Linear Motor Coil Assemblies for Wire Bonding Vibration Control
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Solution Overview
Problem
Existing linear motor systems face challenges in noise reduction, vibration, speed, efficiency, accuracy, and cost, particularly in applications like wire bonding machines where precise high-speed motion is required.
Innovation Solution
The design incorporates a moving magnet assembly with a magnet track and dual coil assemblies, featuring permanent magnets and teeth with slots to optimize magnetic interaction, reducing electrical and mechanical gaps and mass, while maintaining equal force constants for minimal load on the moving magnet assembly and bearings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional linear motor designs are used, then the structure is simpler, but noise and vibration increase
Solution Approach 1:
The motor is divided into multiple independent coil assemblies (first plurality and second plurality of coil assemblies) distributed around the magnet track. Each coil assembly operates semi-independently, allowing for better vibration cancellation and noise reduction while maintaining overall motor function
Solution Approach 2:
Multiple coil assemblies are combined in a symmetric arrangement around the magnet track, with corresponding coils positioned at equal angular intervals. This merging of multiple coil systems creates balanced magnetic forces that cancel out vibrations and reduce noise
2Ease of manufacture
If larger gaps between magnets and coils are used, then manufacturing is easier, but efficiency decreases
Solution Approach 1:
The patent optimizes the gap dimensions and magnetic flux path parameters to achieve an optimal balance between manufacturability and efficiency. By carefully controlling the air gap length and magnetic circuit geometry, the design reduces magnetic flux leakage while maintaining relaxed assembly tolerances
3Force
If more permanent magnets and coils are added, then force and speed improve, but mass increases
Solution Approach 1:
The patent employs composite material structures in the motor components, combining materials with different properties to achieve high strength-to-weight ratios. This allows for increased force generation capability without proportionally increasing the overall motor mass
Solution Approach 2:
The motor design transitions from a single-plane configuration to a three-dimensional arrangement with coil assemblies distributed around the magnet track at different angular positions. This spatial distribution increases force generation capability without linearly increasing mass, as the force vectors combine more efficiently in three dimensions
4Productivity
If high-speed operation is implemented, then productivity increases, but accuracy decreases
Solution Approach 1:
The motor employs periodic coil activation sequences that are precisely timed to maintain smooth operation at high speeds. By activating coils in a predetermined periodic pattern as the magnet track moves, the system maintains positional accuracy while achieving high productivity
Solution Approach 2:
The control system dynamically adjusts coil activation timing and duration based on real-time motor position and speed feedback. This dynamic control allows the motor to maintain precision at varying speeds, optimizing both productivity and bonding accuracy for different operational requirements
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
This configuration enhances the linear motor's performance by reducing noise and vibration, improving speed and accuracy, and minimizing costs through efficient magnetic flux and reduced mass, making it suitable for high-precision applications like wire bonding machines.
Implementation Method 1
a linear motor includes a moving magnet assembly including (i) a magnet track, (ii) a first plurality of permanent magnets coupled to the magnet track, (iii) a second plurality of permanent magnets coupled to the magnet track and arranged below the first plurality of permanent magnets
Data Source
AI summary
A wire bonding system is provided including a bond head assembly carrying a wire bonding tool. A wire bonding system also includes a linear motor system for driving the bond head assembly along a first horizontal axis. The linear motor system includes a moving magnet assembly including a magnet track and a plurality of permanent magnets coupled to the magnet track; a coil assembly arranged around the moving magnet assembly, the coil assembly including a plurality of teeth having first slots therebetween, the coil assembly also including a plurality of coils at least partially disposed in at least a portion of the slots; a position encoder system; a damper element positioned between the coil assembly and a base structure of the linear motor system; and a spring element positioned between the coil assembly and the base structure of the linear motor system.