Decoupled Bonding Tool Axes for Precision Force Control
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Solution Overview
Problem
Conventional bond arms suffer from increased load on the drive system due to coupling between rotary and linear motion axes, leading to adverse effects on actuation, stop characteristics, and positioning accuracy, and result in inconsistent bonding forces.
Innovation Solution
A bonding tool with a decoupling mechanism, featuring separate rotary and linear motion modules actuated by direct driving mechanisms, effectively decoupling the rotary and linear movements to improve position control and consistency of bonding force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a timing belt is used to drive the rotary axis for decoupling, then the coupling between rotary and linear axes is decoupled, but latency occurs before the rotary shaft is driven causing inconsistent bonding force
Solution Approach 1:
The patent replaces the timing belt mechanical transmission system with a direct-drive mechanism where the rotary motor is directly coupled to the rotary shaft through a magnetic coupling system. This eliminates the intermediate timing belt transmission that caused latency, achieving direct and immediate transmission of rotational motion from the motor to the shaft without mechanical belt slip or inertia delays.
2Reliability
If a set of gears is used to drive the rotary axis for decoupling, then the coupling between rotary and linear axes is decoupled, but friction between gear teeth causes inconsistent bonding force and clearances result in rotational clearance
Solution Approach 1:
The patent eliminates the gear mechanism entirely by using a direct-drive magnetic coupling system. The rotary motor's magnetic field directly couples with the rotary shaft, eliminating mechanical gear teeth, friction, and clearances. This substitution of mechanical gear transmission with magnetic field-based direct drive resolves the issues of gear friction and rotational clearance while maintaining decoupling functionality.
3Device complexity
If conventional bond arms with coupled rotary and linear motion axes are used, then the structure is simpler, but the load on the drive system increases adversely affecting actuation, stop characteristics and positioning accuracy
Solution Approach 1:
The patent segments the bond arm drive system into two independent modules: a rotary motion module with its own motor and shaft for rotational movement, and a linear motion module with its own actuator for linear movement. This segmentation decouples the previously coupled axes, allowing each module to be controlled independently without interfering with the other, thereby improving positioning accuracy while maintaining structural simplicity through modular design.
Data Source
AI summary
A bonding tool with a decoupling mechanism includes a shaft, a rotary module coupled to a first portion of the shaft, a rotary motion actuator operatively connected to the rotary module and operative to drive the rotary module and the shaft to rotate about a rotary axis extending substantially along a central axis of the shaft, a linear motion module coupled to a second portion of the shaft separate from the first portion, and a linear motion actuator operatively connected to the linear motion module and operative to drive the linear motion module and the shaft to move in directions parallel to the rotary axis.