SEMICONDUCTOR MANUFACTURING APPARATUS

The present invention correctly identifies the size and shape of a substrate in order to avoid damage to a substrate holder and wasteful disposal of a substrate. Provided is a semiconductor manufacturing device for processing a rectangular substrate. This semiconductor manufacturing device: comprises a first sensor pair, which is used to measure a first length of the rectangular substrate along a first line and which comprises a sensor configured to detect the position of one end of the rectangular substrate on the first line and a sensor configured to detect the position of the other end of the rectangular substrate on the first line, and a second sensor pair, which is used to measure a second length of the rectangular substrate along a second line and which comprises a sensor configured to detect the position of one end of the rectangular substrate on the second line and a sensor configured to detect the position of the other end of the rectangular substrate on the second line; and identifies the size or shape of the rectangular substrate on the basis of the first length and the second length.

TECHNICAL FIELD

The present invention relates to a semiconductor manufacturing apparatus.

BACKGROUND ART

There are plural kinds of substrates, which have sizes different from one another, in substrates treated in a semiconductor manufacturing apparatus, and it is necessary to use substrate holders which fit sizes of substrates, respectively (for example, refer to Patent Literature 1). In the case that an inadequate substrate and a substrate holder are combined with each other, there may be a risk that the substrate holder may be damaged, and/or the substrate may be damaged and may accordingly be required to be discarded.

CITATION LIST

Patent Literature

SUMMARY OF INVENTION

Technical Problem

For preventing damaging of a substrate holder and wasteful discarding of a substrate, it is important to correctly recognize the size, shape, or the like of a substrate.

Solution to Problem

(Mode 1) According to mode 1, a semiconductor manufacturing apparatus for processing a rectangular substrate is provided and the semiconductor manufacturing apparatus comprises: a first sensor pair for measuring a first length of the rectangular substrate along a first line, wherein the first sensor pair comprises a sensor constructed to detect a position of one edge of the rectangular substrate on the first line, and a sensor constructed to detect a position of the other edge of the rectangular substrate on the first line; a second sensor pair for measuring a second length of the rectangular substrate along a second line, wherein the second sensor pair comprises a sensor constructed to detect a position of one edge of the rectangular substrate on the second line, and a sensor constructed to detect a position of the other edge of the rectangular substrate on the second line; and one or plural processors, wherein the processor is constructed to: calculate the first length based on the positions of the one edge and the other edge, that are on the first line and detected by the first sensor pair, of the rectangular substrate; calculate the second length based on the positions of the one edge and the other edge, that are on the second line and detected by the second sensor pair, of the rectangular substrate; and identify the size or the shape of the rectangular substrate, based on the calculated first length and the calculated second length.

(Mode 2) According to mode 2 which comprises the semiconductor manufacturing apparatus in the mode 1, the first sensor pair and the second sensor pair are arranged in such a manner that the first line and the second line correspond to a lateral direction and a longitudinal direction, respectively, in the rectangular substrate.

(Mode 3) According to mode 3 which comprises the semiconductor manufacturing apparatus in the mode 2, the semiconductor manufacturing apparatus further comprises a third sensor pair for measuring a third length of the rectangular substrate along a third line parallel to the first line or the second line, wherein the third sensor pair comprises a sensor constructed to detect a position of one edge of the rectangular substrate on the third line, and a sensor constructed to detect a position of the other edge of the rectangular substrate on the third line; and the processor is further constructed to: calculate the third length based on the positions of the one edge and the other edge, that are on the third line and detected by the third sensor pair, of the rectangular substrate; and identify deviation of the shape of the rectangular substrate from a square shape or a rectangular shape, based on the calculated first length, the calculated second length, and the calculated third length.

(Mode 4) According to mode 4 which comprises the semiconductor manufacturing apparatus in the mode 1, the first sensor pair and the second sensor pair are arranged in such a manner that two diagonal lines of the rectangular substrate are set as the first line and the second line, respectively.

(Mode 5) According to mode 5 which comprises the semiconductor manufacturing apparatus in the mode 4, the processor is further constructed to identify deviation of the shape of the rectangular substrate from a square shape or a rectangular shape, based on the calculated first length and the calculated second length.

(Mode 6) According to mode 6 which comprises the semiconductor manufacturing apparatus in any one of the modes 1-3, the two sensors included in each of the sensor pairs comprise a light emitter which emits belt-shaped measuring light toward the rectangular substrate, and a light receiver which receives a part of the belt-shaped measuring light, wherein the part of the belt-shaped measuring light is light, in the belt-shaped measuring light, that was not blocked by the rectangular substrate; and detection of each of the positions of the rectangular substrate is based on the quantity of light received by the light receiver in the each sensor.

(Mode 7) According to mode 7 which comprises the semiconductor manufacturing apparatus in the mode 4 or 5, each of the two sensors included in each of the sensor pairs is a camera arranged to take an image of one of four corners of the rectangular substrate; detection of the position by each of the sensors is detection of a vertex of the rectangular substrate based on edge detection in the image taken by each of the cameras; and calculation of the first length and the second length is calculation of lengths of the diagonal lines of the rectangular substrate, respectively, based on the detected vertexes.

(Mode 8) According to mode 8 which comprises the semiconductor manufacturing apparatus in any one of the modes 1-7, the semiconductor manufacturing apparatus further comprises a substrate holder storage for storing plural kinds of substrate holders corresponding to rectangular substrates having different sizes and shapes, respectively, wherein each of the substrate holders is that for holding a rectangular substrate; and the processor is further constructed to select, from the substrate holder storage, a substrate holder which fits the identified size or shape of the rectangular substrate.

(Mode 9) According to mode 9 which comprises the semiconductor manufacturing apparatus in any one of the modes 1-8, the semiconductor manufacturing apparatus further comprises a sensor for detecting a warp of the rectangular substrate, wherein the sensor comprises a light emitter which emits belt-shaped measuring light in a direction parallel to the rectangular substrate, and a light receiver which receives a part of the belt-shaped measuring light, wherein the part of the belt-shaped measuring light is light, in the belt-shaped measuring light, that was not blocked by the rectangular substrate; and the processor is further constructed to identify a warp of the rectangular substrate based on the quantity of light received by the light receiver in the sensor.

(Mode 10) According to mode 10 which comprises the semiconductor manufacturing apparatus in any one of the modes 1-9, the processor is further constructed to perform at least one of (i) an action for discontinuing or suspending processing of the rectangular substrate and (ii) an action for communicating an alarm, in the case that the identified size, shape, or warp of the rectangular substrate is judged to be inappropriate in view of a predetermined criteria.

DESCRIPTION OF EMBODIMENTS

In the following description, embodiments of the present invention will be explained with reference to the figures. In the figures which will be explained below, a reference symbol that is the same as that assigned to one component is assigned to the other component which is the same as or corresponds to the one component, and overlapping explanation of these components will be omitted.

FIG.1is a general layout drawing of a plating apparatus100according to an embodiment of the present invention. The plating apparatus100is an example of a semiconductor manufacturing apparatus. In the following description, an embodiment of the present invention will be explained with reference to the plating apparatus100; however, the subject to which the present invention can be applied is not limited to a plating apparatus, and the present invention can be applied, within the scope of the gist of the present invention, to semiconductor manufacturing devices (for example, a CPM (Chemical mechanical Polishing) apparatus and so on) other than a plating apparatus.

As shown inFIG.1, the plating apparatus100is roughly divided into a load/unload module110which loads a substrate into a substrate holder (which is not shown in the figure) or unloads a substrate from a substrate holder, a processing module120which processes a substrate, and a washing module50a. Further, the processing module120comprises a pre-processing/post-processing module120A which performs pre-processing and post-processing of a substrate, and a plating processing module120B which applies a plating process to a substrate.

The load/unload module110comprises a handling stage26, a substrate transfer device27, and a fixing station29. For example, in the present embodiment, the load/unload module110comprises two handling stages26, specifically, a handling stage26A for loading, which handles a substrate to which no process has been applied, and a handling stage26B for unloading, which handles a substrate with respect to which a process applied thereto has been completed. In the present embodiment, the construction of the handling stage26A for loading is the same as that of the handling stage26B for unloading, and they are arranged in such a manner that the directions thereof are 180-degree opposite from each other. In this regard, the handling stage26is not limited to that comprising the handling stage26A for loading and the handling stage26B for unloading, and the handling stages may be used without discrimination, i.e., without setting one of them to be a handling stage for loading and the other of them to be a handling stage for unloading. Further, in the present embodiment, the load/unload module110comprises two fixing stations29. The mechanisms of the two fixing stations29are identical with each other; and one, which is free (i.e., which is not handling a substrate), of them is used. In this regard, one or three or more handling stage/stages26and one or three or more fixing station/stations29may be installed according to the space in the plating apparatus100.

Substrates are conveyed from plural cassette tables25(for example, three inFIG.1) to the handling stage26(the handling stage26A for loading) via a robot24. The cassette table25is provided with a cassette25ain which a substrate is stored. For example, the cassette is a FOUP. The handling stage26is constructed in such a manner that it adjusts (aligns) the position and the direction of a substrate put thereon. The substrate transfer device27is arranged in a position between the handling stage26and the fixing station29for conveying a substrate between them. The substrate transfer device27is constructed to convey a substrate between the handling stage26, the fixing station29, and the washing module50a. Further, a stocker30, which is used for storing substrate holders, is installed in a position near the fixing station29.

The washing module50acomprises a washing device50which washes a substrate, with respect to which a plating process applied thereto has been completed, and dries it. The substrate transfer device27is constructed to convey a substrate, with respect to which a plating process applied thereto has been completed, to the washing device50, and take the washed substrate out of the washing device50. Thereafter, the washed substrate is delivered to the handling stage26(the handling stage26B for unloading) by the substrate transfer device27, and returned to the cassette25avia the robot24.

The pre-processing/post-processing module120A comprises a pre-wet tank32, a pre-soak tank33, a pre-rinse tank34, a blow tank35, and a rinse tank36. In the pre-wet tank32, a substrate is soaked into pure water. In the pre-soak tank33, an oxide film on a surface of a conductive layer, such as a seed layer or the like, formed on a surface of a substrate is removed by etching. In the pre-rinse tank34, a substrate, with respect to which a pre-soaking process applied thereto has been completed, is washed together with a substrate holder by using cleaning liquid (pure water or the like). In the blow tank35, liquid removal of a washed substrate is performed. In the rinse tank36, a plated substrate is washed together with a substrate holder by using cleaning liquid. In this regard, the construction of the pre-processing/post-processing module120A in the plating apparatus100is a mere example, so that the construction of the pre-processing/post-processing module120A in the plating apparatus100is not limited thereto, and a different construction may be adopted therein.

The plating processing module120B is constructed, for example, in such a manner that plural plating tanks39are housed in the inside of an overflow tank38. Each plating tank39is constructed in such a manner that it stores a single substrate therein, and makes the substrate be soaked into plating liquid held in the inside thereof and applies plating such as copper plating or the like to a surface of the substrate.

The plating apparatus100comprises a transporter37which adopts a linear motor system, for example, and is arranged in a position on a side of the pre-processing/post-processing module120A and the plating processing module120B for conveying a substrate holder together with a substrate. The transporter37is constructed to convey a substrate holder between the fixing station29, the stocker30, the pre-wet tank32, the pre-soak tank33, the pre-rinse tank34, the blow tank35, the rinse tank36, and the plating tank39.

An example of a series of plating processes performed by the plating apparatus100will be explained. First, by the robot24, a single substrate is taken out of the cassette25aloaded in the cassette table25, and the substrate is conveyed to the handling stage26(the handling stage26A for loading). The handling stage26aligns the position and the direction of the conveyed substrate with a predetermined position and a predetermined direction. The substrate, with respect to which the position and the direction have been aligned in the handling stage26, is conveyed to the fixing station29by the substrate transfer device27.

On the other hand, a substrate holder stored in the stocker30is conveyed to the fixing station29by the transporter37, and put horizontally on the fixing station29. Thereafter, the substrate conveyed by the substrate transfer device27is put on the substrate holder which is in the above state, and the substrate and the substrate holder are coupled with each other.

Next, the substrate holder, which holds the substrate, is grasped by the transporter37to store it in the pre-wet tank32. Next, the substrate holder, which holds the substrate with respect to which the process applied thereto in the pre-wet tank32has been completed, is conveyed to the pre-soak tank33by the transporter37, to etch an oxide film on the substrate in the pre-soak tank33. Following thereto, the substrate holder, which holds the above substrate, is conveyed to the pre-rinse tank34to water-wash the surface of the substrate by pure water stored in the pre-rinse tank34.

The substrate holder, which holds the substrate, with respect to which the water-washing process applied thereto has been completed, is conveyed from the pre-rinse tank34to the plating processing module120B by the transporter37to store it in the plating tank39which is filled with plating liquid. The transporter37repeats the above procedures sequentially to store respective substrate holders, which hold respective substrates, in respective plating tanks39in the processing module120B sequentially.

In each of the plating tanks39, a surface of the substrate is plated by applying a plating voltage between an anode (which is not shown in the figure) in the plating tank39and the substrate.

After completion of plating, the substrate holder, which holds the plated substrate, is grasped by the transporter37and conveyed to the rinse tank36to soak it into pure water stored in the rinse tank36to wash the surface of the substrate by the pure water. Next, the substrate holder is conveyed to the blow tank35by the transporter37to remove water droplets remaining on the substrate holder by air-blowing or the like. Thereafter, the substrate holder is conveyed to the fixing station29by the transporter37.

In the fixing station29, the processed substrate is taken out of the substrate holder by the substrate transfer device27, and conveyed to the washing device50in the washing module50a. The washing device50washes and dries the substrate, with respect to which the plating process applied thereto has been completed. The dried substrate is delivered to the handling stage26(the handling stage26B for unloading) by the substrate transfer device27, and returned to the cassette25avia the robot24.

As explained above, in the plating apparatus100according to the present embodiment, the substrate is taken out of the cassette25aput on the cassette table25, and conveyed to the fixing station29to connect it with the substrate holder. The plating apparatus100according to the present embodiment comprises plural sensors (which are not shown inFIG.1) for measuring the size and the shape of a substrate before connecting the substrate to a substrate holder. In the following description, further explanation relating to measurement of a substrate in the plating apparatus100will be provided.

FIG.2is a figure showing plural sensors200which are components of the plating apparatus100according to the present embodiment, and a substrate210which is being measured by using the plural sensors200. The plural sensors200are arranged in positions on the path through which the substrate210taken out of the cassette25ais conveyed to the fixing station29. With respect to the substrate210, the size and the shape thereof are measured by the plural sensors200, in a position in the middle of the conveyance path from the cassette25ato the fixing station29. The positions where the plural sensors200are arranged may be any positions on the conveyance path. For example, the plural sensors200may be arranged in the handling stage26. When aligning of the substrate210is performed by the handling stage26, the size and the shape of the substrate210is measured by the plural sensor200. In a different construction, the plating apparatus100may comprise a stage, that is used for measuring the substrate210, in the middle of the conveyance path from the cassette25ato the fixing station29, and the measurement stage may be provided with the plural sensors200. The substrate210is put on the measurement stage temporarily by the robot24or the substrate transfer device27, and, in the measurement stage, measurement of the substrate210is performed by using the plural sensors200.

The substrate210handled by the plating apparatus100according to the present embodiment is a rectangular substrate. In the present embodiment, a rectangular substrate refers to a substrate wherein a substrate surface thereof, on which plating processing is applied by the plating apparatus100(or a substrate surface on which processing is applied by a semiconductor manufacturing apparatus of a different kind), has a square shape or a rectangular shape. For example, the rectangular substrate210, which has a shape such as that explained above, may be a printed substrate or a glass substrate. In this regard, as will be explained below, the plating apparatus100has a function for judging whether the substrate210duly has a square or rectangular substrate surface. Thus, in the case that the term “rectangular substrate210” is used in the following description, the expression ideally means a substrate having a substrate surface having an exact square or rectangular shape, and, in addition thereto, may mean a substrate having a substrate surface having a shape that slightly deviates from a square or rectangular shape.

In the example inFIG.2, the plural sensors200comprises four sensors200A,200B,200C, and200D. The sensor200A and the sensor200C are arranged on a first line (the line in the horizontal direction inFIG.2) that crosses two sides, that are opposite to each other, of the rectangular substrate210and is perpendicular to the two sides, and form a first sensor pair200-1. The sensor200B and the sensor200D are arranged on a second line (the line in the vertical direction inFIG.2) that crosses other two sides, that are opposite to each other, of the rectangular substrate210and is perpendicular to the other two sides, and form a second sensor pair200-2. The first sensor pair200-1measures the length L1of the rectangular substrate210along the first line (that is, the horizontal length of the rectangular substrate210), and the second sensor pair200-2measures the length L2of the rectangular substrate210along the second line (that is, the vertical length of the rectangular substrate210).

The sensors200A,200B,200C, and200D are constructed to detect positions of edges of the sides of the rectangular substrate210, respectively. Specifically, the sensor200A detects a position PAof one of the edges of the rectangular substrate210on the first line, and the sensor200C detects a position PCof the other of the edges of the rectangular substrate210on the first line. Based on the positions PAand PCof the above two edges, the length L1of the rectangular substrate210along the first line can be obtained. Further, the sensor200B detects a position PBof one of the edges of the rectangular substrate210on the second line, and the sensor200D detects a position PDof the other of the edges of the rectangular substrate210on the second line. Based on the positions PBand PDof the above two edges, the length L2of the rectangular substrate210along the second line can be obtained. Detection of the position of the edge of the rectangular substrate210by each sensor200may be based on, for example, measurement of the quantity of belt-shaped measuring light220(for example, laser light) blocked by the rectangular substrate210.

FIG.3is a figure showing a construction of a sensor200(for example, the sensor200A) and an operation method of the sensor. The above figure shows, for example, a state of the sensor200A viewed from the direction of an arrow A inFIG.2. As shown inFIG.3, the sensor200comprises a light emitter202and a light receiver204. The light emitter202is arranged in a position on a side of the rectangular substrate210, and the light receiver204is arranged in a position on a side that is opposite to the side where the light emitter202is arranged. The light emitter202is constructed and arranged in such a manner that it emits belt-shaped measuring light220toward the rectangular substrate210(for example, in the direction perpendicular to the rectangular substrate210). For example, the measuring light220has a width W1in the direction perpendicular to the direction of propagation of the measuring light220. A part, in the width direction, of the measuring light220is blocked by the rectangular substrate210, and the remaining part of the measuring light220passes over the rectangular substrate210and propagates toward the light receiver204. The width W2of the measuring light220propagating toward the side where the light receiver204has been arranged is dependent on the position P (for example, the position PAinFIG.2) of an edge of the rectangular substrate210. The light receiver204is constructed and arranged in such a manner that it can receive the measuring light220having the width W2. Thus, based on the quantity of the measuring light220received by the light receiver204(or based on the ratio of the quantity of the measuring light220received by the light receiver204to the quantity of the measuring light220emitted from the light emitter202), the position P of the edge of the rectangular substrate210can be detected.

In the manner explained above, by using the sensors200A,200B,200C, and200D included in the plating apparatus100, the positions P of the edges of the rectangular substrate210are detected, respectively. Thus, by using the first sensor pair200-1, the length L1of the rectangular substrate210in the horizontal direction is measured based on the positions PAand PCof the edges, and, by using the second sensor pair200-2, the length L2of the rectangular substrate210in the vertical direction is measured based on the positions PBand PDof the edges. In this manner, the plating apparatus100can obtain information of the size of a substrate (i.e., L1and L2), in a stage before the stage for connecting a rectangular substrate210to a substrate holder.

FIG.4is a figure showing plural sensors200which are components of a plating apparatus100according to a present embodiment, and a substrate210which is being measured by using the plural sensors200, wherein the example shown inFIG.4is different from that shown inFIG.2. In the example shown inFIG.4, the plural sensors200comprises eight sensors, specifically, sensors200A,200B,200C,200D,200E,200F,200G, and200H. In the above sensors, the sensors200A,200B,200C, and200D form a first sensor pair200-1and a second sensor pair200-2in a manner similar to that in the example shown inFIG.2. Further, in addition to the first sensor pair200-1and the second sensor pair200-2, the sensors200E and200G form a third sensor pair200-3and the sensors200F and200H form a fourth sensor pair200-4. The third sensor pair200-3(i.e., the sensors200E and200G) are arranged on a third line that is a line parallel to a first line relating to the first sensor pair200-1and crosses sides of the rectangular substrate210, and the fourth sensor pair200-4(i.e., the sensors200F and200H) are arranged on a fourth line that is a line parallel to a second line relating to the second sensor pair200-2and crosses sides of the rectangular substrate210.

As explained above with reference toFIG.2, the first sensor pair200-1and the second sensor pair200-2measure the length L1and the length L2of the rectangular substrate210along the first line and the second line, respectively. Further, in the example shown inFIG.4, the third sensor pair200-3measures, in a manner similar to that in the case of the first sensor pair200-1, a length L3of the rectangular substrate210along the third line, and the fourth sensor pair200-4measures, in a manner similar to that in the case of the second sensor pair200-2, a length L4of the rectangular substrate210along the fourth line. As explained above, in the example shown inFIG.4, the lengths of two parts of the rectangular substrate210in the horizontal direction, i.e., the part along the first line and the part along the third line (the lengths L1and L3), are measured, and the lengths of two parts of the rectangular substrate210in the vertical direction, i.e., the part along the second line and the part along the fourth line (the lengths L2and L4), are measured.

In this regard, the method for measuring the length L3by using the third sensor pair200-3and the method for measuring the length L4by using the fourth sensor pair200-4are the same as those explained in relation to the first sensor pair200-1and the second sensor pair200-2. That is, the length L3of the rectangular substrate210along the third line can be obtained based on detection, by the sensor200E, of a position PE of one of the edges of the rectangular substrate210on the third line (refer toFIG.3: the same hereinafter) and detection, by the sensor200G, of a position PG of the other of the edges of the rectangular substrate210on the third line. Further, in a manner similar to the above manner, the length L4of the rectangular substrate210along the fourth line can be obtained based on detection, by the sensor200F, of a position PFof one of the edges of the rectangular substrate210on the fourth line and detection, by the sensor200H, of a position PH of the other of the edges of the rectangular substrate210on the fourth line.

In the example shown inFIG.4, information relating to the shape of a substrate, in addition to information of the size of the substrate (i.e., L1, L2, L3, and L4), can be obtained. For example, if L1=L3and L2=L4, it can be judged that the substrate210has a square or rectangular shape, and, if not, it can be judged that the substrate210does not has an exact square or rectangular shape (the shape is distorted). For example, as shown inFIG.5, in the case that the length L1measured by the first sensor pair200-1and the length L3measured by the third sensor pair200-3are not equal to each other (i.e. L1≠L3) although the length L2measured by the second sensor pair200-2and the length L4measured by the fourth sensor pair200-4are equal to each other (i.e., L2=L4), it can be judged that the substrate210has a trapezoidal shape.

FIG.6is a figure showing plural sensors200which are components of a plating apparatus100according to a present embodiment, and a substrate210which is being measured by using the plural sensors200, wherein the example shown inFIG.6is different from those shown inFIGS.2and4. In the example shown inFIG.6, the plural sensors200comprise four sensors200A,200B,200C, and200D. The sensors200A and200C are arranged on one of two lines diagonally passing through a rectangular substrate210(a first line), and form a first sensor pair200-1. The sensors200B and200D are arranged on the other of the two lines diagonally passing through the rectangular substrate210(a second line), and form a second sensor pair200-2. The first sensor pair200-1measures a length L1of the rectangular substrate210along the first line (i.e., the length of one of the diagonal lines of the rectangular substrate210), and the second sensor pair200-2measures a length L2of the rectangular substrate210along the second line (i.e., the length of the other of the diagonal lines of the rectangular substrate210).

The sensors200A,200B,200C, and200D are constructed to detect positions of vertexes of the rectangular substrate210, respectively. Specifically, the sensor200A detects a position PAof one of vertexes on the first diagonal line (the first line) of the rectangular substrate210, and the sensor200C detects a position PCof the other of vertexes on the first diagonal line of the rectangular substrate210. Based on the positions PAand PCof the two vertexes, the length L1of the first diagonal line of the rectangular substrate210can be obtained. Similarly, the sensor200B detects a position PBof one of vertexes on the second diagonal line (the second line) of the rectangular substrate210, and the sensor200D detects a position PDof the other of vertexes on the second diagonal line of the rectangular substrate210. Based on the positions PBand PDof the two vertexes, the length L2of the second diagonal line of the rectangular substrate210can be obtained. The sensors200may be cameras arranged in positions close to vertexes of the rectangular substrate210, respectively, for example. In the example shown inFIG.6, detection of each of the vertexes of the rectangular substrate210can be based on image processing (for example, edge detection) of an image taken by a camera (the sensor200) arranged at each of four corners of the rectangular substrate210.

As explained above, in the exampled shown inFIG.6, by using the first sensor pair200-1, the length L1of the first diagonal line of the rectangular substrate210is measured based on the detected positions PAand PCof the vertexes, and, by using the second sensor pair200-2, the length L2of the second diagonal line of the rectangular substrate210is measured based on the detected positions PBand PDof the vertexes. In the manner explained above, the plating apparatus100can obtain information of the size of a substrate (i.e., L1and L2), in a stage before the stage for connecting a rectangular substrate210to a substrate holder. Further, it is possible to obtain information relating the shape of the substrate. For example, if L1=L2, it can be judged that the substrate210has a square or rectangular shape, and, if not, it can be judged that the substrate210does not has an exact square or rectangular shape (the shape is distorted). For example, as shown inFIG.7, in the case that the length L1measured by the first sensor pair200-1and the length L2measured by the second sensor pair200-2are not equal to each other (i.e. L1≠L2), it can be judged that the substrate210has a parallelogram shape.

FIG.8is a figure showing plural sensors200which are components of a plating apparatus according to a present embodiment, and a substrate210which is being measured by using the plural sensors200, wherein the example shown inFIG.8is different from those shown inFIGS.2,4, and6. In the example shown inFIG.8, the plural sensors200comprise two sensors2001and200J. Each of the sensors2001and200J comprises a light emitter202and a light receiver204. The light emitter202and the light receiver204in the sensor200I are arranged on one of two lines diagonally passing through the rectangular substrate210, and the light emitter202and the light receiver204in the sensor200J are arranged on the other of the two lines diagonally passing through the rectangular substrate210.

FIG.9is a figure showing an operation method of one of the sensors200(for example, the sensor200I) in the example shown inFIG.8. For example,FIG.9shows a state of the substrate210and the sensor200I viewed from the direction of an arrow A inFIG.8. As shown inFIG.9, the light emitter202of the sensor200I is arranged in a position close to one end of a diagonal line of the rectangular substrate210, and the light receiver204of the sensor200I is arranged in a position close to the other end of the diagonal line of the rectangular substrate210. The light emitter202is constructed and arranged in such a manner that it emits belt-shaped measuring light220in parallel with the rectangular substrate210(i.e., along the surface of the rectangular substrate210). For example, the measuring light220has a width W1in a direction perpendicular to its propagation direction and also perpendicular to the surface of the substrate210. In the case that the substrate210is flat, the measuring light220arrives at the light receiver204without any blockage thereof by the substrate210. Thus, the light receiver204receives the measuring light220having the width W1as it stands.

FIG.10shows states of the measuring light220in the cases that the rectangular substrates210have warps or undulation. In each of the above cases, a part, in the width direction, of the measuring light220is blocked by the part of the warp or undulation in the rectangular substrate210, and the remaining part of the measuring light220is received by the light receiver204. Thus, based on the quantity of the measuring light220received by the light receiver204(or based on the ratio of the quantity of the measuring light220received by the light receiver204to the quantity of the measuring light220emitted from the light emitter202), existence/nonexistence of the warp or undulation in the rectangular substrate210and/or the size of the warp or undulation can be identified.

In general, the warp or undulation in a substrate often exists only in a specific direction in a surface of the substrate. For example, there is a case that a rectangular substrate210has a warp in a lateral direction of the substrate, and has no warp in a longitudinal direction. According to the arrangement of the sensors shown inFIG.8, the sensor200I can detect a warp or undulation of a substrate existing in the direction of one of the diagonal lines of the rectangular substrate210, and the sensor200J can detect warp or undulation existing in a direction different from the above direction, i.e., the direction of the other of the diagonal lines of the rectangular substrate210. Accordingly, by using the sensors2001and200J arranged in two different directions, a warp or undulation that may exist in the substrate210can surely be detected without overlooking it.

In this regard, the directions along those the sensors2001and200J are to be arranged are not limited to the directions of the diagonal lines of the rectangular substrate210. For example, the light emitter202and the light receiver204of the sensor200I may be arranged along a line of the rectangular substrate210in a lateral direction (i.e., arranged in a manner similar to the manner in the case of the first sensor pair200-1inFIG.2), and the light emitter202and the light receiver204of the sensor200J may be arranged along a line of the rectangular substrate210in a longitudinal direction (i.e., arranged in a manner similar to the manner in the case of the second sensor pair200-2inFIG.2).

FIG.11is a configuration diagram of an example control system300for controlling operation of a plating apparatus100according to an embodiment of the present invention. The control system300comprises a control apparatus310, a computer320for manipulation, and a computer330for a scheduler. Each of the control apparatus310, the manipulation computer320, and the scheduler computer330is communicably connected to others. The whole or part of the control apparatus310, the manipulation computer320, and the scheduler computer330may be incorporated in the plating apparatus100as part of components of the plating apparatus100. The manipulation computer320and the scheduler computer330are shown as separate computers; however, a single computer comprising the above two computers may be constructed.

The control apparatus310is connected to the robot24, the substrate transfer device27, and the transporter37which have been explained with reference toFIG.1, and to the plural sensors200which have been explained with reference toFIGS.2-10. The control apparatus310sends instructions to the robot24, the substrate transfer device27, and the transporter37for activating them, and also obtains, from the sensors200, information with respect to result of measurement relating to the rectangular substrate210. For example, although it is preferable to make the control apparatus310comprise a PLC (Programmable Logic Controller), the control apparatus310may be a different kind of computer. Each of the manipulation computer320and the scheduler computer330may be constructed by incorporating predetermined application software (a program) into a general purpose computer. The control apparatus310, the manipulation computer320, and the scheduler computer330comprise processors (311,321, and331) and memories (312,322, and332), respectively. Predetermined programs are stored in the memories, respectively, and the functions of the control apparatus310, the manipulation computer320, and the scheduler computer330are realized by reading the programs from the memories and executing the programs by the processors, respectively.

FIG.12is a flow chart showing operation of a plating apparatus100according to an embodiment of the present invention. In the following description, operation of the plating apparatus100will be explained with reference toFIGS.11and12.

First, in step S401, an instruction for starting operation of the plating apparatus100is inputted to the manipulation computer320by an operator of the plating apparatus100. Inputting of the instruction for starting operation comprises, for example, inputting of information for designating a cassette25awhich stores a rectangular substrate210and/or information for designating details of plating processes (for example, the type of plating, the plated film thickness, the time of plating, and so on) applied to a substrate210.

Next, in step S402, the scheduler computer330constructs a time table based on the instruction for starting operation. The time table comprises a substrate conveyance schedule relating to action to take a rectangular substrate210out of a cassette25aand convey the rectangular substrate210to the fixing station29, and a substrate-holder conveyance schedule relating to action to take a substrate holder out of the stocker30and convey the substrate holder to the fixing station29. In a plating apparatus100in which plural kinds of substrate holders (plural kinds of substrate holders which have been designed to correspond to specific substrates having specific sizes and shapes, respectively) are stored in the stocker30, it is assumed in step S402that a default substrate holder is to be used in the plating apparatus100, and a time table is constructed accordingly.

Next, in step S403, the control apparatus310makes the robot24and the substrate transfer device27perform action according to the time table. As a result, a rectangular substrate210is taken out of a cassette25aand conveyed to a measurement area where plural sensors200have been installed. As explained above, the measurement area may be set in the handling stage26or may be set in a measurement stage arranged in a position in the middle of the conveyance path from the cassette25ato the fixing station29, for example.

Next, in step S404that is performed after conveying the rectangular substrate210to the measurement area, the control apparatus310instructs the respective sensors200in the measurement area to start measurement of the substrate. After receiving the above instruction, the respective sensors200perform measurement of the rectangular substrate210in step S405, and, next, send data representing result of measurement to the control apparatus310in step S406. Details with respect to measurement of the rectangular substrate210are those that have been explained with reference toFIGS.2-10. For example, in the example shown inFIG.2, the sensors200A,200B,200C, and200D detect positions PA, PB, PC, and PDof the edges of the rectangular substrate210, respectively (step S405), and send data representing the respective positions to the control apparatus310(step S406). Regarding each of the examples of the sensors200shown in other figures, steps S405and S406are also performed therein in a manner similar to the above manner.

Next, in step S407, the control apparatus310calculates the size of the rectangular substrate210, based on the data of measurement result obtained by the respective sensors200. For example, in the above-explained example shown inFIG.2, the length L1of the rectangular substrate210in the lateral direction is calculated from the data of the edge positions PAand PC, and the length L2in the longitudinal direction is calculated from the data of the edge positions PBand PD. Further, in addition to calculation of the size of the substrate, the control apparatus310may identify the shape of the rectangular substrate210(whether it has a square shape, a rectangular shape, or a shape other than the above shapes) as explained in relation to the above-explained examples shown inFIGS.4and6, and/or perform detecting of a warp or undulation in the rectangular substrate210as explained in relation to the above-explained example shown inFIG.8.

Next, in step S408, the control apparatus310performs judgment with respect to fitness between the rectangular substrate210and a substrate holder stored in the stocker30, based on the size, the shape, and the warp or undulation of the rectangular substrate210. For example, in the case that plural kinds of substrate holders exist in the stocker30, the control apparatus310selects, from the plural kinds of substrate holders, a substrate holder which fits the size of the rectangular substrate210, by comparing each of sizes of substrates which can be received by the substrate holders with the measured substrate size, wherein the sizes of the substrates have been stored in advance. Further, for example, in the cases that (i) no substrate holder, which fits the size of the rectangular substrate210, exists in the stocker30, (ii) the degree of deviation of the shape of the rectangular substrate210from a square shape or a rectangular shape is equal to or greater than a threshold value, (iii) the size of a warp or undulation in the rectangular substrate210is equal to or greater than a threshold value, or the like, the control apparatus310may judge that the rectangular substrate210is an incompatible (abnormal) substrate. Regarding each of the above cases (ii) and (iii), the threshold value, that is used for judging whether a rectangular substrate210is abnormal, may be allowed to be changed by an operator of the plating apparatus100by using the manipulation computer320.

Next, in step S409, the scheduler computer330obtains information relating to fitness between the rectangular substrate210and the substrate holder from the control apparatus310, and updates the time table based on the information. For example, the scheduler computer330replaces the default substrate holder relating to the time table constructed in the above-explained step S402by the substrate holder (i.e., the substrate holder that fits the size of the rectangular substrate210) selected by the control apparatus310in the step S408. Further, in the case that the rectangular substrate210is an incompatible (abnormal) substrate, the scheduler computer330rewrites the time table to avoid use of the above rectangular substrate210(i.e., to exclude the above rectangular substrate210from objects of processing by the plating apparatus100).

In the case that the substrate holder relating to the time table is replaced by the substrate holder that fits the size of the rectangular substrate210, step S410and step S411are performed next. On the other hand, in the case that the time table is rewritten to exclude the rectangular substrate210from objects of processing, step S413is performed next.

In step S410, the control apparatus310makes the transporter37perform action according to the updated time table. As a result, a substrate holder which fits the size of the rectangular substrate210is selected from and taken out of the stocker30, and conveyed to the fixing station29. Further, in step S411, the control apparatus310makes the substrate transfer device27(or both the robot24and the substrate transfer device27) perform, according to the time table, a normal-case processing action that is performed after measurement of a substrate. As a result, the measured rectangular substrate210is conveyed from the measurement area to the fixing station29. Next, in step S412, the control apparatus310makes the substrate transfer device27perform action for connection between the substrate holder, which has been conveyed to the fixing station29, and the rectangular substrate210(i.e., for making the rectangular substrate210be held by the substrate holder).

On the other hand, in step S413, the control apparatus310makes the robot24perform an abnormal-case processing action that is performed after measurement of a substrate. The abnormal-case processing action comprises at least one of an action performed by the robot24for returning the rectangular substrate210, which is regarded as an incompatible substrate, to the cassette25aand an action for activating an alarm device, which is installed in the robot24or a position other than positions in the robot24, for communicating an alarm to an operator. It may be possible to adopt the construction that the operator manually returns the rectangular substrate210to the cassette25aafter communicating of the alarm.

As explained above, according to each of the plating apparatuses100according to the present embodiments, the size of a rectangular substrate210is measured by using plural sensors200, and, based on result of measurement, a substrate holder which fits the size of the rectangular substrate210is selected. Thus, it becomes possible to connect a correct substrate holder to the rectangular substrate210, and, as a result, prevent damaging of a substrate holder and prevent a rectangular substrate210from becoming a defective product due to a mismatch between sizes. Further, if it is judged as a result of measurement by the plural sensors200that a rectangular substrate210does not fit a substrate holder, abnormal-case processing actions such as an action for stopping conveying of a substrate, an action for communicating an alarm, and so on are performed. Thus, it becomes possible to prevent damaging of a substrate holder and prevent a rectangular substrate210from becoming a defective product due to connecting of, or due to an attempt to connect, an incompatible rectangular substrate210and a substrate holder with each other.

In the above description, embodiments of the present invention have been explained based on some examples; and, in this regard, the above explained embodiments of the present invention are those used for facilitating understanding of the present invention, and are not those used for limiting the present invention. It is obvious that the present invention can be changed or modified without departing from the scope of the gist thereof, and that the present invention includes equivalents thereof. Further, it is possible to arbitrarily combine components or omit a component(s) disclosed in the claims and the specification, within the scope that at least part of the above-stated problems can be solved or within the scope that at least part of advantageous effect can be obtained.

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