Automated interface apparatus and method for use in semiconductor wafer handling systems

Aspects of the present disclosure describe a smart docking station. The smart docking station may contain a data transfer and an electrical connection which allow a sensor wafer to be charged and to upload and download data. The smart docking station may be located at an off-track storage position above a tool. This location enables an automated materials handling system (AMHS) to retrieve the sensor wafer and deliver it to a tool requiring analysis. The sensor wafer may be stored in a smart front opening unified pod (FOUP). It is emphasized that this abstract is provided to comply with the rules requiring an abstract that will allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims.

FIELD OF THE INVENTION

Embodiments of the present invention relate to an apparatus and a method for automating a wafer handling system that is capable of performing diagnostics on a tool in a cleanroom environment.

BACKGROUND OF THE INVENTION

Sensor wafers are used to perform process characterizations of a tool. A sensor wafer may measure many different parameters of the process, such as, but not limited to, substrate temperature profiles, and report those back to an engineer. Originally sensor wafers were used as a tool for research and development. The information provided to the engineer enabled him to refine or improve a processing step. However, with tighter tolerances and increased demands on product yield, sensor wafers have also become a valuable process monitoring tool.

A sensor wafer may be deployed to help identify problems in a processing step when the processing step begins to produce results that exceed predetermined tolerances. Currently, the use of a sensor wafer requires a substantial downtime for the tool being characterized. In order to deploy a sensor wafer in a production setting, a technician must first take the tool offline. Then he must get a cart in order to carry the front opening unified pod (FOUP) housing the sensor wafer. After manually delivering the FOUP to the tool, the sensor wafer must be processed under the desired conditions. Thereafter, the technician must download the data logged by the sensor wafer to a laptop. The technician then needs to reassign the tool back into production. This process may take approximately 3-4 hours under ideal conditions.

Consequently, sensor wafers are typically only utilized when a processing step begins to produce devices that exceed specified tolerances. However, it would be useful to minimize the time a tool is taken off-line in order to allow for process analyses before a process begins producing devices that exceed the specified tolerances. It is within this context that embodiments of the present invention arise.

DESCRIPTION OF THE SPECIFIC EMBODIMENTS

In the following Detailed Description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific embodiments in which the invention may be practiced. The drawings show illustrations in accordance with examples of embodiments, which are also referred to herein as “examples”. The drawings are described in enough detail to enable those skilled in the art to practice the present subject matter. The embodiments can be combined, other embodiments can be utilized, or structural, logical, and electrical changes can be made without departing from the scope of what is claimed. In this regard, directional terminology, such as “top,” “bottom,” “front,” “back,” “leading,” “trailing,” etc., is used with reference to the orientation of the figure(s) being described. Because components of embodiments of the present invention can be positioned in a number of different orientations, the directional terminology is used for purposes of illustration and is in no way limiting. It is to be understood that other embodiments may be utilized and structural or logical changes may be made without departing from the scope of the present invention.

In this document, the terms “a” and “an” are used, as is common in patent documents, to include one or more than one. In this document, the term “or” is used to refer to a nonexclusive “or,” such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.

According to aspects of the present disclosure, a sensor wafer may be housed in a sensor FOUP. The sensor FOUP may contain data transfer connections and an electrical connection that allows the sensor wafer to be charged and to upload and download data to the sensor wafer. The sensor FOUP may also contain similar connections which allow the sensor FOUP to be charged and to upload and download data to a smart docking station. The smart docking station may be located at an off-track storage position above a tool. This location enables an automated materials handling system (AMHS) to retrieve the sensor FOUP and deliver the sensor FOUP to a desired tool.

According to additional aspects of the present disclosure, the smart docking station may also be incorporated into a substrate processing tool. This configuration allows for the sensor wafer to be transported in a FOUP that does not contain an electrical and data transfer connection. The data may be uploaded and downloaded from the sensor wafer directly to the smart docking station within the tool. Additionally, the smart docking station may provide an electrical connection directly to the sensor wafer in order to charge the sensor wafer. This aspect of the present disclosure allows for the sensor wafer to be transported to a tool that needs to be analyzed with the use of a standard FOUP used to transport wafers.

An additional aspect of the present disclosure describes the automated system that may be used to implement an analysis of a tool with a sensor wafer. According to this aspect of the present disclosure a factory automation (FA) server may provide a smart docking station with a mission for a sensor wafer. The smart docking station may upload the mission to the sensor wafer. The FA server may also deliver a recipe to the tool being analyzed. As used herein, the “tool being analyzed” may also be referred to as a “device under test” (DUT). The FA server may also instruct a robotic wafer delivery system an AMHS to retrieve the sensor wafer from the smart docking station and deliver it to the DUT. Once the sensor wafer has been delivered to the DUT, the recipe is run on the sensor wafer and the processing conditions are logged and stored in a memory of the sensor wafer. When the recipe is complete, the DUT may send a signal to the FA server indicating that the sensor wafer may be returned to a smart docking station. The FA server may then instruct the AMHS to retrieve the sensor wafer from the DUT and deliver it to an available smart docking station. When docked at a smart docking station, the sensor wafer may download the logged data to the smart docking station. The smart docking station may thereafter transmit the data to a sensor wafer server. In order to access the logged data, the FA server may then request the logged data from the sensor wafer server.

FIG. 1Ais a schematic diagram of an automated tool diagnostic system100according to an aspect of the present disclosure. A smart docking station103may be accessed by a sensor wafer server109and an FA server110over a network160. The smart docking station103may be one of a plurality of smart docking stations103accessible by the FA server110. The FA server110may also communicate with an AMHS106(not shown) and a DUT118(not shown) over the network160. It is noted that the sensor wafer server109and the FA server110may be implemented as virtualized machines running on the same hardware, e.g., a common general-purpose computer running different virtual machines using specially configured software. Alternatively, the sensor wafer server109and the FA server110may be implemented on separate pieces of hardware.

A transportable sensor FOUP104may be configured to receive a sensor wafer108and retain the sensor wafer as the FOUP is transported, e.g., from one tool to another, from a tool to docking station, or from a docking station to a tool. The sensor FOUP104may have an electrical connection111that connects the sensor FOUP104to the smart docking station103. The electrical connection111may be configured to charge a battery in the sensor FOUP104. By way of example, and not by way of limitation, the electrical connection111may connect a power supply142of the smart docking station103to the battery charging controller142′ of the sensor FOUP104. The battery charging controller142′ in turn charges and maintains the battery153′. The sensor FOUP104may also have a data connection112that connects the sensor FOUP104to the smart docking station103. The data connection112may be configured to allow data to be uploaded to or downloaded from the smart docking station103. By way of example, and not by way of limitation, the data connection112may connect an input/output circuit141of the smart docking station103to an input/output circuit141′ of the sensor FOUP104. The electrical connection111and the data connection112may be implemented as a single connection capable of providing both an electrical path and a data path between the smart docking station103and the sensor FOUP104. By way of example, and not by way of limitation, the single connection may be a USB connection. Again by way of example, and not by way of limitation, the data path may be implemented wirelessly using radiofrequency (RF) or infrared (IR) data paths. Examples of RF data paths include Bluetooth and examples of infrared data paths include IRDA.

Smart docking station103may include a central processor unit (CPU)131. By way of example, a CPU131may include one or more processors, which may be configured according to, e.g., a dual-core, quad-core, multi-core, or Cell processor architecture. Smart docking station103may also include a memory132(e.g., RAM, DRAM, ROM, and the like). The CPU131may execute a process-control program133, portions of which may be stored in the memory132. The smart docking station103may also include well-known support circuits140, such as input/output (I/O) circuits141, power supplies (P/S)142, a clock (CLK)143, and cache144. The smart docking station103may optionally include a mass storage device134such as a disk drive, CD-ROM drive, tape drive, or the like to store programs and/or data. The smart docking station103may also optionally include a display unit137and a user interface unit138to facilitate interaction between the smart docking station103and a user who requires direct access to the smart docking station103. The display unit137may be in the form of a cathode ray tube (CRT) or flat panel screen that displays text, numerals, or graphical symbols. The user interface unit138may include a keyboard, mouse, joystick, light pen, or other device. The smart docking station103may include a network interface139, configured to enable the use of Bluetooth, Wi-Fi, an Ethernet port, or other communication methods.

The network interface139may incorporate suitable hardware, software, firmware or some combination of two or more of these to facilitate communication via an electronic communications network160. The network interface139may be configured to implement wired or wireless communication over local area networks and wide area networks such as the Internet. The smart docking station103may send and receive data and/or requests for files via one or more data packets over the network160.

The preceding components may exchange signals with each other via an internal system bus150. The smart docking station103may be a general purpose computer that becomes a special purpose computer when miming code that implements embodiments of the present invention as described herein.

The sensor FOUP104may include a central processor unit (CPU)131′. By way of example, a CPU131′ may include one or more processors, which may be configured according to, e.g., a dual-core, quad-core, multi-core, or Cell processor architecture. The sensor FOUP104may also include a memory132′ (e.g., RAM, DRAM, ROM, and the like). The CPU131′ may execute a process-control program133′, portions of which may be stored in the memory132′. The sensor FOUP104may also include well-known support circuits140′, such as input/output (I/O) circuits141′, battery management controller (CHG)142′, a clock (CLK)143′, and cache144′. The sensor FOUP104contains a battery153′ which is the power source for the sensor FOUP104while performing a mission. The sensor FOUP104may optionally include a mass storage device134′ such as a disk drive, CD-ROM drive, tape drive, or the like to store programs and/or data. The sensor FOUP104may also optionally include a display unit137′ and a user interface unit138′ to facilitate interaction between the sensor FOUP104and a user who requires direct access to the sensor FOUP104. The display unit137′ may be in the form of a Liquid Crystal Display (LCD) or flat panel screen that displays text, numerals, or graphical symbols. The user interface unit138′ may include a keyboard, mouse, joystick, light pen, or other device. The sensor FOUP104may include a network interface139′, configured to enable the use of Wi-Fi, Bluetooth, an Ethernet port, or other communication methods. It is noted that in some implementations, the network interface139′ may be configured to establish a wireless communication link between the sensor FOUP104and a remote server independent of the smart docking station103.

The network interface139′ may incorporate suitable hardware, software, firmware or some combination of two or more of these to facilitate communication via an electronic communications network160. The network interface139′ may be configured to implement wired or wireless communication over local area networks and wide area networks such as the Internet. The sensor FOUP104may send and receive data and/or requests for files via one or more data packets over the network160.

The sensor FOUP104may include one or more receptacles107configured to receive a sensor wafer108. The receptacle107may include a charging contact configured to provide an electrical charge to a battery114within the sensor wafer108. The sensor FOUP104may be configured to exchange data with the sensor wafer108. For example, the FOUP104may include a wireless transceiver, e.g., based on radiofrequency ID (RFID), infrared (IR), electromagnetic induction, or other suitable technology configured to transmit data to and/or receive data from the sensor wafer108via a corresponding wireless transceiver. Alternatively, the receptacle107may include a data contact configured to transfer data to and/or from a memory132SWin the sensor wafer108. It is noted that a sensor wafer108is shown inFIG. 1Afor the purpose of illustrating certain aspects of the disclosure. However, the sensor wafer108is not, strictly speaking a part of the sensor FOUP104. Instead, the sensor wafer108may be regarded as a workpiece upon which the sensor FOUP operates.

The preceding components may exchange signals with each other via an internal system bus150′. The sensor FOUP104may be a general purpose computer that becomes a special purpose computer when miming code that implements embodiments of the present invention as described herein. By way of example, and not by way of limitation, the sensor FOUP104may be a SmartFOUP, sold by KLA-Tencor of Milpitas, Calif.

FA server110may include a central processor unit (CPU)131″. By way of example, a CPU131″ may include one or more processors, which may be configured according to, e.g., a dual-core, quad-core, multi-core, or Cell processor architecture. FA server110may also include a memory132″ (e.g., RAM, DRAM, ROM, and the like). The CPU131″ may execute a process-control program133″, portions of which may be stored in the memory132″. The FA server110may also include well-known support circuits140″, such as input/output (I/O) circuits141″, power supplies (P/S)142″, a clock (CLK)143″, and cache144″. The FA server110may optionally include a mass storage device134″ such as a disk drive, CD-ROM drive, tape drive, or the like to store programs and/or data. The FA server110may also optionally include a display unit137″ and a user interface unit138″ to facilitate interaction between the FA server110and a user who requires direct access to the FA server110. The display unit137″ may be in the form of a cathode ray tube (CRT) or flat panel screen that displays text, numerals, or graphical symbols. The user interface unit138″ may include a keyboard, mouse, joystick, light pen, or other device. The FA server110may include a network interface139″, configured to enable the use of Wi-Fi, an Ethernet port, or other communication methods.

The network interface139″ may incorporate suitable hardware, software, firmware or some combination of two or more of these to facilitate communication via an electronic communications network160. The network interface139″ may be configured to implement wired or wireless communication over local area networks and wide area networks such as the Internet. The FA server110may send and receive data and/or requests for files via one or more data packets over the network160.

The preceding components may exchange signals with each other via an internal system bus150″. The FA server110may be a general purpose computer that becomes a special purpose computer when running code that implements embodiments of the present invention as described herein.

Sensor wafer server109may include a central processor unit (CPU)131′″. By way of example, a CPU131′″ may include one or more processors, which may be configured according to, e.g., a dual-core, quad-core, multi-core, or Cell processor architecture. Sensor wafer server109may also include a memory132′ (e.g., RAM, DRAM, ROM, and the like). The CPU131′ may execute a process-control program133′, portions of which may be stored in the memory132′″. The sensor wafer server109may also include well-known support circuits140′″, such as input/output (I/O) circuits141′, power supplies (P/S)142′, a clock (CLK)143′, and cache144′″. The sensor wafer server109may optionally include a mass storage device134′″ such as a disk drive, CD-ROM drive, tape drive, or the like to store programs and/or data. The sensor wafer server109may also optionally include a display unit137′″ and a user interface unit138′ to facilitate interaction between the sensor wafer server109and a user who requires direct access to the sensor wafer server109. The display unit137′″ may be in the form of a cathode ray tube (CRT) or flat panel screen that displays text, numerals, or graphical symbols. The user interface unit138′″ may include a keyboard, mouse, joystick, light pen, or other device. The sensor wafer server109may include a network interface139′″, configured to enable the use of Wi-Fi, an Ethernet port, or other communication methods.

The network interface139′″ may incorporate suitable hardware, software, firmware or some combination of two or more of these to facilitate communication via an electronic communications network160. The network interface139′″ may be configured to implement wired or wireless communication over local area networks and wide area networks such as the Internet. The sensor wafer server109may send and receive data and/or requests for files via one or more data packets over the network160.

The preceding components may exchange signals with each other via an internal system bus150′. The sensor wafer server109may be a general purpose computer that becomes a special purpose computer when miming code that implements embodiments of the present invention as described herein. By way of example, and not by way of limitation, the sensor wafer server may be a Klarity ACE XP system sold by KLA Tencor of Milpitas, Calif.

FIG. 1Bis a schematic diagram of an automated tool diagnostic system101according to an additional aspect of the present disclosure. Automated diagnostic system101is similar to automated diagnostic system100except that the sensor wafer108is docked directly to the smart docking station103without being housed in a sensor FOUP104. The smart docking station103may be accessed by a sensor wafer server109and an FA server110over a network160. The smart docking station103may be one of a plurality of smart docking stations103accessible by the FA server110. The FA server110may also communicate with an AMHS106(not shown) and a DUT118(not shown) over the network160. Sensor wafer108may be one of a plurality of sensor wafers108.

Sensor wafer108may include a central processor unit (CPU)131SW. By way of example, a CPU131SWmay include one or more processors, which may be configured according to, e.g., a dual-core, quad-core, multi-core processor architecture. Sensor wafer108may also include a memory132SW(e.g., RAM, DRAM, ROM, and the like). The CPU131SWmay execute a process-control program133SW, portions of which may be stored in the memory132SW. The sensor wafer108may also include well-known support circuits140SW, such as input/output (I/O) circuits141SW, a battery charger controller (CHG)142SWfor a battery153SW, a clock (CLK)143SW, and cache144SW. The sensor wafer108may optionally include a mass storage device134SWsuch as a disk drive, CD-ROM drive, tape drive, or the like to store programs and/or data. The sensor wafer108may also optionally include a display unit137SWand a user interface unit138SWto facilitate interaction between the sensor wafer108and a user who requires direct access to the sensor wafer108. The display unit137SWmay be in the form of a cathode ray tube (CRT) or flat panel screen that displays text, numerals, or graphical symbols. The user interface unit138SWmay include a keyboard, mouse, joystick, light pen, or other device. The sensor wafer108may optionally include a network interface139SW, configured to enable the use of Wi-Fi, an Ethernet port, or other communication methods.

The network interface139SWmay incorporate suitable hardware, software, firmware or some combination of two or more of these to facilitate communication via an electronic communications network160. The network interface139SWmay be configured to implement wired or wireless communication over local area networks and wide area networks such as the Internet. The sensor wafer108may send and receive data and/or requests for files via one or more data packets over the network160.

The preceding components may exchange signals with each other via an internal system bus150SW. The sensor wafer108may be regarded as a general purpose computer that becomes a special purpose computer when running code that implements aspects the present disclosure as described herein. By way of example, and not by way of limitation, the sensor wafer108may be a sensor substrate such as the SensArray series of sensor substrates, the EtchTemp sensor, the BakeTemp sensor, the MaskTemp sensor, and the WetTemp-LP, each sold by KLA-Tencor of Milpitas, Calif.

FIG. 2Ais a diagram of the mechanical components of an automated tool diagnostic system200according to an aspect of the present disclosure. Diagnostic system200may utilizes a smart docking station203that may be located at a height higher than a tool205, at floor level, or at some intermediate level, such as table-top level. By way of example, the tool205may be any tool used in a fabrication facility, such as a review tool, or a processing tool. It should be noted that smart docking station203does not need to be directly above a tool205. The smart docking station203may also be located in an off-track storage location. The off-track storage location may be a shelf that is located adjacent to the main pathways used by the AMHS206, but are still accessible by the AMHS206. This real estate is relatively inexpensive in a fabrication facility since the location is off of the floor, and outside of the main pathways of the AMHS206. As such, this choice of location for a smart docking station203may allow for multiple smart docking stations203to be utilized in a single facility at a minimum cost. While the real estate is more expensive if the smart docking station203is located elsewhere, the smart docking station203may be located at any other location accessible by a robotic wafer delivery system, such as an AMHS206in the form of an overhead track (OHT) system. It is noted for the sake of clarity that inFIG. 2A, the AMHS moves a sensor FOUP perpendicular to the plane of the drawing and the docking station includes a mechanism that can translate the FOUP parallel to the plane of the drawing. It should be noted that a robotic wafer delivery system may also include alternative FOUP delivery systems, wafer transporting robots, or any combination thereof.

Smart docking station203may be configured to provide a docking location for a sensor FOUP204. When a sensor FOUP204is docked at a smart docking station203, a data connection212and an electrical connection211may be made between the sensor FOUP204and the smart docking station203. The data connection212may allow for the smart docking station203to deliver data to the sensor FOUP204. By way of example and not by way of limitation, the data connection212may be a USB connection, a wireless connection, or an Ethernet connection. By way of example, the data transferred over the data connection212may be a mission that a sensor wafer208within the sensor FOUP204may need to execute. The sensor FOUP204may be further configured to deliver the data received from the smart docking station203to a sensor wafer208housed within the sensor FOUP204. Further, the sensor FOUP204may be configured to download data from the sensor wafer208housed in the sensor FOUP204and deliver the downloaded data to the smart docking station203over the data connection212. By way of example and not by way of limitation, the downloaded data may be data that has been logged by the sensor wafer208while it was executing a mission. Additionally, the sensor FOUP204may be able to deliver data to the smart docking station203informing the smart docking station203of the identification number of the sensor wafer208or identification numbers of the sensor wafers208that are presently stored within the sensor FOUP204.

The electrical connection211may allow the smart docking station203to charge a battery213within the sensor FOUP204. Additionally, the sensor FOUP204may be configured to provide a charge to a battery214within a sensor wafer208stored in the sensor FOUP204. By way of example, the electrical connection may be a USB connection. The electrical connection211may also be the same connection as the data connection212.

FIG. 2Bis a diagram of the mechanical components of an automated tool diagnostic system201according to an additional aspect of the present disclosure. Automated diagnostic system201utilizes a smart docking station203that is located within a tool205. By utilizing available space in a preexisting substrate processing tool205, no additional real estate is needed for this aspect of the present disclosure.

In principle any tool might be configured to accommodate a sensor wafer and its associated support to implement the functions of the smart docking station203. It is particularly convenient to implement these functions in a tool that already includes an equipment front end module (EFEM) interface that is suitable for an added location. By way of example, and not by way of limitation, the tool205may be a diagnostic inspection tool, such as a macro inspection tool or surface inspection tool.

Additionally, the sensor wafer208may be docked directly on the smart docking station203without being stored in a sensor FOUP204. Therefore, the sensor wafer208may be transported in a regular FOUP204′ that does not require electrical211and data connections212. The hardware and software of the smart docking station203, such as, but not limited to, the CPU131and the memory132, may be separate or logically separate from the hardware and software of the tool205. Alternatively, the hardware and software of the smart docking station203may be integrated, or partially integrated, into the hardware and software of the tool205.

In order to transport the sensor wafer208, the smart docking station must be accessible to a robotic wafer delivery system. As used herein, the term “robotic wafer delivery system” may refer to any robotic devices that physically move a sensor wafer208, a sensor FOUP204, a FOUP204′, or any combination thereof, from one location to another. By way of example, and not by way of limitation, a robotic wafer delivery system may include a system for delivering FOUPS and/or one or more wafer transporting robot. By way of example, and not by way of limitation, a system for delivering FOUPS may be an AMHS. By way of example, and not by way of limitation, a wafer transporting robot may be a selective compliant articulated robot arm (SCARA). According to the aspects of the present disclosure depicted inFIG. 2B, the robotic wafer delivery system may be comprised of a wafer transporting robot207and an AMHS (not shown). The wafer transporting robot207may be used to retrieve the sensor wafer208from the smart docking station203and deliver it to a FOUP204′. The wafer transporting robot207may be located in an equipment front end module (EFEM)215that is attached to the tool205. Once the sensor wafer has been delivered to the FOUP204′, an AMHS may deliver the FOUP204′ to the DUT.

The smart docking station203may have a data connection212that connects the sensor wafer208to the smart docking station203. By way of example, and not by way of limitation, the data connection212may be a USB connection, a wireless connection, or an Ethernet connection. By way of example, the data transmitted over the data connection212may be a mission that a sensor wafer208may need to execute. Further, the smart docking station203may be configured to download data from the sensor wafer208to the smart docking station203through the data connection212. By way of example and not by way of limitation, the downloaded data may be data that has been logged by the sensor wafer208while it was executing a mission. Additionally, the sensor wafer208may be able to deliver data to the smart docking station203informing the smart docking station203of the identification number of the sensor wafer208or identification numbers of the sensor wafers208that are presently docked at the smart docking station203.

The smart docking station203may also have an electrical connection211that is configured to provide a charge to a battery214(not shown) within the sensor wafer208. By way of example, the electrical connection may be a USB connection. The electrical connection211may be the same connection as the data connection212.

FIGS. 3A-3Fare process flow diagrams of the automated tool diagnostic system300according to an aspect of the present disclosure. In the figures, solid lines indicate the transfer of data over the network160, and the dotted lines indicate physical motion of a component.

FIG. 3Adepicts the process at an initial starting state. At this starting state, a sensor wafer308is housed within a sensor FOUP304. The sensor FOUP is currently docked at a smart docking station303. There may exist one or more smart docking station(s)303with or without attached smart FOUP304. In this starting state, the smart docking station303may be providing a charge to the batteries213in the sensor FOUP304. The sensor FOUP304may also be providing a charge to the battery214in the sensor wafer308. The process is initiated by the FA server310sending a mission request to the smart docking station303over the network160as indicated by arrow1A. By way of example, and not by way of limitation, the mission may include instructions for the sensor wafer308indicating which tool needs to be analyzed, what process needs to be analyzed, which wafer is needed for the analysis, and what data needs to be logged during the analysis.

The FA server310may also deliver a recipe to the DUT318over the network160as indicated by arrow1B. By way of example, and not by way of limitation, the recipe may include the processing conditions that need to be used for the analysis and the identification number of the sensor wafer308that will be logging the data. The recipe may be delivered to the DUT318before, after, or at the same time the mission is delivered to the smart docking station303.

The sensor wafer data server319may instruct the smart docking station303to have the sensor FOUP304to start a mission on the wafer308. This may be done over the network160as indicated by the arrow1C. The smart docking station303may then deliver the mission to the sensor FOUP304over the data connection212. The sensor FOUP304may optionally send a confirmation message back to the smart docking station303that the appropriate sensor wafer308is located within the sensor FOUP304. The smart docking station303may then transmit the confirmation back to the sensor wafer data server319. This information may then be reconveyed to the FA server310via the network160as indicated by arrow1A. If the sensor wafer assigned to carry out the mission is not located in the smart docking station303that received the instruction from the FA server310, then an exception may be delivered to the FA server310.

In alternative implementations, the sensor FOUP304may be configured to communicate directly with the sensor wafer data server319, e.g., by a wireless link. For example, the sensor FOUP may receive the mission wirelessly as indicated by dotted arrow1Dinstead of receiving the mission via the smart docking station303. In such implementations, the sensor FOUP304may also be configured to transmit the confirmation back to the sensor wafer data server319or communicate directly with the FA server310via wireless link, as indicated by dotted arrow1E.

Once the recipe and the mission have been delivered, the FA server310may send instructions over the network to the AMHS306instructing it to retrieve the sensor FOUP304and deliver it to the DUT318as indicated by arrow2inFIG. 3B. The instructions sent to the AMHS306may also include a priority level for the analysis. By way of example, if the analysis needs to be done immediately, a high priority level may be assigned to the task, or if the analysis is not critical, a low priority may be assigned to the task. The AMHS306travels to the sensor smart docking station303as indicated by the dashed arrow3inFIG. 3B. Next, inFIG. 3C, the AMHS306retrieves the sensor FOUP304housing the sensor wafer308and delivers it to the DUT318as indicated by the dashed arrow4inFIG. 3C. The electrical connection211and the data connection212between the smart docking station303and the sensor FOUP304are each disconnected when the AMHS306moves the sensor FOUP304to the DUT318.

FIG. 3Ddepicts the process once the sensor FOUP304has been delivered to the DUT318. The DUT318may extract the sensor wafer308from the sensor FOUP304and begin executing the recipe. By way of example, and not by way of limitation, the DUT may extract the sensor wafer308in a manner similar to how a wafer would be processed under normal processing conditions. This may include using a wafer transporting robot, such as a SCARA, or by manually extracting the sensor wafer from the sensor FOUP304.

Once the recipe has been completed, the DUT318may deliver the sensor wafer back to the sensor FOUP304. The DUT318may also deliver a message to the FA server310over the network160indicating that the analysis has been competed as indicated by arrow5. The FA server310may then send an instruction over the network160instructing the AMHS306to retrieve the sensor FOUP304and deliver it back to a smart docking station303, as indicated by arrow6. The AMHS306may then travel to the DUT318as indicated by arrow7to pick up the sensor FOUP304. It should be noted that the sensor FOUP304does not need to be delivered back to the same smart docking station303that it originated from. By way of example, and not by way of limitation, the sensor FOUP304may be delivered to the nearest available smart docking station303or a smart docking station303that is proximate to a tool where the next analysis may be performed.FIG. 3Edepicts the AMHS306retrieving the sensor FOUP304and delivering it to a smart docking station303as indicated by arrow8.

When the sensor FOUP304is docked at the smart docking station303and the data connection212has been reestablished, the data logged by the sensor wafer308may be downloaded by the smart docking station303. Additionally, once the electrical connection211has been reestablished, the smart docking station303may begin providing a charge to the battery213in the sensor FOUP304and the battery214in the sensor wafer308so they are each ready for their next mission. As indicated by arrow9, the smart docking station may then upload the logged data from the sensor wafer308to the sensor wafer server319over the network160. In implementations where the sensor FOUP304is configured to communicate wirelessly, the upload of the logged data may be implemented directly between the sensor FOUP and the sensor wafer server319via wireless link, as indicated by the dotted arrow9A. Data may optionally be sent directly from the sensor FOUP304to the FA server310by wireless link, as indicated by the dotted arrow9B. The sensor wafer server319may save the raw data and may also process the data into a desired format. By the way of example and not by the way of limitation, the data may be processed such to extract relevant statistical summaries useful for the Fabrication facility to perform Statistical Process Charts (SPC). A data summary in a standard format such similar to Microsoft Excel® or OpenOffice™ may also be available. Excel® is a registered trademark of Microsoft Corporation of Redmond, Wash.

In some implementations, the FA server310may optionally send a request for the data to the sensor wafer server319over the network160as indicated by arrow10inFIG. 3F. The sensor wafer server319may then deliver the requested data to the FA server310as indicated by arrow11. The sensor wafer server319may deliver the processed data, the raw data, or both to the FA server310. According to some aspects of the present disclosure, the FA server310and the sensor wafer server319may be implemented on the same hardware, but remain logically separate. Alternatively, the FA server310, and the sensor wafer server319may be implemented on separate hardware. It is further noted that there is no requirement that the FA server310and sensor wafer server319to exchange data directly.

As shown inFIG. 3G, a set of smart docking station instructions370may be implemented, e.g., by the smart docking station303. The smart docking station instructions370may be formed on a non-transitory computer readable medium such as the memory132or the mass storage device134. The smart docking station instructions370may also be part of the process control program133. The instructions include receiving, from a robotic wafer delivery system, a sensor wafer308that has completed a mission and has one or more sets of data stored in its memory132SWat371. Next, the smart docking station instructions370include establishing a data connection312between the smart docking station303and the sensor wafer308at372. Next at373, the smart docking station303is instructed to download the one or more sets of data from the memory132SWof the sensor wafer308. Once the data has been downloaded, the instructions370continue by instructing the smart docking station303to deliver the downloaded data over the network160to a server at374. Optionally, at375the smart docking station303is provided with instructions for receiving a mission from a factory automation server310over the network160. Then at376, the instructions370optionally include delivering the mission to the sensor wafer308over the data connection312.

The reverse holds true as well. In particular, the processes indicated at371through376deal with how to transmit a command to start a mission. After a FOUP (and its wafer308) are returned back as shown inFIG. 3F, steps371through375can be performed again but this time the mission data acquired by the sensor wafer during the mission is moved from the wafer to the FOUP.

FIGS. 4A-4Fare process flow diagrams of the automated tool diagnostic system400according to an additional aspect of the present disclosure. In the figures, solid lines indicate the transfer of data over the network, and the dotted lines indicate physical motion of a component.

FIG. 4Adepicts the process at an initial starting state. At this starting state, a sensor wafer408is housed within a smart docking station403. The smart docking station403may be located within a tool405in a cleanroom environment. A dumb FOUP404′ (i.e., a FOUP that may be used for transporting regular wafers and does not require an electrical or data connection) is currently docked at the tool405that houses the smart docking station403. In this starting state, the smart docking station403may be providing a charge to the battery214in the sensor wafer408. The process is initiated by the FA server410sending a mission to the smart docking station403over the network160as indicated by arrow1A. By way of example, and not by way of limitation, the mission may include instructions for the sensor wafer408indicating which tool needs to be analyzed, what process needs to be analyzed and what data needs to be logged during the analysis. The smart docking station403may then deliver the mission to the sensor wafer408over the data connection212. The smart docking station403may optionally send a confirmation message back to the FA server410indicating that the appropriate sensor wafer408is located at the smart docking station403. If the sensor wafer408assigned to carry out the mission is not located at the smart docking station403that received the instruction from the FA server410, then an exception may be delivered to the FA server410.

The FA server410may also deliver the recipe to the DUT418over the network160as indicated by arrow1B. By way of example, and not by way of limitation, the recipe may include the processing conditions that need to be used for the analysis and the identification number of the sensor wafer408that will be logging the data. The recipe may be delivered to the DUT418before, after, or at the same time the mission is delivered to the sensor wafer408.

InFIG. 4B, the sensor wafer408is extracted from the smart docking station403by the tool405and inserted into a FOUP404′ so it may be transported by the AMHS406. By way of example, and not by way of limitation, the tool405may extract the sensor wafer408in a manner similar to how a wafer would be handled under normal processing conditions. This may include using a wafer transporting robot, such as a SCARA, or by extracting the sensor wafer408from the smart docking station403and inserting it into the FOUP404′ manually. The electrical connection211and the data connection212between the smart docking station403and the sensor wafer408are each disconnected when the sensor wafer408is extracted from the smart docking station403.

Once the recipe and the mission have been delivered, the FA server410may send instructions over the network to the AMHS406instructing it to retrieve the sensor wafer408and deliver it to the DUT418as indicated by arrow2inFIG. 4B. The AMHS406may travel to the tool405from an arbitrary location as indicted by the dashed arrow3The instructions sent to the AMHS306may also include a priority level for the analysis. By way of example, if the analysis needs to be done immediately, a high priority level may be assigned to the task, or if the analysis is not critical, a low priority may be assigned to the task. Next, inFIG. 4C, the AMHS406retrieves the FOUP404′ housing the sensor wafer408and delivers it to the DUT418as indicated by arrow4.

FIG. 4Ddepicts the process once the FOUP404′ has been delivered to the DUT418. The DUT418may extract the sensor wafer408from the FOUP404and begin executing the recipe. By way of example, and not by way of limitation, the DUT418may extract the sensor wafer408in a manner similar to how a wafer would be handled under normal processing conditions. This may include using a wafer transporting robot, such as a SCARA, or by manually extracting the sensor wafer from the FOUP404′.

Once the recipe has been completed, the DUT418may deliver the sensor wafer back to the FOUP404. The DUT418may also deliver a message to the FA server410over the network160indicating that the analysis has been competed as indicated by arrow5. The FA server410may then send an instruction over the network160instructing the AMHS406to retrieve the FOUP404′ and deliver it back to a tool405with a smart docking station403, as indicated by arrow6. The AMHS406may travel from an arbitrary location to the DUT418as indicated by the dashed arrow7. It should be noted that the FOUP404′ does not need to be delivered back to the same tool405that it originated from. By way of example, and not by way of limitation, the FOUP404′ may be delivered to the nearest tool405with an available smart docking station403or a tool405with a smart docking station403that is proximate to a second DUT418where the next analysis may be performed.FIG. 4Edepicts the AMHS406retrieving the FOUP404′ and delivering it to a tool405with a smart docking station403as indicated by arrow8.

FIG. 4Fdepicts the process once the FOUP404′ has been delivered to a tool405housing the smart docking station403. The tool405may extract the sensor wafer408from the FOUP404. By way of example, and not by way of limitation, the tool205may extract the sensor wafer408in a manner similar to how a wafer would be handled under normal processing conditions. This may include using a wafer transporting robot, such as a SCARA, or by manually extracting the sensor wafer from the FOUP404′.

After the sensor wafer408is docked at the smart docking station403and the data connection212has been reestablished, the data that has been logged by the sensor wafer408may be downloaded by the smart docking station403. Additionally, after the electrical connection211has been reestablished, the smart docking station403may begin providing a charge to the battery214in the sensor wafer408so that the sensor wafer408is ready for its next mission. As indicated by arrow9, the smart docking station may then upload the logged data from the sensor wafer408to the sensor wafer server419over the network160. The sensor wafer server419may save the raw data and may also process the data into a desired format.

In an optional process, the FA server410may send a request for the data to the sensor wafer server419over the network160as indicated by arrow10. The sensor wafer server419may then optionally deliver the requested data to the FA server410as indicated by arrow11. The sensor wafer server419may deliver the processed data, the raw data, or both to the FA server410. According to some aspects of the present disclosure, the FA server410and the sensor wafer server419may be implemented on the same hardware, but remain logically separate. Alternatively, the FA server410, and the sensor wafer server419may be implemented on separate hardware. It is further noted that there is no requirement that the FA server410and sensor wafer server419to exchange data directly.

It is noted that, for the purposes of example, the tool405having the smart docking station403and the device under test418are shown as being different devices, e.g., different tools. However, it is within the scope of aspects of the present disclosure for both tool405and the DUT418to be the same device, e.g., the smart docking station may be a component of the DUT418. In such cases, transfer of the sensor wafer408to the docking station may be implemented without having to transfer the FOUP404′ from the DUT418back to the tool405and the docking station at the DUT418(not shown) may upload data from the sensor wafer408to the sensor wafer server419or FA server410.

It is further noted that in the examples shown inFIGS. 3A-3FandFIGS. 4A-4Fthe sensor wafer server and the factory automation server are shown as being different servers. This is not a strict requirement, although it is sometimes convenient in practical implementations. Alternatively, the functions of the sensor wafer server and factory automation server may be implemented by the same hardware, e.g., a common server. For example, functions of the sensor wafer data server419may be implemented by the factory automation server410. In such a case, the factory automation server410may communicate directly with the sensor wafer408via the smart docking station403.

The appended claims are not to be interpreted as including means-plus-function limitations, unless such a limitation is explicitly recited in a given claim using the phrase “means for.” Any element in a claim that does not explicitly state “means for” performing a specified function, is not to be interpreted as a “means” or “step” clause as specified in 35 USC §112, ¶6. In particular, the use of “step of” in the claims herein is not intended to invoke the provisions of 35 USC §112, ¶6.