Photoresist bottle replacement system

The present disclosure describes a method for replacing a photoresist (PR) bottle using a vehicle. An exemplary vehicle includes a processor configured to receive a request signal to replace a first PR bottle. The processor is also configured to transmit an order based on the request signal. The vehicle also includes a plurality of wheels configured to move the vehicle from the first location to a second location, and from the second location to the first location. The vehicle further includes a robotic arm configured to load, at the first location, the first PR bottle into a first container; load a second PR bottle in a second container; remove a cap from the second PR bottle and a socket from the first PR bottle; couple the socket of the first PR bottle to the second PR bottle; and unload the second PR bottle from the second container.

BACKGROUND

Photoresist (PR) is a crucial element in semiconductor industry. PR is used in various stages of semiconductor fabrication process for forming patterns on wafers. PR bottles (e.g., bottles that contains PR for semiconductor fabrication usage) have been manually replaced for PR refill/replacement. However, manual replacement of PR bottles can be time-consuming and costly, and can be susceptible to human mistakes and damages.

DETAILED DESCRIPTION

The following disclosure provides many different embodiments, or examples, for implementing different features of the provided subject matter. Specific examples of components and arrangements are described below to simplify the present disclosure. These are merely examples and are not intended to be limiting. In addition, the present disclosure repeats reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and, unless indicated otherwise, does not in itself dictate a relationship between the various embodiments and/or configurations discussed.

In semiconductor fabrication, PR is a crucial element for forming various patterns/features. PR is kept in PR bottles, which are distributed at different locations of a fabrication facility. When a PR bottle is low in PR or is empty, the PR bottles can be manually replaced/refilled. The replacement/refill of PR bottles can include the manually transporting the empty PR bottles to a specific location (e.g., warehouse) to refill/replace the PR bottles. The transport and refill/replacement of PR bottles can be susceptible to PR bottle damage, PR spill, and human error: this process can also be time-consuming and costly.

Embodiments of the present disclosure describe a system and a method to automatically transport PR bottles and replace an empty PR bottle with a filled PR bottle. The system includes a central controller, a vehicle, and a plurality of receiving devices. The central controller communicates with and controls the operation of the vehicle and the receiving devices. The vehicle, being controlled by the central controller, can automatically transport an empty PR bottle from a fabrication location to a location for PR bottle replacement (e.g., warehouse), replace the cap of a full PR bottle with the socket of the empty PR bottle, and transport the full PR bottle back to the fabrication location. A benefit, among others, includes that the transport and replacement/refill of PR bottles can be automated so that the transport and replacement/refill of PR bottles are less susceptible to uncertainties/errors caused by human operations. Being protected by a container and transported by the vehicle, the PR bottles are less susceptible to damage/spill/leakage, and the transport can be less time-consuming. Further, the PR bottles can be loaded and unloaded to the vehicle using automated means with improved stability, reducing the chances of PR bottle damages/spill/leakage. Further, the socket replacement process is more reliable and predictable by using a robotic arm. Less labor is thus needed for the loading, transport, and replacement of PR bottles.

FIG. 1illustrates an exemplary system100that can automatically transport and replace PR bottles, according to some embodiments. System100can include a vehicle120, a central controller130, receiving devices140-1and140-2, and communication networks113and114. Central controller130can communicate with and control vehicle120to move to a first location (e.g., a location where an empty PR bottle is located), load the empty PR bottle onto vehicle120, transport the loaded empty PR bottle to a second location (e.g., a location where a full PR bottle is located), load the full PR bottle onto vehicle120, take off the cap from the full PR bottle and the socket from the empty PR bottle, and place the socket onto the full PR bottle, according to some embodiments. Central controller130can also communicate with and control vehicle120to unload the empty PR bottle (e.g., at the second location), transport the full PR bottle back to the first location, and unload the full PR bottle, according to some embodiments. For ease of description, an “empty PR bottle” can stand for any PR bottle that is to be replaced, a “full PR bottle” can stand for any other PR bottle for replacing the empty PR bottle, and a “socket” can stand for the cap/socket (e.g., of the empty PR bottle) that a hose is fixed within. The hose can be a flexible tube, going through the socket, for conveying PR from the PR bottle to, e.g., a fabrication platform. Central controller130can be located at any suitable location. For example, central controller130can be inside or outside the fabrication facility, or can be installed on one or more vehicles120.

In some embodiments, vehicle120includes a vehicle body101, a plurality of wheels108, a robotic arm102, a plurality of rotatable stages109, a plurality of rotatable bases115connecting the rotatable stages109and vehicle body101, a supporting pillar112, an identification (ID) sensing device116, a supporting stage111, and an imaging device110. Vehicle120can be powered by power of various forms, such as DC current, AC current, battery, etc. For illustrative purposes, two wheels108-1and108-2, two rotatable stages109-1and109-2, and two rotatable bases115-1and115-2are shown. The plurality of wheels108can be designed to rotate and carry vehicle body101to different locations in the fabrication facility. The plurality of rotatable stages109can maintain stable in the same horizontal plane (e.g., the x-y plane). In some embodiments, the plurality of rotatable stages109are horizontally aligned in the same horizontal plane. For example, rotatable base115-1and rotatable stage109-1can be the same as or similar to rotatable base115-2and rotatable stage109-2, respectively, and the top surfaces of rotatable stages109-1and109-2can be horizontally aligned in the horizontal plane (e.g., having the same elevation from the ground). The plurality of rotatable stages109can fix the horizontal and vertical positions of the PR bottles placed thereon and ensure that PR bottles are at least substantially at a same elevation from the ground. The PR bottles can be located within the range in which imaging device110captures images of the PR bottles with sufficient resolution for further processing and recognition. Robotic arm120can rotate to clamp onto caps/sockets without touching the PR bottles. In some embodiments, rotatable bases115-1and115-2can each be connected to a motor that can drive rotatable stages109-1and109-2, respectively, to rotate clockwise and/or counter-clockwise in the same horizontal plane so that when robotic arm102clamps onto the cap/socket of a PR bottle placed on a rotatable stage109, a corresponding rotatable base115can drive rotatable stage109to rotate clockwise or counter-clockwise for robotic arm102to turn the cap/socket more easily.

ID sensing device116can include any suitable devices that can detect and verify that the correct PR bottles are placed on rotatable stages109. For example, the PR bottles and/or the containers (that hold the PR bottles) can include radio frequency ID (RFID) tags. ID sensing device116can include a (RFID) reader. ID sensing device116can detect a full PR bottle placed on rotatable stage109matches an empty PR bottle so that cap/socket replacement can be operated between the two PR bottles. The full PR bottle that matches the empty PR bottle can be any suitable PR bottle that is can replace the empty PR bottle. The full PR bottle can be filled with the same type of or a different type of PR as of the empty PR bottle. The full PR bottle can have the same dimension as or different dimensions than the empty PR bottle. In some embodiments, system100(e.g., central controller130, vehicle120, and/or receiving devices140) records a PR bottle and any other PR bottle (e.g., matching PR bottles) that can replace the PR bottle.

Imaging device110can be mounted/placed on supporting stage111to record and monitor that the hose and socket of the empty PR bottle are properly placed in the matching full PR bottle, according to some embodiments. Imaging device110can be any suitable device that can record images for a pattern recognition and/or an image recognition process. For example, one end of the hose can be connected with a weight (e.g., an object that is sufficiently heavy to immerse into the PR) that has a detectable shape/size (e.g., a shape/size that can be detected using a recognition function) so that when the weight sinks into the PR, the end of the hose that is connected with the weight can also immerse into the PR to allow sufficient PR to be drawn for fabrication operations. Meanwhile, imaging device110can record the position of the weight and an image recognition can be performed based on the recorded real-time position of the weight to ensure the end of the hose, with the weight, is properly positioned under the surface of the PR. In some embodiments, with the weight, the hose can be straightened and facing substantially upwardly. Imaging device110can also record the real-time positions of the caps and sockets, and image recognitions can be performed to ensure the caps and the sockets are properly taken off or placed on the suitable PR bottles. In some embodiments, imaging device110can include a dual charged-coupled device (CCD) camera and the image recognition can include a three-dimensional (3D) positioning process. For example, system100(e.g., vehicle120, central controller130, and/or receiving devices140) can recognize the position of the weight and/or compare the position (e.g., along the x-y plane and the z-axis) with a stored position to determine whether the weight and the socket have been placed properly (e.g., at the bottom of the PR and/or under the surface of the PR).

Supporting pillar112can be any suitable supporting structure with sufficient stiffness and strength to provide suitable positions/angles for ID sensing device116and imaging device110. Supporting stage111can be any suitable structure that can stably position imaging device110thereon. In some embodiments, imaging device110moves according to the movement of supporting stage111. In some embodiments, ID sensing device116is mounted along supporting pillar112and its position along a vertical axis (e.g., the z-axis) can be adjusted automatically/manually. In some embodiments, supporting pillar112can rotate clockwise and/or counter-clockwise to adjust the position of ID sensing device116. Accordingly, the position of ID sensing device116can be adjusted (e.g., vertically and/or horizontally) so that ID sensing device116can be placed at a desired angle/height to more accurately detect and verify the identification (e.g., ID numbers and/or RFIDs) of the PR bottles placed on rotatable stages109. In some embodiments, supporting pillar112can drive supporting stage111to rotate clockwise/counter-clockwise so that the orientation of imaging device110can be adjusted and imaging device110can face desired PR bottles (e.g., the PR bottles of which the caps/sockets are being replaced). In some embodiments, supporting pillar112can also extend along the vertical axis (e.g., the z-axis) so that the elevation of imaging device110can be adjusted to allow imaging device110to record features of different heights. For example, PR bottles of different height can be placed on rotatable stages109-1and109-2, and the positions and/or orientations of imaging device110can be automatically adjusted to monitor the replacement of the bottles' caps/sockets. That is, the positions and/or orientations of imaging device110can be adjusted based on the PR bottles placed on rotatable stages109.

Robotic arm102can include an arm base104, a first connecting portion103-1, a first arm portion105-1, a second connecting portion103-2, a second arm portion105-2, a third connecting portion103-3, an arm top portion106, a fourth connecting portion103-4, and a gripping portion107. Gripping portion107can include a plurality of clamping structures rotationally connected together.

Arm base104can be fixed on vehicle body101to provide support for structures/objects attached to arm base104. Arm base104can sustain a force/weight applied on robotic arm102. As shown inFIG. 1, first arm portion105-1can be connected to arm base104through first connecting portion103-1, second arm portion105-2can be connected to first arm portion105-1through second connecting portion103-2, arm top portion106can be connected to second arm portion105-2through third connecting portion103-3, and gripping portion107can be connected to arm top portion106through fourth connecting portion103-4. First arm portion105-1and second arm portion105-2can be of any suitable shape that can move in various directions and can be made of a suitable material of sufficient stiffness and strength. In some embodiments, first arm portion105-1and second arm portion105-2each has a pillar shape and includes a metal material (e.g., stainless steel). First connecting portion103-1, second connecting portion103-2, and third connecting portion103-3can jointly connect arm portions on both sides and allow connected arm portions to move horizontally and/or vertically (e.g., x- and z-directions, respectively). Arm top portion106can be of any suitable shape that can be connected to and can suspend gripping portion107so the clamping structures of gripping portion107can be aligned with one another in a same plane for clamping onto caps/sockets. In some embodiments, arm top portion106has an “L” shape, with one end connected to third connecting portion103-3and the other end connected to fourth connecting portion103-4. Clamping structures of gripping portion107can thus be suspended to fourth connecting portion103-4and can rotate in a horizontal plane (e.g., x-plane). In some embodiments, connecting portions103-1to103-4each include pivot connections and are made of materials with sufficient stiffness and strength such as metal (e.g., stainless steel).

Gripping portion107can include a plurality of clamping structures rotationally connected together. For illustrative purposes, two clamping structures107-1and107-2are shown. In the present disclosure, the term “rotationally connected” can refer to one end of each clamping structure being mounted together to allow the other ends of the clamping structures to rotate and grip on the cap/socket of PR bottles. The rotationally connected clamping structures can be suspended from fourth connecting portion103-4and can rotate about a vertical central line121(e.g., along the z-axis). In some embodiments, the rotationally connected clamping structures are positioned in a same horizontal plane and can rotate in the horizontal plane to grip on desired caps/sockets. In some embodiments, fourth connecting portion103-4includes a spring structure that allows gripping portion107to extend or withdraw vertically (e.g., adjust its position along the z-axis) when clamping caps/sockets. The position of a clamping structure can thus be adjusted horizontally and vertically. Gripping portion107can be made of suitable materials with sufficient stiffness and strength to sustain reaction force applied by clamped objects. In some embodiments, gripping portion107can be made of metal (e.g., stainless steel) and/or reinforced plastics.

Vehicle120can also include a control unit (not shown) that controls various operations of vehicle120. For example, the control unit can control the communication between vehicle120and central controller130, the automated loading and unloading of PR bottles, the moving of robotic arms102, the rotation of rotatable bases115, the detection of ID signals by ID sensing device116, the transmission and processing of the sensed ID signals, the recording of cap/socket replacement by imaging device110, and/or the transmission and processing of the recorded images. The control unit can include suitable software and hardware, such as computer programs stored in a memory, and a processor and related circuitry, to execute various operations. In some embodiments, vehicle120stores a map of the fabrication facility and is installed with suitable positioning systems, so that vehicle120can move in the fabrication facility following designated routes. For example, the control unit of vehicle120can include a global positioning system (GPS) receiver, a receiving device/program with a Bluetooth-based indoor positioning system, and/or a receiving device/program with a WiFi-based indoor positioning system for navigating in the fabrication facility according to the indoor map. The fabrication facility can include corresponding devices for the indoor positioning system, such as Bluetooth beacons and/or WiFi access points distributed at various locations for the indoor positioning functions. The control unit can be arranged at any suitable position of vehicle120. In some embodiments, the control unit is positioned in vehicle body101.

Central controller130can include any suitable computer system that controls the overall operation of vehicle120and receiving devices140. Receiving devices140(e.g., tablet140-1and cell phone140-2) can include any suitable portable device and can be used for communication with central controller130. In some embodiments, each receiving device140includes a processor and related circuitry for processing and responding to the notifications/commands transmitted by central controller130. For example, central controller130can receive real-time data from vehicle120and transmit notifications including the real-time status of vehicle120to receiving device140-1and/or140-2. Vehicle120can communicate with central controller130through communication network113, and receiving devices140can communicate with central controller130through communication network114. Communication networks113and114can each be a suitable wired or wireless communication means. In some embodiments, communication networks113and114include WiFi. Detail description of the computers/processors in vehicle120, central controller130, and receiving devices140are described below.

FIG. 2Aillustrates an overview200of an exemplary gripping portion, according to some embodiments. The gripping portion shown inFIG. 2Acan be the same as or similar to gripping portion107illustrated inFIG. 1. In some embodiments, the gripping portion includes two clamping structures107-1and107-2. The two clamping structures107-1and107-2can each include a clamp base (201-1and202-1) and a pair of clamps (201-2and202-2). A clamp base and its clamps can each be of any suitable shape for clamping caps/sockets of various sizes. In some embodiments, the clamps have the shape of prongs. In some embodiments, the clamp base and the clamps are made of suitable materials of sufficient stiffness and strength for gripping and moving clamped objects. For example, the clamp base and the clamps can be made of metal (e.g., stainless steel). The two clamping structures107-1and107-2can form a rigid connection at one end of the clamp bases. The two pairs of clamps201-2and202-2, at the other end, can be exposed to point at opposite directions for clamping onto objects. For ease of description,FIG. 2Ais illustrated in the x1-y1 plane, a plane formed by the connected clamping structures. The x1-axis is referred to as the longitudinal direction and the y1-axis is referred to as the lateral direction. For example purposes, the clamping structures are rigidly connected along the x1-axis.

In some embodiments, clamping structures107-1and107-2are connected through a hub structure208at one end. Hub structure208can include a suitable material with sufficient stiffness and strength to connect clamping structures107-1and107-2as one piece. Hub structure208can be connected to the arm top portion (e.g.,106inFIG. 1) through fourth connecting portion (e.g.,103-4inFIG. 1). In some embodiments, at least one of clamping structures107-1and107-2includes a connecting portion at one end of the clamp base opposite of the clamps for connecting the other clamping structure. In some embodiments, the two clamping structures107-1and107-2are welded together. In some embodiments, clamping structures107-1and107-2are similar or same clamping structures. In some embodiments, the gripping portion includes more than two clamping structures rigidly connected together, and the clamps can be pointed in various different directions.

Clamping structures107-1and107-2can rotate about vertical central line121ofFIG. 1(viewed as a dot along the vertical direction/z-axis at the center point of the gripping portion in the x1-y1 plane) in the x1-y1 plane so that a desired pair of clamps can face and approach the cap/socket to be operated on. In some embodiments, the two clamping structures107-1and107-2move/rotate as one piece along line207(ofFIG. 2A), which lies across the center point of clamping structures107-1and107-2along the x1-axis. In some embodiments, the two clamping structures107-1and107-2move/rotate as one piece along line209, which lies across the center point of clamping structures107-1and107-2along the y1-axis. In some embodiments, the center points of clamping structures107-1and107-2along the x1-axis and along the y1-axis each overlaps with vertical central line121.

In some embodiments, clamping bases (e.g.,201-1and202-1) are rigidly connected together and clamps (e.g.,201-2and202-2) are movable laterally along the y1-direction (indicated by the double-headed arrows). The central controller (e.g.,130inFIG. 1) and/or the vehicle (e.g.,120inFIG. 1) can control the movement of clamps to widen or reduce the spacing between the two prongs so that the desired cap/socket can be placed in the spacing before the clamps contact the cap/socket.

FIG. 2Billustrates a top view250of clamping structure107-2clamping onto a cap/socket, according to some embodiments. Element220can represent a cap or a socket of a PR bottle. Cap/socket220can be of different sizes and clamps202-2can move along the y1-axis to adjust to the size of cap/socket220. Accordingly, clamp structure107-2can contact and tightly fix/couple cap/socket220on the outer sidewall of cap/socket220. Further, central controller and/or vehicle can control clamping structure107-2to rotate cap/socket220in the x1-y1 plane, and cap/socket220can be rotated on or off a PR bottle.

FIGS. 3A and 3Bare illustrations300and350of an exemplary vehicle in an operation of replacing cap/socket of PR bottles, according to some embodiments. Compared to vehicle120illustrated inFIG. 1, the vehicle inFIGS. 3A and 3Beach further includes two PR bottles (e.g.,305-1and305-2), each in a container302, loaded on rotatable stages109-1and109-2. In some embodiments, containers302are part of the system (e.g., system100shown inFIG. 1). For illustrative purposes, PR bottle305-2in container302-2and on rotatable stage109-2represents an empty PR bottle, and PR bottle305-1in container302-1and on rotatable stage109-1represents a full PR bottle. PR bottle305-2can include a socket301-2which has a hose307inserted through. A weight310can be attached to one end of hose307to allow hose to immerse in PR properly. PR bottle305-1can include a cap301-1. As shown inFIGS. 3A and 3B, each PR bottle (e.g.,305-1and305-2) is placed in a respective container (e.g.,302-1and302-2), and the container is loaded on the respective rotatable stage (e.g.,109-1and109-2). Each container can include a lid (e.g.,303-1and303-2), a container body (e.g.,304-1and304-2), and a collision-preventing portion (e.g.,308-1and308-2). Each container can further include a carrier-insertion portion (e.g.,309-1and309-2) fixed/attached at the bottom of the container, where the carrier-insertion portion can include a plurality of insertion openings (e.g.,306-1and306-2). For illustrative purposes, two insertion openings are shown.

A PR bottle (e.g.,305-1or305-2) can be secured in the corresponding container (e.g.,302-1or302-2) during fabrication and PR can be drawn out of the PR bottle through hose307. Lid (e.g.,303-1or303-2) can be maintained closed to secure the position and orientation of the PR bottle in the container, and collision-preventing portion (e.g.,308-1or308-2) can further buffer any impact caused by the PR bottle and avoid any collision between the PR bottle and parts of the container. When PR in PR bottle305-2is low, a signal can be transmitted to the central controller requesting a replacement of PR bottle305-2. In some embodiments, the signal can include the location of PR bottle305-2(e.g., the first location), the time, the ID number of container302-2/PR bottle305-2, and the approximately percentage of the remaining PR. The request can also be manually transmitted (e.g., by a technician operating on the PR bottle305-2) to a receiving device (e.g., same as or similar to receiving device140shown inFIG. 1) or automatically transmitted by container302-2. In some embodiments, container302-2includes a PR detecting mechanism that can automatically detect the remaining PR in PR bottle305-2, e.g., based on weight of PR bottle305-2. In some embodiments, container302-2includes an integrated circuit (IC) that can communicate with the vehicle and/or the central controller.

When receiving the request, the central controller can transmit the vehicle to the location of PR bottle305-2. The vehicle can follow the stored indoor map and choose a designated route to reach the location, according to some embodiments. In some embodiments, after PR bottle305-2is loaded onto rotatable stage109-2, the central controller can be notified. In some embodiments, the vehicle can approach PR bottle305-2and determine an optimized distance between the vehicle and PR bottle305-2, and robotic arm102can automatically insert clamping structures (e.g.,107-1or107-2) into insertion openings306-2to load/raise/lift container302-2onto rotatable stage109-2, and the vehicle can transmit a vehicle status update to the central controller about the loading of PR bottle305-2. In some embodiments, ID sensing device116detects the ID number of container302-2after it is placed on rotatable stage109-2and transmits a vehicle status update, including the ID number of container302-2, to the central controller about the loading of PR bottle305-2. The central controller can then verify the ID number of container302-2matches the request and send the vehicle to the location that PR bottle305-1is stored (e.g., the second location). In some embodiments, the vehicle includes, e.g., a command button and/or a keypad, in which a second location can be entered by pressing the command button and/or typing on the keypad. Further, the vehicle can communicate with the central controller to update the status of the vehicle, e.g., the loading of PR bottle305-2and the transporting of PR bottle305-2to the second location.

After the vehicle arrives at the second location, PR bottle305-1(e.g., full in PR and contained in container302-1) can be loaded onto rotatable stage109-1, in a similar manner (manual or automated loading) as described above. In some embodiments, PR bottles305-1and305-2are substantially fixed onto rotatable stages109-1and109-2, respectively, to allow rotating of socket301-2and cap301-1. For example, rotatable stages109-1and109-2can each include features/patterns (e.g., snaps and/or hooks) to limit the movement of containers302-1and302-2. In another example, the friction between a rotatable stage (e.g.,109-1or109-2) and the corresponding bottom of carrier-insertion portion (e.g.,309-1or309-2) can be sufficiently large to effectively limit the movement and sliding of the corresponding container (e.g.,302-1or302-2). In some embodiments, ID sensing device116can verify the ID number of container305-1to ensure PR bottle305-1matches PR bottle305-1. In some embodiments, when it is detected that PR bottle305-1is not a match to PR bottle305-2, the central controller commands (e.g., transmits instructions to) the vehicle to unload container302-1and search for the matching PR bottle. In some embodiments, when no matching PR bottle is located, the vehicle notifies the central controller and the central controller transmits a notification to one or more receiving devices to request additional assistance (e.g., from a technician) to locate the matching PR bottle. In some embodiments, when no matching PR bottle is located, a status update can be transmitted to the central controller reporting the insufficient storage of the matching PR bottle, and the central controller automatically requests for ordering of additional matching PR bottle. In some embodiments, the second location is a warehouse for storing empty and/or full PR bottles.

As shown inFIGS. 3A and 3B, the vehicle can first remove the cap from the full PR bottle (e.g., cap301-1from PR bottle305-1) and then remove the socket from the empty PR bottle (e.g., socket301-2from PR bottle305-2), to avoid entanglement or contact between robotic arm102and hose307. For similar reasons, the vehicle can point a clamping structure (e.g., clamping structure107-1) towards cap301-1of PR bottle305-1and clamp onto cap301-1on the outer sidewall. When clamps (e.g.,201-2inFIG. 2A) of clamping structure107-1adjust to the size of cap301-1and tightly clamps onto the outer sidewall of cap301-1, rotatable base115-1can drive rotatable stage109-1to turn, e.g., clockwise, so that the relative movement between cap301-1and PR bottle305-1can be counter-clockwise, and cap301-1can be taken off from PR bottle305-1. Further, socket301-2can be taken off from PR bottle305-2. In some embodiments, gripping structure107removes socket301-2when carrying the removed cap301-1, as shown inFIG. 3B. In the present disclosure, it is assumed that clock-wise relative movement between the cap/socket and the PR bottle can fix/couple the cap/socket onto the PR bottle and counter clock-wise relative movement between the cap/socket and the PR bottle can remove the cap/socket from the PR bottle.

Further, robotic arm102can lift socket301-2, cap301-1, and hose307to avoid contact between hose307and PR bottles (e.g.,305-1and305-2), and place hose307into PR bottle305-1. After hose307is properly placed in PR bottle305-1, rotatable base115-1can first drive rotatable stage109-1to rotate clockwise so that the relative movement between socket301-2and PR bottle305-1is counter-clockwise, allowing socket301-2to match to the thread of PR bottle305-1. After socket301-2matches to the thread of PR bottle305-1, rotatable base115-1can drive rotatable stage109-1to rotate counter-clockwise, so that the relative movement between socket301-2and PR bottle305-1is clockwise, allowing socket301-2to screw into the thread of PR bottle305-1. Clamping structure107-1can continue to screw socket301-2and fix/couple socket301-2onto PR bottle305-1. Meanwhile, rotatable base115-1can keep rotating counter-clockwise to allow socket301-2to tightly fix/couple onto PR bottle305-1. Optionally, after socket301-2is screwed onto PR bottle305-1, clamps of clamping structure107-1can move laterally (e.g., along the y1-axis inFIGS. 2A and 2B) to release socket301-2. Optionally, after releasing socket301-2, robotic arm102can rotate gripping portion107and move clamping structure107-1and cap301-1towards PR bottle305-2. Robotic arm102can further screw cap301-1onto PR bottle305-2. The operation process to screw cap301-1onto PR bottle305-2can be similar to the operation of socket301-2and is not repeated herein.

The cap/socket replacement operation can be controlled by the central controller (e.g., central controller130inFIG. 1) and/or the vehicle, and executed by different parts of the vehicle. For example, when the vehicle detects two matching PR bottles (e.g.,305-1and305-2) are placed properly on the rotatable stages (e.g.,109-1and109-2), the control unit of the vehicle can control robotic arm102to remove cap301-1of PR bottle305-1and socket301-2of PR bottle305-2. The control unit can monitor the operation through imaging device110. In an example, the control unit can monitor the cap/socket replacement through imaging device110by monitoring the position of weight310. In some embodiments, imaging device110records and transmits the real-time images of weight310to the control unit and/or the central controller, and the control unit and/or the central controller can perform an image recognition process to determine whether weight310is taken out of PR bottle305-2, contacting PR bottles305-1and305-2, or placed in PR bottle305-1. That is, the position of weight310is precisely monitored and controlled to ensure the cap/socket replacement process is performed properly. In some embodiments, weight310can touch the bottom of PR bottle305-2to be considered being properly placed. In some embodiments, imaging device110includes a dual CCD camera, and the control unit and/or the central controller cross match the images of weight310along the x-axis, the y-axis, and/or the z-axis to determine the position of weight310(e.g., a 3D positioning method).

Further, during the cap/socket replacement process, the control unit and/or the central controller can perform torque control when clamping structures (e.g.,107-1and107-2) are turning the cap/socket. The timing and magnitude of the torque, and the direction of the twist applied on rotatable bases (e.g.,115-1and115-2) can be determined and controlled by the control unit and/or the central controller. In some embodiments, some parameters are predetermined and stored in the control unit and/or the central controller to enable the operation process to be more predictable/controllable. For example, the distance between the PR bottles (e.g.,305-1and305-2), the orientations of the PR bottles, and the dimensions of the containers (e.g.,302-1and302-2) can be predetermined and stored in the control unit and/or the central controller. Thus, the control unit and/or the central controller can more precisely control and monitor the placement and movements of parts during the operation.

Further, after the cap/socket replacement process is completed, the vehicle can unload container302-2and PR bottle305-2and/or the vehicle can transmit a status update (e.g., including the completion of cap/socket replacement, the time, and the ID numbers of the containers) to the central controller. The central controller can also transmit a notification (e.g., including the status update) to one or more receiving devices. The central controller can further transmit the location of the vehicle's next destination to the control unit or the vehicle can automatically return to the first location. The vehicle can transport container302-1and PR bottle305-1to the designated location and unload container302-1and PR bottle305-1at the location.

For illustrative purposes, two containers/PR bottles are shown to describe the operation. In some embodiments, more than two containers/PR bottles can be loaded onto the vehicle for cap/socket replacement. In some embodiments, the vehicle can transport to different locations to load more than two containers/PR bottles. In some embodiments, the dimensions of containers/PR bottles vary. The difference in dimensions can be stored in the control unit and/or the central controller in the form of ID numbers. Thus, when containers/PR bottles of various dimensions are loaded onto the vehicle, the control unit and/or central controller can detect the differences through, e.g., ID sensing device116. The movement of robotic arm102can be adjusted accordingly.

FIG. 4illustrates an exemplary PR bottle replacement method/process400using the system disclosed by the present disclosure, according to some embodiments. In some embodiments, operations of method400can be performed in a different order. Variations of method400are within the scope of the present disclosure.

In operation401, a vehicle receives a request signal indicating a PR bottle is low in PR (e.g., an empty PR bottle). The vehicle can generate orders based on the request signal and control the operation of different parts of the vehicle based on the orders. In some embodiments, the request signal can be transmitted from the container that contains the PR bottle low in PR and/or from the receiving device that discovers the PR bottle low in PR. In some embodiments, the request signal is transmitted to the central controller, and the central controller can further transmit a command to a vehicle for PR bottle refill/replacement. The request signal can include detailed information of the empty PR bottle such as the location of the empty PR bottle (e.g., the first location), the time of the request, the ID number of the empty PR bottle, etc. In some embodiments, the ID number of a PR bottle is uniquely stored in system. The ID number can include any suitable label/code such as a string of numbers/characters, a RFID, a bar code, etc. The ID number can reflect the type of PR contained in the PR bottle, the dimensions of the PR bottle, etc. The ID number can be imprinted on the PR bottle and/or the container with the PR bottle. In some embodiments, the ID number can be scanned/read out by a corresponding scanner/reader such as a RFID reader, bar code reader, etc. Details of the system can be referred to the description ofFIG. 1.

In operation402, the vehicle moves to the location of the empty PR bottle upon receiving the request signal and loads the empty PR bottle onto the vehicle. In some embodiments, commands including the coordinates of the first location and the ID number of the empty PR bottle are transmitted to a vehicle. After receiving the commands, the vehicle can approach the first location by choosing a designated route according to the coordinates and an indoor map. In some embodiments, the central controller receives the request signal and commands (e.g., transmits instructions to) the vehicle to move to the location of the empty PR bottle. Details of the vehicle can be referred to the description ofFIG. 1.

In operation403, the vehicle transports the empty PR bottle to a location for PR bottle replacement and loads a full PR bottle onto the vehicle at this location. In some embodiments, after arriving at the first location, the empty PR bottle and its corresponding container can be loaded onto the vehicle manually (e.g., by a technician) or automatically (e.g., by the vehicle). The vehicle can verify the identification of the empty PR bottle by scanning the ID number on the container and/or on the empty PR bottle. In some embodiments, after loading the container and verifying the ID number of the PR bottle, the vehicle transports the empty PR bottle and its corresponding container to the second location (e.g., a warehouse) and a full PR bottle and its corresponding container is loaded onto the vehicle manually or automatically. Similarly, the vehicle can verify the identification of the full PR bottle by scanning the ID number on the container and/or on the full PR bottle. In some embodiments, the central controller commands (e.g., transmits instructions to) the vehicle to transport the empty PR bottle and load the full PR bottle. Details of the process can be referred to the description ofFIGS. 3A and 3B.

In operation404, the vehicle removes the cap of the full PR bottle and couples the socket of the empty PR bottle on the full PR bottle. In some embodiments, the vehicle rotates the rotatable stages that support and fix the PR bottles to facilitate the removal and replacement of the cap and the socket. In some embodiments, the cap of the full PR bottle is removed, and the socket (e.g., along with the hose and the weight) of the empty PR bottle is taken out from the empty PR bottle and placed into the full PR bottle. To avoid contact and entanglement with the hose, in some embodiments, the cap and the socket are clamped onto from the outer sidewall. In some embodiments, the imaging device of the vehicle can be used to monitor the real-time placement of the socket by performing 3D positioning of the weight. After the socket, the hose, and the weight are properly placed onto the full PR bottle, the socket can be turned to be fixed onto the full PR bottle. In some embodiments, the status of the empty/full PR bottle in the system is updated. In some embodiments, the central controller commands (e.g., transmits instructions to) the vehicle to remove the cap of the full PR bottle and place the socket of the empty PR bottle on the full PR bottle. Details of the process can be referred to the description ofFIGS. 3A and 3B.

In operation405, the vehicle transports the full PR bottle back to the first location. After the replacement of the socket is completed, in some embodiments, the vehicle transports the full PR bottle to the first location where the empty PR bottle was loaded. The full PR bottle can then be unloaded manually or automatically. In some embodiments, the status of the empty/full PR bottle in the system is updated. In some embodiments, the central controller commands (e.g., transmits instructions to) the vehicle to transport the full PR bottle back to the first location. Details of the process can be referred to the description ofFIGS. 3A and 3B.

By using the disclosed apparatus and method, the loading/unloading, transport, and replacement of empty PR bottles can be automated, and less labor is needed. The automated operation can reduce the number of PR bottles that are damaged during the replacement process, and the vehicle and the container can reduce the chances of PR bottle damages and leakage. The accuracy of the replacement process can also be improved. Further, it takes less time to replace the empty PR bottles. Thus, replacing empty PR bottles can be less costly.

FIG. 5is an illustration of an example computer system500in which various embodiments of the present disclosure can be implemented, according to some embodiments. Computer system can be used in the control unit of the vehicle, the IC of the container, the receiving devices, and the central controller, as described above. Computer system500can be any well-known computer capable of performing the functions and operations described herein. For example, and without limitation, computer system500can be capable of processing and transmitting signals. Computer system500can be used, for example, to execute one or more functions of the vehicle, which describes example operations of communications amongst different parts of the vehicle and between the vehicle and the central controller.

Computer system500includes one or more processors (also called central processing units, or CPUs), such as a processor504. Processor504is connected to a communication infrastructure or bus506. Computer system500also includes input/output device(s)503, such as monitors, keyboards, pointing devices, etc., that communicate with communication infrastructure or bus506through input/output interface(s)502. Computer system500can receive instructions to implement functions and operations described herein—e.g., functions of the vehicle and method400—via input/output device(s)503. Computer system500also includes a main or primary memory508, such as random access memory (RAM). Main memory508can include one or more levels of cache. Main memory508has stored therein control logic (e.g., computer software) and/or data. In some embodiments, the control logic (e.g., computer software) and/or data can include one or more of the functions described above with respect to the container.

Computer system500can also include one or more secondary storage devices or memory510. Secondary memory510can include, for example, a hard disk drive512and/or a removable storage device or drive514. Removable storage drive514can be a floppy disk drive, a magnetic tape drive, a compact disk drive, an optical storage device, tape backup device, and/or any other storage device/drive.

Removable storage drive514can interact with a removable storage unit518. Removable storage unit518includes a computer usable or readable storage device having stored thereon computer software (control logic) and/or data. Removable storage unit518can be a floppy disk, magnetic tape, compact disk, DVD, optical storage disk, and/or any other computer data storage device. Removable storage drive514reads from and/or writes to removable storage unit518in a well-known manner.

According to some embodiments, secondary memory510can include other means, instrumentalities or other approaches for allowing computer programs and/or other instructions and/or data to be accessed by computer system500. Such means, instrumentalities or other approaches can include, for example, a removable storage unit522and an interface520. Examples of the removable storage unit522and the interface520can include a program cartridge and cartridge interface (such as that found in video game devices), a removable memory chip (such as an EPROM or PROM) and associated socket, a memory stick and USB port, a memory card and associated memory card slot, and/or any other removable storage unit and associated interface. In some embodiments, secondary memory510, removable storage unit518, and/or removable storage unit522can include one or more of the functions described above with respect to the container.

Computer system500can further include a communication or network interface524. Communication interface524enables computer system500to communicate and interact with any combination of remote devices, remote networks, remote entities, etc. (individually and collectively referenced by reference number528). For example, communication interface524can allow computer system500to communicate with remote devices528over communications path526, which can be wired and/or wireless, and which can include any combination of LANs, WANs, the Internet, etc. Control logic and/or data can be transmitted to and from computer system500via communication path526.

The functions/operations in the preceding embodiments can be implemented in a wide variety of configurations and architectures. Therefore, some or all of the operations in the preceding embodiments—e.g., functions of the vehicle and the central controller, and method400—can be performed in hardware, in software or both. In some embodiments, a tangible apparatus or article of manufacture including a tangible computer useable or readable medium having control logic (software) stored thereon is also referred to herein as a computer program product or program storage device. This includes, but is not limited to, computer system500, main memory508, secondary memory510and removable storage units518and522, as well as tangible articles of manufacture embodying any combination of the foregoing. Such control logic, when executed by one or more data processing devices (such as computer system500), causes such data processing devices to operate as described herein. In some embodiments, computer system500includes hardware/equipment for the manufacturing of photomasks and circuit fabrication. For example, the hardware/equipment can be connected to or be part of element528(remote device(s), network(s), entity(ies)528) of computer system500.

Embodiments of the present disclosure describe a system and a method to automatically transport PR bottles and replace an empty PR bottle with a filled PR bottle. The system includes a central controller, a vehicle, and a plurality of receiving devices. The central controller communicates with and controls the operation of the vehicle and the receiving devices. The vehicle, being controlled by the central controller, can automatically transport an empty PR bottle from a fabrication location to a location for PR bottle replacement (e.g., warehouse), replace the cap of a full PR bottle with the socket of the empty PR bottle, and transport the full PR bottle back to the fabrication location. A benefit, among others, includes that the transport and replacement/refill of PR bottles can be automated so that the transport and replacement/refill of PR bottles are less susceptible to uncertainties/errors caused by human operations. Being protected by a container and transported by the vehicle, the PR bottles are less susceptible to damage/spill/leakage, and the transport can be less time-consuming. Further, the PR bottles can be loaded and unloaded to the vehicle using automated means with improved stability, reducing the chances of PR bottle damages/spill/leakage. Further, the socket replacement process is more reliable and predictable by using a robotic arm. Less labor is thus needed for the loading, transport, and replacement of PR bottles.

In some embodiments, a method for replacing a PR bottle using a vehicle is provided. The method includes receiving a request signal for replacing a first PR bottle. The request signal includes a first location associated with the first PR bottle. The method also includes moving to the first location, loading the first PR bottle, transporting the first PR bottle to a second location associated with a second PR bottle, and loading the second PR bottle. The method further includes removing a cap from the second PR bottle and a socket from the first PR bottle, coupling the socket of the first PR bottle to the second PR bottle, and transporting the second PR bottle to the first location.

In some embodiments, a vehicle provided by the present disclosure includes a processor configured to receive a request signal to replace a first PR bottle. The request signal includes a first location associated with the first PR bottle. The processor is also configured to transmit an order based on the request signal. The vehicle also includes a plurality of wheels configured to move the vehicle from the first location to a second location, and from the second location to the first location. The vehicle further includes a robotic arm configured to load, at the first location, the first PR bottle into a first container, load, at the second location, a second PR bottle in a second container, remove a cap from the second PR bottle and a socket from the first PR bottle, couple the socket of the first PR bottle to the second PR bottle, and unload, at the first location, the second PR bottle from the second container.

In some embodiments, a computer system for replacing a PR bottle includes a memory configured to store a program and data for replacing the PR bottle and a processor configured to receive a request signal for replacing a first PR bottle. The request signal includes a first location associated with a first PR bottle. The processor is further configured to send a vehicle to the first location and control the vehicle to load the first PR bottle onto the vehicle, transport the first PR bottle to a second location where a second PR bottle is located, and load the second PR bottle onto the vehicle. The processor is further configured to remove a cap of the second PR bottle and a socket of the first PR bottle, couple the socket of the first PR bottle onto the second PR bottle, and transport the second PR bottle to the first location.

It is to be appreciated that the Detailed Description section, and not the Abstract of the Disclosure, is intended to be used to interpret the claims. The Abstract of the Disclosure section may set forth one or more but not all exemplary embodiments contemplated and thus, are not intended to be limiting to the subjoined claims.