HIGH-FREQUENCY POWER SUPPLY DEVICE AND REFLECTED WAVE POWER CONTROL METHOD

• US 20150084509A1
• Filed: 06/03/2013
• Published: 03/26/2015
• Est. Priority Date: 06/18/2012
• Status: Active Grant

• Current Assignee: Kyosan Electric Manufacturing Company Limited
• Original Assignee: Kyosan Electric Manufacturing Company Limited
• Inventors: Yuzurihara, Itsuo, Aikawa, Satoshi, Kunitama, Hiroshi
• Granted Patent: US 9,070,537 B2
• Time in Patent Office: Days
• US Class Current: 315/111.21
• CPC Class Codes: H01J 37/32082 Radio frequency generated discharge H01J37/32357, H01J37/32366, H01J37/32394 and H01J37/32403 take precedence
• CPC Class Codes: H01J 37/32146 Amplitude modulation, includes pulsing
• CPC Class Codes: H01J 37/32174 Circuits specially adapted for controlling the RF discharge
• CPC Class Codes: H01J 37/32183 Matching circuits
• CPC Class Codes: H01J 37/32944 Arc detection
• CPC Class Codes: H01J 37/3299 Feedback systems
• CPC Class Codes: H02M 1/08 Circuits specially adapted for the generation of control voltages for semiconductor devices incorporated in static converters
• CPC Class Codes: H02M 7/539 with automatic control of output wave form or frequency H02M7/5375 - H02M7/5387 take precedence
• CPC Class Codes: H05H 1/46 using applied electromagnetic fields, e.g. high frequency or microwave energy H05H1/26 takes precedence
• CPC Class Codes: H05H 2242/26 Matching networks

Abstract

In an RF power supply for supplying RF power to a plasma load, reflected wave power control is performed in which the reflected wave power of an RF generator is detected and the RF generator is controlled. For a short-time variation in reflected wave power, control is performed based on a peak value variation in the detection value of reflected wave power. For a long-time variation in reflected wave power, control is performed based on a variation in a smoothed value obtained by smoothing detection values of reflected wave power. A reflected wave power control loop system includes a reflected wave power peak value dropping loop system and an arc blocking system that perform control based on a peak variation in reflected wave power and a reflected wave power amount dropping loop system that performs control based on a smoothed power amount of reflected wave power.

Claims

1. An RF power supplying device that supplies RF power to a plasma load, said RF power supplying device comprising:

an RF generator unit that converts DC of a DC power supply to RF AC through a switching operation and outputs RF power; and

a feedback system that feeds back a detection value of the RF output of said RF generator unit for performing feedback control, wherein

said feedback system comprises;

a forward wave power control loop system that feeds back a detection value of forward wave power, which is sent from said RF generator unit to a plasma load, for controlling the forward wave power; and

a plurality of reflected wave power control loop systems each of which feeds back a detection value of reflected wave power, which is sent from said plasma load to said RF generator unit, for controlling the reflected wave power,

said reflected wave power control loop system comprising;

a reflected wave power peak value dropping loop system and an arc blocking system that control a peak variation in reflected wave power and a reflected wave power amount dropping loop system that controls a smoothed power amount of reflected wave power, wherein

said reflected wave power peak value dropping loop system controls a DC voltage of the DC power supply of said RF generator unit based on a peak value of reflected wave power and, through the voltage control of the DC power supply, controls whether to drop the peak value of reflected wave power,

said arc blocking system controls whether to output from an RF amplifier unit of said RF generator unit, based on the peak value of reflected wave power, to control whether to supply power to the plasma load and thereby controls arc blocking at the plasma load, and

said reflected wave power amount dropping loop system controls a duty ratio (time ratio) between an ON state and an OFF state of the RF amplifier unit of said RF generator unit, based on a smoothed power amount of reflected wave power, to control a supply amount of power to the plasma load and thereby controls dropping of a power amount of reflected wave power.

2. The RF power supplying device according to claim 1, wherein

said reflected wave power peak value dropping loop system comprises a reflected wave power peak limit value as a threshold for determining whether peak value dropping control of reflected wave power is to be performed, and

a difference between the detection value of reflected wave power and the reflected wave power peak limit value is fed back to said forward wave power control loop system to control a pulse width of a PWM signal, which drives a DC/DC converter provided in said RF generator unit, for controlling the DC voltage of the DC power supply.

3. The RF power supplying device according to claim 1, wherein

said ark blocking system comprises an arc limit value as a threshold for determining whether RF power is to be output, and

an RF gate signal is controlled based on a comparison between the detection value of reflected wave power and the arc limit value for controlling whether RF power of the RF amplifier unit is to be output, the RF gate signal controlling the RF amplifier unit provided in said RF generator unit.

4. The RF power supplying device according to claim 1, wherein

said reflected wave power amount dropping loop system comprises:

a power smoothing unit that outputs an average value or an effective value of the detection values of reflected wave power; and

a reflected wave power average limit value or a reflected wave power effective limit value as a reflected wave power dropping limit value that defines whether to drop a power amount of RF power as well as a dropping amount, wherein

based on a comparison between an average value output of said power smoothing unit and the reflected wave power average limit value or a comparison between an effective value output of said power smoothing unit and the reflected wave power effective limit value, a duty ratio (time ratio between an ON state and an OFF state of the RF amplifier unit) of a pulse control signal is determined for controlling a power amount dropping of RF power of the RF amplifier unit, the pulse control signal controlling the RF amplifier unit provided in said RF generator unit.

5. The RF power supplying device according to one of claims 1 to 3 wherein

at least one of said reflected wave power peak value dropping loop system and said arc blocking system comprises a sharp variation removing unit that removes a sharp variation from the detection value of reflected wave power, wherein

said sharp variation removing unit removes a sharp variation amount, generated by a sharp variation, from the detection value of reflected wave power and feeds back a signal corresponding to a peak value of reflected wave power not generated by the sharp variation.

6. The RF power supplying device according to claim 5 wherein

said sharp variation removing unit is a first-order lag circuit that causes a first-order lag in the detection values of reflected wave power.

7. A reflected wave power control method for an RF power supply that supplies RF power to a plasma load, said RF power supply comprising:

an RF generator unit that converts DC of a DC power supply to RF AC through a switching operation and outputs RF power; and

a feedback system that feeds back a detection value of the RF output of said RF generator unit for performing feedback control, wherein

said feedback system comprises;

a forward wave power control loop system that feeds back a detection value of forward wave power, which is sent from said RF generator unit to a plasma load, for controlling the forward wave power; and

a plurality of reflected wave power control loop systems each of which feeds back a detection value of reflected wave power, which is sent from said plasma load to said RF generator unit, for controlling the reflected wave power,

said reflected wave power control loop system comprising;

a reflected wave power peak value dropping loop system and an arc blocking system that control a peak variation in reflected wave power; and

a reflected wave power amount dropping loop system that controls a smoothed power amount of reflected wave power, wherein

said reflected wave power peak value dropping loop system controls a DC voltage of the DC power supply of said RF generator unit based on a peak value of reflected wave power and, through the voltage control of the DC power supply, controls whether to drop the peak value of reflected wave power,

said arc blocking system controls whether to output from an RF amplifier unit of said RF generator unit, based on the peak value of reflected wave power, to control whether to supply power to the plasma load and thereby controls arc blocking at the plasma load, and

said reflected wave power amount dropping loop system controls a duty ratio (time ratio) between an ON state and an OFF state of the RF amplifier unit of said RF generator unit, based on a smoothed power amount of reflected wave power, to control a supply amount of power to the plasma load and thereby controls dropping of a power amount of reflected wave power.

8. The reflected wave power control method according to claim 7, wherein

said reflected wave power peak value dropping loop system comprises a reflected wave power peak limit value as a threshold for determining whether peak value dropping control of reflected wave power is to be performed, and

a difference between the detection value of reflected wave power and the reflected wave power peak limit value is fed back to said forward wave power control loop system to control a pulse width of a PWM signal, which drives a DC/DC converter provided in said RF generator unit, for controlling the DC voltage of the DC power supply.

9. The reflected wave power control method according to claim 7, wherein

said ark blocking system comprises an arc limit value as a threshold for determining whether RF power is to be output, and

an RF gate signal is controlled based on a comparison between the detection value of reflected wave power and the arc limit value for controlling whether RF power of the RF amplifier unit is to be output, the RF gate signal controlling the RF amplifier unit provided in said RF generator unit.

10. The reflected wave power control method according to claim 7, wherein

said reflected wave power amount dropping loop system comprises:

a power smoothing unit that outputs an average value or an effective value of the detection values of reflected wave power; and

a reflected wave power average limit value or a reflected wave power effective limit value as a reflected wave power dropping limit value that defines whether to drop a power amount of RF power as well as a dropping amount, wherein

based on a comparison between an average value output of said power smoothing unit and the reflected wave power average limit value or a comparison between an effective value output of said power smoothing unit and the reflected wave power effective limit value, a duty ratio (time ratio between an ON state and an OFF state of the RF amplifier unit) of a pulse control signal is determined for controlling a power amount dropping of RF power of the RF amplifier unit, the pulse control signal controlling the RF amplifier unit provided in said RF generator unit.

11. The reflected wave power control method according to one of claims 7 to 9 wherein

at least one of said reflected wave power peak value dropping loop system and said arc blocking system comprises a sharp variation removing unit that removes a sharp variation from the detection value of reflected wave power, wherein

said sharp variation removing unit removes a sharp variation amount, generated by a sharp variation, from the detection value of reflected wave power and feeds back a signal corresponding to a peak value of reflected wave power not generated by the sharp variation.

12. The reflected wave power control method according to claim 11 wherein

said sharp variation removing unit removes the sharp variation, generated by a sharp variation, from the detection value of reflected wave power by causing a first-order lag in the detection value of reflected wave power.