Vacuum Robot Transfer Control for Linear Tool Throughput

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Solution Overview

Problem

The existing transferring methods for semiconductor processing wafers in linear tools are inefficient due to differences in processing steps and operation conditions, particularly when processing steps are completed in a single process chamber and the same kinds of wafers are continuously processed, as they do not account for the unique characteristics of linear tools, leading to suboptimal operation rates and throughput.

Innovation Solution

A semiconductor processing apparatus with process chambers, vacuum robots, transferring intermediate units, and a controlling unit that determines the most efficient transferring methods based on the processing time required for each process chamber, allowing for dynamic control of transferring operations to optimize the operation rates of both vacuum robots and process chambers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Area of stationary object

If a linear tool structure is used to reduce installation area, then the installation area is reduced, but the transferring efficiency deteriorates because existing transferring methods are designed for cluster tools and do not account for the unique characteristics of linear tools

Engineering Contradiction:
Improveinstallation areaVSAvoidtransferring efficiency
Core Design Contradiction:
Area of stationary objectVSProductivity

Solution Approach 1:

The patent applies dynamics by making the transferring method adaptable and changeable based on processing conditions. The controlling unit dynamically selects between different transferring methods (first method for single-process wafers, second method for multi-process wafers) according to the specific processing step and operation conditions, rather than using a fixed transferring approach. This dynamic adaptation resolves the contradiction by enabling efficient transferring in the linear tool structure without requiring a cluster tool configuration.

Inventive Principle:
Principle #15Dynamics

2Device complexity

If a fixed transferring method is used for all processing steps, then the control is simplified, but the operation rates of vacuum robots and process chambers deteriorate because different processing steps require different transferring approaches

Engineering Contradiction:
Improvecontrol complexityVSAvoidoperation rates
Core Design Contradiction:
Device complexityVSProductivity

Solution Approach 1:

The patent segments the transferring control into distinct methods based on processing characteristics. The first transferring method is applied to processing steps completed in a single process chamber, while the second transferring method is applied to processing steps completed through multiple process chambers. This segmentation allows each method to be optimized for its specific use case, improving operation rates without significantly increasing overall control complexity through automated selection based on processing step identification.

Inventive Principle:
Principle #1Segmentation

3Device complexity

If wafers are transferred without considering processing time variations, then the transferring process is simplified, but the waiting times of vacuum robots and process chambers increase, reducing throughput

Engineering Contradiction:
Improvetransferring control complexityVSAvoidwaiting time
Core Design Contradiction:
Device complexityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by determining and storing the processing time for each processing step in advance. The controlling unit uses this pre-determined processing time information to select the appropriate transferring method before actual wafer transfer begins. This preliminary preparation enables optimized transferring decisions without adding complexity during the actual transfer operation, thereby reducing waiting times and improving throughput.

Inventive Principle:
Principle #10Preliminary action

Data Source

PatentUS8849446B2Vacuum processing apparatus and program
Publication Date: 2014.09.30 HITACHI HIGH TECH CORP
  • US8849446B2 patent drawing
  • US8849446B2 patent drawing
  • US8849446B2 patent drawing

AI summary

The present invention provides an efficient transferring control method in a vacuum processing apparatus of a linear tool in which plural vacuum robots are arranged in transferring mechanical units to which process chambers are connected and processing-target members are passed and received among the plural vacuum robots. In addition, the present invention provides a vacuum processing apparatus in which there are provided plural controlling methods, and a unit which determines whether rates of the transferring robots are to be controlled or rates of the process chambers are to be controlled on the basis of processing time of each processing-target member and switches the controlling method in accordance with a site whose rate is controlled.