Process control system and method for transferring process data therefor

• US 6,233,492 B1
• Filed: 04/24/1998
• Issued: 05/15/2001
• Est. Priority Date: 05/02/1997
• Status: Expired due to Term

• Current Assignee: Tokyo Electron Limited
• Original Assignee: Tokyo Electron Limited
• Inventors: Nakamura, Tsuyoshi, Tochiori, Satoshi
• Primary Examiner(s): Sheikh, Ayaz R.
• Assistant Examiner(s): Backer, Firmin
• Application Number:
  US09/065,720
• Time in Patent Office: 1,117 Days
• Field of Search: 700/2, 711/113, 711/118, 711/124, 711/119, 711/144, 712/41, 712/205, 712/215, 712/226, 710/131, 710/129, 710/22, 395/842, 395/846
• US Class Current: 700/2
• CPC Class Codes: G05B 19/41865 characterised by job scheduling, process planning, material flow
• CPC Class Codes: G05B 2219/31206 Exchange of parameters, data, programs between two station, station and central or host or remote
• CPC Class Codes: G05B 2219/31394 Field management, low level, instruments and controllers acting in real time
• CPC Class Codes: G05B 2219/31395 Process management, specification, process and production data, middle level
• CPC Class Codes: G05B 2219/31396 Business management, production, document, asset, regulatory management, high level
• CPC Class Codes: G05B 2219/31422 Upload, download programs, parameters from, to station to, from server
• CPC Class Codes: G05B 2219/31455 Monitor process status
• CPC Class Codes: G05B 2219/32015 Optimize, process management, optimize production line
• CPC Class Codes: G05B 2219/45031 Manufacturing semiconductor wafers
• CPC Class Codes: H01L 21/67276 Production flow monitoring, e.g. for increasing throughput program-control systems per se G05B19/00, e.g. total factory control G05B19/418
• CPC Class Codes: Y02P 90/02 Total factory control, e.g. smart factories, flexible manufacturing systems [FMS] or integrated manufacturing systems [IMS]

Abstract

A process control system includes a plurality of machine controllers for individually controlling a plurality of process chambers and a main controller for controlling the machine controllers. Each of the machine controllers has a function of transferring process data detected by its corresponding process chamber to the main controller. The main controller has a storage device for accumulating process data transferred from the machine controllers and a function of transferring the accumulated process data to a host computer when the main controller is in a predetermined control load state.

Claims

1. A process control system comprising:

a plurality of first controllers for individually controlling a plurality of process chambers; and

a second controller for controlling said plurality of first controllers, and wherein

each of said plurality of first controllers includes first transferring means for transferring process data detected by a corresponding process chamber to said second controller, and

said second controller includes accumulating means for accumulating process data transferred from said plurality of first controllers to obtain accumulated process data therein, second transferring means for transferring the accumulated process data to an outside, measuring means for measuring a control load quantitatively in real time, and transfer control means for causing the second transferring means to externally transfer the accumulated process data when the control load measured by the measuring means has a value which is not more than a set value.

2. The process control system according to claim 1, wherein said second transferring means of said second controller transfers the accumulated process data to the outside when said second controller is set in a substantial control no-load state.

3. The process control system according to claim 2, wherein said second controller includes means for detecting a control low-load state, which controls some of the plurality of process chambers through said plurality of first controllers, as the substantial control no-load state.

4. The process control system according to claim 1, wherein said second controller includes means for setting a control no-load state, which continues for a longer time than a time required for transferring the accumulated process data externally from said second controller, as the substantial control load state.

5. The process control system according to claim 1, wherein said transfer control means of said second controller causes said transferring means to exclusively transfer the process data until transfer of the process data is completed.

6. The process control system according to claim 1, wherein said transfer control means of said second controller causes said transferring means to transfer the process data to the outside at a predetermined timing.

7. A process control system comprising:

a plurality of first controllers for individually controlling a plurality of process chambers; and

a second controller for controlling said plurality of first controllers, and wherein

each of said plurality of first controllers includes means for transferring process data detected by a corresponding one of said process chambers to said second controller, and

said second controller includes means for accumulating process data transferred from said plurality of first controllers to obtain accumulated process data, means for measuring a control load imposed on said second controller to obtain measured control load, and means for transferring the accumulated process data to an outside when the measured control load corresponds to at least one of a time period immediately after a series of process for all wafers in one cassette has been completed, a standby state until a cassette carry-in request is made, and a time when said system is interrupted due to an operation error.

8. The process control system according to claim 7, wherein said second controller further includes means for inhibiting an interrupt from outside while the accumulated process data is transferred to the outside.

9. A process control system comprising:

a plurality of first controllers for individually controlling a plurality of process chambers; and

a second controller for controlling said plurality of first controllers, and wherein

each of said plurality of first controllers includes means for transferring process data detected by a corresponding one of said process chambers to said second controller, and

said second controller includes means for accumulating process data transferred from said plurality of first controllers to obtain accumulated process data, setting means for setting an arbitrary timing at which the accumulated process data is transferred to an outside, the arbitrary timing corresponding to least one of a time period immediately after a series of processes for all wafers in one cassette has been completed, a standby state until a cassette carry-in request is made, and a time when said system is interrupted due to an operation error, and means for transferring the accumulated process data to the outside in accordance with the set timing.

10. The process control system according to claim 9, wherein said second controller further includes means for inhibiting an interrupt from outside while the process data is transferred to the outside.

11. A method of transferring process data, comprising the steps of:

individually controlling a plurality of process chambers by a plurality of first controllers;

controlling said plurality of first controllers by a second controller;

transferring process data detected by said plurality of process chambers to said second controller;

accumulating the transferred process data in storage means; and

transferring the accumulated process data to an outside when a control load detected by said second controller is not more than a predetermined value.

12. The method according to claim 11, wherein said step of transferring the accumulated process data to the outside includes a step of transferring the accumulated process data to the outside when said second controller is in a predetermined control no-load state.

13. The method according to claim 11, wherein said step of transferring the accumulated process data to the outside includes a step of transferring the accumulated process data to the outside in accordance with preset arbitrary timing corresponding to at least one of a time period immediately after a series of processes for all wafers in one cassette has been completed, a standby state until a cassette carry-in request is made, and an interruption due to an operation error.

14. A method of transferring process data, comprising the steps of:

individually controlling a plurality of process chambers by a plurality of first controllers;

controlling said plurality of first controllers by a second controller;

transferring process data detected by said plurality of process chambers to said second controller;

accumulating the transferred process data to obtain accumulated process data;

measuring a control load imposed to said second controller to obtain a measured control load; and

transferring the accumulated process data to an outside when the measured control load corresponds to at least one of a time period immediately after a series of processes for all wafers in one cassette has been completed, a standby state until a cassette carry-in request is made, and a time when said system is interrupted due to an operation error.

15. A process control system comprising:

a plurality of first controllers configured to individually control a plurality of process chambers; and

a second controller configured to control said plurality of first controllers, and wherein

each of said plurality of first controllers includes a first transferring unit configured to transfer process data detected by a corresponding one of said process chambers to said second controller, and

said second controller includes an accumulating unit configured to accumulate process data transferred from said plurality of first controllers to obtain accumulated process data therein, a second transferring unit configured to transfer the accumulated process data to an outside, a measuring unit configured to measure a control load quantitatively in real time, and a transfer control unit configured to cause said second transferring unit to externally transfer the accumulated process data when the control load measured by the measuring means has a value which is not more than a set value.

16. A process control system comprising:

a plurality of first controllers configured to individually control a plurality of process chambers; and

a second controller configured to control said plurality of first controllers, and wherein

each of said plurality of first controllers includes a first transferring unit configured to transfer process data detected by a corresponding one of said process chambers to said second controller, and

said second controller includes an accumulating unit configured to accumulate process data transferred from said plurality of first controllers to obtain accumulated process data, a measuring unit configured to measure a control load imposed to said second controller to obtain a measured control load, and a second transferring unit configured to transfer the accumulated process data to an outside when the measured control load corresponds to at least one of a time period immediately after a series of processes for all wafers in one cassette has been completed, a standby state until a cassette carry-in request is made, and a time when said system is interrupted due to an operation error.

17. A process control system comprising:

a plurality of first controllers configured to individually control a plurality of process chambers; and

a second controller configured to control said plurality of first controllers, and wherein

each of said plurality of first controllers includes a first transferring unit configured to transfer process data detected by a corresponding one of said process chambers to said second controller, and

said second controller includes an accumulating unit configured to accumulate process data transferred from said plurality of first controllers to obtain accumulated process data, a setting unit configured to set an arbitrary timing in which the accumulated process data is transferred to an outside, the arbitrary timing corresponding to at least one of a time period immediately after a series of processes for all wafers in one cassette has been completed, a standby state until a cassette carry-in request is made, and a time when said system is interrupted due to an operation error, and a second transferring unit configured to transfer the accumulated process data to the outside in accordance with the set timing.