processes.
Innovation Solution
A moveable air bearing stage system with a semi-spherical receiving interface, connected by springs, featuring a chuck with gripper jaws and a floating yoke for multi-axis movement, utilizing air and vacuum for precise alignment and gripping, and a tactile system for assessing alignment with a secondary reference plane.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If dual ball-and-socket assemblies are used to provide enhanced range of movement, then the range of movement is improved, but the planar alignment precision for irregularly shaped devices deteriorates
Solution Approach 1:
The system divides the alignment function into two independent parts: a spherical bearing stage that provides multi-axis movement capability, and a separate planar alignment mechanism that ensures precise planar positioning. This segmentation allows each component to optimize its specific function without compromising the other.
Solution Approach 2:
The invention transitions from conventional single-plane alignment to multi-dimensional positioning by incorporating a spherical bearing stage that enables movement across multiple axes while maintaining planar alignment precision through the integrated planar alignment mechanism.
2Device complexity
If conventional alignment mechanisms are used for automated equipment, then the system complexity is reduced, but the alignment accuracy and delicateness deteriorate
Solution Approach 1:
The spherical bearing stage acts as an intermediary component between the automated positioning system and the component holder, providing a mechanism that simultaneously achieves high precision planar alignment and multi-axis movement capability without requiring overly complex control systems.
3Manufacturing precision
If highly refined alignment mechanisms are implemented, then the alignment precision is improved, but the device complexity increases
Solution Approach 1:
The system employs a dynamic spherical bearing stage that can adapt its degrees of freedom based on operational requirements, providing high precision planar alignment when needed while maintaining the capability for multi-axis movement, thereby achieving high precision without permanently fixed complex mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables highly accurate and flexible planar alignment and placement of components, enhancing manufacturing efficiency and precision, particularly in robotics-based processes by allowing multiple ranges of movement and improved alignment accuracy.
Implementation Method 1
an air bearing stage for use in automated or semi-automated, such as in robotics-based, manufacturing processes
Implementation Method 2
a vacuum associated with the chuck and suitable for grasping the component or device
Data Source
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AI summary
The disclosure provides an apparatus, system and method for a moveable bearing stage that allows for highly refined alignment and placement, and particularly planar alignment and placement, of component or devices through the use of robotics. The apparatus, system and method of providing at least a planar alignment of at least one component or device in relation to a secondary reference plane may include at least: a frame and stator assembly, having, at an upper portion thereof, at least a semi-spherical receiving interface; a movable assembly that moves within the frame and stator assembly, and that is connectively associated therewith by at least a plurality of springs; a semi-spherical stage, suitable for reception by the semi-spherical receiving interface and capable of at least rotational movement therewithin; a chuck within the semi-spherical stage and capable of at least co-planar, post-planar, and ante-planar positioning in relation to a plane provided by a topmost portion of the semispherical stage, wherein the chuck is capable of receiving the component or device; and at least two gripper jaws suitable for receiving and holding, at an upper portion thereof, the component or device, wherein the two gripper jaws comprise, at a lower portion thereof, at least ramps capable of physically interacting with ones of the motion stops.