Active Shelf Stocker Layout for Higher Carrier Density
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Solution Overview
Problem
Stocker systems used in semiconductor and display device manufacturing require significant space due to their horizontal and vertical shelves, load ports, and transfer robots, leading to reduced space utilization and increased transfer times.
Innovation Solution
A stocker system with an active shelf module that includes a foldable movable frame and a driving device with a cam mechanism and electric actuator, allowing the shelf to extend and retract, enabling multi-level storage and reducing footprint by utilizing ceiling or wall space, thereby increasing carrier loading capacity and improving productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If traditional stocker systems with horizontal and vertical shelves are used, then carriers can be stored and transferred, but the system requires ample space leading to reduced space utilization
Solution Approach 1:
The patent transitions from traditional horizontal/vertical shelf arrangements to a multi-level three-dimensional shelf structure with active shelf modules that can extend and retract. This dimensional transformation allows carriers to be stored at multiple heights and depths, dramatically increasing storage capacity within the same facility footprint by utilizing vertical and depth dimensions more effectively.
Solution Approach 2:
The patent employs active shelf modules with extendable and retractable components that can dynamically adjust their position. The shelves can extend outward to receive and store carriers, then retract to minimize the system's footprint when not in use. This dynamic behavior allows the stocker to adapt its configuration, maximizing space utilization while maintaining carrier storage capacity.
2Quantity of substance
If traditional stocker systems with fixed shelves are used, then carriers can be accommodated, but transfer time between shelves is increased
Solution Approach 1:
The active shelf modules incorporate extendable and retractable mechanisms that dynamically adjust shelf positions to optimize carrier transfer operations. When a carrier needs to be transferred, the relevant shelf extends to bring the carrier closer to the transfer robot, reducing the transfer distance and time. This dynamic positioning significantly improves carrier transfer efficiency compared to fixed shelf systems.
Solution Approach 2:
The system can pre-position shelves in optimal locations based on anticipated carrier transfer needs. The active shelf modules can be programmed to extend or retract to predetermined positions in advance, ensuring that carriers are already in optimal locations when transfer operations are required, thereby minimizing transfer time and improving overall process efficiency.
3Quantity of substance
If multi-level shelf structure with active shelf module is implemented, then carrier loading capacity increases, but device complexity increases
Solution Approach 1:
The patent divides the stocker system into multiple independent active shelf modules, each capable of independent extension and retraction. This segmentation allows the complex functionality to be distributed across multiple simpler, identical units rather than requiring one complex integrated mechanism. Each module can be controlled independently, simplifying the overall system architecture while achieving high carrier loading capacity through the multi-level structure.
Solution Approach 2:
The active shelf modules are designed as universal components that perform multiple functions: storing carriers at different positions, facilitating carrier transfer to robots, and dynamically adjusting to optimize space utilization. By creating a multi-functional shelf module that can adapt to various operational requirements, the system achieves high carrier loading capacity without proportionally increasing complexity, as the same modular component handles diverse tasks.
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
The active shelf module enhances space utilization, increases carrier loading capacity, and reduces transfer times by enabling efficient extension and retraction of the shelf, thus improving semiconductor productivity and process efficiency while minimizing facility size.
Implementation Method 1
a cam member installed on one side or both sides of the base and having a cam groove portion extending from an upward path to a forward/backward path; a cam protrusion guided along the cam groove portion of the cam member
Implementation Method 2
an electric actuator configured to receive a control signal from the controller and raise and move the moving carriage forward and backward
Data Source
AI summary
A stocker system having an active shelf module capable of accommodating a plurality of carriers and a control method thereof are provided. The stocker system may include a stocker body having at least one accommodation space therein; an active shelf module installed on the stocker body and having at least a portion extended or retracted in a forward and reverse direction; and a controller configured to extend the active shelf module to receive a carrier from the outside of the stocker body and control the active shelf module to accommodate the carrier in the accommodation space inside the stocker body.