Abstract: Apparatuses and methods for changing the friction and stiffness characteristics of a linear guide assembly are disclosed. Micro-shims are strategically added between a carriage of the linear guide assembly and a mating component to increase or decrease the clearance between the carriage and a linear rail of the linear guide assembly.

Abstract: A programmable control system and related features and methods are provided for the operation an automated, actuator-based component inspection system. In one implementation, the invention can be characterized as an actuator control system comprising: a controller adapted to be coupled to and control an actuator including a probe moveable by the actuator about an axis in response to control signals from the controller; a user input device coupled to the controller and configured to receive inputs from a user to define an automated sequence of multiple locations of the probe and configured to cause an encoder measurement to be retrieved from the actuator; and the user input device further configured to receive a tolerance value from the user corresponding to the encoder measurement.

Abstract: A system for programming and controlling the movement of a probe of a voice coil actuator along a path includes a control module that is mounted on a voice coil actuator. Specifically, the control module is connected to a clock and to an encoder to selectively establish a plurality of sequential positions for the probe. Each position in this sequence is defined by a location on the path (translation and rotation), and a time at the location. More specifically, the control module includes a key pad for inputting data to identify each position and also, there is a display for providing a visual presentation of the data. In operation the plurality of sequential positions specify a work cycle for the probe and the voice coil actuator uses the input data to perform a series of work cycles.

Abstract: A system for programming and controlling the movement of a probe of a voice coil actuator along a path includes a control module that is mounted on a voice coil actuator. Specifically, the control module is connected to a clock and to an encoder to selectively establish a plurality of sequential positions for the probe. Each position in this sequence is defined by a location on the path (translation and rotation), and a time at the location. More specifically, the control module includes a key pad for inputting data to identify each position and also, there is a display for providing a visual presentation of the data. In operation the plurality of sequential positions specify a work cycle for the probe and the voice coil actuator uses the input data to perform a series of work cycles.

Abstract: A linear actuator includes a plurality of magnetic plates and a ferrite core with a conductive cover which are mounted on the actuator body to generate a permanent magnetic field. The linear actuator also includes a metal bobbin which has an outer surface and which is formed with an aperture that defines an inner surface for the bobbin. Further, the bobbin is formed with a gap which extends along its length and which intersects the bobbin from its inner to its outer surface. An insulating insert is placed in the gap. Finally, a winding is wrapped around the outer surface of the bobbin to form an electromagnetic coil, and the coil on the bobbin is slidingly mounted on the actuator to receive the ferrite core through the bobbin's aperture. Electrical current can then be selectively applied to the winding to interact with the permanent magnetic field and thereby cause reciprocating motion of the coil.

Abstract: An electric voice coil actuator includes two coils slidingly mounted on a ferromagnetic housing. The coils, which are connected to each other in most applications, are mounted co-axially for linear reciprocal movement in respective magnetic fields. The north poles of a first pair of magnets are affixed to the housing to create the magnetic fields in which the first coil moves. The south poles of a second pair of magnets are affixed to the housing to create the magnetic fields in which the second coil moves. Alternately, the coils can move in the same magnetic field. Opposing poles of the pairs of magnets are affixed to the housing to prevent magnetic saturation of the housing. The coils are electrically connected to an electric current source to produce magnetic fields that interact with the magnetic fields of the magnets to cause movement of the coils. The electric current source may be electrically connected in parallel to each coil, to cause substantially identical movement of the coils.

Abstract: The, present invention is a gripper for use in combination with a machine for repositioning a component. Structurally, the present invention includes a housing formed with a chamber. A fixed-pole housing magnet is positioned inside of the chamber. A pair of grips are slidingly mounted for movement relative to the housing. Each grip is partially contained in the chamber and partially projects from the housing. An electromagnetic coil is attached to each grip. Functionally, the gripper is positioned with an assembly component between the grips. A separate electric current is then passed through each of the electromagnetic coils mounted on each of the respective grips. The electric current causes each electromagnetic coil to generate a magnetic field which interacts with the housing magnet. The interaction between the magnetic fields generated by the electromagnetic coils and the housing magnet creates a force on each grip, causing each grip to move translationally to hold, or squeeze, the component.

Abstract: A method for manufacturing a linear voice coil actuator, capable of continuously generating a one hundred kilogram force with less than two amperes of current, requires using a coil for generating an electrical field and an unsaturated permanent magnet circuit for generating a magnetic field. In the method of manufacture, a flat surface of the electrical coil is positioned parallel to a flat surface of the magnet to establish a gap therebetween. Before operating the actuator, when no current is running through the coil, a distance of approximately 0.75 mm is established across the gap. Subsequently, during operation of the actuator, when a current of less than approximately two amperes is driven through the coil, the electrical field generated by the coil interacts with the magnetic field of the magnet to generate as much as a 100 kg force on the coil.

Abstract: A controller for a voice coil actuator includes sensors that are connected with the actuator probe to monitor both the linear and angular position of the probe, as well as the axial and rotational forces on the probe. Using predetermined instructions, the probe can be controlled in either an open loop mode or in a closed loop feedback mode, for either static or dynamic operations. For static operations, the axial and rotational forces on the probe can be controlled by referencing set values for the forces which are to be applied to/by the probe. For dynamic operations, in addition to the axial and rotational forces on the probe, the linear and angular movements of the probe can be controlled. In the closed loop mode, linear and angular positions, velocities, and accelerations can be used for control.

Abstract: A method and device for moving a probe assembly into soft contact with a work surface includes initially placing the probe into an approach position. Advancement of the probe along a substantially perpendicular path toward the work surface is then controlled by applying a restraining force on the probe. This resisting force is decreased until the weight of the probe assembly just overcomes the static friction forces that are acting on the probe. After the static friction forces are overcome, the probe advances along a path toward the work surface. By monitoring this advancement, soft contact of the probe with the work surface can be determined when the velocity of the probe changes to zero. First, the position of the probe can be monitored to advance the probe along the path through a known travel distance. Second, the velocity of probe advancement can be monitored to indicate soft contact when velocity changes to zero.

Abstract: A thin film field effect transistor includes: a) a thin film channel region; b) a pair of opposing electrically conductive first and second source/drain regions adjacent the thin film channel region; c) a gate insulator and a gate positioned adjacent the thin film channel region for electrically energizing the channel region to switch on the thin film field effect transistor; d) the first source/drain region having a first thickness, the second source/drain region having a second thickness, the channel region having a third thickness; at least one of the first and second thicknesses being greater than the third thickness. Methods are disclosed for making thin field effect transistors.

Abstract: A linear voice coil actuator using a removable electromagnetic coil includes an electrically conductive wire wound on a plastic bobbin. The wire which is wrapped around the bobbin is connected to an external power source as the electromagnetic coil is attached to the linear voice coil actuator. Current applied from the external power source causes the electromagnetic coil to selectively generate a magnetic field and, in response to generation of the magnetic field, to move translationally within a fixed magnetic field. The translational movement of the coil moves a grip which is mounted on the coil to allow the grip to selectively position and manipulate objects and things.

Abstract: An in-line linear/rotary drive mechanism for a voice coil actuator includes an electro-magnetic drive motor having a rotatable drive shaft. Specifically, both the drive motor and its rotatable shaft are slidably mounted for translational movement on the housing of the actuator. An actuator probe is also slidably mounted on the actuator housing. Importantly, a bearing unit constrains the actuator probe to translational movement along a predetermined axis on the actuator housing. Further, a rotary-servo coupling selectively connects the rotatable drive shaft of the electro-magnetic drive motor with the actuator probe. Within this combination, the actuator probe moves in direct translation with the drive motor along the predetermined axis. Also, within this combination the actuator probe moves in rotation about the predetermined axis in response to the rotatable drive shaft.

Abstract: The invention comprises an electrical connector assembly having a wire housing with a wire contact disposed therein. The wire contact has two ends, one of the ends having insulation displacing slots for receiving a magnet wire therein, the other of the ends having a resilient contact finger. The assembly further includes a connector housing having a tab contact disposed therein. The tab contact has a poke-in tab and a contact tab for mating with a matable connector. The wire housing is matable with the connector housing, the poke-in tab engages the resilient contact finger to provide electrical connection therebetween and to provide electrical connection between the magnet wire and the matable connector.

Abstract: An actuator for precisely moving and positioning a manufacturing component includes a housing on which a magnet is mounted. An electromagnetic is slidingly mounted on the housing for movement within the magnetic field generated by the magnet. A rod, having a member for gripping the component, is attached for translational movement with the electromagnetic coil. In the operation of the actuator, a current is selectively applied to the electromagnetic coil. The current in the coil creates a magnetic field that moves the electromagnetic coil and the attached grip within the magnetic field to position the component as desired in translation. A retractor causes the grip to preferentially adopt a predetermined position, or dwell configuration.

Abstract: A mechanism for precise translational positioning of a rotatable rod includes a reciprocating piston. A rotary motor is mounted on the piston for establishing rotation about a first axis, and a flexible coupling connects the rotary motor with a rod for precise rotation of the rod about an axis substantially parallel to the first axis. Further, the mechanism includes a pair of roller bearings. These roller bearings are distanced from each other, and each interconnect the rotatable rod with the reciprocating piston to permit rotation of the rod relative to the piston while preventing translation relative thereto. Additionally, a sleeve with a pair of O-rings is mounted to the rod between the pair of roller bearings to create a fluid chamber between the O-rings, the rod, and the piston. A fluid passageway in the rod then allows a vacuum pump to draw a vacuum from the chamber to the distal end of the rod.

Abstract: An apparatus for precisely moving and positioning a manufacturing component includes a housing on which a magnet is mounted. An electrical coil is wound around a coil piston which is slidingly mounted on the housing for movement within the magnetic field generated by the magnet. A rod, having a member for gripping the component, is attached for translational movement with the coil piston, and a source of electrical current is connected to the coil which is wrapped around the coil piston. A pneumatic rotary actuator is mounted on the apparatus, and a coupling connects the rotary actuator to the grip for rotation of the grip as desired. A vacuum source can be connected to the grip to allow picking up a fragile workpiece. In the operation of the apparatus, a current is selectively passed through the coil. This current in the coil then moves the coil piston and the attached grip within the magnetic field to position the component as desired in translation.

Abstract: An actuator for precisely moving and positioning a manufacturing component includes a housing on which a magnet is mounted. An electrical coil is wound around a coil piston which is slidingly mounted on the housing for movement within the magnetic field generated by the magnet. A grip, having a member for gripping the component, is attached for movement with the coil piston. In the operation of the actuator, a current is selectively passed through the coil. This current in the coil then moves the coil piston and the attached grip within the magnetic field to position the component as desired. Additionally, a position sensor can be mounted on the device to determine the location of the coil piston and a controller can be incorporated in the actuator to use this position determination for controlling movement of the coil piston and the attached grip. The grip is removably attached to the coil piston and is slidingly journaled within a resilient bushing mounted to the housing.

Abstract: An actuator for precisely moving and positioning a manufacturing component includes a housing on which a magnet is mounted. An electrical coil is wound around a coil piston which is slidingly mounted on the housing for movement within the magnetic field generated by the magnet. A rod, having a member for gripping the component, is attached for translational movement with the coil piston, and a source of electrical current is connected to the coil which is wrapped around the coil piston. A drive motor is mounted on the device, and a linkage connects the drive motor to the grip for rotation of the grip as desired. In the operation of the actuator, a current is selectively passed through the coil. This current in the coil then moves the coil piston and the attached grip within the magnetic field to position the component as desired in translation. Also, the drive motor can be activated to move the grip in rotation as desired.

Abstract: A method and apparatus for measuring and sorting component parts of an assembly includes a single station wherein parts are continuously fed, precisely measured, sorted by measurement, and then transported. For measuring the parts a contact member is mounted for extremely precise and controlled movements by a voice coil motor. The contact member is initially referenced with respect to a datum and is then placed into contact with the part. An optical encoder senses the position of the contact member to enable a determination of the critical dimension. The contact member includes a removable portion that is shaped to measure a desired critical dimension. This may include the height, inside diameter, outside diameter, roundness, or location of a feature of the part.