Patent Description:
Examples of a currently-used first apparatus of this type includes one including a memory unit, an image capturing unit , an abnormality detecting unit, and a display unit. See, for example, <CIT>.

<CIT> discloses a movable part position detection method, a substrate treatment method, a substrate treatment device and a substrate treatment system.

The memory unit stores in advance normal video data indicating a normal processing state in the apparatus. The imaging unit obtains video data while the apparatus operates actually. The abnormality detecting unit calculates a degree of abnormality in accordance with the video data and the normal video data. The display unit displays the degree of abnormality in association with the video data. With the first apparatus, an abnormality can easily be detected while the apparatus that actually performs treatment to a substrate is at work.

Moreover, examples of a currently-used second apparatus of this type includes one including a generating unit, an extracting unit, and a video image generating unit. See, for example, <CIT>.

The generating unit generates detection operation data of a component from history information of operation regarding the component that forms the apparatus. The extracting unit extracts a shape of the component or design operation data from CAD data. The video image generating unit generates a video image that simulates design operation, which is operation during design, and detection operation, which is real operation at work, in accordance with the design operation data and the detection operation data. With the second apparatus, the video image that simulates the operation during designing and the real operation at work is displayed in such a form that both operations can be contrasted. Accordingly, after some inconvenience occurs at work, a cause of the inconvenience can be easily identified after work.

However, the example of the currently-used apparatus with such a construction has the following problems. That is, the currently-used first apparatus cannot calculate a degree of abnormality correctly when the normal video data is different from the video data at work in imaging condition. Accordingly, such a drawback is present that the abnormality cannot be detected accurately.

Moreover, the second apparatus specifies a cause of the abnormality after the abnormality occurs at work by comparison with and observation of the video images. Accordingly, the second apparatus is effective in investigating the cause after the occurrence of the abnormality, but the second apparatus cannot detect the abnormality when the apparatus is at work. Consequently, improper treatment to the substrate may be performed continuously.

The present invention has been made regarding the state of the art noted above, and its object is to provide a substrate treating apparatus, a substrate treating system, and a substrate treating method that can detect an abnormality accurately at work by synchronizing an image based on design information with a recipe and using the image.

The present invention is constituted as stated below to achieve the above object.

One aspect of the present invention provides a substrate treating apparatus for performing predetermined treatment to a substrate, the substrate treating apparatus including: a recipe memory unit configured to store a recipe, specifying operation details and an execution order of a component that forms the substrate treating apparatus, to perform the predetermined treatment; an imaging unit provided at a predetermined location and configured to image the component as a real image at work; a normal image memory unit configured to simulate a condition in advance where the component normally operates in response to the recipe and store in advance a normal image at this time in a view from the location of the imaging unit in accordance with three-dimensional design information of the substrate treating apparatus; an operation controller configured to control the component in response to the recipe to perform the predetermined treatment; and an abnormality detecting unit configured to detect an abnormality in accordance with a difference between the normal image synchronized with operation of the recipe and the real image at work when the operation controller actually treats the substrate in response to the recipe.

According to the aspect of the present invention, the abnormality detecting unit detects an abnormality in accordance with the difference between the normal image synchronized with operation of the recipe and the real image at work when the operation controller actually treats the substrate in response to the recipe. The normal image is an image obtained by simulating a condition in advance where the component normally operates in response to the recipe and storing in advance the normal image at this time in the view from the location of the imaging unit in accordance with the three-dimensional design information of the substrate treating apparatus. Accordingly, since all the apparatus have the same imaging condition, an adverse effect due to difference in imaging condition can be avoided. Moreover, an image to be compared can be prevented from deviation since it is synchronized with the operation of the recipe. Accordingly, an abnormality can be detected accurately at work.

Moreover, it is preferred in the aspect of the present invention that the imaging unit captures the real image as a video image and the normal image memory unit stores the normal image as a video image.

Both the real image and the normal image are the video images, an abnormality can be easily detected between the image when the component moves and the image after the component moves. Moreover, this yields increase in number of target areas for abnormality detection.

Moreover, it is preferred in the aspect of the present invention that the abnormality detecting unit performs synchronization with reference to an arbitrary step among a plurality of steps constituting the recipe.

The abnormality detection is performable at any timing within the recipe. This yields easy setting of a desired abnormality detection position.

Moreover, it is preferred in the aspect of the present invention that the substrate treating apparatus further includes a spin chuck configured to support a substrate in a horizontal posture and rotate the substrate, a nozzle configured to eject a treatment liquid from its distal end to the substrate supported by the spin chuck, and a nozzle moving mechanism configured to move the distal end of the nozzle from an origin position laterally apart from the substrate and an ejecting position above the substrate, and that the abnormality detecting unit detects an abnormality about movement of the nozzle.

The abnormality detecting unit can detect an abnormality about the movement of the nozzle by the nozzle moving mechanism.

Moreover, it is preferred in the aspect of the present invention that the substrate treating apparatus further includes a spin chuck configured to support a substrate in a horizontal posture and rotate the substrate, and a fixed nozzle whose arrangement is fixed and configured to eject a treatment liquid from its distal end to the substrate supported by the spin chuck, and that the normal image memory unit includes, as the normal image, an image obtained by simulating a normal ejection condition of the treatment liquid from the fixed nozzle in view of the location by a fluid simulator.

The normal image contains an image simulated by the fluid simulator. Accordingly, an abnormality about ejection of the treatment liquid from the fixed nozzle can be detected.

Moreover, it is preferred in the aspect of the present invention that a substrate treating system includes a plurality of any type of the substrate treating apparatus described above.

The substrate treating system provided with the plurality of substrate treating apparatus can also detect an abnormality accurately at work.

Moreover, it is preferred in the aspect of the present invention that the substrate treating apparatus each include a score memory unit configured to store a score in accordance with the difference detected by the abnormality detecting unit, and further include a system controller configured to read out a score of the score memory unit and a display unit configured to display the score read out by the system controller.

The system controller reads out the score of the score memory unit in the substrate treating apparatus, and displays it on the display unit. This can easily understand a difference between the substrate treating apparatus having the same construction. Consequently, visualizing the difference in operation can contribute to reduction of the difference between the substrate treating apparatus.

For the purpose of illustrating the invention, there are shown in the drawings several forms which are presently preferred, it being understood, however, that the invention is not limited to the precise arrangement and instrumentalities shown.

The following describes one embodiment of the present invention with reference to drawings.

<FIG> is a side view of a substrate treating apparatus according to an embodiment. <FIG> is a plan view of the substrate treating apparatus according to the embodiment.

A substrate treating apparatus <NUM> is a single-wafer processing apparatus for treating substrates W one by one. The substrate W has a circular shape in plan view, for example. The substrate treating apparatus <NUM> performs predetermined treatment on the substrate W by supplying a treatment liquid while rotating the substrate W.

The substrate treating apparatus <NUM> includes a casing CA. The casing CA blocks the interior thereof from the surrounding atmosphere. The substrate treating apparatus <NUM> includes a spin chuck <NUM>. The spin chuck <NUM> has a circular shape whose diameter is larger than a diameter of the substrate W in plan view. The spin chuck <NUM> includes a lower face connected to an upper end of a rotary shaft <NUM>. A lower end of the rotary shaft <NUM> is connected to a motor <NUM>. When the motor <NUM> is driven, the spin chuck <NUM> rotates around a rotation center P1. The rotation center P1 extends in a vertical direction.

The spin chuck <NUM> includes a plurality of chucks <NUM>. The spin chuck <NUM> includes the chucks <NUM> at a peripheral edge of an upper face thereof. In the present embodiment, the spin chuck <NUM> includes four chucks <NUM>. The number of chucks <NUM> is not limited to four as long as the substrate W can rotate stably around the rotation center P1 while being supported in a horizontal posture.

The chucks <NUM> each include a back face supporting portion <NUM> and a periphery edge supporting portion <NUM>. The back face supporting portion <NUM> contacts and supports a back face of the substrate W. It is preferred that the back face supporting portion <NUM> is formed so as to have a small contact area to the back face of the substrate W. This can reduce a degree of mutual contamination. The back face supporting portion <NUM> is attached to the upper face of the spin chuck <NUM> so as to rotate freely around a rotation center P2. The rotation center P2 extends in a vertical direction. The periphery edge supporting portion <NUM> is erected on an upper face of the back face supporting portion <NUM>. It is preferred that the periphery edge supporting portion <NUM> is formed so as to have a height from the front face of the back face supporting portion <NUM> larger than a thickness of the substrate W. Such a construction can hold the periphery edge of the substrate W stably. The periphery edge supporting portion <NUM> is provided apart from the rotation center P2 toward an outer edge of the back face supporting portion <NUM> in plan view. In other words, the periphery edge supporting portion <NUM> is eccentric from the rotation center P2.

A rotating magnet <NUM> is attached to the lower face of the spin chuck <NUM> at a position corresponding to the rotation center P2. The rotating magnet <NUM> is connected to the back face supporting portion <NUM>. The rotating magnet <NUM> is provided so as to rotate freely around the rotation center P2. A chuck drive mechanism <NUM> is located below the rotating magnet <NUM>.

The chuck drive mechanism <NUM> is located more adjacent to the rotary shaft <NUM> than the chucks <NUM>. The chuck drive mechanism <NUM> includes an air cylinder <NUM> and a driving magnet <NUM>, for example. The driving magnet <NUM> has an annular shape in plan view. The air cylinder <NUM> is located in a posture where an operating shaft thereof is directed along the vertical direction. The driving magnet <NUM> is attached to a tip end of the operating shaft of the air cylinder <NUM>. The chuck drive mechanism <NUM> is operated in response to a chuck operation command. When the chuck drive mechanism <NUM> is in an actuated state, the driving magnet <NUM> moves upward to approach the chucks <NUM>. When the chuck drive mechanism <NUM> is in a non-actuated state, the driving magnet <NUM> moves downward to move apart from the chucks <NUM>.

The chucks <NUM> each include a bias mechanism not shown. When the driving magnet <NUM> moves downward, the chuck <NUM> comes into a closed position. When the driving magnet <NUM> moves upward, the chuck <NUM> comes into an open position. In the closed position, the periphery edge supporting portion <NUM> rotates about the rotation center P2, and approaches toward the rotation center P1 to contact the periphery edge of the substrate W. This can cause the chucks <NUM> to grip the substrate W at the closed position. In the open position, the periphery edge supporting portion <NUM> rotates about the rotation center P2, and moves apart from the rotation center P1. This can cause the chucks <NUM> to load and unload the substrate W at the open position. Here, when the driving magnet <NUM> moves downward while the substrate W is not placed, the periphery edge supporting portion <NUM> is moved into an origin position shifted slightly inward from an outer diameter of the substrate W. In other words, the periphery edge supporting portion <NUM> is located more adjacent to the rotation center P1 at the origin position of the chucks <NUM> than at the closed position.

An origin sensor Z <NUM> is located adjacent to the rotating magnet <NUM> of the chuck <NUM>. The origin sensor Z1 changes an output signal when the chuck <NUM> moves to the closed position or the origin position. For example, the origin sensor Z1 turns an output signal on when the chuck <NUM> moves to the closed position or the origin position.

A guard <NUM> is arranged around the spin chuck <NUM>. The guard <NUM> surrounds the spin chuck <NUM> laterally. The guard <NUM> prevents scattering of a treatment liquid to the surrounding. The guard <NUM> has a tubular shape. An opening 23a of the guard <NUM> is formed at an upper part. An internal diameter of the opening 23a is larger than an outer contour of the spin chuck <NUM>.

The guard <NUM> includes a guard moving mechanism <NUM>. The guard moving mechanism <NUM> includes an air cylinder <NUM> and a locking piece <NUM>, for example. The guard moving mechanism <NUM> is located adjacent to an outer periphery of the guard <NUM>, for example. The guard moving mechanism <NUM> may be located adjacent to an inner periphery of the guard <NUM> as long as the guard <NUM> can move upward and downward. The air cylinder <NUM> is located in an attitude where an operating shaft thereof is directed toward the vertical direction. The locking piece <NUM> is attached to a tip end of the operating shaft of the air cylinder <NUM>. The locking piece <NUM> is fixed to an outer peripheral face of the guard <NUM>. The guard moving mechanism <NUM> is not limited to this construction as long as the guard <NUM> can move upward and downward.

The guard moving mechanism <NUM> moves the guard <NUM> between the origin position and the treating position in response to a guard operation command. The origin position is a position where an upper end of the guard <NUM> is low. The origin position is lower than the treating position. The treating position is higher than the origin position. An upper edge of the guard <NUM> is lower than the substrate W, supported by the spin chuck <NUM>, in a state where the guard <NUM> is located at the origin position. The upper edge of the guard <NUM> is higher than the substrate W, supported by the spin chuck <NUM>, in a state where the guard <NUM> is located at the treating position. For example, an origin sensor Z2 is located adjacent to the inner periphery of the guard <NUM>. The origin sensor Z2 changes an output signal when the guard <NUM> moves to the origin position. For example, the origin sensor Z2 turns an output signal on when the guard <NUM> moves to the origin position.

The guard <NUM> includes a plurality of drain ports, not shown, adjacent to the inner periphery thereof. It is preferred that a plurality of guards <NUM> are provided such that the guard moving mechanism <NUM> moves upward and downward to perform switching of the drain ports. In this case, the drain ports are switched in accordance with the treatment liquid, and accordingly, the guard moving mechanism <NUM> changes levels of the guards <NUM>.

A treatment liquid supplying mechanism <NUM> is located adjacent to the outer periphery of the guard <NUM>. The treatment liquid supplying mechanism <NUM> includes a nozzle <NUM> and a nozzle moving mechanism <NUM>, for example. In the present embodiment, the treatment liquid supplying mechanism <NUM> includes two nozzles <NUM>, for example. In the following description, a nozzle on the left side in <FIG> is referred to as a nozzle 33A and a nozzle on the right side is referred to as a nozzle 33B appropriately if the two nozzles <NUM> need to be distinguished. The number of nozzles <NUM> of the treatment liquid supplying mechanism <NUM> may be one or three or more. In the present embodiment, the two nozzles <NUM> have the same construction.

The nozzle <NUM> includes an extension part 33a, a hang-down part 33b, and a distal end 33c. One end of the extension part 33a of the nozzle <NUM> is attached to a base part <NUM>. The extension part 33a extends in a horizontal direction. The other end of the extension part 33a is connected to the hang-down part 33b. The hang-down part 33b extends downward along the vertical direction from the extension part 33a. The distal end 33c forms a lower end of the hang-down part 33b. The distal end 33c ejects a treatment liquid from a lower face thereof. Examples of the treatment liquid include a photoresist, a spin-on glass (SOG) liquid, a developer, a rinse liquid, deionized water, and a cleaning liquid.

The nozzle moving mechanism <NUM> includes a motor <NUM>, a rotary shaft <NUM>, and a position detector <NUM>, for example. The motor <NUM> is arranged in a vertical posture. The rotary shaft <NUM> is rotated around a rotation center P3 by the motor <NUM>. The rotary shaft <NUM> is connected to the base part <NUM>. The base part <NUM> is rotated by drive of the motor <NUM>. The nozzle <NUM> swings around the rotation center P3 together with the base part <NUM>. The position detector <NUM> detects a rotation position of the rotary shaft <NUM>. The position detector <NUM> detects an angle of the rotary shaft <NUM> around the rotation center P3 in plan view. The position detector <NUM> outputs a pulse in accordance with the rotation position.

A standby cup <NUM> is located at a position apart laterally from the guard <NUM> in plan view. The standby cup <NUM> is located opposite to the base part <NUM> and adjacent to the distal end 33c of the nozzle <NUM> in plan view. The standby cup <NUM> is located at the origin position of the nozzle <NUM>. The standby cup <NUM> prevents drying of the distal end 33c of the nozzle <NUM>. The standby cup <NUM> is used for idle ejection of the nozzle <NUM>. The nozzle moving mechanism <NUM> drives the motor <NUM> to swing the nozzle <NUM>. The nozzle moving mechanism <NUM> moves the distal end 33c between the origin position and the ejecting position of the nozzle <NUM> above the rotation center P1 of the spin chuck <NUM>.

For example, an origin sensor Z3 is located adjacent to an outer periphery of the rotary shaft <NUM>. The origin sensor Z3 changes an output signal when the nozzle <NUM> is located at the origin position. For example, the origin sensor Z3 turns an output signal on when the nozzle <NUM> moves to the origin position. Here, the origin sensor Z3 is omittable for a simple construction. In this case, a projection is provided on a part of the rotary shaft <NUM> and a projection is provided on a fixed and immovable side of the rotary shaft <NUM>. The projections contact through rotation of the rotary shaft <NUM> and the position detector <NUM> detects a position where no more rotation is possible. The position is set as the origin position. Such configuration can be adopted. In this case, a position where a pulse of the position detector <NUM> is invariable may be set as the origin position.

A fixed nozzle RN is located at a position apart laterally from the guard <NUM> in plan view. The fixed nozzle RN is arranged on a line, for example, that connects a standby pot <NUM> and the rotation center P1 in plan view. A position of the fixed nozzle RN is fixed. The position is fixed in a height direction and a horizontal direction. A distal end of the fixed nozzle RN is directed toward the rotation center P1. The fixed nozzle RN supplies a treatment liquid. The treatment liquid is supplied from a treatment liquid supplying unit SU to the fixed nozzle RN. Examples of the treatment liquid include deionized water, and a cleaning liquid. The treatment liquid supplying unit SU includes, for example, a control valve, a flow rate regulating valve, and a treatment liquid supplying source, not shown. When the treatment liquid is supplied from the treatment liquid supplying unit SU to the fixed nozzle RN, the treatment liquid is ejected in an annularly trace line, for example. A flow rate or a flow speed of the treatment liquid ejected from the fixed nozzle RN is adjusted by a flow rate regulating valve, not shown, so as for the treatment liquid to drop near an intersection of a front face of the substrate W and the rotation center P1.

A camera CM is attached to one area of the casing CA. For example, the camera CM is attached in a predetermined location corresponding to a corner adjacent to the guard moving mechanism <NUM> and on which side the standby cup <NUM> of the nozzle <NUM> is located in plan view. Here, a position where the camera CM is located may be any location as long as a component, described later, is within the field of view. A lens of the camera CM has a viewing angle at which the component described later is entirely within the field of view. The component is an element that constitutes the substrate treating apparatus <NUM>. The component includes a fluid like the treatment liquid. The component is almost one whose position moves over time due to execution of the recipe. The camera CM captures a static image. The camera CM can also capture a video image at a predetermined number of frames per hour.

The substrate treating apparatus <NUM> further includes a control unit <NUM>, an instruction unit <NUM>, and a notification unit <NUM>. Details of the control unit <NUM> is to be described later. The instruction unit <NUM> is operated by an operator of the substrate treating apparatus <NUM>. The instruction unit <NUM> is, for example, a keyboard or a touch panel. The instruction unit <NUM> instructs a component, a timing to check, a tolerance, recipes, start of processing, and the like, which are to be described later. When the control unit <NUM> determines the presence of an abnormality, the notification unit <NUM> notifies the abnormality to the operator. Examples of the notification unit <NUM> include an indicator, a lamp, and a speaker.

Reference is now made to <FIG> is a block diagram of the substrate treating apparatus according to the embodiment.

The control unit <NUM> includes a CPU and a memory, for example. The control unit <NUM> is formed by a plurality of function blocks. Specifically, the control unit <NUM> includes an operation controller <NUM>, a recipe memory <NUM>, a parameter memory <NUM>, a normal image memory unit <NUM>, an image processing unit <NUM>, an image comparison unit <NUM>, an abnormality detecting unit <NUM>, and a score memory unit <NUM>.

The operation controller <NUM> operates the motors <NUM> and <NUM>, the air cylinders <NUM> and <NUM>, the camera CM, and the treatment liquid supplying unit SU described above. The operation controller <NUM> receives signals from the origin sensors Z1 to Z3, and the position detector <NUM>. The operation controller <NUM> operates in response to a recipe specified by the recipe memory <NUM>. For example, the operator instructs a recipe and start of processing, and thereafter the operation controller <NUM> outputs various types of operation commands in accordance with the recipe to actuate the motor <NUM> and the like at a predetermined timing.

The recipe memory <NUM> stores various types of recipes in advance. The recipes define various procedures for treating the substrate W. The recipe specifies operation details and an execution order of a component and a timing of the execution, for example. Specific examples and details of the recipe are to be described later. The operator can operate the instruction unit <NUM> to instruct a desired recipe.

The parameter memory <NUM> stores a target component to be detected for abnormal operation described later, a timing to check, a tolerance, and the like. The component is one of elements, forming the substrate treating apparatus <NUM>, that is detected for abnormality. The timing to check is a timing for checking an operational status of the component. The timing to check is one time point on a time base of the recipe described later. The timing to check synchronizes the execution of the recipe. The timing to check corresponds to one normal image described later. The timing to check is specified during simulation described later, and a desired timing to check can be specified from the instruction unit <NUM>. The operator may optionally operate the instruction unit <NUM> to set the component, the timing to check, the tolerance and the like. The operator may cause the instruction unit <NUM> to instruct which element is set as the component to be detected for abnormal operation, which timing is set as the timing to check, to which degree a timing error or a positional error is acceptable as the tolerance.

The component is, for example, the chuck <NUM>, the guard <NUM>, the nozzle <NUM>, and a treatment liquid from the fixed nozzle RN. The timing to check is, for example, a predetermined timing where the nozzle <NUM> is moved from the origin position to the ejecting position by the nozzle operation command, and a predetermined timing when the treatment liquid is ejected from the fixed nozzle RN.

The tolerance indicates a degree of acceptance of deviation of the real image, described later, for a position where the target component should be (normal image to be described later) if normal operation is performed at the timing to check. The tolerance indicates, for example, an acceptable degree of deviation from a position or an angle where the component is intended by design. The tolerance indicates a range of the deviation of the target component at the timing to check that allows treatment to the substrate W even if the component deviates from the position or the angle intended by design at the timing to check with respect to the treatment to the substrate W as a reference.

The operation controller <NUM> described above informs the image comparison unit <NUM> and the camera CM of the timing to check while executing the recipe in accordance with the timing to check in the parameter memory <NUM>.

The normal image memory unit <NUM> stores a normal image in advance. The normal image is, for example, a static image. The normal image is stored for each recipe stored in the recipe memory <NUM> in association with the timing to check. The normal image is an image based on the three-dimensional design information about assembly and operation of the substrate treating apparatus <NUM>. The normal image is an image obtained by a simulator simulating a condition in advance where the component normally operates in response to the recipe in accordance with the three-dimensional design information of the substrate treating apparatus <NUM> and at this time viewed from the location same as that of the camera CM in a host computer. The normal image is an image obtained in association with a timing to check on a time base of the recipe. A plurality of timings to check may be set at the simulation. In other words, a plurality of normal images can be provided for one recipe. The set timing to check is in association with the recipe. The timing to check is transmitted from the host computer to the parameter memory <NUM>. Specifically, the design information of component corresponds to design information about the components that constitute the substrate treating apparatus <NUM> and a substrate W to be treated. The design information is, for example, data of three-dimensional computer aided design (3D CAD). The design information may contain physical property information about the treatment liquid and various materials used for treatment.

3D CAD data is represented by three axes of orthogonal coordinate, for example. When the components are arranged in a three-dimensional space, the 3D CAD data is represented by positional information about a position and an angle. A host computer, not shown, stores three-dimensional design information as the 3D CAD data about all the components and materials of the substrate treating apparatus <NUM>. The simulator is used for simulating operation of the substrate treating apparatus <NUM>. The simulator is executed by the host computer. The simulator receives the three-dimensional design information of the substrate treating apparatus <NUM> and the recipes. The simulator can operate the substrate treating apparatus <NUM> in response to the recipe. The simulator can operate the components in response to the recipe at predetermined timing and order. In other words, the simulator can operate the substrate treating apparatus <NUM>, assembled along the three-dimensional design information, normally in response to the recipe virtually.

The image processing unit <NUM> processes the real image captured by the camera CM. The image processing unit <NUM> performs an image processing to the real image, and extracts a real image containing a two-dimensional shape of the component. The image processing unit <NUM> performs contour extraction to all the components in the real image, for example. Here, a contour contains not only an outer contour but also an edge part inside of the outer contour. The real image extracted by the image processing unit <NUM> is sent to the image comparison unit <NUM>.

The image comparison unit <NUM> performs comparison between the images. Specifically, comparison is made between the normal image and the real image. The normal image is an image sent from the normal image memory unit <NUM>. The real image is an image sent from the image processing unit <NUM>. The normal image and the real image are synchronized with execution of the recipe by the operation controller <NUM>. That is, the normal image is captured at the timing to check in the recipe when the simulator executes the recipe in advance. The real image is an image that the operation controller <NUM> causes the camera CM to capture in accordance with the timing to check from the parameter memory <NUM> associated with the recipe when the recipe is executed. The image comparison unit <NUM> performs comparison between the normal image and the real image to identify components in the normal image and components in the real image. With such identification, the same components can be compared with each other among the components present in the normal image and the components present in the real image.

The abnormality detecting unit <NUM> performs comparison between the normal image and the real image synchronized by the recipe and detects an abnormality in accordance with a difference between the images. The abnormality is detected taking into consideration of a tolerance in the parameter memory <NUM>. In other words, an abnormality is not detected if positions and the like of the components in the normal image and the real image are not coincident accurately but are within the tolerance. The abnormality detecting unit <NUM> causes the notification unit <NUM> to perform notification operation in accordance with the detection results. Specifically, the abnormality detecting unit <NUM> causes the notification unit <NUM> to perform notification operation only when an abnormality is detected. The notification unit <NUM> may perform notification operation about the component detected as abnormal or a degree of difference together with occurrence of the abnormality, for example. It is also preferred that the abnormality detecting unit <NUM> calculates the degree of difference as a score.

The score memory unit <NUM> stores the score calculated by the abnormality detecting unit <NUM>. It is preferred that the score memory unit <NUM> stores the score in association with the timing to check. This can determine not only a degree of abnormality but also when and how large the abnormality occurs in accordance with a size of the score.

The following describes the recipe with reference to <FIG>. Here, <FIG> is a schematic view of details of the recipe as one example.

In this example, the recipe is formed by a process and a processing content. The process defines an execution order. The processing content defines what operation is performed. Specifically, the processing content defines operation details of the component. In detail, the recipe is divided into recipe steps that define further detailed operations. However, description of the recipe steps is to be omitted for easy understanding of the invention. In addition, detailed processing to be actually performed is omitted.

The recipe contains the following contents as under, for example.

In a first process, preparation of processing a treatment liquid (guard movement) is performed, and the guard <NUM> is moved to a treating position. In a second process, the preparation of processing a treatment liquid (nozzle movement) is performed, and the nozzle <NUM> is moved to an ejecting position. In a third process, start of processing a treatment liquid is performed, and treatment of a substrate W with the treatment liquid starts. In a sixth process, completion of processing the treatment liquid is performed, and thus the processing with the treatment liquid is completed. In a seventh process, start of a regular rinse treatment is performed, and treatment with the fixed nozzle RN starts. In a tenth process, completion of the regular rinse treatment is performed, and thus the processing with the fixed nozzle RN is completed. In an eleventh process, start of a rinse treatment is performed, and thus the treatment with the rinse liquid from the nozzle <NUM> starts. In a fourteenth process, completion of the rinse treatment is performed, and thus completion of the treatment with the rinse liquid from the nozzle <NUM> is performed (including movement of the nozzle <NUM>). In a fifteenth process, start of a dry processing is performed, and thus a process of increasing a number of rotations of a motor <NUM> starts. In an eighteenth process, completion of the dry processing is performed, and thus the motor <NUM> stops. In a nineteenth process, completion of the recipe processing is performed, and a process of unloading the substrate W is performed.

Description is now made of the normal image and the real image with reference to <FIG> and <FIG>. Here, <FIG> is a schematic view of one example of the normal image, and <FIG> is a schematic view of one example of the real image. <FIG> is a schematic view of one example of the normal image about a fixed nozzle, and <FIG> is a schematic view of one example of the real image about the fixed nozzle.

<FIG> is one example of a normal image CI at one timing to check. At this timing to check, such a condition is shown that the guard <NUM> moves upward to the treating position and the nozzle <NUM> is moved to the origin position, for example. Here, a parenthesis is added to a symbol CI to indicate the timing to check by a symbol T plus number. For example, the normal image in <FIG> is denoted by CI(T00). <FIG> is one example of a real image RI(T00) captured at a timing to check T00 while the substrate treating apparatus <NUM> is in a normal condition. In a condition where the substrate treating apparatus <NUM> is at work, the image comparison unit <NUM> compares the normal image CI(T00) with the real image RI(T00).

<FIG> is one example of a normal image CI at another timing to check T01 from <FIG>. At this timing, such a condition is shown that the guard <NUM> moves upward to the treating position, the nozzle <NUM> is moved to the ejecting position, and the treatment liquid is ejected from the fixed nozzle RN, for example. For example, the normal image in <FIG> is denoted by CI(T01). <FIG> is one example of a real image RI(T01) captured at a timing to check T01 while the substrate treating apparatus <NUM> is in a normal condition. In a condition where the substrate treating apparatus <NUM> is at work, the image comparison unit <NUM> compares the normal image CI(T01) with the real image RI(T01).

As illustrated in <FIG>, a region of interest ROI is each set in the normal image CI(T01) and the real image RI(T01). When the regions of interest ROI are set, the image comparison unit <NUM> also compares the regions of interest ROI between each other. The region of interest ROI in this example is set adjacent to an upper edge around the center portion of a trace line of the treatment liquid, ejected from the fixed nozzle RN, between an ejection port of the fixed nozzle RN and a portion on the front face of the substrate W where the treatment liquid drops. Accordingly, the comparison is made for an upper edge shape formed by a flow of the treatment liquid. The comparison can detect an abnormality at a treatment liquid supplying unit SU of the fixed nozzle RN.

Reference is now made to <FIG>. Here, <FIG> is a schematic view for explanation of synchronization of the recipe and the normal image.

The recipe and the normal image are synchronized by associating the process of the recipe with the timing to check, for example. In <FIG>, only the processes are illustrated as part of the recipe, and the processes are in correspondence with the timings to check T1 to T4 individually. The timings to check T1 to T4 are set with reference to a start timing of the recipe. In the example of the recipe, the timings to check T1 to T4 are set with reference to a start timing of the first process. Here, the timings to check T1 to T4 may be set with reference to any process (step) of the processes (steps) that form the recipe. As described later, when the substrate treating apparatus <NUM> is at work, the real image is captured in response to the timing to check of the recipe, and comparison is made between the normal image and the real image. Accordingly, the normal image and the real image are synchronized with operation in the recipe.

In this example, it is assumed that a timing to check is each set in the third process and the seventh process as shown in <FIG>, for example. In the third process, timings to check T1 to T3 are set. In the seventh process, a timing to check T4 is set. The timing to check T1 corresponds to a normal image CI(T1) where the nozzle <NUM> is at the origin position. The timing to check T2 corresponds to a normal image CI(T2) where the nozzle <NUM> is on the way to the ejecting position. The timing to check T3 corresponds to a normal image CI(T3) where the nozzle <NUM> is moved to the ejecting position. The timing to check T4 corresponds to a normal image CI(T4) where the treatment liquid is ejected from the fixed nozzle RN and the region of interest ROI is set.

Description is now made of the treatment with reference to <FIG> and <FIG>. Here, <FIG> is a flowchart illustrating a series of treatment of the substrate treating apparatus according to the embodiment. <FIG> is a schematic view for explanation of comparison between the normal image and the real image when an apparatus is at work.

The operator can operate the instruction unit <NUM> to specify a desired recipe. The operator operates the instruction unit <NUM> as necessary to specify a desired timing to check among the timings to check associated with the specified recipe. If no timing to check is specified, all the associated timings to check may be specified. Here in this example, it is assumed that the recipe shown in <FIG> is specified. In addition, it is assumed that the timings to check T1 to T4 shown in <FIG> are all specified. Here, it is assumed that a substrate W to be treated is already held with the chucks <NUM>.

The operation controller <NUM> operates each component in response to the recipe to advance the treatment. For example, the first process is executed along with the recipe shown in <FIG>. Specifically, the operation controller <NUM> operates the guard moving mechanism <NUM>. Then, the operation controller <NUM> moves the guard <NUM> from the origin position to the treating position.

It is determined whether it is the timing to check or not, and then the processing is branched. Specifically, the operation controller <NUM> refers to the parameter memory <NUM> to determine whether or not there is a timing to check corresponding to the process in the recipe. As shown in <FIG>, since the timing to check is not set in the first process in the recipe, the processing is branched to the step S7.

The operation controller <NUM> branches the processing in accordance with whether the recipe is the final process or not. Here, since only the first process is executed, the processing returns to the step S2.

The operation controller <NUM> executes a next second process in accordance with a recipe. Specifically, the operation controller <NUM> performs preparation of the treatment liquid. Specifically, the operation controller <NUM> operates the nozzle moving mechanism <NUM>. The operation controller <NUM> operates the nozzle moving mechanism <NUM> to move the nozzle <NUM> from the origin position to the ejecting position.

It is determined whether it is the timing to check, and then the process is branched. Here, as shown in <FIG>, since the timings to check T1 to T4 are set, the processing is shifted to the step S4.

Imaging is performed. Specifically, the operation controller <NUM> operates the camera CM to perform imaging at the timing to check T1. A captured image is a real image RI(T1).

Image comparison is made. Specifically, the image comparison unit <NUM> sets a condition where the same components can be compared in the normal image CI(T1) and the real image RI(T1), corresponding to the timing to check T1, in the normal image memory unit <NUM>.

The abnormality detecting unit <NUM> performs comparison between the normal image CI(T1) and the real image RI(T1) synchronized by the recipe and detects an abnormality in accordance with a difference between the images. At this time, a tolerance in the parameter memory <NUM> is preferably taken into consideration. Consequently, this can prevent false detection of an abnormality caused by the processing errors or assembly errors. Like the second process as above, the steps S3 to S6 are repeated as long as no abnormality is determined in the step S6 when a plurality of timings to check are set in the same process. In this example, since the three timings to check T1 to T3 are set in the second process, the steps S4 to S6 are repeatedly performed at all the timings to check T1 to T3 as long as no abnormality is detected.

Here, the processing is shifted to the step S7 under an assumption that no abnormality is detected.

The operation controller <NUM> branches the processing in accordance with whether the recipe is the final process or not. Here, since only the second process is executed, the processing returns to the step S2.

The operation controller <NUM> executes further processing in accordance with a recipe. Here, it is assumed that the steps S2 and steps S3 and S7 are repeatedly performed during the third to sixth processes.

The operation controller <NUM> executes a seventh process in accordance with a recipe.

As shown in <FIG>, a timing to check T4 is set in the seventh process. Accordingly, the operation controller <NUM> causes the camera CM to perform imaging. The abnormality detecting unit <NUM> detects an abnormality in accordance with a difference between the components while the image comparison unit <NUM> can make comparison of the same component between a normal image (T4) and a real image (T4). Since regions of interest ROI are provided in the normal image (T4) and the real image (T4) individually, comparison of the regions of interest ROI is also made. Here, under assumption that no abnormality is detected, the processing is shifted to the step S7.

It is assumed that the processing described above advances in accordance with the recipe as shown in <FIG> and <FIG> to a nineteenth process as the final process. Since the nineteenth process is the final process of the recipe, the processing is branched to the step S8 to be completed. This finishes the treatment to the substrate W with the recipe.

The following describes a case where the abnormality detecting unit <NUM> detects an abnormality in the step S6 described above. In this case, the process is shifted to the step S9.

When the abnormality detecting unit <NUM> detects an abnormality, the abnormality detecting unit <NUM> causes the notification unit <NUM> to perform notification operation. At this time, the abnormality detecting unit <NUM> calculates a score in accordance with a difference upon detecting the abnormality. It is preferred that the score is of a size in number proportional to the difference. This can determine a degree of abnormality in accordance with the size of the score.

The operation controller <NUM> stops the processing. This can prevent continuous improper treatment to the substrate W by the substrate treating apparatus <NUM>.

According to this example, the abnormality detecting unit <NUM> detects an abnormality in accordance with the difference between the normal image CI synchronized with operation of the recipe and the real image RI at work when the operation controller <NUM> actually treats the substrate W in response to the recipe. The normal image CI is an image obtained by simulating a condition in advance where the component normally operates in response to the recipe and storing in advance the normal image at this time in the view from the location of the camera CM in accordance with the three-dimensional design information of the substrate treating apparatus <NUM>. Accordingly, since all the apparatus have the same imaging condition, an adverse effect due to difference in imaging condition can be avoided. Moreover, the normal image CI to be compared can be prevented from deviation from the real image RI since it is synchronized with the operation of the recipe. Accordingly, an abnormality can be detected accurately at work.

Here, a correspondence between the above example and the present invention is as under.

The camera CM corresponds to the "imaging unit" in the present invention. The process of the recipe corresponds to the "step" in the present invention. The step S2 corresponds to the "processing step" in the present invention. The step S4 corresponds to the "imaging step" in the present invention. The steps S5 and S6 correspond to the "abnormality detecting step" in the present invention.

While the embodiment described above is a single configuration of the substrate treating apparatus <NUM>, the present invention can also be applied to the following construction. Reference is now made to <FIG> is a schematic view of a substrate treating system according to one embodiment.

The substrate treating system <NUM> includes towers TW in which four stages of the substrate treating apparatus <NUM> are arranged in a height direction, for example. In the substrate treating system <NUM>, the towers TW are arranged so as to face apart from each other. In the substrate treating system <NUM>, transport robot TR is arranged between the towers TW. The transport robot TR is configured so as to move upward and downward freely in the height direction. The transport robot TR is configured so as to advance and withdraw an arm, not shown, to and from the substrate treating apparatus <NUM> freely. The transport robot TR delivers a substrate W among the substrate treating apparatus <NUM>.

The substrate treating system <NUM> further includes a system controller <NUM>, and a display unit <NUM>. The system controller <NUM> controls en bloc the substrate treating apparatus <NUM> and the transport robot TR. The system controller <NUM> can access the score memory unit <NUM> of the substrate treating apparatus <NUM>. The system controller <NUM> displays a score of the score memory unit <NUM> on the display unit <NUM>. The score is displayed on every substrate treating apparatus <NUM>.

This can easily help understanding of a difference between the substrate treating apparatus <NUM> having the same construction. Consequently, visualizing the difference in operation can contribute to simple work upon adjustment for reduction in difference between the substrate treating apparatus <NUM>.

Moreover, the substrate treating system <NUM> may include a camera CM that keeps the transport robot TR in the field of view. The substrate treating system <NUM> may be configured as in the recipe of the substrate treating apparatus <NUM> described above in such a manner that comparison is made between the normal image CI in the recipe of transportation and the real image RI and an abnormality is detected for the transport robot TR.

The present invention is not limited to the foregoing examples, but may be modified as follows.

Claim 1:
A substrate treating apparatus (<NUM>) for performing a predetermined treatment on a substrate, the apparatus comprising:
a recipe memory unit (<NUM>) configured to store a recipe, specifying operation details and an execution order of a component that forms the substrate treating apparatus, to perform the predetermined treatment;
an imaging unit (CM) provided at a predetermined location and configured to image the component as a real image at work;
a normal image memory unit (<NUM>) configured to simulate a condition in advance where the component normally operates in response to the recipe and store in advance a normal image at this time in a view from the location in accordance with three-dimensional design information of the substrate treating apparatus;
an operation controller (<NUM>) configured to control the component in response to the recipe to perform the predetermined treatment; and
an abnormality detecting unit (<NUM>) configured to detect an abnormality in accordance with a difference between the normal image synchronized with operation of the recipe and the real image at work when the operation controller actually treats the substrate in response to the recipe.