SUBSTRATE PROCESSING APPARATUS AND CONTROL POSITION SETTING METHOD

A substrate processing apparatus includes a vacuum container, a rotary table, a stage, a lifter, and a controller that controls an operation of the lifter. The controller automatically sets a control position in the operation of the lifter. The controller, in (A), repeatedly raises the lifter by a first pitch and then determines whether or not the lifter has come into contact with a substrate, thereby bring the lifter to come into contact with the substrate to set a next position. The controller, in (B), repeatedly raises the lifter from the next position by a second pitch shorter than the first pitch and then determines whether or not the lifter has come into contact with the substrate, thereby detecting a touch position and calculating the control position based on the touch position.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is based on and claims priority from Japanese Patent Application No. 2023-033019, filed on Mar. 3, 2023, with the Japan Patent Office, the disclosure of which is incorporated herein in its entirety by reference.

TECHNICAL FIELD

The present disclosure relates to a substrate processing apparatus and a control position setting method.

BACKGROUND

Japanese Patent Application Laid-open Publication No. 2015-060936 discloses a substrate processing apparatus including a vacuum container and a rotary table that rotates a plurality of substrates placed thereon within the vacuum container. For example, the substrate processing apparatus performs substrate processing on each substrate placed on the rotary table by supplying a processing gas into the vacuum container while rotating the rotary table.

This type of substrate processing apparatus includes a vertically movable lifter near a transfer port of the vacuum container in order to place the substrates on a plurality of stages of the rotary table. A user of the substrate processing apparatus sets, at the time of startup of the apparatus or during maintenance, control positions for use in the vertical movement of the lifter.

SUMMARY

According to an aspect of the present disclosure, a substrate processing apparatus includes a vacuum container, a rotary table rotatably provided within the vacuum container, a stage that places a substrate thereon at a position away from a rotation center of the rotary table, a lifter that is displaced relative to the stage to raise or lower the substrate, and a controller that controls an operation of the lifter, wherein the controller is configured to automatically set a control position in the operation of the lifter, and wherein, in setting of the control position, the controller controls a process including (A) repeatedly raising the lifter by a first pitch and then determining whether or not the lifter has come into contact with the substrate placed on the stage, thereby detecting a position where the lifter comes into contact with the substrate and setting a next position based on the detected position, and (B) repeatedly raising the lifter from the next position by a second pitch shorter than the first pitch and then determining whether or not the lifter has come into contact with the substrate placed on the stage, thereby detecting a touch position where the lifter comes into contact with the substrate and calculating the control position based on the touch position.

DETAILED DESCRIPTION

Hereinafter, embodiments for carrying out the present disclosure will be described with reference to the drawings. In each drawing, the same reference numerals may be given to the same components, and redundant descriptions may be omitted.

Configuration of Substrate Processing Apparatus

A substrate processing apparatus1will be described with reference toFIGS.1to3.FIG.1is a longitudinal cross-sectional view illustrating an example configuration of the substrate processing apparatus1according to an embodiment.FIG.2is a plan view illustrating an internal configuration of a vacuum container11of the substrate processing apparatus1ofFIG.1. InFIG.2, for the convenience of description, the illustration of a ceiling plate is omitted.FIG.3is a perspective view illustrating a configuration of a rotary table21and a stage211of the substrate processing apparatus1ofFIG.1.

The substrate processing apparatus1includes a processing unit10, a rotational drive device20, a lifter30, and a controller90.

The processing unit10executes a film formation processing to form a film on a substrate W. The processing unit10includes a vacuum container11, a gas introduction unit12, a gas exhaust unit13, a transfer port14, a heating unit15, and a cooling unit16.

The vacuum container11is a processing container with a depressurizable internal space. The vacuum container11is formed as a flat case having a substantially circular planar shape and may accommodate a plurality of substrates W in the internal space. The substrates W may be, for example, semiconductor wafers. The vacuum container11includes a main body111, a ceiling plate112, a sidewall body113, and a bottom plate114(FIG.1). The main body111has a cylindrical shape. The ceiling plate112is removably mounted on an upper surface of the main body111. The main body111and the ceiling plate112are airtightly in close contact with each other by a seal115. The sidewall body113has a cylindrical shape and is airtightly connected to a lower surface of the main body111. The bottom plate114is airtightly connected to a bottom surface of the sidewall body113.

The gas introduction unit12includes a raw material gas nozzle121, a reaction gas nozzle122, and separation gas nozzles123and124(FIG.2). The raw material gas nozzle121, reaction gas nozzle122, and separation gas nozzles123and124are arranged, above the rotary table21to be described later, at intervals along the circumferential direction of the vacuum container11(direction indicated by arrow A inFIG.2). In the illustrated example, the separation gas nozzle123, raw material gas nozzle121, separation gas nozzle124, and reaction gas nozzle122are arranged in this order in the clockwise direction (rotational direction of the rotary table21) from the transfer port14. Each of the raw material gas nozzle121, reaction gas nozzle122, and separation gas nozzles123and124has a gas introduction port121p,122p,123p, or124p(FIG.2) at a base end thereof for introducing various gases. The gas introduction ports121p,122p,123p, and124pare fixed to a sidewall of the main body111and protrude outward of the main body111. The raw material gas nozzle121, reaction gas nozzle122, and separation gas nozzles123and124are inserted into the vacuum container11from the sidewall of the main body111and extend radially inward of the main body111. The raw material gas nozzle121, reaction gas nozzle122, and separation gas nozzles123and124are made of, for example, quartz and are arranged parallel to the rotary table21.

The raw material gas nozzle121is connected to a raw material gas source through a pipe, a flow rate controller, etc. (although not illustrated). For example, a silicon-containing gas or metal-containing gas may be used as a raw material gas. The raw material gas nozzle121has a plurality of discharge holes (not illustrated), which are open toward the rotary table21and are arranged at intervals along the axial direction of the raw material gas nozzle121. An area below the raw material gas nozzle121serves as a raw material gas adsorption area P1for adsorbing the raw material gas to the substrate W.

The reaction gas nozzle122is connected to a reaction gas source through a pipe, a flow rate controller, etc. (although not illustrated). For example, an oxidizing gas or nitriding gas may be used as a reaction gas. The reaction gas nozzle122has a plurality of discharge holes (not illustrated), which are open toward the rotary table21and are arranged at intervals along the axial direction of the reaction gas nozzle122. An area below the reaction gas nozzle122serves as a reaction gas supply area P2for oxidizing or nitriding the raw material gas adsorbed onto the substrate W in the raw material gas adsorption area P1. In the present embodiment, a processing gas for processing the substrate W includes the above raw material gas and reaction gas.

Both the separation gas nozzles123and124are connected to a separation gas source through a pipe, a flow rate control valve, etc. (although not illustrated). For example, an inert gas such as an argon (Ar) gas or nitrogen (N2) gas may be used as a separation gas. The separation gas nozzles123and124have a plurality of discharge holes (not illustrated), which are open toward the rotary table21and are arranged at intervals along the axial direction of the separation gas nozzles123and124.

Further, as illustrated inFIG.2, two convex sectors17are provided within the vacuum container11. The convex sectors17constitute a separation area D in conjunction with the separation gas nozzles123and124, and therefore, are attached to the underside of the ceiling plate112to protrude toward the rotary table21. Each convex sector17has a fan-like planar shape with a top portion cut into an arc shape, and is oriented such that an inner arc is connected to a protrusion18and an outer arc follows the sidewall of the vacuum container11.

The gas exhaust unit13includes a first exhaust port131and a second exhaust port132(FIG.2). The first exhaust port131is formed in the bottom of a first exhaust area E1that communicates with the raw material gas adsorption area P1. The second exhaust port132is formed in the bottom of a second exhaust area E2that communicates with the reaction gas adsorption area P2. The first exhaust port131and the second exhaust port132are connected to an exhaust device (not illustrated) through an exhaust pipe (not illustrated).

The transfer port14is provided on the sidewall of the main body111(FIG.2). The substrate W is transferred through the transfer port14between the rotary table21inside the vacuum container11and a transfer device14aoutside the vacuum container11. The transfer port14is opened or closed by a gate valve (not illustrated).

The heating unit15includes a fixed shaft151, a heater support152, and a heater153(FIG.1).

The fixed shaft151has a cylindrical shape with the center of the vacuum container11as the central axis. The fixed shaft151penetrates the bottom plate114of the vacuum container11inside a rotating shaft23of the rotational drive device20to be described later.

The heater support152is fixed to an upper end of the fixed shaft151and has a disc shape. The heater support152supports the heater153.

The heater153is installed to an upper surface of the heater support152. The heater153may also be installed on the main body111, in addition to the upper surface of the heater support152. The heater153generates heat upon receiving power supplied from a power supply (not illustrated), thus heating the substrate W. Further, the heater153may have a shield plate on an upper surface thereof (facing the rotary table21) to prevent the heater153from being exposed to the processing gas.

The cooling unit16includes fluid flow paths161ato164a, chiller units161bto164b, inlet pipes161cto164c, and outlet pipes161dto164d(FIG.1). The fluid flow paths161ato164aare formed respectively within the main body111, the ceiling plate112, the bottom plate114, and the heater support152. The chiller units161bto164boutput a temperature-regulated fluid. The temperature-regulated fluid output from the chiller units161bto164bflows through the inlet pipes161cto164c, the fluid flow paths161ato164a, and the outlet pipes161dto164din this order for circulation. This allows for the temperature adjustment of the main body111, the ceiling plate112, the bottom plate114, and the heater support152. For example, a fluorine-based fluid such as Galden (registered trademark) or water may be used as the temperature-regulated fluid.

The rotational drive device20includes the rotary table21, an accommodating box22, a rotating shaft23, a revolution motor24, and an outer cylinder25.

The rotary table21is provided inside the vacuum container11and has a rotation center at the center of the vacuum container11. The rotary table21has, for example, a disc shape and is made of quartz. A plurality of (e.g., six) stages211are provided on an upper surface of the rotary table21along the rotational direction (circumferential direction). The rotary table21is connected to the accommodating box22via a connector214(FIG.3).

Each stage211has a slightly larger disc shape than the substrate W, and is made of, for example, quartz. A placement surface211sfor placing the substrate W is formed on an upper surface of each stage211. Each stage211is connected to a rotation motor213via a rotation shaft212and is configured to be rotatable relative to the rotary table21(FIG.1).

The rotation shaft212connects a lower surface of the stage211to the rotation motor213accommodated in the accommodating box22and transmits the power of the rotation motor213to the stage211. The rotation shaft212is configured to be rotatable about the center of the stage211as a rotation center. The rotation shaft212is provided to penetrate a ceiling222of the accommodating box22and the rotary table21. A seal263is provided near a penetrating portion of the ceiling222of the accommodating box22to maintain an airtight state inside the accommodating box22. An example of the seal263includes a magnetic fluid seal.

The rotation motor213rotates the stage211relative to the rotary table21via the rotation shaft212, thereby allowing the substrate W to rotate around the center of the substrate W. For example, a servo motor may be applied as the rotation motor23.

The connector214connects a lower surface of the rotary table21to an upper surface of the accommodating box22(FIG.3). A plurality of connectors214are arranged along the circumferential direction of the rotary table21.

The accommodating box22is located below the rotary table21within the vacuum container11. The accommodating box22is connected to the rotary table21via the connectors214and rotates integrally with the rotary table21. The accommodating box22may be configured to be vertically movable within the vacuum container11by a lifting mechanism (not illustrated). The accommodating box22includes a main body portion221and a ceiling portion222.

The main body portion221is formed into a concave shape in longitudinal cross-section and has a ring shape along the rotational direction of the rotary table21(FIG.1).

The ceiling portion222is provided on an upper surface of the main body portion221to cover an opening of the main body portion221. This allows the main body portion221and the ceiling portion222to define a rotating compartment223isolated from the inside of the vacuum container11.

The rotating compartment223is formed into a rectangular shape in longitudinal cross-section and has a ring shape along the rotational direction of the rotary table21. The rotating compartment223accommodates the rotation motor213(rotation source). A communication path224is formed in the main body portion221to communicate the rotating compartment223with the outside of the substrate processing apparatus1. This allows the atmospheric air to be introduced into the rotating compartment223from the outside of the substrate processing apparatus1, so that the inside of the rotating compartment223is cooled and is maintained at atmospheric pressure. In order to rotatably arrange the rotating compartment223, the vacuum container11has a rotation source accommodating space19surrounded by the sidewall body113, bottom plate114, and heating unit15.

The rotating shaft23is fixed to a lower portion of the accommodating box22. The rotating shaft23is provided to penetrate the bottom plate114of the vacuum container11. The rotating shaft23transmits the power of the revolution motor24to the rotary table21and the accommodating box22, causing the rotary table21and the accommodating box22to rotate integrally. A seal154is provided between an outer wall of the fixed shaft151and an inner wall of the rotating shaft23of the rotational drive device20. This allows the rotating shaft23to rotate relative to the fixed shaft151while maintaining an airtight state inside the vacuum container11. For example, a magnetic fluid seal may be applied to the seal154.

The outer cylinder25of the rotational drive device20is connected to the lower surface center of the bottom plate114of the vacuum container11. The outer cylinder25supports the vacuum container11in conjunction with the fixed shaft151of the vacuum container11. A seal116is provided between the rotating shaft23and the outer cylinder25to maintain an airtight state inside the vacuum container11. For example, a magnetic fluid seal may be applied to the seal116.

A passage231is formed within the rotating shaft23. The passage231is connected to the communication path224of the accommodating box22and functions as a fluid flow path for introducing the atmospheric air into the accommodating box22. Further, the passage231also functions as a wiring duct for introducing power lines and signal lines into the accommodating box22to drive the rotation motor213. For example, the passage231is provided in the same number as the rotation motor213.

Further, as illustrated inFIG.1, when the transfer device14a(FIG.2) loads or unloads the substrate W onto or from the stage211, the lifter30raises or lowers a plurality of (three in the present embodiment) lift pins31to receive or transfer the substrate W from or to the transfer device14a. In the substrate processing apparatus1, the lifter30is positioned vertically below a position opposite to the stage adjacent to the transfer port14. The lifter30includes a plurality of (three) upper structures40, each having a corresponding one of the plurality of lift pins31, and a single lower actuator50, which simultaneously raises or lowers the plurality of lift pins31, within the vacuum container11. Further, the substrate processing apparatus1includes a camera (imaging device)60positioned vertically above the position opposite to the stage to capture images of the substrate W transferred onto the stage211(FIG.2).

Each upper structure40is provided to penetrate the heater support152and the heater153and accommodates the lift pin31in a displaceable manner. The lower actuator50is attached to a lower surface of the bottom plate114of the vacuum container11. The lower actuator50has a plurality of (three) plungers51, which are displaced along the vertical direction to press a lower end32of each lift pin31, respectively. In other words, the lifter30has a two-stage structure in which the plurality of lift pins31, which are movable to come into direct contact the substrate W, and the plurality of plungers51, which indirectly raise or lower the substrate W via the lift pins31, are separately provided in the vertical direction.

The lower actuator50includes, in addition to each plunger51, a case52and a plunger drive53. Further, the plunger drive53includes a drive source54, a drive transmitter55that transmits the operating force of the drive source54, and a movable body56that supports each plunger51and is displaced within the case52by the drive transmitter55.

The case52is fixed to the bottom plate114at the later side of the outer cylinder25and is formed into a suitable shape to accommodate each component of the lower actuator50. The drive source54is installed to the bottom of the case52and operates based on the control of the controller90to transmit the operating force thereof to the drive transmitter55. The drive transmitter55vertically moves the movable body56by appropriately reducing or converting the operating force of the drive source54. The movable body56extends radially outwardly (horizontally) from the drive transmitter55and supports a lower end of each plunger51. The movable body56is vertically moved by the drive transmitter55, thereby integrally displacing each plunger51.

Further, the drive transmitter55includes an encoder (not illustrated) that measures the amount of rotation of the drive source54(or the position of the plunger51), thus detecting the height position of the plunger51, i.e., the height position of the lift pin31. This allows the controller90to recognize the height position of the lift pin31. Furthermore, the drive transmitter55sets the minimum control unit of each plunger51to, for example, 0.05 mm, allowing the lift pin31to be raised or lowered in increments of 0.05 mm. The minimum control unit when raising or lowering the lift pin31is not limited to 0.05 mm and may be designed arbitrarily.

Each plunger51has an elongated solid rod shape and is fixed to the movable body56, thereby extending in parallel in the vertical direction. The bottom plate114has a bottom plate side through-hole114aformed at a location opposite to each plunger51to allow the passage of each plunger51therethrough. Further, the accommodating box22has a box side through-hole225formed at a location opposite to each plunger51near the rotating shaft23to allow the passage of each plunger51therethrough.

Each plunger51is in a standby state with an upper end thereof slightly protruding from the bottom plate side through-hole114ain the non-operational state of the lift pin31. Then, each plunger51is moved upward together with the movable body56to move within the rotation source accommodating space19when receiving or transferring the substrate W. Each plunger51passes through the side of the accommodating box22or the box side through-hole225to come into contact with the lift pin31of each upper structure40, thereby pushing up the lift pin31.

FIG.4is an enlarged partial cross-sectional view illustrating the periphery of each upper structure40of the lifter30ofFIG.1. InFIG.4, two lift pins31and two upper structures40are illustrated as representative. Each upper structure40includes the lift pin31, a receptacle41for accommodating the lift pin31in a lifting manner, and a cylinder member45located in an upper region of the receptacle41so as to be displaced simultaneously with the lift pin31.

The plurality of (three) upper structures40are arranged in the circumferential direction of the stage211at positions with a spacing in the radial direction from the rotation shaft212. The stage211includes a plurality of (three) through-holes211ato allow the passage of each lift pin31therethrough at positions corresponding to the respective upper structures40(see alsoFIG.2).

The lift pin31is a linearly extending cylindrical member and has the lower end32and an upper end33. The lower end32of the lift pin31is located below a lower surface of the heater support152when the plunger51is at a downwardly moved position. The upper end33of the lift pin31is moved vertically higher than the heater153when pressed by the plunger.

The upper structure40is configured to support the lift pin31accommodated in the receptacle41to prevent the lift pin31from being detached in a vertical downward direction. For example, the lift pin31has a lower rod portion34, a flange forming portion35, and an upper rod portion36in this order from the bottom to the top. The lower rod portion34, flange forming portion35, and upper rod portion36are integrally molded with each other.

The lower rod portion34is formed thicker than the upper rod portion36, increasing the area of the lower end32. The plunger51raised by the lower actuator50comes into contact with the lower end32to push up the lower end32, thereby raising the entire lift pin31. The flange forming portion35is caught by an inner protrusion42provided on an inner wall constituting the receptacle41, thereby restricting the lift pin31from being removed from a standby position PS to be described later. The upper rod portion36extends linearly from the flange forming portion35to the upper end33. The upper end33is formed in a substantially hemispherical shape to come into point contact with the substrate W.

The receptacle41for accommodating the lift pin31is vertically formed through the heating unit15and is provided with the inner protrusion42at a lower side in the vertical direction. The receptacle41may be configured by mounting a cylindrical blanket (not illustrated), which is formed separately from the heating unit15, into a bore.

The cylinder member45takes the form of a cylinder that may be positioned inside an upper region of the receptacle41, and the upper rod portion36of the lift pin31is positioned within the cylinder member45. The cylinder member45is supported by a coil spring46, which is in turn supported by an upper surface of the flange forming portion35. The cylinder member45is movable relative to the receptacle41, and is pushed upward by the coil spring46when the lift pin31is raised, thereby being raised together with the lift pin31. The raised cylinder member45comes into contact with the underside of the stage211, allowing communication between the through-hole211aof the stage211and the receptacle41. When the cylinder member45comes into contact with the stage211, the cylinder member45stops to be raised, while the lift pin31continues to be raised relative to the cylinder member45. This allows the lift pin31to pass through the through-hole211a, protruding upward of the stage211to support the substrate W.

FIG.4illustrates a configuration in which each lift pin31is supported along the vertical direction, but each upper structure40may support each lift pin31in an inclined posture so that an upper end thereof approaches the rotating shaft23(revolution shaft) of the rotary table21. This allows each upper structure40to be obliquely raised in the direction toward the rotating shaft23when each lift pin31is raised. In other words, each lift pin31is raised to approach the substrate W, which has been moved radially outward due to centrifugal force during rotation of the rotary table21, toward the center of the rotating shaft23, helping to avoid friction between the rotary table21and the substrate W, and preventing the generation of particles.

In the meantime, the camera60is installed to the ceiling plate112at a position adjacent to the transfer port to capture images of the stage211revolving (rotating) within the vacuum container11. The imaging direction of the camera60is not limited to the vertical downward direction but may be inclined with respect to the vertical direction. The camera60, under the control of the controller90, captures images of a part (or all) of the inner edge of the stage211and a part (or all) of the outer edge of the substrate W placed on the stage211, transmitting the resulting imaging information to the controller90.

Returning toFIG.1, the controller90controls each component of the substrate processing apparatus1. The controller90includes a control main body91and a user interface95. The control main body91is a computer having one or more processors92, a memory93, an input/output interface (not illustrated) and a communication interface (illustrated). The one or more processors92include one or a combination of two or more of a central processing unit (CPU), graphics processing unit (GPU), application specific integrated circuit (ASIC), field-programmable gate array (FPGA), a circuit including a plurality of discrete semiconductors, and others, and executes programs stored in the memory93. The memory93includes a non-volatile memory and a volatile memory (e.g., compact disk, digital versatile disc (DVD), hard disk, flash memory, etc.).

Further, the user interface95is connected to the input/output interface of the control main body91. This user interface95is not particularly limited, but may include, for example, a touch panel, monitor, keyboard, mouse, etc.

The controller90controls each component of the substrate processing apparatus1, thereby controlling the reception of the substrate W from the transfer device14a(FIG.2) to each stage211, the processing of each substrate W, the transfer of the substrate W from each stage211to the transfer device14a, etc. For example, when receiving the substrate W, the controller90controls the stage211, which is intended for placing the substrate W, so as to be positioned adjacent to the transfer port14of the vacuum container11. Then, after advancing the transfer device14afrom the transfer port14, the controller90operates the lifter30to raise each lift pin31from the stage211, thus receiving the substrate W from the transfer device14a. After retreating the transfer device14a, the controller90lowers each lift pin31to place the substrate W on the stage211. Further, by sequentially replacing the stage211adjacent to the transfer port14through the rotation of the rotary table21, the controller90repeats the above operation, thereby placing the substrate Won each stage211.

During substrate processing, the controller90depressurizes the vacuum container11to a predetermined internal pressure and controls the heating unit15to heat each substrate W. Furthermore, the controller90rotates each stage211around the rotation shaft212while rotating the rotary table21around the rotating shaft23. In this state, the controller90controls the gas introduction unit12to supply the raw material gas through the raw material gas nozzle121, to supply the reaction gas through the reaction gas nozzle122, and to supply the separation gas through the separation gas nozzles123and124, thereby forming a desired film on a surface of each substrate W.

In the transfer of the substrate W after substrate processing, the controller90positions the stage211for the transfer of the substrate W adjacent to the transfer port14of the vacuum container11, and then, raises each lift pin31of the lifter30to lift the substrate W from the stage211. Then, after the entry of the transfer device14a, the controller90transfers the substrate W to the transfer device14aby lowering each lift pin31. This allows the transfer device14ato unload the substrate W from the vacuum container11. Further, by sequentially replacing the stage211adjacent to the transfer port14through the rotation of the rotary table21, the controller90repeats the above operation, thereby unloading each substrate W from each stage211.

Further, when each lift pin31is raised or lowered by the lifter30, the controller90controls the operation of each lift pin31based on the previously recognized control positions of each lift pin31. As illustrated inFIG.4, the control positions of each lift pin31include the standby position PS, touch position PT, load position PL, unload position PU, transfer device support position PP1, and lifting upper limit position PP2.

The standby position PS is a position where each lift pin31is waiting during the substrate processing of the substrate processing apparatus1. For example, in the standby position PS, the upper end33of each lift pin31is set to a position where it slightly protrudes from an upper surface of the heater153. This allows the lifter30to shorten the distance when raising each lift pin31to receive or transfer the substrate W before or after substrate processing, thereby improving processing efficiency. The standby position PS may be mechanically defined by the configuration of the lift pin31and the receptacle41, or may be set by the controller90controlling the lifter30.

The touch position PT is a position where the upper end33of each lift pin31, which has been raised, comes into contact with the substrate W placed on the stage211. Thus, the touch position PT may be rephrased as the height position of the placement surface211sof the stage211. Here, the height positions of the plurality of placement surfaces211s(stages211) may slightly differ from each other due to a slight inclination, mechanical dimensional tolerances, etc. of the rotary table21. It may be necessary for the controller90to recognize the touch position PT at each stage211and to set other control positions (load position PL, unload position PU, etc.) based on the touch position PT, thereby operating the lifter30accordingly. Therefore, in a control position setting method for the lifter30, the controller90detects the touch position PT where the raised lifter30comes into contact with the substrate W, and calculates other control positions based on the touch position PT. The control position setting method for the lifter30will be described later.

In the meantime, the load position PL is set lower than the placement surface211sof the stage211(i.e., the touch position PT). For example, the load position PL is set lower than the touch position PT in the vertical direction by an appropriate interval within the range of 0.3 mm to 0.9 mm. This load position PL may be set based on the unload position PU.

When controlling the lifter30, the controller90recognizes the height position of the plunger51based on the detection of the encoder, and determines whether or not the upper end33of each lift pin31has reached the load position PL, thereby switching the speed of each lift pin31at the load position PL. In other words, the load position PL is used as the control position for switching the speed of each lift pin31. For example, when raising each lift pin31, the controller90reduces the rising speed of each lift pin31based on the fact that the upper end33has been raised to the load position PL. Conversely, when lowering each lift pin31, the controller90increases the lowering speed of each lift pin31based on the fact that the upper end33has been lowered to the load position PL.

The unload position PU is set higher than the placement surface211sof the stage211(i.e., the touch position PT). For example, the unload position PU is set higher than the touch position PT in the vertical direction by an appropriate interval within the range of 0.4 mm to 1.0 mm. The unload position PU is above the stage211, and the substrate W supported by each lift pin31is present at this unload position Pu. In order to prevent any influence such as the warping of the substrate W supported by each lift pin31, the distance between the touch position PT and the unload position PU may be set longer than the distance between the touch position PT and the load position PL.

When controlling the lifter30, the controller90determines whether or not the upper end33of each lift pin31has reached the unload position PU, thereby switching the speed of each lift pin31at this unload position PU. In other words, the unload position PU is also used as the control position for switching the speed of each lift pin31. For example, when raising each lift pin31, the controller90increases the rising speed of each lift pin31based on the fact that the upper end33has been raised to the unload position PU. Conversely, when lowering each lift pin31, the controller90reduces the lowering speed of each lift pin31based on the fact that the upper end33has been lowered to the unload position PU.

Further, the transfer device support position PP1is a position where the transfer device14asupports the substrate W when it enters the vacuum container11. In other words, the transfer device support position PP1corresponds to the support surface of an end effector of the transfer device14a. This transfer device support position PP1is not a relative position set based on the touch position PT, but a preset fixed value for controlling the transfer device14a. Once the upper end33of each lift pin31is raised to the transfer device support position PP1in a state where the transfer device14asupports the substrate W, the lift pin31may receive the substrate W. Once the upper end33of each lift pin31supporting the substrate W is lowered to the transfer device support position PP1in a state where the transfer device14ais empty, the lift pin31may deliver the substrate W to the transfer device14a.

The lifting upper limit position PP2is the limit position when each lift pin31(upper end33) is raised, and is defined by mechanical elements of the lifter30or under the control of the controller90. The lifting upper limit position PP2is a fixed value set at a position vertically spaced apart upward from the transfer device support position PP1by a certain distance. After receiving the substrate W supported by the transfer device14a, the controller90raises each lift pin31until the upper end33reaches the lifting upper limit position PP2, thereby ensuring smooth retreat of the transfer device14a. Further, the controller90raises each lift pin31supporting the substrate W until the lift pin31reaches the lifting upper limit position PP2, thereby allowing the transfer device14ato smoothly enter below the substrate W in the vertical direction.

The controller90sets the control positions (touch position PT, load position PL, and unload position PU) used when controlling the lifter30by executing a control position setting method for the lifter30. The control position setting method for the lifter30is executed after the installation of the substrate processing apparatus1or after maintenance (such as replacement, repairs, etc. of components of the apparatus). Next, the control position setting method for the lifter30will be described.

Control Position Setting Method

FIG.5is a flowchart illustrating the processing flow of a control position setting method for the lifter30. As illustrated inFIG.5, in the control position setting method for the lifter30, the controller90controls a start determination process S1, a substrate transfer process S2, a first adjustment process S3, a second adjustment process S4, a slot determination process S5, and an error checking process S6in this order.

In the start determination process S1, the controller90determines whether or not a trigger condition to start the control position setting method has been satisfied, and when the trigger condition is satisfied, transitions to control after the first adjustment process S3. This trigger condition may involve the user operating the execution of the control position setting method through the user interface95connected to the controller90.

FIG.6is a diagram illustrating an example of screen information100displayed on the user interface95. In the start determination process S1, the controller90displays, for example, the screen information100as illustrated inFIG.6under the user's operation using the user interface95. The screen information100includes a current position display section101, a load position display section102, a touch position display section103, an unload position display section104, a detailed adjustment start position display section105, and an operation button group106.

The current position display section101is a display area indicating the current position of the upper end33of the lift pin31. For example, the current position display section101displays the current position of the upper end33in millimeters as well as other information such as the name of a position corresponding to the current position.

The load position display section102is a display area indicating the load position PL for each of a plurality of slots (stages211). For example, the load position display section102includes a previous value display column102a, which displays the load position PL set at the previous time for each slot, and a current value display column102bpositioned adjacent to the previous value display column102a, which displays the load position PL set at the current time for each slot. By displaying the previous value display column102aand the current value display column102bside by side, it becomes easier for the user to recognize a change in the values set during the current control position setting method.

The touch position display section103is a display area indicating the touch position PT for each of the plurality of slots (stages211). For example, the touch position display section103includes a current value display column103a, which displays the touch position set at the current time, and a touch position status column103bpositioned adjacent to the current value display column103a, which displays information regarding the touch positions between the slots.

For example, the touch position status column103bdisplays the difference between the maximum and minimum values of the touch positions PT for each slot, and also displays, based on the calculated difference, the presence or absence of an abnormality in each stage211. In other words, if the difference between the touch positions PT for each slot is large, there is a possibility that an abnormality occurred in the installation state of the stages211from the first. Therefore, the controller90compares the difference between the touch positions PT for each slot with a preset threshold thereof, and determines normality when the difference is less than the threshold, but determines an abnormality and displays (notifies) the result when the difference is equal to or greater than the threshold.

The unload position display section104is displayed in the same manner as the load position display section102and is a display area indicating the unload position PU for each of the plurality of slots (stages211). For example, the unload position display section104includes a previous value display column104a, which displays the unload position PU set at the previous time for each slot, and a current value display column104bpositioned adjacent to the previous value display column104a, which displays the unload position PU set at the current time for each slot. By displaying the previous value display column104aand the current value display column104bside by side, it becomes easier for the user to recognize a change in the values set during the current control position setting method.

The detailed adjustment start position display section105is a display area indicating a detailed adjustment start position (next position) set in the first adjustment process S3of the control position setting method for the lifter30. This detailed adjustment start position will be explained in detail later.

In the meantime, the operation button group106is an area that displays a row of buttons that are operable by the user. The buttons in the operation button group106may include, for example, an execution button106a, execution interruption button106b, save button106c, stop button106d, and exit button106e.

The execution button106ais a button for operating the execution of the control position setting method for the lifter30. When the user presses the execution button106a, as illustrated inFIG.6, the controller90displays a separate window107indicating selection boxes for selecting one or more of the plurality of slots (stages211) and a selection box for selecting all the slots. In this separate window107, the user determines the slot for which the control position setting method will be performed by selecting the appropriate selection box. After this determination, the controller90starts the control position setting method based on the user's settings.

Further, the execution interruption button106bis a button for interrupting the control position setting method in the middle of execution. The save button106cis a button for saving the touch position PT, load position PL, and unload position PU set at the current time, enabling the operation of the lifter30based on these positions. The stop button106dis a button for terminating the control position setting method without saving the touch position PT, load position PL, and unload position PU set at the current time. The exit button106eis a button for terminating the display of the screen information100(i.e., the control position setting method).

In other words, in the start determination process S1illustrated inFIG.5, the controller90sequentially controls each process after the substrate transfer process S2based on the user pressing the execution button106aof the screen information100. The controller90may automatically execute the control position setting method regardless of the user's operation, for example, within the flow of various settings performed after the installation of the substrate processing apparatus1or after maintenance.

In the next substrate transfer process S2, the controller90transfers the substrate W to each stage211for which the control position setting method will be performed. The substrate W for use in the control position setting method may be a dummy substrate. For example, when executing the control position setting method for all the slots (stages211), the controller90, while changing the position of each stage211of the rotary table21, transfers the substrate W using the transfer device14ato place the substrate W on all the stages211. The operation of the lifter30at this time may utilize the previous control position values or a default control position. In the meantime, when executing the control position setting method for only the slot specified by the user, the controller90may rotate the rotary table21to place the substrate Won the target stage211.

Then, in the first adjustment process S3, the controller90roughly sets the touch position PT where each lift pin31of the lifter30comes into contact with the substrate W. Furthermore, in the second adjustment process S4, the controller90sets the more detailed touch position PT compared to the touch position PT set in the first adjustment process S3. Hereinafter, the first adjustment process S3and second adjustment process S4will be described with reference toFIGS.7and8.FIG.7is a flowchart illustrating the processing flow of the first adjustment process S3.FIG.8is a flowchart illustrating the processing flow of the second adjustment process S4.

In the first adjustment process S3, the controller90controls the operations in steps S101to S111illustrated inFIG.7. First, the controller90determines whether or not the substrate W is placed on the stage211(slot where the control position is to be set) opposite to the lifter30(step S101). For example, the controller90captures images of the stage211using the camera60and determines whether or not the substrate W is included in the captured information, thereby determining the presence or absence of the substrate W on the stage211. Then, if there is no substrate W on the stage211(step S101: NO), the controller90notifies an error indicating the absence of the substrate W, and terminates the current control position setting method. In the meantime, when there is the substrate Won the stage211(step S101: YES), the controller90proceeds to step S102.

In step S102, the controller90operates the lower actuator50to raise each plunger51, moving the upper end of each plunger51to a position where it comes into contact with the lower end32of each lift pin31. This allows each lift pin31to be ready to rise immediately from the standby position PS within the receptacle41.

Next, the controller90operates the lower actuator50to raise the upper end33of each lift pin31to a rough adjustment start position (step S103). This rough adjustment start position is the start position for a first adjustment operation of raising each lift pin31in increments of a first pitch and is preset in the controller90. For example, the rough adjustment start position may be set to be lower than the previous unload position PU by a predetermined separation distance (e.g., 1 mm). The rough adjustment start position may be configured for user setting using the user interface95. Alternatively, the user may also set the separation distance.

Once the upper end33reaches the rough adjustment start position, the controller90starts the determination of contact of the substrate W based on the first adjustment operation and the imaging information from the camera60. Specifically, the controller90raises each lift pin31by a preset first pitch (step S104). The first pitch is not particularly limited, but may be set to, for example, be at least twice the minimum control unit for raising or lowering each lift pin31. For example, in case of a mechanism where the lifter30raises or lowers each lift pin31in increments of 0.05 mm, setting the first pitch to 0.1 mm may be considered.

Once each lift pin31is raised by the first pitch, the controller90waits for the operation over a certain period (step S105). This eliminates any instability during the rising of each lift pin31. After that, the controller90captures images of the substrate W and the stage211using the camera60. By subjecting the imaging information to appropriate image processing, the controller90may extract information on the substrate W and information on the stage211from the imaging information (step S106).

Then, the controller90determines whether or not the upper end33of each lift pin31has come into contact with the substrate W based on the information on the substrate W and the information on the stage211acquired from the imaging information (step S107). A method for determining the contact between each lift pin31and the substrate W may be, for example, to monitor the shadow of the outer edge of the substrate W in the imaging information. In other words, when the substrate W is placed on the placement surface211s, there is almost no shadow around the outer edge of the substrate W. In contrast, when the substrate W is even slightly raised from the placement surface211s, the shadow around the outer edge of the substrate W becomes more pronounced. Therefore, the controller90may determine that the substrate W has been raised by each lift pin31based on a change in the shadow (black and white binarized pixels acquired through image processing) around the outer edge of the substrate W.

When it is determined that the upper end33of each lift pin31has not come into contact with the substrate W (step S107: NO), the controller90proceeds to step S108. In step S108, the controller90counts (increments) the number of executions of the first adjustment operation of raising each lift pin31and determines whether or not the count has reached a preset count threshold or more. When the count has reached the count threshold or more, it indicates that even though each lift pin31reaches a position where it is supposed to reliably come into contact with the substrate W, the lift pin31has not come into contact with the substrate W. In this case, there is a possibility that the lifter30has an abnormality. Therefore, when the count has reached the count threshold or more (step S108: YES), the controller90notifies an error in the lifter30and terminates the current control position setting method.

In the meantime, when the count has not reached the count threshold or more (step S108: NO), the controller90returns to step S104and raises each lift pin31again by the first pitch. The controller90repeats the above processing flow of steps S104to S108until each lift pin31comes into contact with the substrate W, thereby ensuring reliable determination of the contact between each lift pin31and the substrate W. Then, when it is determined that the upper end33of each lift pin31has come into contact with the substrate W (step S107: YES), the controller90proceeds to step S109.

In step S109, the controller90sets the current position of each lift pin31as the touch position PT for each lift pin31in the first adjustment process S3.

Then, the controller90calculates the detailed adjustment start position (next position) in the second adjustment process S4using the current position of each lift pin (step S110). The detailed adjustment start position is calculated, for example, by adding a preset offset value to the current position (touch position PT) of each lift pin31in the first adjustment process S3. This offset value is set to a value (negative value) that lowers the detailed adjustment start position below the current position in the vertical direction. For example, when the first pitch was set to 0.1 mm, the offset value may be set within the range of approximately −0.1 mm to −0.3 mm. This allows the detailed adjustment start position to be slightly lower than the current position, enhancing the processing efficiency of the next second adjustment process S4. The offset value may be arbitrarily set by the user.

After step S110, the controller90sets the calculated detailed adjustment start position as a parameter for the next second adjustment process S4and retreats each lift pin31to the standby position PS (step S111). This terminates the first adjustment process S3. Further, when setting the detailed adjustment start position, the controller90displays the set detailed adjustment start position in the detailed adjustment start position display section105of the screen information100, as illustrated inFIG.6. The controller90may allow the user to input (update) the detailed adjustment start position into the detailed adjustment start position display section105, and may implement the second adjustment process S4based on the detailed adjustment start position set by the user. For example, the user may input the detailed adjustment start position based on the previous value of the touch position PT.

After completing the above first adjustment process S3, the controller90transitions to the second adjustment process S4, controlling the operations in steps S201to S212illustrated inFIG.8. Steps S201and S202are the same processing as steps S101and S102in the first adjustment process S3. Since the substrate W is reliably placed on the stage211after going through the first adjustment process S3, the controller90may omit step S201.

In step S203, the controller90operates the lower actuator50to raise the upper end33of each lift pin31to the detailed adjustment start position set in the first adjustment process S3. Once the upper end33reaches the detailed adjustment start position, the controller90starts the determination of contact of the substrate W based on the second adjustment operation and the imaging information from the camera60.

For example, the controller90raises each lift pin31by a preset second pitch (step S204). The second pitch may be set as the minimum control unit for raising or lowering each lift pin31, for example. For example, in case of a mechanism where the lifter30raises or lowers each lift pin31in increments of 0.05 mm, the second pitch may be set to 0.05 mm.

Once each lift pin31has been raised by the second pitch, the controller90waits for the operation over a certain period (step S205). This eliminates any instability during the rising of each lift pin31. After that, the controller90captures images of the substrate W and the stage211using the camera60. By subjecting the imaging information to appropriate image processing, the controller90may extract information on the substrate W and information on the stage211from the imaging information (step S206).

Then, the controller90determines whether or not the upper end33of each lift pin31has come into contact with the substrate W based on the information on the substrate W and the information on the stage211acquired from the imaging information (step S207).

When it is determined that the upper end33of each lift pin31has not come into contact with the substrate W (step S207: NO), the controller90proceeds to step S208. In step S208, the controller90counts (increments) the number of executions of the second adjustment operation of raising each lift pin31and determines whether or not the count has reached a preset count threshold or more. When the count has reached the count threshold or more (step S208: YES), the controller90notifies an error in the lifter30and terminates the current control position setting method.

In the meantime, when the count is less than the count threshold (step S208: NO), the controller90returns to step S204and raises the lift pin31again by the second pitch. The controller90repeats the above processing flow of steps S204to S208until each lift pin31comes into contact with the substrate W. Then, when it is determined that the upper end33of each lift pin31has come into contact with the substrate W (step S207: YES), the controller90proceeds to step S209.

In step S209, the controller90sets the current position of each lift pin31as the touch position PT for each lift pin31.

Then, the controller90calculates the unload position PU, which is the control position, using the current position (touch position PT) of each lift pin31(step S210). The unload position PU is calculated, for example, by adding a preset unload position adjustment value to the current position of each lift pin31. This unload position adjustment value is a value (positive value) in the vertical upward direction from the current position, and is set to an appropriate interval (e.g., 0.6 mm) within the above range of approximately 0.4 mm to 1.0 mm. The unload position adjustment value may be arbitrarily set by the user.

Subsequently, the controller90uses the calculated unload position PU to calculate the load position PL, which is the control position (step S211). The load position PL is calculated, for example, by adding a preset load position adjustment value to the unload position PU. The load position adjustment value is a value (negative value) in the vertical downward direction from the unload position PU, and is set to a lower value (e.g., −1.0 mm) than the touch position PT within the range of approximately −0.8 mm to −1.3 mm. The load position adjustment value may also be arbitrarily set by the user.

After step S111, the controller90sets the calculated touch position PT, load position PL, and unload position PU as parameters for use in the transfer of the substrate W from that slot, and then retreats each lift pin31to the standby position PS (step S212). This terminates the second adjustment process S4. The controller90displays the touch position PT in the touch position display section103of the screen information100, as illustrated inFIG.6, based on the setting of the touch position PT. Similarly, the controller90displays the load position PL in the current value display column102bof the load position display section102based on the setting of the load position PL. Furthermore, the controller90displays the unload position PU in the current value display column104bof the unload position display section104based on the setting of the unload position PU.

Returning toFIG.5, after the second adjustment process S4, the controller90performs the slot determination process S5to determine whether or not there is any other slot where the control position needs to be adjusted. When there is another slot requiring the adjustment of the control position, the controller90returns to the first adjustment process S3, repeating the subsequent same processing. Then, for example, when adjusting the control positions for all six slots, the controller90performs the first adjustment process S3and second adjustment process S4on all the slots. When there is no slot requiring the adjustment of the control position in the slot determination process S5, the controller90proceeds to the next error checking process S6.

In the error check process S6, the controller90calculates the difference between the maximum and minimum values of the touch positions PT for each slot, and then determines whether or not the calculated difference falls within a preset allowable range. The calculated difference and determination results are displayed in the touch position status column103b. Further, when the difference does not fall within the allowable range, the controller90notifies the user of information indicating that an abnormality has occurred in each stage211through the screen information100, etc. This allows the user to perform necessary maintenance, etc. on the rotary table21of the substrate processing apparatus1at an early stage. The error checking process S6is not limited to being executed after setting the control positions for all the slots, but may be executed after setting the control positions for two or more slots (e.g., first and second slots). This enables early recognition of differences in the touch positions PT between the first slot and the second slot.

As described above, the substrate processing apparatus1may automatically set the control positions for each slots (stage211). Here, in the conventional substrate processing apparatus, when setting the control positions for each slot, the user visually confirmed whether or not the substrate W and the lifter30were in contact based on images captured by a camera, and this confirmation was repeated for each slot. Therefore, a significant time was required for setting the control positions for each slot. In contrast, the substrate processing apparatus1according to the embodiment may achieve enhanced operational efficiency by performing the first adjustment operation and the second adjustment operation for the lifter30and determining the contact between the lifter30and the substrate W through the control position setting method described above. In particular, the substrate processing apparatus1may achieve a significant reduction in time when setting the control positions for all the plurality of (six) slots.

FIG.9is a graph illustrating touch positions set by the control position setting method and actual measured values of the placement surface211susing a displacement gauge. InFIG.9, the bar graph represents the touch positions for each slot set by the control position setting method, while the line graph represents the actual measured values for each slot from a displacement gauge. The actual measured values from the displacement gauge were obtained by fixing the displacement gauge to the main body111through a jig with the ceiling plate112of the vacuum container11removed, and measuring the height position of the placement surface211sof each stage211using the displacement gauge.

As illustrated inFIG.9, in the substrate processing apparatus1, the height positions of the placement surfaces211sof the respective stages211differ from each other. However, the touch positions set by the control position setting method and the actual measured values from the displacement gauge vary approximately in the same manner. Then, when calculating the difference between the set touch positions for each slot and the actual measured values from the displacement gauge, the error was converged within the range of 0.03 mm. In other words, the control positions acquired by executing the control position setting method may be considered to be almost identical to the actual measured values from the displacement gauge. Therefore, it can be seen that the control positions for each slot may be set very precisely by implementing the control position setting method according to the present embodiment.

It is needless to say that the substrate processing apparatus1and the control position setting method according to the present disclosure are not limited to the above-described embodiments and may take various modifications. For example, the above embodiment has exemplified the substrate processing apparatus1in which each stage211revolves around the rotating shaft23of the rotary table21and each stage211itself rotates. However, the substrate processing apparatus1is not limited to this configuration but may have a configuration in which each stage211does not rotate and only the rotary table21rotates (i.e. a configuration having only a revolution mechanism without a rotation mechanism).

Further, the substrate processing apparatus1may also perform the maintenance of the rotary table21using the touch position PT acquired by the control position setting method. In other words, the touch position PT is equivalent to the position (height position) of each surface211sof the rotary table21. Therefore, for example, when adjusting the height of the rotary table21for the replacement of the rotary table21, the user compares the touch position PT in the screen information100before and after the replacement of the rotary table21. This allows the user to easily and precisely adjust the height of the rotary table21, ensuring that the position of each placement surface211safter the replacement roughly matches the position before the replacement.

Summary

The technical ideas and effects of the present disclosure described in the above embodiment will be described below.

A substrate processing apparatus1according to a first aspect of the present disclosure includes a vacuum container11, a rotary table21rotatably provided within the vacuum container11, a stage211that places a substrate W thereon at a position away from a rotation center of the rotary table21, a lifter30that is displaced relative to the stage211to raise or lower the substrate W, and a controller90that controls an operation of the lifter30, wherein the controller90is configured to automatically set a control position in the operation of the lifter30, and wherein, in setting of the control position, the controller90controls (A) repeatedly raising the lifter30by a first pitch and then determining whether or not the lifter30has come into contact with the substrate W placed on the stage211, thereby detecting a position where the lifter30comes into contact with the substrate W and setting a next position (detailed adjustment start position) based on the detected position and (B) repeatedly raising the lifter30from the next position by a second pitch shorter than the first pitch and then determining whether or not the lifter30has come into contact with the substrate W placed on the stage211, thereby detecting a touch position PT where the lifter30comes into contact with the substrate W and calculating the control position based on the touch position PT.

According to the above, the substrate processing apparatus1may automatically set the control position, thereby reducing the user's burden in setting the control position of the lifter30. In particular, the substrate processing apparatus1may precisely set the control position of the lifter30in order to detect the touch position PT of the stage211with the short pitch in (B). Further, by obtaining the detailed adjustment start position through the driving of the lifter with the first pitch in (A), the substrate processing apparatus1may effectively reduce the number of times (B) is executed, leading to improved operational efficiency. Therefore, even when replacing the stage211during maintenance or the like, it is possible to efficiently set the control position of the lifter30to start substrate processing. For example, compared to the task of determining the touch position by visually confirming imaging information from the camera60, it is possible to shorten the operation time to less than half and to significantly reduce the user's burden.

Further, the control position is a position where a speed of the lifter30is switched when the lifter30paces the supported substrate W onto the stage211or when the lifter30lifts the substrate from the stage211. This allows the substrate processing apparatus1to smoothly acquire the control position required for speed control when raising or lowering the lifter30.

Further, the control position includes a load position PL set vertically below the substrate W placed on the stage211and an unload position PU set vertically above the substrate W placed on the stage211. This allows the substrate processing apparatus1to stably raise or lower the substrate W based on the set load position PL and unload position PU.

Further, the controller90calculates the unload position PU by adding an unload position adjustment value to the touch position PT detected in (B), and calculates the load position PL by further adding a load position adjustment value to the calculated unload position PU. This allows the controller90to easily calculate the load position PL and unload position PU, which are relative positions to the touch position PT.

Further, the next position (detailed adjustment start position) is a position obtained by adding an offset value in a lowering direction to the position where the lifter30comes into contact with the substrate W in (A). This allows the substrate processing apparatus1to smoothly obtain the next position in (B) to start (B).

Further, the substrate processing apparatus further includes an imaging device (camera60) that captures an image of the substrate W placed on the stage211from vertically above the lifter30, and wherein in (A), the controller90captures an image of the substrate W using the imaging device each time the lifter30is raised by the first pitch and and determines whether or not the lifter30has come into contact with the substrate W based on resulting imaging information, and in (B), the controller90captures an image of the substrate using the imaging device each time the lifter is raised by the second pitch, and determines whether or not the lifter30has come into contact with the substrate based on resulting imaging information. This allows the substrate processing apparatus1to effectively determine the contact between the substrate W and the lifter30.

Further, the controller90determines whether or not the lifter30has come into contact with the substrate W based on a change in a shadow of an outer edge of the substrate W in the imaging information when the substrate W is lifted from the stage211. As such, by utilizing the shadow of the outer edge of the substrate W, the controller90may determine the contact between the substrate W and the lifter30with sufficiently high precision.

Further, in both (A) and (B), the controller90counts the number of times an operation of raising the lifter30for each pitch is executed, and continues to raise the lifter when the execution count is less than a count threshold, but notifies an abnormality if the execution count is equal to or greater than the count threshold. This allows notifying the user of an error in which the lift pin31fails to come into contact with the substrate W due to an abnormality in the stage211, allowing the user to take a necessary action promptly.

Further, the rotary table21includes a plurality of stages211and is configured to rotate a plurality of substrates W, and the controller90sets the touch position PT and the control position by performing (A) and (B) for the plurality of stages211, calculates a difference in the set touch position PT between the plurality of stages211, determines a normality or abnormality in the plurality of stages211based on the calculated difference, and notifies the user when the abnormality is detected in the plurality of stages. This allows the substrate processing apparatus1to easily compare the height positions of the plurality of stages211.

A second aspect of the present disclosure relates to a control position setting method of setting a control position in an operation of a lifter30in a substrate processing apparatus1comprising a vacuum container11, a rotary table21rotatably provided within the vacuum container11, a stage211that places a substrate W thereon at a position away from a rotation center of the rotary table21, and the lifter30that is displaced relative to the stage211to raise or lower the substrate W, the method comprising: (A) repeatedly raising the lifter30by a first pitch and then determining whether or not the lifter30has come into contact with the substrate W placed on the stage211, thereby detecting a position where the lifter30comes into contact with the substrate W and setting a next position (detailed adjustment start position) based on the detected position; and (B) repeatedly raising the lifter30from the next position by a second pitch shorter than the first pitch and then determining whether or not the lifter30has come into contact with the substrate W placed on the stage211, thereby detecting a touch position PT where the lifter30comes into contact with the substrate and calculating the control position based on the touch position PT. Even in this case, the control position setting method allows for the accurate setting of the control position of the lifter30and improves the operational efficiency.

According to an aspect, it is possible to precisely set the control position of a lifter and to achieve an enhanced efficiency in operation.