Closed loop control for reliability
First Claim
1. A semiconductor manufacturing tool monitoring system, comprising:
- a first sensor system configured to measure one or more processing conditions of a semiconductor manufacturing tool and to generate a first monitoring response based thereupon;
a second sensor system configured to measure the one or more processing conditions of the semiconductor manufacturing tool and to generate a second monitoring response based thereupon;
a comparison element configured to compare the first monitoring response to the second monitoring response to identify a deviation between the first and second monitoring responses is indicative of an error in the first or second sensor systems;
a control system configured to receive a warning signal from the comparison element and upon receiving the warning signal to suspend operation of the semiconductor manufacturing tool; and
wherein the comparison element is configured to generate the warning signal if the first monitoring response deviates from the second monitoring response, which is measured at a substantially same time as the first monitoring response, by a value greater than a threshold value.
1 Assignment
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Accused Products
Abstract
The present disclosure relates to semiconductor tool monitoring system having multiple sensors configured to concurrently and independently monitor processing conditions of a semiconductor manufacturing tool. In some embodiments, the disclosed tool monitoring system comprises a first sensor system configured to monitor one or more processing conditions of a semiconductor manufacturing tool and to generate a first monitoring response based thereupon. A redundant, second sensor system is configured to concurrently monitor the one or more processing conditions of the manufacturing tool and to generate a second monitoring response based thereupon. A comparison element is configured to compare the first and second monitoring responses, and if the responses deviate from one another (e.g., have a deviation greater than a threshold value) to generate a warning signal. By comparing the first and second monitoring responses, errors in the sensor systems can be detected in real time, thereby preventing yield loss.
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Citations
16 Claims
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1. A semiconductor manufacturing tool monitoring system, comprising:
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a first sensor system configured to measure one or more processing conditions of a semiconductor manufacturing tool and to generate a first monitoring response based thereupon; a second sensor system configured to measure the one or more processing conditions of the semiconductor manufacturing tool and to generate a second monitoring response based thereupon; a comparison element configured to compare the first monitoring response to the second monitoring response to identify a deviation between the first and second monitoring responses is indicative of an error in the first or second sensor systems; a control system configured to receive a warning signal from the comparison element and upon receiving the warning signal to suspend operation of the semiconductor manufacturing tool; and wherein the comparison element is configured to generate the warning signal if the first monitoring response deviates from the second monitoring response, which is measured at a substantially same time as the first monitoring response, by a value greater than a threshold value. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8)
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9. A semiconductor manufacturing tool, comprising:
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a semiconductor manufacturing tool; a first sensor system configured to measure one or more processing conditions of the semiconductor manufacturing tool and to generate a first monitoring response based thereupon, wherein the first sensor drives a closed control loop configured to adjust the one or more processing conditions of the semiconductor manufacturing tool; a second sensor system configured to measure the one or more processing conditions of the semiconductor manufacturing tool at a substantially same time as the first sensor system and to generate a second monitoring response based thereupon; and a comparator configured to compare the first and second monitoring responses, to generate a warning signal if the first and second monitoring responses deviate from one another by an amount greater than a threshold value, and upon receiving the warning signal to suspend operation of the semiconductor manufacturing tool. - View Dependent Claims (10, 11, 12, 13)
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14. A method for reliably monitoring processing conditions of a semiconductor manufacturing tool, comprising:
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operating a first sensor system to generate a first monitoring response corresponding to one or more processing conditions of a manufacturing tool; operating a second sensor system to generate a second monitoring response corresponding to the one or more processing conditions of the manufacturing tool; comparing the first monitoring response to the second monitoring response to determine if an error is present in the first or second sensor systems; comparing the first monitoring response to a tool setting value; adjusting one or more processing conditions of the manufacturing tool if the first monitoring response violates the tool setting value; and generating a warning signal if the first monitoring response deviates from the second monitoring response, which is measured at a substantially same time as the first monitoring response, by more than a threshold value. - View Dependent Claims (15, 16)
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Specification