Power minimizing controller for a stage assembly

1. A method for moving a workpiece a movement step, the method comprising the steps of:

coupling a stage mover to the workpiece, the stage mover including (i) a magnet array including a plurality of magnets that are positioned substantially adjacent to one another; and (ii) a conductor array positioned adjacent to the magnet array, the conductor array including a first layer of conductors and a second layer of conductors that is adjacent to the first layer of conductors, wherein the first layer of conductors is closer to the magnet array than the second layer of conductors, wherein the magnet array is positioned on only one side of the conductor array, and wherein a first force constant of the first layer of conductors is larger than a second force constant of the second layer of conductors; and

directing current to the first layer of conductors and the second layer of conductors independently with a control system, wherein the control system simultaneously directs a first current to the first layer of conductors and a second current to the second layer of conductors, and wherein the first current is greater than the second current during the movement step; and

wherein the control system directs current so that a current ratio of the first current relative to the second current is greater than one, and wherein the current ratio is approximately equal to the ratio of (i) a resistance of the second layer of conductors multiplied by the first force constant of the first layer of conductors, and (ii) a resistance of the first layer of conductors multiplied by the second force constant of the second layer of conductors.

2. The method of claim 1 wherein the first layer of conductors is positioned in a stronger magnetic field than the second layer of conductors.

3. The method of claim 1 wherein the step of directing includes directing current so that the first current is at least approximately 1.2 times greater than the second current during the movement step.

4. The method of claim 1 wherein the step of directing includes directing current so that the first current is at least approximately two times greater than the second current during the movement step.

5. The method of claim 1 wherein the step of directing includes using the current ratio to determine the first current and the second current.

6. The method of claim 1 wherein the step of coupling includes coupling one of a planar motor, a linear motor and a voice coil motor to the workpiece.

7. The method of claim 1 wherein the step of coupling includes the magnet array having one or more magnet groups, each of the magnet groups including a plurality of magnets that are positioned substantially adjacent to one another.

8. A method for moving a workpiece a movement step, the method comprising the steps of:

coupling a stage mover to the workpiece, the stage mover including (i) a magnet array including a plurality of magnets that are positioned substantially adjacent to one another; and (ii) a conductor array positioned adjacent to the magnet array, the conductor array including a first layer of conductors and a second layer of conductors that is adjacent to the first layer of conductors, wherein a first force constant of the first layer of conductors is always larger than a second force constant of the second layer of conductors;

determining a current ratio of the first current relative to the second current using the first force constant of the first layer of conductors and the second force constant of the second layer of conductors; and

directing current to the first layer of conductors and the second layer of conductors independently with a control system, wherein the control system simultaneously directs a first current to the first layer of conductors and a second current to the second layer of conductors, wherein the first current is greater than the second current during the movement step, and wherein the current ratio is used to determine the first current and the second current; and

wherein the control system directs current so that the current ratio of the first current relative to the second current is greater than one, and wherein the current ratio is approximately equal to the ratio of (i) a resistance of the second layer of conductors multiplied by the first force constant of the first layer of conductors, and (ii) a resistance of the first layer of conductors multiplied by the second force constant of the second layer of conductors.

9. The method of claim 8 wherein the step of directing includes directing current so that the first current is at least approximately 1.2 times greater than the second current during the movement step.

10. The method of claim 8 wherein the step of directing includes directing current so that the first current is at least approximately two times greater than the second current during the movement step.

11. The method of claim 8 wherein the step of coupling includes coupling one of a planar motor, a linear motor and a voice coil motor to the workpiece.

12. The method of claim 8 wherein the step of coupling includes the magnet array having one or more magnet groups, each of the magnet groups including a plurality of magnets that are positioned substantially adjacent to one another.

13. The method of claim 8 wherein the step of coupling includes the stage mover further comprising at least a third layer of conductors, wherein the third layer of conductors is further from the magnet array than the second layer of conductors, and wherein the step of directing current includes the control system also directing a third current to the third layer of conductors, and wherein the second current is greater than the third current during the movement step to reduce the power consumption.

14. A method for moving a workpiece a movement step, the method comprising the steps of:

coupling a stage mover to the workpiece, the stage mover including (i) a magnet array including a plurality of magnets that are positioned substantially adjacent to one another; and (ii) a conductor array positioned adjacent to the magnet array, the conductor array including a first layer of conductors and a second layer of conductors that is adjacent to the first layer of conductors, wherein a first force constant of the first layer of conductors is larger than a second force constant of the second layer of conductors;

determining a current ratio of the first current relative to the second current using the first force constant of the first layer of conductors and the second force constant of the second layer of conductors; and

directing current to the first layer of conductors and the second layer of conductors independently with a control system, wherein the control system simultaneously directs a first current to the first layer of conductors and a second current to the second layer of conductors, wherein the first current is greater than the second current during the movement step, and wherein the current ratio is used to determine the first current and the second current;

wherein the step of coupling includes the magnet array including a first magnet group and a second magnet group that is spaced apart from the first magnet group;

wherein the stage mover includes a third layer of conductors;

wherein the first layer of conductors is closer to the first magnet group than the second layer of conductors, and the second layer of conductors is closer to the first magnet group than the third layer of conductors;

wherein the third layer of conductors is closer to the second magnet group than the second layer of conductors, and the second layer of conductors is closer to the second magnet group than the first layer of conductors; and

wherein the step of directing current includes the control system directing a third current to the third layer of conductors, and wherein the third current is greater than the second current during the movement step to reduce the power consumption.

15. A stage assembly for moving a workpiece a movement step, the stage assembly comprising:

a stage mover that is coupled to the workpiece, the stage mover including (i) a magnet array including a plurality of magnets that are positioned substantially adjacent to one another; and (ii) a conductor array positioned adjacent to the magnet array, the conductor array including a first layer of conductors and a second layer of conductors that is adjacent to the first layer of conductors, wherein the first layer of conductors is closer to the magnet array than the second layer of conductors, wherein the magnet array is positioned on only one side of the conductor array, and wherein a first force constant of the first layer of conductors is larger than a second force constant of the second layer of conductors; and

a control system that directs current to the first layer of conductors and the second layer of conductors independently, wherein the control system simultaneously directs a first current to the first layer of conductors and a second current to the second layer of conductors, and wherein the first current is greater than the second current during the movement step; and

wherein the control system directs current so that a current ratio of the first current relative to the second current is greater than one, and wherein the current ratio is approximately equal to the ratio of (i) a resistance of the second layer of conductors multiplied by the first force constant of the first layer of conductors, and (ii) a resistance of the first layer of conductors multiplied by the second force constant of the second layer of conductors.

16. The stage assembly of claim 15 wherein the first layer of conductors is positioned in a stronger magnetic field than the second layer of conductors.

17. The stage assembly of claim 15 wherein the control system directs current so that the first current is at least approximately 1.2 times greater than the second current during the movement step.

18. The stage assembly of claim 15 wherein the control system directs current so that the first current is at least approximately two times greater than the second current during the movement step.

19. The stage assembly of claim 15 wherein the stage mover is selected from the group that includes a planar motor, a linear motor, and a voice coil motor.