Substrate processing apparatus

A substrate processing apparatus includes: a processing chamber; a substrate holder that is disposed in the processing chamber and holds a substrate; a processing liquid supply that supplies a processing liquid to the substrate held in the substrate holder; an infrared camera that acquires an infrared image of the processing chamber; and a controller that detects at least a state of the processing liquid based on the infrared image and monitors presence/absence of an abnormality.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a national phase of PCT application No. PCT/JP2019/000985, filed on 16 Jan. 2019, which claims priority from Japanese Patent Application No. 2018-011845, filed on 26 Jan. 2018, all of which are incorporated herein by reference.

TECHNICAL FIELD

The present disclosure relates to a substrate processing apparatus that performs a liquid processing on a substrate.

BACKGROUND

During a liquid processing of a substrate, the positional deviation of a nozzle that ejects the processing liquid, dripping of the liquid from the nozzle, splash of the liquid of the substrate, or the like may cause a product defect. As a result, it may be required that a substrate processing apparatus is equipped with the function of monitoring the presence/absence of the abnormalities.

As for such an abnormality detection technology, for example, a method is known in which the nozzle position is monitored by an encoder that detects the position of a drive arm to which the nozzle is attached. Further, a technology is known in which the ejection state of the processing liquid is captured by a charge-coupled device (CCD) sensor, and the ejection amount of the processing liquid is monitored by performing an imaging processing on the captured image (see, Patent Document 1).

PRIOR ART DOCUMENT

Patent Document

SUMMARY OF THE INVENTION

Problem to be Solved

However, in the technology in the related art, the presence/absence of an abnormality that may cause a product defect may not be appropriately monitored. For example, in case of monitoring the position of the drive arm by the encoder, when a problem such as loosening of a screw of the driving unit occurs, the actual position of the drive arm may be deviated from the position indicated by the encoder value.

Further, since the captured image used in the device disclosed in Patent Document 1 is a visible light image, the monitoring technology disclosed in Patent Document 1 may not be used in principle under the situation where the substrate is not illuminated with visible light. Particularly recently, it is worried that the substrate (e.g., a copper film) may be damaged by irradiation of visible light, or degree of a liquid processing (e.g., an etching amount of an oxide film) may be changed by the irradiation of visible light, and thus, there is also an increasing number of cases where the liquid processing of the substrate is performed while the light is turned off. In this case, the monitoring technology disclosed in Patent Document 1 using a visible light image may not be used in the first place.

The present disclosure has been made under such circumstances and is to provide a technology capable of detecting presence/absence of an abnormality of a liquid processing, even under a situation where a substrate is not illuminated with visible light.

Means to Solve the Problem

An aspect of the present disclosure is a substrate processing apparatus including: a processing chamber; a substrate holder that is disposed in the processing chamber and holds a substrate; a processing liquid supply that supplies a processing liquid to the substrate held in the substrate holder; an infrared camera that acquires an infrared image of the processing chamber; and a controller that detects at least a state of the processing liquid based on the infrared image and monitors presence/absence of an abnormality.

Effect of the Invention

According to the present disclosure, it is possible to detect presence/absence of an abnormality, even under a situation where a substrate is not illuminated with visible light.

DETAILED DESCRIPTION TO EXECUTE THE INVENTION

Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. First, descriptions will be made on a typical example of a substrate processing system to which the present disclosure may be applied.

FIG.1is a view illustrating a schematic configuration of a substrate processing system according to an embodiment. In the following, in order to clarify positional relationships, the X-axis, Y-axis, and Z-axis are defined as being orthogonal to each other. The positive Z-axis direction is regarded as a vertically upward direction.

As illustrated inFIG.1, a substrate processing system1includes a carry-in/out station2and a processing station3. The carry-in/out station2and the processing station3are provided adjacent to each other.

The carry-in/out station2is provided with a carrier placing section11and a transfer section12. In the carrier placing section11, a plurality of carriers C are placed to horizontally accommodate a plurality of substrates, i.e., semiconductor wafers (hereinafter, “wafers W”) in the present embodiment.

The transfer section12is provided adjacent to the carrier placing section11, and provided with a substrate transfer device13and a delivery unit14. The substrate transfer device13is provided with a wafer holding mechanism configured to hold the wafer W. Further, the substrate transfer device13is movable horizontally and vertically and pivotable around a vertical axis, and transfers the wafers W between the carriers C and the delivery unit14by using the wafer holding mechanism.

The processing station3is provided adjacent to the transfer section12. The processing station3is provided with a transfer section15and a plurality of processing units16. The plurality of processing units16are disposed at both sides of the transfer section15.

The transfer section15is provided with a substrate transfer device17therein. The substrate transfer device17is provided with a wafer holding mechanism configured to hold the wafer W. Further, the substrate transfer device17is movable horizontally and vertically and pivotable around a vertical axis. The substrate transfer device17transfers the wafers W between the delivery unit14and the processing units16by using the wafer holding mechanism.

The processing units16perform a predetermined substrate processing on the wafer W transferred by the substrate transfer device17.

Further, the liquid processing system1is provided with a control device4. The control device4is, for example, a computer, and includes a controller18and a storage unit19. The storage unit19stores a program that controls various processings performed in the substrate processing system1. The controller18controls the operations of the liquid processing system1by reading and executing the program stored in the storage unit19.

Further, the program may be recorded in a computer-readable recording medium, and installed from the recording medium to the storage unit19of the control device4. The computer-readable recording medium may be, for example, a hard disk (HD), a flexible disk (FD), a compact disk (CD), a magnet optical disk (MO), or a memory card.

In the substrate processing system1configured as described above, the substrate transfer device13of the carry-in/out station2first takes out a wafer W from a carrier C placed in the carrier placing section11, and then, places the taken wafer W on the delivery unit14. The wafer W placed on the delivery unit14is taken out from the delivery unit14by the substrate transfer device17of the processing station3, and carried into a processing unit16.

The wafer W carried into the processing unit16is processed by the processing unit16, and then, carried out from the processing unit16and placed on the delivery unit14by the substrate transfer device17. The processed wafer W placed on the delivery unit14returns to the carrier C of the carrier placing section11by the substrate transfer device13.

As illustrated inFIG.2, the processing unit16is provided with a chamber20, a substrate holding mechanism30, a processing fluid supply40, and a recovery cup50.

The chamber20accommodates the substrate holding mechanism30, the processing fluid supply40, and the recovery cup50. A fan filter unit (FFU)21is provided on the ceiling of the chamber20. The FFU21forms a downflow in the chamber20.

The substrate holding mechanism30is provided with a holder31, a column unit32, and a driving unit33. The holder31holds the wafer W horizontally. The column unit32is a vertically extending member, and has a base end portion supported rotatably by the driving unit33and a tip end portion supporting the holder31horizontally. The driving unit33rotates the column unit32around the vertical axis. The substrate holding mechanism30rotates the column unit32by using the driving unit33, so that the holder31supported by the column unit32is rotated, and thus, the wafer W held in the holder31is rotated.

The processing fluid supply40supplies a processing fluid onto the wafer W. The processing fluid supply40is connected to a processing fluid source70.

The recovery cup50is disposed to surround the holder31, and collects the processing liquid scattered from the wafer W by the rotation of the holder31. A drain port51is formed on the bottom of the recovery cup50, and the processing liquid collected by the recovery cup50is released from the drain port51to the outside of the processing unit16. Further, an exhaust port52is formed on the bottom of the recovery cup50to release a gas supplied from the FFU21to the outside of the processing unit16.

As described above, the substrate processing system1is provided with the plurality of processing units (substrate processing apparatuses)16, and each of the processing units16is provided with the chamber (processing chamber)20, the holder (substrate holder)31that is disposed in the chamber20and holds the wafer (substrate) W, and the processing fluid supply (processing liquid supply)40that supplies the processing liquid to the wafer W held in the holder31. The processing unit16according to the embodiment further includes an infrared camera that acquires an infrared image of the inside of the chamber20, and the control device (controller)4detects at least a state of the processing liquid based on the infrared image and monitors presence/absence of an abnormality. The infrared camera60performs various operations such as image capturing under the control of the control device4(particularly, a main control unit to be described later).

Hereinafter, a typical example of abnormality monitoring using an infrared image will be described. Although a plurality of typical examples will be described below, the control device4may monitor the presence/absence of one type of abnormality, or may monitor the presence/absence of multiple types of abnormality.

FIG.3is a view for explaining a first typical example of abnormality monitoring using an infrared image, and illustrates an arrangement of the infrared camera60, the processing fluid supply40, and the wafer W.FIG.4is a view illustrating an example of an infrared image I acquired by the infrared camera60illustrated inFIG.3.FIG.5is a functional block diagram of the control device4according to the first typical example of the abnormality monitoring using an infrared image.

In the typical example, the presence/absence of an abnormality with respect to the position of the processing fluid supply40that ejects the processing liquid L is monitored by the control device4.

The processing fluid supply40illustrated inFIG.3includes a nozzle41, and the processing liquid L from the processing fluid source70is ejected from the nozzle41. The nozzle41is fixedly attached to a drive arm42, and the drive arm42is pivotally provided under the control of the control device4. Therefore, the placing position of the nozzle41is determined in accordance with a pivot operation of the drive arm42. For example, when the wafer W is attached to or detached from the holder31, the drive arm42disposes the nozzle41at a position that does not interfere with the wafer W (i.e., a standby position). Meanwhile, when the processing liquid L is ejected toward the wafer W from the nozzle41, the drive arm42disposes the nozzle41at a predetermined position (i.e., an ejection position) above the waver W, so that the processing liquid L is ejected from the nozzle41toward a desired position of the processing surface (i.e., the upper surface) of the wafer W.

The nozzle41(processing fluid supply40) ejects the processing liquid L having a temperature higher than a temperature of the atmosphere in the chamber20. The temperature of the processing liquid L ejected from the nozzle41is determined in accordance with conditions of the liquid processing (e.g., composition of the processing liquid L or composition of the wafer W), but is typically about 20° C. to about 70° C. The control device4monitors the presence/absence of the abnormality by detecting the state (e.g., the temperature or the position) of the processing liquid L based on the temperature difference between the processing liquid L and the atmosphere.

When the liquid processing is performed on the wafer W, the precessing liquid L is ejected toward the processing surface of the wafer W from the nozzle41, and a liquid film L1of the processing liquid L is formed on the processing surface, and a liquid column L2of the processing liquid L is formed between the nozzle41and the liquid film L1. The infrared camera60captures the liquid film L1and the liquid column L2(particularly, the liquid column L2) formed as described above, and acquires an infrared image I as illustrated inFIG.4.

The attaching position and the attaching aspect of the infrared camera60are not particularly limited as long as a desired target may be appropriately captured. In the typical example, the attaching position and the attaching aspect of the infrared camera60are not limited as long as the liquid film L1and the liquid column L2(particularly, the liquid column L2) may be appropriately captured. Further, the specific specifications of the infrared camera60are not particularly limited as long as the infrared image I useful for appropriately monitoring the presence/absence of the abnormality may be acquired. Therefore, the infrared camera60may capture a moving image, may capture a still image, or may perform so-called consecutive shot in which a plurality of still images are consecutively captured in a short time.

Further, the wavelength of the infrared rays that may be captured by the infrared camera60is not particularly limited. The infrared camera60may capture images based on a wavelength in the near infrared region, based on a wavelength in the mid infrared region, or based on a wavelength in the far infrared region, and may capture images based on the wavelengths of two or more wavelength regions among the plurality of wavelength regions, or based on the wavelengths of other infrared regions. Further, the infrared camera60may acquire an image obtained by analyzing the intensity of infrared rays to calculate the temperature distribution as the infrared image I. For example, a thermography that provides the infrared image I obtained by visualizing the ray amount distribution of the far infrared rays may be used as the infrared camera60. Further, an infrared camera (e.g., a near infrared camera) that provides a monochrome image may be used as the infrared camera60.

As is clear fromFIG.4, the infrared image I acquired by the infrared camera60of the typical example includes a liquid film image I1that corresponds to the liquid film L1of the processing liquid L and a liquid column image12that corresponds to the liquid column L2of the processing liquid L, and the position of the liquid column12in the infrared image I may be specified. Therefore, the control device4specifies the position of the liquid column image12by performing the imaging processing on the infrared image I, and the placing position of the nozzle41(processing fluid supply40) may be specified based on the position of the liquid column image12. Meanwhile, the control device4acquires information on the drive position of the drive arm42, and the placing position of the nozzle41(processing fluid supply40) may be specified based on the drive position. Therefore, the control device4may monitor the presence/absence of the abnormality with respect to the placing position of the nozzle41by acquiring both the information on the placing position of the nozzle41obtained from the liquid column image12and the information on the placing position of the nozzle41obtained from the drive position of the drive arm42.

As illustrated inFIG.5as an example, the control device4includes a main control unit81, an image processing unit82, and a monitoring unit83.

The main control unit81controls the overall liquid processing. The main control unit81performs, for example, drive control of the drive arm42, opening/closing control of a flow rate adjusting valve (not illustrated) that adjusts the flow rate of the processing liquid L flowing through a pipe connecting the processing fluid source70and the nozzle41, and rotation control of the holder31. As a result, the main control unit81includes information on the placing position of the drive arm42, and also information (i.e., “first nozzle position information”) that indicates directly or indirectly the placing position of the nozzle41integrally attached to the drive arm42. The main control unit81provides the first nozzle position information to the monitoring unit83.

Meanwhile, the image processing unit82receives the infrared image I from the infrared camera60, acquires image processing information by performing the image processing on the infrared image I, and provided the image processing information to the monitoring unit83. Positional information of the liquid column image12in the infrared image I is acquired by the image processing, and information (i.e., “second nozzle position information”) that indicates directly or indirectly the placing position of the nozzle41is acquired from the positional information of the liquid column image12. The image processing unit82provides the second nozzle position information to the monitoring unit83.

Then, the monitoring unit83compares the first nozzle position information from the main control unit81and the second nozzle position information from the image processing unit82, and monitors the presence/absence of the abnormality with respect to the position of the nozzle41(processing fluid supply40). When there is no abnormality in the position of the nozzle41, the first nozzle position information and the second nozzle position information indicate data that corresponds to each other. Meanwhile, when there is an abnormality in the position of the nozzle41, the first nozzle position information and the second nozzle position information indicate data that does not correspond to each other. The monitoring unit83may monitor the presence/absence of the abnormality in the position of the nozzle, based on the correspondence between the first nozzle position information and the second nozzle position information.

When the presence/absence of the abnormality in the position of the nozzle is monitored as described above, the processing liquid L is ejected from the nozzle41. As a result, the monitoring unit83may acquire ejection information of the processing liquid L from the main control unit81(will be described later), and monitor the presence/absence of the abnormality in the position of the nozzle by confirming that the ejection information is information (i.e., “ejection ON information”) indicating that the processing liquid L is being ejected from the nozzle41.

Further, the timing of performing the image processing on the infrared image I in the image processing unit82is not particularly limited. For example, the image processing unit82may perform the image processing when the first nozzle position information is provided to the image processing unit82from the main control unit81, and the first nozzle position information indicates that the nozzle41enters a specific area (e.g., the area above the wafer W) or the nozzle41is disposed at a specific position (e.g., a predetermined position at which the processing liquid L is ejected toward the wafer W). That is, the infrared image I captured and acquired while the nozzle41is disposed in a specific area or at a specific position may be used as the image processing target. By switching the execution/non-execution of the image processing according to the position of the nozzle41in this way, useless image processing may be avoided and the processing load on the control device4may be reduced.

FIG.6is a view for explaining a second typical example of abnormality monitoring using an infrared image, and illustrates an arrangement of the infrared camera60, the processing fluid supply40, and the wafer W.FIG.7is a view illustrating an example of an infrared image I acquired by the infrared camera60illustrated inFIG.6.FIG.8is a functional block diagram of the control device4according to the second typical example of the abnormality monitoring using an infrared image. The arrangement of the infrared camera60, the processing fluid supply40, and the wafer W according to the typical example illustrated inFIG.6is equal to that of the first typical example (seeFIG.3) described above. Further, the functional block diagram of the control device4according to the typical example illustrated inFIG.8is also equal to the first typical example (seeFIG.5) described above.

In the typical example, the presence/absence of an abnormality with respect to unexpected dripping of the processing liquid L from the nozzle41(processing fluid supply40) is monitored by the control device4.

The ejection state of the processing liquid L from the nozzle41(processing fluid supply40) is adjusted by opening/closing the flow rate adjusting valve (not illustrated) provided between the processing fluid source70and the nozzle41, under the control of the control device4(particularly, main control unit81). As a result, the main control unit81includes information (i.e., “ejection information”) indicating whether the processing liquid L is being ejected from the nozzle41, and provides the ejection information to the monitoring unit83.

Meanwhile, the infrared camera60consecutively captures, particularly, the area between the nozzle41and the liquid film L1of the processing liquid L on the wafer W, while the processing liquid L is not ejected from the nozzle41. When an unintended droplet L3of the processing liquid L is dropped from the nozzle41, the infrared image I acquired by the infrared camera60includes an image (i.e., “liquid dripping image”)13of the droplet L3as illustrated inFIG.7. Meanwhile, when the processing liquid L is not ejected from the nozzle41and the droplet L3is not dropped, the liquid dripping image13is not captured in the infrared image I acquired by the infrared camera60.

Therefore, the image processing unit82of the control device4according to the typical example receives the infrared image I from the infrared camera60, and performs the image processing on the infrared image I, and acquires information on the presence/absence of the liquid dripping image13in the infrared image I as image processing information. The image processing unit82provides the image processing information (liquid dripping information) to the monitoring unit83.

Then, the monitoring unit83compares the liquid dripping information from the main control unit81and the ejection information from the image processing unit82, and monitors the presence/absence of the liquid dripping abnormality. When there is no liquid dripping abnormality, the ejection information is ejection OFF information indicating that the ejection of the processing liquid L from the nozzle41is stopped, and the liquid dripping information also indicates that the infrared image I does not include the liquid dripping image13. Meanwhile, when there is the liquid dripping abnormality, even when the ejection information is the ejection OFF information, the liquid dripping information indicates that the infrared image I includes the liquid dripping image13. In this manner, the monitoring unit83may monitor the presence/absence of the abnormality with respect to the liquid dripping, based on the image processing information (liquid dripping information) and the ejection information (ejection OFF information).

Further, the timing of performing the image processing on the infrared image I in the image processing unit82is not particularly limited. For example, the image processing unit82may perform the image processing while the ejection information (particularly ejection OFF information) is also provided to the image processing unit82from the main control unit81, and the processing liquid L is not being ejected from the nozzle41. That is, the infrared image I captured and acquired while the processing liquid L is not being ejected from the nozzle41may be used as the image processing target. By switching the execution/non-execution of the image processing according to the ejection state of the processing liquid L from the nozzle41in this way, useless image processing may be avoided.

FIG.9is a view for explaining a third typical example of abnormality monitoring using an infrared image, and illustrates an arrangement of the infrared camera60, the processing fluid supply40, and the wafer W.FIG.10is a view illustrating an example of an infrared image I acquired by the infrared camera60illustrated inFIG.9.FIG.11is a functional block diagram of the control device4according to the third typical example of the abnormality monitoring using an infrared image. The arrangement of the infrared camera60, the processing fluid supply40, and the wafer W according to the typical example illustrated inFIG.9is equal to that of the first typical example (seeFIG.3) and that of the second typical example (seeFIG.6) described above. Further, the functional block diagram of the control device4according to the typical example illustrated inFIG.11is also equal to the first typical example (seeFIG.5) and the second typical example (seeFIG.8) described above.

In the typical example, the presence/absence of an abnormality with respect to unexpected splash of the processing liquid L is monitored by the control device4. When the processing liquid L ejected from the nozzle41collides with the processing liquid L forming the liquid film L1on the wafer W, spray L4of the processing liquid L may be generated. In the typical example, the presence/absence of an abnormality with respect to the splash of the processing liquid L is monitored by detecting the presence/absence of the generation of the spray L4.

The main control unit81in the typical example provides the ejection information indicating whether the processing liquid L is being ejected from the nozzle41to the monitoring unit83, similarly to the main control unit81in the second typical example described above.

Meanwhile, the infrared camera60consecutively captures, particularly, the area near an intersection of the liquid column L2and the liquid film L1, while the processing liquid L is being ejected from the nozzle41. When unintended spray L4of the processing liquid L is generated, the infrared image I acquired by the infrared camera60includes an image (i.e., “liquid splash image”)14of the spray L4as illustrated inFIG.10. Meanwhile, when the spray L4is not generated, the liquid splash image14is not captured in the infrared image I acquired by the infrared camera60.

The image processing unit82of the control device4receives the infrared image I from the infrared camera60, and performs the image processing on the infrared image I, and acquires information on the presence/absence of the liquid splash image14in the infrared image I as image processing information. The image processing unit82provides the image processing information (liquid splash information) to the monitoring unit83.

The monitoring unit83compares the liquid splash information from the main control unit81and the ejection information from the image processing unit82, and monitors the presence/absence of the liquid splash abnormality. When there is no liquid splash abnormality, the ejection information is ejection ON information indicating that the processing liquid L is being ejected from the nozzle41, and the liquid splash information also indicates that the infrared image I does not include the liquid splash image14. Meanwhile, when there is the liquid splash abnormality, even when the ejection information is the ejection ON information, the liquid splash information indicates that the infrared image I includes the liquid splash image14. In this manner, the monitoring unit83may monitor the presence/absence of the abnormality with respect to the liquid splash, based on the image processing information (liquid splash information) and the ejection information.

Further, the timing of performing the image processing on the infrared image I in the image processing unit82is not particularly limited. For example, the image processing unit82may perform the image processing while the ejection information (particularly ejection ON information) is also provided to the image processing unit82from the main control unit81, and the processing liquid L is being ejected from the nozzle41. That is, the infrared image I captured and acquired while the processing liquid L is being ejected from the nozzle41may be used as the image processing target. By switching the execution/non-execution of the image processing according to the ejection state of the processing liquid L from the nozzle41in this way, useless image processing may be avoided.

[Monitoring of Liquid Film Temperature and Monitoring of Wafer Temperature]

FIG.12is a view for explaining a fourth typical example of abnormality monitoring using an infrared image, and illustrates an arrangement of the infrared camera60, the processing fluid supply40, and the wafer W.

The infrared camera60may be movably provided under the control of the control device4, and the capturing position and/or the capturing angle of the infrared camera60may be variable. Therefore, the control device4may monitor a plurality of locations in the chamber20with the single infrared camera60. For example, even in a case where it is difficult for the infrared camera60to capture the nozzle41and the entire processing surface of the wafer W simultaneously, when the infrared camera60is disposed at a first position (see the infrared camera60illustrated by a solid line inFIG.12), the infrared camera60may capture the processing liquid L from the nozzle41, and when the infrared camera60is disposed at a second position (see the infrared camera60illustrated by a broken line inFIG.12), the infrared camera60may capture the liquid film L1over the entire processing surface of the wafer W or the entire processing surface of the wafer W.

Therefore, the control device4according to the typical example may, for example, monitor the presence/absence of the abnormality described as the first typical example to the third typical example (seeFIGS.3to11) described above, and monitor the presence/absence of an abnormality with respect to the temperature of the processing liquid L on the wafer W using the common infrared camera60. Therefore, the control device4may, for example, detect whether the liquid film L1has an appropriate temperature for the liquid processing, and thus, may monitor the presence/absence of an abnormality with respect to the progress of the liquid processing.

Further, the control device4according to the typical example may detect the temperature of the wafer W based on the infrared image I acquired by the infrared camera60, and monitor the presence/absence of the abnormality based on the temperature of the wafer W. Therefore, for example, the suitability of spin dry drying of the wafer W may be monitored. The spin dry drying is a processing in which the wafer W is rotated by the holder31in a state where the ejection of the processing liquid L from the nozzle41is stopped, and liquid such as the processing liquid L on the wafer W is evaporated so as to dry the wafer W. Due to the vaporization heat of the processing liquid L, the temperature of the wafer W decreases as the spin dry drying progresses. Therefore, it is possible to monitor accurately whether the wafer W is completely dried by detecting the change over time in the temperature of the wafer W or the temperature of the processing liquid L on the wafer W based on the infrared image I acquired by the infrared camera60. The control device4may perform controls such as continuing the spin dry drying as necessary while the monitoring result indicates that the processing surface of the wafer W is not completely dried.

As described above, when the temperature itself of the processing liquid L and/or the wafer W is monitored, the infrared image I acquired by the infrared camera60needs to include such specific temperature information. Therefore, it is required to use, as the infrared camera60, an infrared image capturing device such as a thermography capable of providing an infrared image I capable of identifying a specific temperature with a certain degree of accuracy.

Further, in the above descriptions, the case where the movable infrared camera60as illustrated inFIG.12is used has been described, the infrared camera60may not be movable as long as the entire desired monitoring area (e.g., the nozzle41and the entire processing surface of the wafer W) may be simultaneously captured. For example, a fixed infrared camera60capable of performing wide-angle photographing may be used, or a plurality of fixed infrared cameras60may be used in combination.

[Monitoring of Ejection Time of Processing Liquid]

As described above, the infrared camera60may capture the state of the ejection of the processing liquid L from the nozzle41(processing fluid supply40). Therefore, the control device4(image processing unit82) may acquire information on the ejection start time of the processing liquid L from the nozzle41, and information on the ejection stop time of the processing liquid L from the nozzle41, by performing the image processing on the infrared image I (e.g., a moving image) consecutively acquired by the infrared camera60. Further, the control device4(image processing unit82or monitoring unit83) may acquire information (i.e., “first ejection time information”) on the time during which the processing liquid L is being ejected from the nozzle41, from the ejection start time information and the ejection stop time information.

Meanwhile, the monitoring unit83may acquire information (i.e., “second ejection time information”) on a predetermined ejection time of the processing liquid L from the nozzle41as recipe information, from the storage unit19or other functional blocks (e.g., the main control unit81).

Then, the monitoring unit83may monitor the presence/absence of an abnormality in the ejection time of the processing liquid L from the nozzle41, by comparing the first ejection time information and the second ejection time information. When there is an abnormality in the ejection time of the processing liquid L from the nozzle41, for example, the monitoring unit83and the main control unit81may adjust the opening/closing timing of the flow rate adjusting valve (not illustrated) provided between the processing fluid source70and the nozzle41, and may change the ejection start timing of the processing liquid L from the nozzle41and/or the ejection stop timing of the processing liquid L from the nozzle41. Alternatively, the control device4may correct the recipe information.

[Monitoring of Abnormality by Comparing Among a Plurality of Processing Units]

The substrate processing system1according to the embodiment includes a plurality of processing units16(including the chambers20), and each of the processing units16is partitioned by the chambers20, and each of the chambers20is provided with the holder31, the processing fluid supply40, and the infrared camera60.

The control device4(particularly the monitoring unit83) may monitor the presence/absence of the abnormality in each processing unit16derived by comparing the states of the processing liquid L detected based on the infrared images I acquired by the plurality of infrared cameras60provided in each of the plurality of chambers20(the plurality of processing units16).

For example, a flow meter (not illustrated) may be provided for each processing unit16, and the flow rate of the processing liquid L supplied to the nozzle41(processing fluid supply40) of each of the processing units16from the processing fluid source70(seeFIG.2) may be measured by the flow meter. The control device4(e.g., main control unit81) may control, for example, the above described flow rate adjusting valve (not illustrated) to adjust the flow rate of the processing liquid L to the nozzle41of each processing unit16. In this case, when the temperature of the processing liquid L ejected from the nozzle41of one processing unit16(hereinafter, referred to as a “abnormal processing unit16a”) is lower than the temperature of the processing liquid L ejected from the nozzle41of other processing units16, it is highly probable that the amount of the processing liquid L supplied to the nozzle41of the abnormal processing unit16afrom the processing fluid source70is smaller than an assumption. In this case, there is a possibility that a problem occurs in the flow meter that measures the flow rate of the processing liquid L supplied to the nozzle41of the abnormal processing unit16afrom the processing fluid source70. Therefore, it is possible to monitor the presence/absence of an abnormality with respect to the flow meter by comparing the temperature of the processing liquid L ejected from the nozzle41among the processing units16.

In this manner, the abnormality that may occur in each processing unit16may be monitored by detecting the states such as the temperature of the processing liquid L in each of the processing units16, and comparing the states of the processing liquid L with each other among the processing units16.

The control device4may monitor abnormalities other than those described above, based on the infrared image I.

As described above, when the ejection amount of the processing liquid L from the nozzle41is smaller than an assumption, the temperature of the processing liquid L ejected from the nozzle41tends to be lower than an assumption. Therefore, the control device4may monitor the presence/absence of an abnormality with respect to the ejection amount of the processing liquid L by comparing the temperature of the processing liquid L (e.g., the liquid column L2or the liquid film L1) ejected from the nozzle41detected based on the infrared image I and the assumption temperature of the processing liquid L preset as the recipe information.

Further, the control device4may monitor the presence/absence of an abnormality with respect to the supply/exhaust state (e.g., the state of the gas supplied from the FFU21) around the outer periphery of the wafer W by detecting the temperature of the processing liquid L on the outer periphery of the wafer W and/or the temperature of the wafer W itself, based on the infrared image I. For example, as the exhaust amount through the exhaust port52increases, the temperature of the outer periphery of the wafer W tends to be lower than the temperature of the central portion. Therefore, the control device4may monitor the presence/absence of an abnormality in the exhaust by detecting the temperature distribution of the processing liquid L (liquid film L1) on the processing surface of the wafer W or the temperature distribution of the wafer W, based on the infrared image I.

Although one nozzle41and one drive arm42are illustrated inFIGS.2,3,6,9, and12described above, the number of the nozzles41and the drive arms42provided in each processing unit16may be one, or may be two or more.

FIG.13is a schematic plan view illustrating an example in which two processing fluid supplies40and one infrared camera60are provided in one chamber20, and each processing fluid supply40is attached to the corresponding drive arm42. The attaching position and the attaching aspect of the infrared camera60are not particularly limited, but the infrared camera60may be provided at a position and at an angle where the entire moving path t (particularly, the moving path t above the wafer W) of the processing fluid supplies40on the wafer W may be captured simultaneously. When the respective processing fluid supplies40and the respective drive arm42have the same structure, the infrared camera60may be provided at a position equidistant from the rotation axis Ar of the drive arms42.

The common infrared camera60is assigned to the plurality of processing fluid supplies40inFIG.13, but unique infrared camera60may be assigned to each processing fluid supply40. Further, a plurality of infrared cameras60may be assigned to one processing fluid supply40.

[Example of Processing of Monitoring Result]

As described above, the control device4may monitor the presence/absence of various types of abnormalities by performing the image processing on the infrared image I of the infrared camera60. The control device4may process the monitoring result of these abnormalities.

For example, the control device4may record information on the presence/absence of the abnormality in the storage unit19. In this case, the control device4may record information on the date and time when the presence/absence of the abnormality is monitored, identification information of the wafer W on which the monitoring is performed, and/or other related information in the storage unit19in association with the information on the presence/absence of the abnormality. Therefore, a user or an arbitrary device may access the storage unit19as necessary, and retrieve the information on the presence/absence of the abnormality.

Further, the control device4may record, when performing the monitoring of the presence/absence of the abnormality, the ejection start time information indicating the time at which the ejection of the processing liquid L from the processing fluid supply40starts, and the ejection stop time information indicating the time at which the ejection of the processing liquid L from the processing fluid supply40stops in the storage unit19as information on the presence/absence of the abnormality. In this case, the control device4may control the ejection time during which the processing liquid L is ejected from the processing fluid supply40, based on the ejection start time information and the ejection stop time information recorded in the storage unit19, and perform optimization of the ejection time of the processing liquid L.

Further, a notification device65(seeFIGS.5,8, and11) connected to the control device4(e.g., the monitoring unit83) is further provided, and when an abnormality is detected, the control device4(e.g., the monitoring unit83) may operate the notification device65to notify a user of the abnormality. The notification device64may be configured by any devices. For example, the notification device65may be configured by a display device and/or a sound device, and may notify the presence/absence of the abnormality by a display or sound.

Further, when an abnormality is detected, the control device4may control various devices so as to correct the abnormality. For example, when a positional deviation abnormality of the nozzle41(processing fluid supply40) is detected, the control device4may automatically optimize the position of the nozzle41by controlling the drive arm42, based on the position information of the nozzle41obtained from the infrared image I.

The present disclosure is not limited to the above described embodiments and modified examples, and may include various aspects to which various modifications that may be conceived by those skilled in the art are added. The effects achieved by the present disclosure are not limited to the above descriptions. Therefore, various additions, changes, and partial deletions may be made to each element described in the claims and the specification without departing from the technical concept or spirit of the present disclosure.

For example, the above described control device4includes the main control unit81, the image processing unit82, and the monitoring unit83(seeFIGS.5,8, and11). However, the control device4may functionally include each of these units, and the functions of the respective units may be implemented by appropriately combining hardware and software.

Further, in addition to the substrate processing apparatus, the present disclosure may be implemented as a substrate processing method, a program for causing a computer to execute the procedure performed in such a substrate processing method and a non-transitory computer readable recording medium in which such a program is recorded, and other objects and methods.

DESCRIPTION OF SYMBOLS