Abstract:
A system for carrying out the automated processing of fluids. The system has combinable and interchangeable process modules ( 38, 39, 40 ), which each contain a control unit ( 6 ) and a fluid unit ( 7 ) that can be controlled by the control unit in order to execute a module-specific process function. The control units ( 6 ) are interconnected via a data bus ( 10 ) which is shared by process modules ( 38, 39, 40 ), and the fluid units ( 7 ) are interconnected via a fluid bus ( 44 ) having a number of channels ( 45 ). The configuration of at least one portion of the channels ( 45 ) of the fluid buses ( 44 ) can be varied in the areas of their respective connection to the fluid units ( 7 ) by using configuration devices, which can be provided in the form of adapters ( 41, 42, 43 ) located between the process modules ( 38, 39, 40 ) and the fluid bus ( 44 ).

Description:
[0001]    This is a Continuation of International Application PCT/DE00/03994, with an international filing date of Nov. 13, 2000, which was published under PCT Article 21(2) in German, and the disclosure of which is incorporated into this application by reference. 
     
    
     
       FIELD OF THE INVENTION  
         [0002]    The invention relates generally to a system used in the field of automated processing of fluids. In particular, the invention relates to a system for the automated processing of fluids using combinable and interchangeable process modules.  
         BACKGROUND OF THE INVENTION  
         [0003]    U.S. Pat. No. 5,083,364 discloses a system for producing semiconductor substrates, which consists of a plurality of aligned process modules. The process modules are supplied with data, energy and the required chemicals, gases and liquids via a shared media bus. The fluids are also discharged via the media bus. At least one of the process modules is configured for feeding the fluids into a fluid bus or discharging the fluids. The media bus has electric lines for data and energy transmission and also has various pipes for carrying the different fluids. At a grid spacing defined by the size of the process modules, terminal boxes with electrical connections and fluid connections are provided along the media bus to which the individual process modules can be connected by means of corresponding mating connections. The fluid connections are equipped with self-closing valves, which outwardly seal the corresponding fluid connection if it is not connected to a respective mating connection of a process module. Within the prior art system disclosed in U.S. Pat. No. 5,083,364, individual process modules can be comparatively easily added, removed or replaced as required.  
           [0004]    The fluid bus of this prior art system is configured especially for the fluids required for the production of semiconductor substrates and for this purpose, the system is equipped with various pipes, which, in some cases, have different diameters and cross sections. The variability and applicability of this prior art system is therefore limited specifically to the production process of semiconductor substrates.  
           [0005]    EP-A-0 303 565 discloses a system for producing a chemical product. Different production steps are carried out in respective fixed or mobile process modules, which each comprise a control unit and a chemical unit. The corresponding production step for each process module is carried out in the respective chemical unit and controlled by the control unit. The control units of the different process modules are connected to a process control system via data lines. The materials required or accumulated during production are supplied to or discharged from the individual chemical units within the process modules via supply and discharge lines. Thus, modularity and flexibility are essentially achieved on the control side, but not on the process side.  
         OBJECTS OF THE INVENTION  
         [0006]    An object of the present invention is to provide a system for the automated processing of fluids and which provides improved modularity and corresponding flexibility.  
         SUMMARY OF THE INVENTION  
         [0007]    In accordance with the invention, the above and other objects are attained by the provision of a system for automated processing of fluids, the system having combinable, interchangeable process modules. Each process module includes a control unit and a fluid unit that can be controlled by the control unit to execute a module-specific process function within the context of the processing of the fluids. The control units are interconnected via a data bus, which is shared by the process modules, and the fluid units are interconnected via a fluid bus which comprises a plurality of channels. The configuration of at least one portion of the channels of the fluid bus can be varied by using a configuration device in the area of the connections of the fluid bus with the fluid units. Processing of fluids should be understood, in particular, as the analysis or synthesis of fluids, including the required secondary functions. These fluids can be liquids, gases, or solids transported by using carrier fluids.  
           [0008]    Due to the adjustability of the channel configuration in the connection areas of individual process modules with the fluid bus, extensive modularity and flexibility of the inventive system is ensured not only on the control side but also on the process side, since, in contrast to the prior art systems, the channels are not pre-assigned. For instance, depending on the configuration settings, fluid units of the same type of process modules can be connected with different channels of the fluid bus as required. Preferably, individual channel segments between adjacent process modules can be shut off using the configuration devices so that, for instance, a channel located on both sides of a particular process module can be occupied with different fluids. Furthermore, individual channels between different predefined process modules can be occupied with a fluid in segments depending on the respective channel configuration set in their area. Individual channels or channel segments can also be connected in parallel to obtain a larger flow cross section.  
           [0009]    The configuration devices can each be designed as adapters, which connect the corresponding process module to the fluid bus. Depending on the particular adapter used, this results in different interconnections between the channels of the incoming and the outgoing fluid bus and the fluid inlets and outlets of the fluid unit in the respective process module.  
           [0010]    The adapter preferably comprises an information interface to the connected process module for transmitting information on the configuration settings to the intra-module control unit. The control unit is configured to forward this information via the data bus to a higher-level control unit and/or to the control units in the other process modules, respectively. The channel configuration settings are then, for instance, displayed on a visualization device of the higher level control unit or are available as information for the other process modules, such that misassignments of the channels, e.g., the unintended introduction of two different fluids into one and the same channel or channel segment can be detected. The information on the channel configuration that is set by the corresponding adapter is available, for instance, in the form of coding, which can be read by the control unit in the associated process module.  
           [0011]    According to an alternative embodiment of the inventive system, the fluid bus is formed by internal fluid bus segments within a succession of process modules. The configuration devices are embodied as configuration modules, which can be inserted between individual process modules in the row of process modules. Depending on the configuration module used, this results in different interconnections of the channels of adjacent process modules.  
           [0012]    Preferably, the configuration modules each have a configuration signaling unit connected to the data bus, which is used to transmit information on the configuration settings via the data bus to a higher level control unit and/or to the control units in the process modules. Consequently, the channel configuration settings are displayed, for instance, on a visualization device of the higher level control unit or are available as information to the process modules, so that any misassignments of the channels can be detected.  
           [0013]    Finally, the configuration devices can also each be a component of at least individual process modules and can be controlled by the intra-module control unit to set the corresponding channel configuration. This makes it possible, e.g., from a central location, automatically to configure the entire fluid bus via the data bus and the control units in the individual process modules.  
           [0014]    The controllable configuration device preferably has controllable valves along the course of the channels of the fluid bus and along the course of channel branchings to the corresponding fluid unit. One-way valves or multi-way valves combining the functions of several one-way valves may be provided.  
           [0015]    The control units are preferably each designed to signal the configuration settings of the channels via the data bus to a higher level control unit that is connected to the data bus and/or to the control units in the respective other process modules. The channel configuration settings are then, for instance, displayed on a visualization device of the higher level control unit or are available as information to the respective other process modules, whose control units can then set the configurations of the channels that they control as a function of the configurations set in the respective other process modules. This makes it possible effectively to detect or prevent misassignments of the channels.  
           [0016]    The fluid bus is preferably formed by internal fluid bus segments within the aligned process modules, such that it is automatically formed by the alignment of the process modules required to construct each system.  
           [0017]    The fluid bus can at least in part be designed by using micro-system technology or a comparable technique. For example, starting from lithographic processes for structure transfer, a three-dimensional configuration, in this case of the channels, can be obtained by different micro-mechanical processes, e.g. anisotropic etching of silicon, micro-electroplating, laser processes, etc. Preferably, the configuration devices are likewise designed by micro-system technology.  
           [0018]    To obtain a precise inter-connection of the individual fluid bus segments, particularly in view of the configuration of the fluid bus by micro-system technology, and, furthermore, to simplify the alignment of the various process modules, the process modules are preferably mounted on a common carrier, e.g., a top hat rail.  
           [0019]    In accordance with yet another embodiment, a system for automated processing of fluids is provided, the system having a plurality of combinable, interchangeable process modules, each process module executing a different, respective module-specific process function. Also, each process module has a control unit operable to control the process module and a fluid unit controlled by the control unit to execute a unique respective module-specific process function. A shared data bus is connected to the control units and interconnects the control units associated with each respective process module. In accordance with this embodiment, a fluid bus is also provided which is connected to the fluid unit and which has a plurality of channels associated therewith. The fluid bus is operable to interconnect the fluid unit of each process module with other fluid units associated with other respective process modules. Also, a configuration device is provided to vary the configuration of at least one portion of the channels of the fluid bus. The configuration device has at least one valve for controlling a flow of a respective fluid from the fluid unit to the fluid bus or from the fluid bus to the fluid unit.  
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0020]    For the further description of the invention, reference will be made to the figures in which:  
         [0021]    [0021]FIG. 1 is a simplified block diagram of a first exemplary embodiment of the inventive system formed by different process modules,  
         [0022]    [0022]FIG. 2 shows an example of one of the process modules, p FIG. 3 is a block diagram, by way of example, of one of the process modules,  
         [0023]    [0023]FIG. 4 is a second embodiment of the inventive system, and  
         [0024]    [0024]FIG. 5 is a third embodiment of the inventive system. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0025]    [0025]FIG. 1 shows a system for the automated processing of fluids, e.g., differing liquids or gases. Processing should be understood, for instance, as the analysis of the fluids or the synthesis by chemical reactions of fluids, including the required secondary functions, such as preparing, mixing, filtering, transporting, or pressurizing using pumps, heating, evaporating, etc. A system in accordance with the present invention includes various process modules connected in succession,  1 - 5 , in each of which module-specific process functions are automatically executed. Depending on the aforementioned processing functions, process modules  1 - 5  can, for instance, be different types of analysis modules, reactor modules, e.g., with microreactors, pump modules, filter modules, energy supply modules, fluid supply and fluid discharge modules, etc. Each process module  1 - 5  has a respective control unit  6   n  (n being 1, 2, 3, 4 or 5) and a respective fluid unit  7   n . The actual process or treatment function each process module is performed within fluid unit  7   n  as a function of control signals  8   n  of control unit  6   n . Process signals  9   n , e.g., pressure values or analysis values that are recorded in fluid unit  7   n , are transmitted to control unit  6   n . Control units  6   n  in the various different process modules  1 - 5  are interconnected via a data bus  10  and a power supply bus  11 . The fluid units  7   n  are interconnected via a fluid bus  12 , which consists of a plurality of parallel channels  13  that conduct the required fluids. In the area of the connection of fluid bus  12  with the individual fluid units  7   n  in process modules  1 - 5 , respective configuration devices  14 , which can be controlled by control units  6   n , are provided. Each of these configuration devices are used to set the configuration of channels  13 , as will be further described below.  
         [0026]    Process modules  1 - 5 , in addition to the connections with data bus  10 , power supply bus  11 , and fluid bus  12 , can have further external connections. In the example shown, process module  1  serves to provide the basic functions for the system. For this purpose, control unit  6   n  is connected to a external power source  15  and, via a data connection, e.g. a external bus  16 , to a higher-level control unit  17  with a visualization device  18 . External fluid lines  19  and  20  are connected to fluid unit  7   n  to supply or discharge the required fluids to and from the system. For energy supply, a battery or fuel cell module (not shown) may also be considered as a alternative. In process module  2 , for example, a fluid is fed into the system via supply reservoir  21 , which can be connected to process module  2 , whereas, a discharge reservoir  22  is connected, for instance, to process module  5  to receive a fluid that is discharged from the system.  
         [0027]    As indicated schematically in the Figure, data bus  10 , power supply bus  11  and fluid bus  12  are each formed by internal bus segments within the aligned process modules  1 - 5 . Process modules  1 - 5  are mounted side by side on a common carrier, in this case a top hat rail  23 . Buses  10 - 12  are formed by sliding or clipping the respectively required process modules  1 - 5  onto top hat rail  23 . In the example shown in FIG. 1, five process modules are shown, however, more or less process modules can be used.  
         [0028]    [0028]FIG. 2 shows a example of a individual process module  24 , which is slid onto top hat rail  23  and has laterally formed bus interfaces  25 ,  26 , and  27  to connect the internal bus segments (not depicted) with those of each adjacent process module to form data bus  10 , power supply bus  11 , and fluid bus  12 , respectively.  
         [0029]    Bus interface  27  for fluid bus  12  is made by using micro system technology and has approximately 20 to 50 channel openings  28 . As FIG. 2 further shows, the front face of process module  24  is provided with display elements  29  and control elements  30  to display and enter basic settings of process module  24 . Also show by way of example is a external supply line  31  for feeding a fluid into the system formed by process module  24  and the other process modules, which are not depicted here.  
         [0030]    [0030]FIG. 3 shows a schematic block diagram of a process module  32  comprising a control unit  6 , a fluid unit  7 , a configuration device  14  and the bus segments of data bus  10 , power supply bus  11 , and fluid bus  12  with channels  13  formed within process module  32 . The configuration device  14 , along the course of channels  13  and along the course of channel branchings  33  to fluid unit  7 , comprises controllable valves  34 , which can be individually switched by control unit  6   n  and are made, for instance, by using micro-system technology. The configuration of channels  13  in the area of the connection of fluid bus  12  with fluid unit  7   n  can be adjusted by switching the valves  34 , in order to connect predefined inlets and outlets  35 ,  36  of fluid unit  7   n  to predefinable channels  13 , to block channel segments to the respectively adjacent process modules (not depicted), or to occupy sections of individual channels  13  between different process modules with a fluid. The setting of the configuration of channels  13  in process module  32  is signaled by control unit  6   n  via data bus  10  to the higher level control unit  17 , where it is displayed on visualization device  18  to give an overview of the channel configuration of the entire fluid bus  12 . The channels  13  of fluid bus  12  in each of the individual process modules  1 - 5 ,  24 ,  32  can be configured from control unit  17 . The valves  34 , as depicted here, can be embodied as one-way valves. Alternatively, a single multiway valve can replace several one-way valves, e.g. the valves labeled  37 .  
         [0031]    In the embodiment of the inventive system show in FIG. 4, process modules  38 ,  39  and  40 , in accordance with the above-described examples, each have a respective control unit  6   n  and a respective fluid unit  7 . The control units  6   n  are interconnected by a data bus  10  and a power supply bus  11 . The configuration devices in this case are embodied as adapters  41 - 43  via which the process modules  38 ,  39  and  40  with their respective fluid units  7   n  are connected to a fluid bus  44 . Depending on the adapter  41  to  43  used, this results in a different interconnection between channels  45  of the incoming and the outgoing fluid bus  44  and the fluid inlets and outlets  46  of fluid unit  7   n  in the corresponding process module  38  to  40 . Each adapter, e.g.  43 , has a information interface  47  to the connected process module, e.g.  40 , to transmit information on the configuration settings to the intra-module control unit  6 . Control unit  6   n  forwards this information in accordance with the example show in FIG. 1 via data bus  10  to a higher level control unit  17 . The corresponding information in this case is stored, for instance, as coding in a chip  48  of adapter  43 , such that control unit  6   n  can read this information via information interface  47 .  
         [0032]    In the embodiment show in FIG. 5 of the inventive system, the process modules  49  and  50 , in accordance with the above-described examples, each have a control unit  6   n  and a fluid unit  7 . The control units  6   n  are again interconnected via a data bus  10  and a power supply bus  11 . The fluid units  7   n  are connected to fluid bus segments  51  or  52  formed within process modules  49  and  50 . The fluid bus segments  51  or  52  of all the aligned process modules  49  and  50  form the fluid bus  53  of the system. The configuration devices in this case are embodied as configuration modules  54  and  55 , which can be inserted between individual process modules in the row of process modules, here  49  and  50 . Depending on the configuration module  54  or  55  used, this results in a different interconnection of channels  56  of adjacent process modules  49  and  50 .  
         [0033]    The configuration modules  54  and  55  in this case each have a configuration signaling unit  57 , which is connected to data bus  10 , to transmit information regarding the configuration settings via data bus  10  to a higher level control unit ( 17 , FIG. 1). As indicated by a dashed line, this information can alternatively or additionally be read as coding by control units  6   n  of the immediately adjacent process modules  49  or  50 , analogous to the example described in FIG. 4, via information interface  58 , and can subsequently be output to data bus  10 .  
         [0034]    The above description of the preferred embodiments has been given by way of example. From the disclosure given, those skilled in the art will not only understand the present invention and its attendant advantages, but will also find apparent various changes and modifications to the structures and methods disclosed. It is sought, therefore, to cover all such changes and modifications as fall within the spirit and scope of the invention, as defined by the appended claims, and equivalents thereof.