Patent ID: 12244972

DETAILED DESCRIPTION TO EXECUTE THE INVENTION

Hereinafter, embodiments will be described in detail with reference to the accompanying drawings. In the following description, the same elements or elements having the same function are denoted by the same reference symbols, and redundant descriptions thereof are omitted.

[Substrate Processing Apparatus]

First, a schematic configuration of a substrate processing system1(substrate processing apparatus) will be described with reference toFIGS.1and2. The substrate processing system1is a system that forms a photosensitive film, exposes the photosensitive film, and develops the photosensitive film on a substrate. The substrate to be processed is, for example, a semiconductor wafer W. The photosensitive film is, for example, a resist film. The substrate processing system1includes a coating/developing apparatus2, an exposure apparatus3, and a control apparatus100. The exposure apparatus3is an apparatus that exposes a resist film (photosensitive film) formed on a wafer W (substrate). Specifically, the exposure apparatus3irradiates the exposed portion of the resist film with energy rays for exposure by a method such as an immersion exposure. The coating/developing apparatus2performs a process of applying a resist (chemical solution) onto the surface of the wafer W (substrate) to form a resist film before the exposure process by the exposure apparatus3. Further, the coating/developing apparatus2performs a resist film developing process after the exposure process.

(Coating/Developing Apparatus)

As illustrated inFIGS.1and2, the coating/developing apparatus2(substrate processing apparatus) includes a carrier block4, a processing block5, and an interface block6.

The carrier block4introduces the wafer W into the coating/developing apparatus2and derives the wafer W from the coating/developing apparatus2. For example, the carrier block4may support a plurality of carriers C for the wafer W, and incorporates a transfer apparatus A1including a delivery arm. Each of the carriers C accommodates, for example, a plurality of circular wafers W. The transfer apparatus A1takes out the wafer W from the carrier C, passes the wafer W to the processing block5, receives the wafer W from the processing block5, and returns the wafer W to the carrier C. The processing block5has a plurality of processing modules11,12,13, and14.

Each of the processing modules11incorporates a liquid processing unit U1, a heat processing unit U2, and a transfer apparatus A3that transfers the wafer W to the units. The processing module11forms an underlayer film on the surface of the wafer W by the liquid processing unit U1and the heat processing unit U2. The liquid processing unit U1applies a processing liquid for forming an underlayer film onto the wafer W. The heat processing unit U2performs various heat processes accompanying the formation of the underlayer film.

Each of the processing modules12incorporates a liquid processing unit U1, a heat processing unit U2, and a transfer apparatus A3that transfers the wafer W to the units. The processing module12forms a resist film on the underlayer film by the liquid processing unit U1and the heat processing unit U2. The liquid processing unit U1applies a resist onto the underlayer film as a processing liquid for forming a resist film. For example, the liquid processing unit U1supplies a processing liquid to the surface of the wafer W, and then rotates the wafer W to form a film of the processing liquid on the surface. The heat processing unit U2performs various heat processes accompanying the formation of the resist film. As a result, a resist film is formed on the surface of the wafer W.

Each of the processing modules13incorporates a liquid processing unit U1, a heat processing unit U2, and a transfer apparatus A3that transfers the wafer W to the units. The processing module13forms an upper layer film on the resist film by the liquid processing unit U1and the heat processing unit U2. The liquid processing unit U1applies a processing liquid for forming an upper layer film onto the resist film. The heat processing unit U2performs various heat processes accompanying the formation of the upper layer film.

Each of the processing modules14incorporates a liquid processing unit U1, a heat processing unit U2, and a transfer apparatus A3that transfers the wafer W to the units. The processing module14develops the resist film after exposure by the liquid processing unit U1and the heat processing unit U2. The liquid processing unit U1rinses the surface of the wafer W in order to wash away the developer. The heat processing unit U2performs various heat processes accompanying the developing process. Specific examples of the heat process accompanying the developing process include a heat process before the developing process (post exposure bake (PEB)) and a heat process after the developing process (post bake (PB)).

A shelf unit U10is provided on the carrier block4side in the processing block5. The shelf unit U10is divided into a plurality of cells arranged in the vertical direction. A transfer apparatus A7including an elevating arm is provided in the vicinity of the shelf unit U10. The transfer apparatus A7raises and lowers the wafer W among the cells of the shelf unit U10.

A shelf unit U11is provided on the interface block6side in the processing block5. The shelf unit U11is divided into a plurality of cells arranged in the vertical direction.

The interface block6delivers the wafer W to and from the exposure apparatus3. For example, the interface block6incorporates a transfer apparatus A8including a delivery arm and is connected to the exposure apparatus3. The transfer apparatus A8passes the wafer W disposed in the shelf unit U11to the exposure apparatus3. The transfer apparatus A8receives the wafer W from the exposure apparatus3and returns the wafer W to the shelf unit U11.

(Liquid Processing Unit)

Subsequently, an example of the liquid processing unit U1of the processing module12will be described with reference toFIG.3. As illustrated inFIG.3, the liquid processing unit U1includes a rotation holding unit30and a processing liquid supply unit40.

The rotation holding unit30holds and rotates the wafer W. The rotation holding unit30includes, for example, a holding unit32and a rotation drive unit34. The holding unit32supports a central portion of the wafer W disposed horizontally with the surface Wa facing up, and holds the wafer W by, for example, vacuum suction. The rotation drive unit34is an actuator including a power source such as an electric motor and rotates the holding unit32around the vertical axis Ax. As a result, the wafer W on the holding unit32rotates. The holding unit32may hold the wafer W so that the center of the wafer W substantially coincides with the axis Ax.

The processing liquid supply unit40supplies a processing liquid to the surface Wa of the wafer W. The processing liquid is a solution (resist) for forming the resist film R. The processing liquid supply unit40includes a nozzle42, a source46, an on-off valve48, and a nozzle moving mechanism44. The nozzle42discharges the processing liquid onto the surface Wa of the wafer W held by the holding unit32. For example, the nozzle42is disposed above the wafer W and discharges the processing liquid downward. The source46supplies the processing liquid to the nozzle42. The on-off valve48is provided in a supply path between the nozzle42and the source46.

The nozzle moving mechanism44moves the nozzle42between a discharge position above the wafer W and a retraction position away from the discharge position. The discharge position is, for example, vertically above the center of rotation of the wafer W (located on the axis Ax). The standby position is, for example, located outside the peripheral edge of the wafer W and set above the discharge position. In this case, the nozzle moving mechanism44includes a horizontal drive unit that moves the nozzle42along the surface Wa of the wafer W, and an elevating drive unit that moves the nozzle42perpendicular to the surface Wa of the wafer W.

(Control Apparatus)

The control apparatus100causes the coating/developing apparatus2to process the wafer W by partially or wholly controlling the coating/developing apparatus2. The wafer W process (liquid process) performed in the liquid processing unit U1includes a process of moving the nozzle42between the standby position and the discharge position, a process of discharging a processing liquid from the nozzle42at the discharge position, and a process of forming a film of the processing liquid on the surface Wa after the processing liquid is supplied. Hereinafter, various processes included in the liquid process performed in the liquid processing unit U1are referred to as a “unit process.” As illustrated inFIG.4, the control apparatus100includes a processing information storage unit120, a nozzle arrangement control unit124, a supply control unit126, and a film formation control unit128as a functional configuration (hereinafter, referred to as a “functional module”).

The processing information storage unit120stores processing information related to the process of the wafer W. The processing information may include a processing schedule of the wafer W by the coating/developing apparatus2and processing condition in each unit process. The processing schedule of the wafer W includes a liquid processing schedule in the liquid processing unit U1. For example, as illustrated inFIG.5, an execution order of the plurality of unit processes included in the liquid process and an execution time of each unit process are defined in the processing schedule of the wafer W. InFIG.5, the arrangement order from top to bottom indicates the execution order. The processing condition in each unit process includes, for example, a moving speed of the nozzle42, a discharge amount of the processing liquid, and a rotation speed of the wafer W.

The nozzle arrangement control unit124performs a unit process of moving the nozzle42in the standby position to the discharge position (hereinafter, referred to as a “nozzle arrangement process”) according to the processing schedule stored in the processing information storage unit120. For example, after moving the nozzle42horizontally by the horizontal driving unit of the nozzle moving mechanism44, the nozzle arrangement control unit124disposes the nozzle42at the discharge position by moving the nozzle42downward by the elevating drive unit of the nozzle moving mechanism44. Further, the nozzle arrangement control unit124performs a unit process of moving the nozzle42at the discharge position to the standby position (hereinafter, referred to as a “nozzle retraction process”) according to the processing schedule stored in the processing information storage unit120. For example, after raising the nozzle42at the discharge position by the elevating drive unit of the nozzle moving mechanism44, the nozzle arrangement control unit124disposes the nozzle42to the standby position by moving the nozzle42horizontally by the horizontal drive unit of the nozzle moving mechanism44. In the nozzle arrangement process and the nozzle retraction process, the nozzle arrangement control unit124moves the nozzle42in the horizontal direction and the vertical direction at a moving speed according to the processing condition.

The supply control unit126performs a unit process in which the processing liquid supply unit40supplies the processing liquid to the surface Wa of the wafer W while the rotation holding unit30rotates the wafer W (hereinafter, a “supplying process”) according to the processing schedule stored in the processing information storage unit120. For example, the supply control unit126starts discharging the processing liquid by switching the on-off valve48from the closed state to the open state while rotating the wafer W by the rotation holding unit30. The supply control unit126stops discharging the processing liquid from the nozzle42by switching the on-off valve48from the open state to the closed state after a predetermined time has elapsed from the start of discharge. In the supplying process, the supply control unit126rotates the wafer W by the rotation holding unit30at a rotation speed according to the processing condition, and discharges the processing liquid from the nozzle42at a discharge amount (discharge amount per unit time) according to the processing condition.

The film formation control unit128performs a unit process of drying the film of the processing liquid supplied onto the surface Wa of the wafer W (hereinafter, a “drying process”) according to the processing schedule stored in the processing information storage unit120. For example, the film formation control unit128causes the rotation holding unit30to continue rotating the wafer W at a predetermined rotation speed for a predetermined period in at least a part of the drying process. In the drying process, the film formation control unit128causes the rotation holding unit30to rotate the wafer W at a rotation speed according to the processing condition.

(Monitoring Apparatus)

The liquid processing unit U1further includes an imaging apparatus110(imaging unit) for monitoring the state of a liquid process. The control apparatus100not only causes the coating/developing apparatus2to process the wafer W, but also monitors the process of the wafer W based on the video data obtained by the imaging apparatus110(individually monitors a plurality of unit processes). That is, the substrate processing system1is provided with a monitoring apparatus20including a control apparatus100and an imaging apparatus110. Examples of monitoring the wafer W process include monitoring whether an abnormality has occurred in the unit process of the wafer W and monitoring how much the unit process of the wafer W is progressing.

The imaging apparatus110is configured to capture an image of the nozzle42and the surface Wa of the wafer W held by the holding unit32. The imaging apparatus110has a camera that captures an image of an imaging region PR including the nozzle42and the surface Wa of the wafer W. The camera generates video data (hereinafter, referred to as “imaging video data MV0”) by capturing an image of the imaging region PR. As an example, the camera of the imaging apparatus110generates imaging video data MV0in which the image size is an “HD size” and the number of frames (frame rate) is 60 fps. In the HD-sized image, the number of pixels in the horizontal direction is 1280, and the number of pixels in the vertical direction is 720. Hereinafter, the image size including the number of pixels is expressed as the “HD size” (1280 pixels horizontally×720 pixels vertically).

The camera of the imaging apparatus110is provided above the inside of the housing of the liquid processing unit U1, for example, so that the imaging region PR may be captured. In at least a part of the period of the wafer W process, the imaging region PR by the imaging apparatus110may be set to include a nozzle42located at the discharge position, a nozzle42located at the standby position, a nozzle42that moves between the discharge position and the standby position, and the entire surface Wa of the wafer W. Alternatively, during the execution of the wafer W process, the imaging region PR by the imaging apparatus110may be fixed to a region including the nozzle42in the above three states and the entire surface Wa of the wafer W. The imaging apparatus110outputs the generated imaging video data MV0to the control apparatus100.

As functional modules, the control apparatus100further includes, for example, a data acquisition unit132, a data buffer unit134, a monitoring data generation unit136, a monitoring condition changing unit138, a reference condition storage unit140, a monitoring condition generation unit142, a monitoring condition storage unit148, a process determination unit150, a storage data recording unit152, and a storage condition changing unit154.

The data acquisition unit132causes the imaging apparatus110to acquire the imaging video data MV0of the imaging region PR. The data acquisition unit132may cause the imaging apparatus110to acquire the imaging video data MV0having a predetermined resolution and number of frames (number of frames per unit time). The resolution is a measure indicating the precision of an image and indicates the magnitude of an amount of information included per unit length (unit area). That is, the size of the imaging region PR (or the angle of view) included in one pixel differs depending on the resolution. When the resolution is high, the size of the imaging region PR per pixel becomes smaller, and when the resolution is low, the size of the imaging region PR per pixel becomes larger.

When the imaging region PR is fixed within a certain range during the execution of the wafer W process, the resolution is determined according to the number of pixels per unit area in the imaging region PR. Hereinafter, a case will be illustrated where the imaging region PR is fixed to a certain range during the execution of the wafer W process. Further, the number of pixels per unit area of the imaging region PR of the imaging video data MV0will be described as a “number of pixels n0,” and the number of frames of the imaging video data MV0will be described as a “number of frames f0.” When the imaging region PR is fixed to a certain range, the resolution may be represented by the image size of video data. For example, in the HD size (1280 pixels horizontally×720 pixels vertically), the VGA size (640 pixels horizontally×480 pixels vertically), and the QVGA size (320 pixels horizontally×240 pixels vertically), the image size becomes larger and the resolution becomes higher in this order. When using these image sizes, depending on the purpose of monitoring, recording, and display, the aspect ratio of the image size may be standardized by performing a process such as cutting out a part of the region or adding a black band.

The data buffer unit134temporarily stores the imaging video data MV0acquired by the data acquisition unit132. For example, the data buffer unit134stores the imaging video data MV0for a predetermined capacity. As an example, the capacity that may be stored in the data buffer unit134is set to such that the imaging video data MV0in the process for several wafers W (liquid process in the liquid processing unit U1) may be stored. The data buffer unit134may store new imaging video data MV0by deleting old data of the imaging video data MV0so that the capacity does not exceed the set value.

The monitoring data generation unit136generates monitoring video data based on the imaging video data MV0by the imaging apparatus110during the execution of the wafer W process. The monitoring data generation unit136generates monitoring video data by, for example, performing a predetermined process on the imaging video data MV0temporarily stored by the data buffer unit134. The monitoring data generation unit136may generate monitoring video data by compressing the imaging video data MV0in at least a part of the period during which the wafer W process is being executed. That is, the monitoring video data may be data in which the imaging video data MV0is compressed. The monitoring data generation unit136reduces at least the resolution or the number of frames to compress the imaging video data MV0. For example, the monitoring data generation unit136may reduce the resolution without changing the number of frames of the imaging video data MV0, may reduce the number of frames without changing the resolution, and may reduce the number of frames and the resolution. As an example, the monitoring data generation unit136may lower the resolution by changing (compressing) the HD-sized imaging video data MV0to the VGA-sized or QVGA-sized video data.

The monitoring condition changing unit138changes the generation condition of the monitoring video data during the execution of the wafer W process. The monitoring data generation unit136generates monitoring video data according to the generation condition changed (set) by the monitoring condition changing unit138. The monitoring condition changing unit138set the generation condition in the first process and the generation condition in the second process so that the generation conditions are different from each other in a unit process (hereinafter, referred to as a “first process”) included in the wafer W process and the other unit process (hereinafter, referred to as a “second process”). For example, the monitoring condition changing unit138changes the generation condition during the execution of the wafer W process so that at least the resolution or the number of frames of the monitoring video data during the execution of the second process (hereinafter, referred to as “second video data MV2”) is different from that of the monitoring video data during the execution of the first process (hereinafter, referred to as “first video data MV1”).

For example, the monitoring condition changing unit138changes the reduction rate in the number of pixels per unit area from the imaging video data MV0during the execution of the wafer W process so that the resolution of the second video data MV2is different from that of the first video data MV1. In this case, the monitoring data generation unit136generates monitoring video data by reducing the number of pixels from the imaging video data MV0according to the reduction rate in the number of pixels per unit area changed by the monitoring condition changing unit138. As an example, the monitoring condition changing unit138changes the generation condition so that the reduction rate in the number of pixels per unit area during execution of the first process is n1/n0, and changes the generation condition so that the reduction rate in the number of pixels per unit area during execution of the second process is n2/n0. “n1” and “n2” are positive integers of n0or less, respectively, and “n1” and “n2” are different values from each other. When explaining the change of the image size, in a case where the HD size is changed to the VGA size, the reduction rate is halved in the horizontal pixel ratio. In a case where the HD size is changed to the QVGA size, the reduction rate is 1/4 in the horizontal pixel ratio. When reducing the number of pixels, the number of pixels may be reduced by any method such as a thinning method or a method of calculating an average value, and any method in the related art may be used as an image processing algorithm for reducing the number of pixels.

The monitoring condition changing unit138may change the reduction rate in the number of frames from the imaging video data MV0during the execution of the wafer W process so that the number of frames of the second video data MV2is different from that of the first video data MV1. In this case, the monitoring data generation unit136generates monitoring video data by reducing the number of frames from the imaging video data MV0according to the reduction rate in the number of frames changed by the monitoring condition changing unit138. As an example, the monitoring condition changing unit138changes the generation condition so that the reduction rate in the number of frames during execution of the first process is f1/f0, and changes the generation condition so that the reduction rate in the number of frames during execution of the second process is f2/f0. “f1” and “f2” are positive integers of f0or less, respectively, and “f1” and “f2” are different values from each other. When the monitoring condition changing unit138changes the number of pixels and the number of frames per unit area as described above, the monitoring data generation unit136generates the first video data having the number of pixels n1the number of frames f1, and the second video data having the number of pixels n2the number of frames f2. When reducing the number of pixels, the number of frames may be reduced by any method such as a thinning method or a method of calculating an average value, and any method in the related art may be used as a processing algorithm for reducing the number of frames.

The monitoring condition changing unit138may change the generation condition during the execution of the wafer W process so that the size of the imaging region of all pixels of the second video data MV2during the execution of the second process is different from that of the first video data MV1during the execution of the first process. For example, the monitoring condition changing unit138changes a region which the monitoring data generation unit136includes in the monitoring video data among the imaging video data MV0(hereinafter, referred to as a “target region IR”). The monitoring condition changing unit138changes the generation condition during the execution of the wafer W process so that the target region IR in the second video data MV2is different from the target region IR in the first video data MV1. Hereinafter, an example of changing the generation condition will be described by exemplifying several processing contents.

When the first process is a process of arranging the nozzle42and the second process is a process of supplying the processing liquid, the monitoring condition changing unit13changes the generation condition during the execution of the wafer W process so that the resolution of the second video data MV2during the execution of the second process is higher than that of the first video data MV1during the execution of the first process. The number of frames of the second video data MV2generated in this case may be the same as the number of frames of the first video data MV1or may be larger than the number of frames of the first video data MV1. The monitoring condition changing unit138changes the generation condition during the execution of the wafer W process so that the target region IR in the second video data MV2is narrower than the target region IR in the first video data MV1.

As an example, as illustrated inFIG.6, the monitoring condition changing unit138matches the target region IR of the first video data MV1in the nozzle arrangement process with the imaging region PR of the imaging video data MV0. That is, the size of the imaging region in all pixels of the first video data MV1is defined as the entire imaging region PR. As an example, the image size of the imaging video data MV0is the HD size, and the image size of the first video data MV1is the VGA size. In this case, as one of the conditions for generating the first video data MV1, the reduction rate in resolution may be set to 1/2 based on the number of horizontal pixels, the reduction rate in resolution may be set to 2/3 based on the number of vertical pixels, or the aspect ratio may be standardized. The monitoring condition changing unit138selects a part including the nozzle42and its periphery from the imaging region PR as the target region IR of the second video data MV2in the supplying process. That is, the size of the imaging region in all pixels of the second video data MV2is made smaller than that of the imaging region PR.

The monitoring condition changing unit138does not change the number of pixels n2per unit area even when the target region IR is narrowed down to the periphery of the nozzle. For example, the image of the second video data MV2corresponds to an image obtained by cutting out the target region IR from the imaging video data MV0whose image size is HD size (an image cut out not to include a region other than the target region IR). The size of the imaging region PR included in all pixels of the second video data MV2is different from the size of the imaging region PR included in all pixels of the first video data MV1. Specifically, the target region IR of the second video data MV2is smaller than the target region IR of the first video data MV1. As a result, even when the second video data MV2has a high resolution, an increase in the data size of the second video data MV2is suppressed.

Similarly, when the first process is a drying process and the second process is a process of supplying the processing liquid, the monitoring condition changing unit13changes the generation condition during the execution of the wafer W process so that the resolution of the second video data MV2is higher than the resolution of the first video data MV1. The number of frames of the second video data MV2generated in this case may be the same as the number of frames of the first video data MV1or may be larger than the number of frames of the first video data MV1. The monitoring condition changing unit138changes the generation condition during the execution of the wafer W process so that the target region IR in the second video data MV2is narrower than the target region IR in the first video data MV1. As an example, the monitoring condition changing unit138matches the target region IR of the first video data MV1in the drying process with the imaging region PR of the imaging video data MV0. The monitoring condition changing unit138selects a part including the nozzle42and its periphery from the imaging region PR as the target region IR of the second video data MV2in the supplying process.

The reference condition storage unit140stores correspondence information in which the processing content of the wafer W and the generation condition of the monitoring video data are associated with each other. The reference condition storage unit140stores, for example, table information in which the content of each unit process of the wafer W and the generation condition according to the content of each unit process are associated with each other. As an example, as illustrated inFIG.8, the reference condition storage unit140stores table information in which the content of the unit process of the wafer W, the resolution (the number of pixels per unit area), the number of frames, and the target region IR are associated with each other.

The monitoring condition generation unit142generates a condition changing schedule for changing the generation condition of the monitoring video data based on the processing schedule of the wafer W and the correspondence information. For example, the monitoring condition generation unit142acquires the processing schedule of the wafer W by referring to the processing information storage unit120. Then, the monitoring condition generation unit142changes a condition changing schedule for determining the generation condition for each unit process included in the processing schedule by referring to the table information in which the processing content stored in the reference condition storage unit140and the generation condition are associated with each other.

The monitoring condition storage unit148stores a condition changing schedule for changing the generation condition of the imaging video data according to the processing schedule of the wafer W by the coating/developing apparatus2. For example, the monitoring condition storage unit148stores the condition changing schedule generated by the monitoring condition generation unit142. The monitoring condition changing unit138may change the generation condition during the execution of the wafer W process based on the condition changing schedule. The monitoring data generation unit136generates monitoring video data by performing a predetermined process on the imaging video data MV0according to the generation condition changed by the monitoring condition changing unit138.

As an example, when the monitoring condition changing unit138changes the resolution of the generation condition to the resolution n1based on the condition changing schedule, the monitoring data generation unit136generates the VGA-sized monitoring video data from the HD-sized imaging video data MV0. When the monitoring condition changing unit138changes the resolution of the generation condition to the resolution n2based on the condition changing schedule, the monitoring data generation unit136generates the HD-sized monitoring video data. Alternatively, when the generation condition is changed to the resolution n1, the monitoring data generation unit136may generate QVGA-sized monitoring video data, and when the generation condition is changed to the resolution n2, the monitoring data generation unit136may generate VGA-sized video data. As another example, when the number of frames in the generation condition is changed to the number of frames f1, the monitoring data generation unit136may generate the monitoring video data of 30 fps from the imaging video data MV0of 60 fps, and when the number of frames in the generation condition is changed to the number of frames f2, the monitoring data generation unit136may generate monitoring video data of 60 fps. Alternatively, when the generation condition is changed to the number of frames f1, the monitoring data generation unit136may generate the monitoring video data of 15 fps from the imaging video data of 60 fps, and when the generation condition is changed to the number of frames f2, the monitoring data generation unit136may generate the monitoring video data of 30 fps.

The process determination unit150determines the state of unit process of the wafer W based on the monitoring video data generated by the monitoring data generation unit136. For example, the process determination unit150(abnormality determination unit) determines an abnormality in the unit process of the wafer W based on the monitoring video data. The process determination unit150may determine the presence/absence of an abnormality in the process by performing an image process on the monitoring video data according to the content of the unit process. As an example, the process determination unit150may determine an abnormality in the unit process of the wafer W based on a difference between the monitoring video data prepared in advance (hereinafter, referred to as “reference video data”) and the monitoring video data generated by the monitoring data generation unit136. The reference video data may be prepared in either format of a video or a still image as long as such data may be compared with each frame of the monitoring video data in chronological order.

Further, the process determination unit150may determine the presence/absence of an abnormality in the unit process by inputting the monitoring video data generated by the monitoring data generation unit136into a learning model that outputs the presence/absence of an abnormality in response to the input of the monitoring video data. The learning model is generated in advance by machine learning (e.g., deep learning) conducted based on the teacher data which is accumulated by associating the monitoring video data with the determination result of the presence/absence of an abnormality. Based on such a learning model, it is expected that the presence/absence of an abnormality may be discriminated even when the presence/absence of an abnormality may not be discriminated by human eyes only from the image alone. For example, even when the presence/absence of an abnormality may not be discriminated only from the image due to the influence of disturbance such as a diffused reflection caused by the uneven pattern on the surface Wa of the wafer W, the presence/absence of the abnormality may be discriminated.

The process determination unit150determines whether there is an abnormality in the process of arranging the nozzle42. Targets for abnormality determination in the process of arranging the nozzle42may include, for example, whether liquid dripping has occurred in the moving nozzle42, and whether droplets have fallen from the moving nozzle42. In the determination of the process of arranging the nozzle42, high image quality is not required, but the region to be monitored is relatively wide. In the present specification, the phrase “image quality” means the precision (fineness) of the video that correlates with at least the resolution or the number of frames of the video data. The phrase “high image quality” may mean the resolution of the video data is high (the imaging region per pixel is small), that the number of frames of the video data is large, or that the resolution of the video data is high and the number of frames is large.

The process determination unit150determines whether there is an abnormality in the supplying process. Examples of targets for abnormality determination in the processing liquid supplying process include whether the processing liquid discharged from the nozzle42has splashed, whether the processing liquid in the nozzle42being discharged has bubbles, whether droplets have fallen from the nozzle42immediately after the end of discharge, and whether the arrangement position of the nozzle42is appropriate. A relatively high image quality is required for the determination in the supplying process of the processing liquid, but the region to be monitored may be relatively narrow.FIG.7Aschematically illustrates a part of an image of the nozzle42when the first video data MV1has a low image quality, andFIG.7Bschematically illustrates a part of an image of the nozzle42when the second video data MV2has a high image quality. In the image illustrated inFIG.7B, the size of a part of the nozzle42included in one pixel becomes smaller than that of the image illustrated inFIG.7A, and a contour shape of the nozzle42becomes finer as a whole. Therefore, a more detailed image analysis of the processing content becomes possible by using video data of high image quality.

The process determination unit150determines whether there is an abnormality in the drying process. Examples of the target of the abnormality determination of the drying process include a determination of whether the spread of a film is appropriate and whether the progress of drying of the film is appropriate. High image quality is not required to determine the drying process, but the region to be monitored is relatively wide.

The storage data recording unit152records the storage video data based on the imaging video data. For example, the storage data recording unit152performs a predetermined process on the imaging video data MV0stored in the data buffer unit134to generate storage video data, and outputs the generated storage video data to an external data storage unit190. The control apparatus100may include a data storage unit190. The storage data recording unit152may generate storage video data according to preset reference storage conditions. The reference storage condition defines the compression rate from the imaging video data. As an example, the compression rate is determined by at least the resolution (the number of pixels per unit area) or the number of frames.

When the determination result by the process determination unit150indicates that the unit process of the wafer W is abnormal, the storage condition changing unit154changes the storage condition of the storage video data to a time when the storage video data is recorded. The storage condition changing unit154may change at least one of the resolution, the number of frames, and the compression format of the storage video data to a time when the storage video data is recorded. For example, when a signal (hereinafter, referred to as an “abnormal signal”) indicating that the unit process of the wafer W is abnormal is received from the process determination unit150, the storage condition changing unit154changes the storage condition of the storage video data during the period in which the unit process when the signal is received is executed. Specifically, the storage condition changing unit154changes the storage condition from the reference storage condition to the storage condition at the time of abnormality. The storage condition at the time of abnormality is predetermined. The storage condition at the time of abnormality is defined, for example, so that at least one of the resolution and the number of frames defined by the storage condition at the time of abnormality becomes larger than the corresponding value of the reference storage condition. When the process determination unit150does not output an abnormal signal, the storage data recording unit152generates storage video data according to the reference storage condition. Meanwhile, when the process determination unit150outputs an abnormal signal, the storage video data is generated according to the storage condition at the time of abnormality changed (set) by the storage condition changing unit154. As a result, when an abnormality occurs, storage video data of high image quality is recorded.

As an example, the resolution may be set to the resolution n1under the reference storage condition, and the resolution may be changed to the resolution n2under the storage condition at the time of abnormality. When the storage condition is set to the resolution n1, the storage data recording unit152may generate VGA-sized storage video data from HD-sized imaging video data MV0. When the storage condition is changed to the resolution n2, the storage data recording unit152may generate HD-sized storage video data. Alternatively, when the storage condition is the resolution n1, the storage data recording unit152generates QVGA-sized storage video data from the HD-sized imaging video data MV0, and when the storage condition is the resolution n2, the storage data recording unit152may generate VGA-sized storage video data.

As another example, the number of frames may be set to the number of frames f1under the reference storage condition, and the number of frames may be changed to the number of frames f2under the storage condition at the time of abnormality. When the storage condition is set to the number of frames f1, the storage data recording unit152may generate storage video data having the number of frames of 30 fps from the imaging video data MV0having the number of frames of 60 fps. When the storage condition is set to the number of frames f2, the storage data recording unit152may generate storage video data of 60 fps having the same number of frames as the imaging video data MV0. When the storage condition is set to the number of frames f1, the storage data recording unit152may generate storage video data having the number of frames of 15 fps from the imaging video data MV0having the number of frames of 60 fps. When the storage condition is set to the number of frames f2, the storage data recording unit152may generate storage video data having the number of frames of 30 fps.

The compression format (compression coding algorithm) of data may be included in the storage condition of the storage video data. For example, when it is desired to save storage video data having a relatively high image quality in the event of an abnormality, the storage data recording unit152may generate storage video data by a reversible coding algorithm (a reversible compression method, e.g., HuffYUV). When it is desired to save storage video data having a relatively low image quality in normal times without any abnormality, the storage data recording unit152may generate storage video data by an irreversible coding algorithm (an irreversible compression method, e.g., H264). In the event of an abnormality, the storage data recording unit152may change two or more of the resolution, the number of frames, and the compression format of the storage video data to a time when the storage video data is stored.

When the determination result by the process determination unit150indicates that the unit process is abnormal, the storage data recording unit152may also record processing information indicating the content of the unit process of the wafer W determined to be abnormal. For example, the storage data recording unit152acquires processing information related to the unit process to be recorded from the process determination unit150, and outputs (records) the processing information to the external data storage unit190together with the storage video data. Examples of the processing information include individual information of the wafer W to be processed, the content of the unit process when an abnormality occurs, processing condition during execution of the unit process, and measurement information from various sensors.

The control apparatus100is constituted by one or a plurality of control computers. For example, the control apparatus100includes a circuit200illustrated inFIG.9. The circuit200includes one or more processors202, a memory204, a storage206, an input/output port208, and a timer212. The storage206includes a storage medium that is readable by a computer, such as a hard disk. The storage medium stores a program for causing the control apparatus100to execute the monitoring procedure (to be described later). The storage medium may be a removable medium such as a non-volatile semiconductor memory, a magnetic disk, or an optical disk. The memory204temporarily stores the program loaded from the storage medium of the storage206and the calculation result obtained by the processor202. The processor202constitutes each of the above-mentioned functional modules by executing the above program in cooperation with the memory204. The input/output port208inputs/outputs an electric signal to/from the imaging apparatus110, the rotation holding unit30, and the processing liquid supply unit40according to a command from the processor202. The timer212measures the elapsed time by counting, for example, a reference pulse having a fixed cycle.

When the control apparatus100is constituted by a plurality of control computers, each functional module may be implemented by an individual control computer. The control apparatus100may be constituted by a control computer including a functional module for executing the unit process of the wafer W by the coating/developing apparatus2, and a control computer including a functional module for monitoring the process of the wafer W and recording storage video data. Alternatively, each of the functional modules may be implemented by a combination of two or more control computers. In these cases, the plurality of control computers may be communicatively connected to each other, and the monitoring procedures (to be described later) may be executed in cooperation with each other. The hardware configuration of the control apparatus100is not necessarily limited to constituting each functional module by a program. For example, each functional module of the control apparatus100may be constituted by a dedicated logic circuit or an application specific integrated circuit (ASIC) in which the logic circuit is integrated.

[Substrate Processing Procedure]

Subsequently, a substrate processing procedure executed in the substrate processing system1will be described as an example of a substrate processing method. The control apparatus100controls the substrate processing system1to execute a substrate process including the coating/developing process by, for example, the following procedure. First, the control apparatus100controls a transfer apparatus A1to transfer the wafer W in a carrier C to a shelf unit U10, and controls the transfer apparatus A7to dispose the wafer W in the cell for a processing module11.

Subsequently, the control apparatus100controls a transfer apparatus A3to transfer the wafer W of the shelf unit U10to a liquid processing unit U1and a heat processing unit U2in the processing module11. Further, the control apparatus100controls the liquid processing unit U1and the heat processing unit U2to form an underlayer film on the surface Wa of the wafer W. After that, the control apparatus100controls the transfer apparatus A3to return the wafer W on which the underlayer film is formed to the shelf unit U10, and controls a transfer apparatus A7to dispose the wafer W in the cell for a processing module12.

Subsequently, the control apparatus100controls the transfer apparatus A3to transfer the wafer W of the shelf unit U10to a liquid processing unit U1and a heat processing unit U2in the processing module12. Further, the control apparatus100controls the liquid processing unit U1and the heat processing unit U2to form a resist film R on the underlayer film of the wafer W. An example of the liquid processing procedure performed in the liquid processing unit U1will be described later. After that, the control apparatus100controls the transfer apparatus A3to return the wafer W to the shelf unit U10, and controls the transfer apparatus A7to dispose the wafer W in the cell for a processing module13.

Subsequently, the control apparatus100controls the transfer apparatus A3to transfer the wafer W of the shelf unit U10to each unit in the processing module13. Further, the control apparatus100controls the liquid processing unit U1and the heat processing unit U2to form an upper layer film on the resist film R of the wafer W. After that, the control apparatus100controls the transfer apparatus A3to transfer the wafer W to the shelf unit U11.

Subsequently, the control apparatus100controls a transfer apparatus A8to send the wafer W accommodated in the shelf unit U11to an exposure apparatus3. In the exposure apparatus3, an exposure process is then performed on the resist film R formed on the wafer W. After that, the control apparatus100receives the wafer W subjected to the exposure process from the exposure apparatus3, and controls the transfer apparatus A8to dispose the wafer W in the cell for a processing module14in the shelf unit U11.

Subsequently, the control apparatus100controls the transfer apparatus A3to transfer the wafer W of the shelf unit U11to the heat processing unit U2of the processing module14. The control apparatus100also controls execution of the developing process and the heat process accompanying the developing process. This completes the coating/developing process.

(Liquid Processing Procedure)

Subsequently, an example of a liquid processing procedure will be described with reference toFIG.10.FIG.10is a flow chart illustrating an example of the liquid processing procedure executed in the liquid processing unit U1of the processing module12. First, the control apparatus100executes step S01in a state where the nozzle42is disposed in the standby position and the wafer W is disposed on the rotation holding unit30(holding unit32). In step S01, the nozzle arrangement control unit124executes a nozzle arrangement process of moving the nozzle42from the standby position to the discharge position by the nozzle moving mechanism44.

Subsequently, the control apparatus100executes steps S02, S03, and S04. In step S02, for example, the supply control unit126starts discharging the processing liquid. Specifically, while rotating the wafer W by the rotation holding unit30, the supply control unit126starts discharging the processing liquid by switching the on-off valve48from the closed state to the open state. In step S03, the supply control unit126waits for a lapse of the processing time of the supplying process from the start of the supplying process while continuing the rotation of the wafer W and the discharge of the processing liquid by the rotation holding unit30and the processing liquid supply unit40, respectively. In step S04after the lapse of the processing time, the supply control unit126stops discharging the processing liquid by, for example, switching the on-off valve48from the open state to the closed state.

Subsequently, the control apparatus100executes steps S05, S06, and S07. In step S05, for example, a film formation control unit128starts the rotation of the wafer W to form a film of the processing liquid. The film formation control unit128may adjust the rotation of the wafer W by the rotation holding unit30so that the rotation speed at the time of stopping the discharge in step S04becomes the rotation speed for film formation. In step S06, for example, the film formation control unit128waits for a lapse of the processing time of the drying process from the start of rotation of the wafer W for film formation. In step S07after the lapse of the processing time of the drying process, for example, the film formation control unit128stops the rotation of the wafer W by the rotation holding unit30. The control apparatus100(nozzle arrangement control unit124) may execute a nozzle retraction process at a timing that overlaps with at least a part of the period in which steps S05to S07are executed. This completes the liquid processing procedure for one wafer W.

[Monitoring Procedure]

FIG.11is a flow chart illustrating an example of a monitoring procedure (monitoring method) by the control apparatus100. The control apparatus100executes a monitoring process of the wafer W process at substantially the same timing as (in parallel with) the execution of the liquid processing procedure. The control apparatus100first executes step S21in a state where the wafer W is loaded into the liquid processing unit U1and the imaging region PR is continuously captured by the imaging apparatus110. In step S21, for example, the monitoring condition generation unit142generates a condition changing schedule in the wafer W process by referring to the processing schedule stored in the processing information storage unit120and the correspondence information stored in the reference condition storage unit140. The condition changing schedule includes, for example, the order of a plurality of unit periods corresponding to the plurality of unit processes, and the generation condition in each unit period.

Subsequently, the control apparatus100executes steps S22and S23. In step S22, for example, the control apparatus100waits until the start timing of the first unit period is reached. In step S23, for example, the monitoring condition change unit138sets a generation condition of the monitoring video data according to the content of the unit process based on the condition changing schedule. As an example, when the unit process is a nozzle arrangement process, the monitoring condition changing unit138sets the number of pixels per unit area included in the generation condition to the number of pixels n1(e.g., the image size is set to the VGA size), sets the number of frames to the number of frames f1(e.g., 30 fps), and sets the target region IR of the monitoring video data to the entire imaging region PR. As a result, the monitoring data generation unit136generates monitoring video data during the execution of the nozzle arrangement process according to the generation condition changed by the monitoring condition changing unit138during the execution of the nozzle arrangement process.

Subsequently, the control apparatus100executes steps S24and S25. In step S24, for example, the monitoring data generation unit136waits until the cycle for generating the monitoring video data is reached. As an example, when the reduction rate in the number of frames is set to 1/2 in the generation condition of the unit process, the timing at which imaging video data MV0(e.g., imaging video data in which the image size is HD size and the number of frames is 60 fps) is obtained by two frames, becomes the generation cycle. In step S25, the monitoring data generation unit136generates one frame of monitoring video data (image data) by compressing the resolution from the imaging video data MV0according to the resolution (the number of frames per unit area) determined by the generation condition changed by the monitoring condition changing unit138. As a result of reducing the number of frames or compressing the resolution, monitoring video data (e.g., video data in which the image size is VGA size and the number of frames is 30 fps) is generated.

Subsequently, the control apparatus100executes step S26. In step S26, for example, the process determination unit150determines whether an abnormality has occurred in the unit process based on the monitoring video data (one frame of monitoring video data generated in step S25) during the execution of the unit process.

Subsequently, the control apparatus100executes step S27. In step S27, for example, the control apparatus100determines whether the end time of the unit process has been reached. When it is determined that the end time of the unit process has not been reached, the control apparatus100repeats the processes of steps S24to S27. As a result, it is determined whether there is an abnormality in the unit process for each generation cycle of the monitoring video data (for each frame of the monitoring video data).

When it is determined that the end time of the unit process has been reached, the control apparatus100executes step S28. In step S28, for example, the control apparatus100determines whether the monitoring process in all unit processes has been completed. When it is determined that the monitoring process in all unit processes has not been completed, the control apparatus100executes step S29. In step S29, the monitoring condition change unit138changes the generation condition of the monitoring video data during the execution of the supplying process based on the condition changing schedule. For example, in a case where the supplying process is monitored after the nozzle arrangement process is completed, while the supply control unit126is executing the supplying process, the monitoring condition changing unit138changes the number of pixels per unit area from the number of pixels n1to the number of pixels n2, changes the number of frames from the number of frames f2to the number of frames f1, and changes the target region IR of the monitoring video data from the entire imaging region PR to the peripheral region of the nozzle42. Then, by repeating steps S24to S27, the monitoring data generation unit136generates monitoring video data during the execution of the supplying process (e.g., video data in which the image size is the HD size and the number of frames is 60 fps) according to the generation condition changed by the monitoring condition changing unit138during the execution of the supplying process.

Further, in a case where the drying process is performed after the supplying process is completed, in step S29, while the film formation control unit128is executing the drying process, the monitoring condition changing unit138changes the number of pixels per unit area from the number of pixels n2to the number of pixels n1, changes the number of frames from the number of frames f2to the number of frames f1, and changes the target region IR of the monitoring video data from the peripheral region of the nozzle42to the entire imaging region PR. Then, by repeating steps S24to S27, the monitoring data generation unit136generates monitoring video data during the execution of the drying process (e.g., video data in which the image size is VGA size and the number of frames is 30 fps) according to the generation condition changed by the monitoring condition changing unit138during the execution of the drying process.

Meanwhile, when it is determined in step S28that the monitoring process in all unit processes has been completed, the monitoring procedure of the unit process in one wafer W is completed.

[Recording Procedure]

FIG.12is a flow chart illustrating a recording procedure (storing procedure) of storage video data. The control apparatus100executes a recording process for processing the wafer W in accordance with the execution of the liquid processing procedure and the monitoring procedure. As an example, the control apparatus100records storage video data in the unit process immediately after the completion of each unit process of the nozzle arrangement process, the supplying process, and the drying process. The control apparatus100first executes step S41in a state where the imaging region PR is continuously captured by the imaging apparatus110. In step S41, for example, the control apparatus100waits until the unit process to be recorded is completed.

When the unit process of the recording target is completed, the control apparatus100executes step S42. In step S42, for example, the process determination unit150determines whether a processing abnormality has been determined in the unit process of the recording target.

When it is determined in step S42that there is no abnormality in the unit process of the recording target, the control apparatus100executes steps S43and S44. In step S43, for example, the storage condition changing unit154maintains the storage condition of the storage video data as a reference storage condition (e.g., the image size is maintained at the VGA size and the number of frames is maintained at 30 fps). In step S44, for example, the storage data recording unit152generates storage video data in the unit process of the recording target from the imaging video data MV0temporarily stored in the data buffer unit134according to the reference storage condition. The storage data recording unit152outputs, for example, the generated storage video data to a data storage unit190outside the control apparatus100.

Meanwhile, when it is determined in step S42that there is an abnormality in the unit process of the recording target, the control apparatus100executes steps S45to S47. In step S45, for example, the storage condition changing unit154changes the storage condition of the storage video data from the reference storage condition to the storage condition at the time of abnormality (e.g., the image size is changed to the HD size and the number of frames is changed to 60 fps). In step S46, for example, the storage data recording unit152generates storage video data in the unit process of the recording target from the imaging video data MV0temporarily stored in the data buffer unit134according to the storage condition at the time of abnormality. The storage data recording unit152outputs, for example, the generated storage video data to the data storage unit190outside the control apparatus100. In step S47, for example, the storage data recording unit152acquires processing information related to the unit process of the recording target from the process determination unit150, and outputs (records) the processing information to (in) the external storage unit together with the storage video data.

Subsequently, the control apparatus100executes step S48. In step S48, for example, the storage condition changing unit154changes the storage condition of the storage video data from the storage condition at the time of abnormality to the reference storage condition. As a result, when no abnormality has occurred in the unit process that is the next recording target, the recording data for storage is recorded according to the reference storage condition.

Subsequently (after the completion of step S44or step S48), the control apparatus100executes step S49. In step S49, for example, the control apparatus100determines whether the recording process in all unit processes has been completed. When it is determined that the recording process in all unit processes has not been completed, the control apparatus100repeats the processes of steps S41to S49so that the recording process in the next unit process is executed. Meanwhile, when it is determined in step S49that the recording process in all unit processes has been completed, the recording process for one wafer W is completed.

[Effect of First Embodiment]

The monitoring apparatus20according to a first embodiment described above is a monitoring apparatus of a doping/developing apparatus2including a holding unit32that holds a wafer W, and a processing liquid supply unit40that supplies a processing liquid to a surface Wa of the wafer W held by the holding unit32by discharging the processing liquid from a nozzle42. The monitoring apparatus20includes: an imaging apparatus110capable of capturing an image of the nozzle42and the surface Wa of the wafer W held by the holding unit32; a monitoring data generation unit136that generates monitoring video data based on the imaging video data MV0by the imaging apparatus110during the execution of the wafer W process by the coating/developing apparatus2including a first process and a second process; and a monitoring condition changing unit13that changes a generation condition of the monitoring video data during the execution of the wafer W process so that at least the resolution or the number of frames of the monitoring video data (second video data MV2) during the execution of the second process is different from that of the monitoring video data (first video data MV1) during the execution of the first process.

The monitoring procedure of the coating/developing apparatus2described above includes: capturing an image of the nozzle42and the surface Wa of the wafer W held by the holding unit32by the imaging apparatus110; generating monitoring video data based on the imaging video data MV0by the imaging apparatus110during the execution of the wafer W process by the coating/developing apparatus2including the first process and the second process; and changing the generation condition of the monitoring video data during the execution of the wafer W process so that at least the resolution or the number of frames of second video data MV2during the execution of the second process is different from that of first video data MV1during the execution of the first process.

It is conceivable to automatically monitor the wafer W by a computer using an image process in order to determine (confirm) the state of the unit process of the wafer W in the liquid processing unit U1. Various unit processes of the wafer W are performed in the liquid processing unit U1. Video data of high image quality may be required to monitor (confirm) the state of a part of the unit processes. Therefore, it is conceivable to determine the state of various unit processes of the wafer W by setting a plurality of cameras at the optimum positions according to the content of the unit process of the wafer W and acquiring plural pieces of video data having image quality suitable for the content of the unit process. However, in this case, the number of cameras increases, which causes the configuration of the imaging apparatus to be complicated. Meanwhile, it is conceivable to simplify the configuration of the imaging apparatus by capturing an image with one camera to include the execution state of various unit processes of the wafer W. However, in this case, the imaging range becomes wider than when a plurality of cameras is installed at the optimum positions. When video data of high image quality is acquired according to the process that requires higher image quality and an image process is performed using the video data for each of various unit processes of the wafer W, the processing load of the computer becomes larger.

In the above-described monitoring apparatus20and monitoring procedure, the generation condition of the monitoring video data is changed during the execution of the wafer W process so that at least the resolution or the number of frames of the second video data MV2during the execution of the second process is different from that of the first video data MV1during the execution of the first process. Therefore, it is possible to generate monitoring video data of high image quality in a process that requires high image quality, and to generate monitoring video data of low image quality in a process that is sufficient even when the image quality is low. That is, the image quality of the monitoring video data may be changed according to the processing content. Therefore, the above-described monitoring apparatus20and monitoring procedure are useful for reducing the processing load of a computer when monitoring the process of the wafer W based on the imaging video.

The monitoring condition changing unit138may change a generation condition during the execution of the wafer W process so that the size of the imaging region PR of all pixels of the monitoring video data during the execution of the second process is different from that of the monitoring video data during the execution of the first process. In this case, it is possible to reduce the size of the imaging region PR in all pixels in the monitoring video data during the execution of the process that requires high image quality. Therefore, it is more useful for reducing the processing load of a computer when monitoring the process of the wafer W based on the imaging video.

The monitoring condition changing unit138may change the reduction rate in the number of pixels per unit area from the imaging video data during the execution of the wafer W process so that the resolution of the monitoring video data during the execution of the second process is different from that of the monitoring video data during the execution of the first process. The monitoring data generation unit136may generate monitoring video data by reducing the number of pixels from the imaging video data MV0according to the reduction rate changed by the monitoring condition changing unit138. In this case, since the reduction rate in the number of pixels per unit area differs in the first process and the second process, monitoring data of image quality suitable for the processing content may be easily obtained.

The first process may be a process of moving the nozzle42, and the second process may be a process of discharging the processing liquid from the nozzle42to the surface Wa of the wafer W. The monitoring condition changing unit138may change a generation condition during the execution of the wafer W process so that the resolution of the monitoring video data during the execution of the second process is different from that of the monitoring video data during the execution of the first process. Video data of low image quality may be sufficient for monitoring the nozzle arrangement process, and video data of high image quality may be required for monitoring the supplying process. With the above-mentioned configuration, it is possible to obtain monitoring video data suitable for the processing content in the nozzle arrangement process and the supplying process. Further, by reducing the size of the imaging region PR included in all pixels in the monitoring video data of the supplying process, an amount of data may be reduced even when the resolution is high. In this case, it is possible to achieve both an appropriate monitoring of the wafer W process and a reduction of the processing load of the computer.

The first process may be a process of forming a film of the processing liquid on the surface Wa of the wafer W, and the second process may be a process of discharging the processing liquid from the nozzle42to the surface Wa of the wafer W. The monitoring condition changing unit138may change a generation condition during the execution of the wafer W process so that the resolution of the monitoring video data during the execution of the second process becomes higher than that of the monitoring video data during the execution of the first process. Video data of high image quality may be sufficient for monitoring the film formation process, and video data of high image quality may be required for monitoring the supplying process. With the above-mentioned configuration, it is possible to obtain monitoring video data suitable for the processing content in the drying process and the supplying process.

The monitoring apparatus20described above may further include a monitoring condition storage unit148that stores a condition changing schedule for changing a generation condition according to the processing schedule of the wafer W by the coating/developing apparatus2. The monitoring condition changing unit138may change a generation condition during the execution of the wafer W process based on the condition changing schedule. In this case, when changing the generation condition, since the condition schedule in the monitoring condition storage unit148may be referred to, the processing load required for changing the generation condition may be reduced.

The monitoring apparatus20described above may further include a process determination unit150that determines an abnormality in the wafer W process based on the monitoring video data, a storage data recording that records storage video data based on the imaging video data MV0, and a storage condition changing unit154that changes a storage condition of the storage video data to a time when the storage video data is recorded when the determination result of the process determination unit150indicates an abnormality. In the configuration, when the determination result indicates an abnormality, it is possible to store the video data of the image quality suitable for such a result. The configuration is useful for both an analysis of abnormality using the storage video data and a suppression of the increase in recording capacity by, for example, improving the image quality of the unit process period in which an abnormality has occurred in the storage video data as compared to other periods in which no abnormality has occurred.

When the determination result of the process determination unit150indicates an abnormality, the storage condition changing unit154may change at least one of the resolution, the number of frames, and the compression format of the storage video data to a time when recording the storage video data. In this case, it is possible to record the period in which an abnormality has occurred in the storage video data with higher image quality than the other periods in which no abnormality has occurred. Therefore, the configuration is useful for both an analysis of abnormality using the storage video data and a suppression of the increase in recording capacity.

When the determination result of the process determination unit150indicates an abnormality, the storage data recording unit152may also record processing information indicating the processing content of the wafer W determined to be abnormal. In this case, when analyzing the abnormality using the storage video data, it is easy to grasp the processing content when the process in which the abnormality has occurred is executed.

In the above-described monitoring apparatus20, by reducing the processing load of the computer, for example, real-time monitoring (determination) of the processing state of the wafer W becomes possible. It is also possible to simplify the configuration of the liquid processing unit U1by monitoring the contents of a plurality of unit processes with one camera.

(Modification of First Embodiment)

The change condition schedule stored in the monitoring condition storage unit148is generated by the monitoring condition generation unit142, but may be created in advance by the operator instead of the monitoring condition generation unit142.

The monitoring condition changing unit138may change a generation condition during the execution of the wafer W process based on the processing schedule of the wafer W and the correspondence information stored in the reference condition storage unit140. Specifically, each time the unit process of the wafer W is switched, the monitoring condition changing unit138acquires a signal indicating the content of the unit process from the processing information storage unit120. Then, by referring to the table information stored in the reference condition storage unit140, the monitoring condition changing unit138acquires the generation condition according to the content of the unit process each time the unit process of the wafer W is switched, and changes the acquired generation condition to the generation condition.

The monitoring apparatus20according to the present modification includes a reference condition storage unit140that stores correspondence information in which the processing content of the wafer W and the generation condition are associated with each other. The monitoring condition changing unit138may change the generation condition during the execution of the wafer W process based on the processing schedule of the wafer W by the coating/developing apparatus2and the correspondence information. In this case, when the coating/developing apparatus2executes the wafer W process according to plural types of processing schedules, it is not necessary to prepare plural change condition schedules in advance. Therefore, it is useful for reducing the storage capacity of the control apparatus100.

The monitoring condition changing unit138may change the generation condition so that the target region IR is set to the periphery of the nozzle and the target region IR is changed according to the movement locus of the nozzle42in the arrangement process of the nozzle42. In this case, the control apparatus100may include an image processing unit that calculates the movement locus of the nozzle42based on the imaging video data acquired by the data acquisition unit132. Alternatively, the monitoring condition changing unit138may adjust the target region IR to the movement locus of the nozzle42according to the information indicating the movement of the nozzle42defined in the processing schedule (information in which the time and the position are associated with each other).

[Second Embodiment]

Next, a control apparatus100provided in a substrate processing system1according to a second embodiment will be described with reference toFIGS.3and13. The control apparatus100according to the second embodiment is different from the control apparatus100according to the first embodiment in that a method of changing the resolution adjusts the imaging optical system of an imaging apparatus110. The imaging apparatus110includes an imaging optical system112illustrated inFIG.3. The monitoring condition changing unit138changes a zoom magnification by the imaging optical system112of the imaging apparatus110during the execution of the wafer W process so that the resolution of second video data MV2, which is the monitoring video data during the execution of the second process, is different from that of first video data MV1, which is the monitoring video data during the execution of the first process.

For example, when the first process is a drying process and the second process is a process of supplying a processing liquid, as illustrated inFIG.13, the monitoring condition changing unit138sets the zoom magnification of the imaging apparatus110in the first process to 1. In this case, the imaging region PR of the imaging video data MV01acquired by the data acquisition unit132includes, for example, a moving nozzle42and the entire surface Wa of the wafer W. Meanwhile, the monitoring condition changing unit138sets the zoom magnification of the imaging apparatus110in the second process to x (x is a value larger than 1) times, and adjusts the imaging optical system112of the imaging apparatus110so that the entire nozzle42at the discharge position is within the angle of view. At this time, the monitoring condition changing unit138sets the number of pixels to the same value as the number of pixels in the first process. In this case, the imaging region PR of the imaging video data MV02acquired by the data acquisition unit132includes, for example, a nozzle42at the discharge position and a part of the surface Wa of the wafer W.

The monitoring data generation unit136may generate monitoring video data by using the first video data MV1as it is without performing a process such as a compression on the imaging video data MV01. The monitoring data generation unit136also does not perform the ROI selection process from the imaging region PR of the imaging video data MV01. In the imaging video data MV01and the first video data MV1, the resolution, the number of frames, and the size of the imaging region PR in all pixels are the same as each other (e.g., the image sizes of both data are VGA size and the number of frames of both data is 60 fps). The monitoring data generation unit136may generate monitoring video data by using the second video data MV2as it is without performing a process such as a compression on the imaging video data MV02. The monitoring data generation unit136also does not perform the ROI selection process from the imaging region PR of the imaging video data MV02. In the imaging video data MV02and the second video data MV2, the resolution, the number of frames, and the size of the imaging region PR in all pixels are the same as each other (e.g., the image sizes of both data are VGA size and the number of frames of both data is 60 fps).

The number of pixels per unit area (the total number of pixels) in the imaging video data MV01and the imaging video data MV02is the same as each other. However, since the zoom magnifications are different, the resolutions, which are the sizes of the imaging region PR per pixel, are different from each other. Therefore, the resolutions of the first video data MV1and the second video data MV2are also different from each other. By changing the zoom magnification in this way, the monitoring condition changing unit138changes the generation condition during the execution of the wafer W process so that the resolution of the second video data MV2is higher than the resolution of the first video data MV1.

The imaging apparatus110may be configured such that the direction or position of a camera is changed. In addition to the zoom magnification, the monitoring condition changing unit138may change the generation condition (imaging region of imaging video data) by changing the direction or position of the camera according to the content of the unit process. In the arrangement process of the nozzle42, the monitoring condition changing unit138may change the direction or position of the camera so that the imaging region matches the movement locus of the nozzle42. The reference condition storage unit140may store the correspondence information in which the content of the unit process and the zoom magnification included in the generation condition are associated with each other.

In the monitoring apparatus20according to the second embodiment described above, the monitoring condition changing unit138may change the zoom magnification by the imaging optical system112of the imaging apparatus110during the execution of the wafer W process so that the resolution of the monitoring video data (second video data MV2) during the execution of the second process is different from that of the monitoring video image data (first video data MV1) during the execution of the first process. The monitoring data generation unit136may generate monitoring video data based on the imaging video data MV0captured by the imaging apparatus110at the zoom magnification changed by the monitoring condition changing unit138.

Also in this case, as in the first embodiment, it is useful for reducing the processing load of the computer. For example, when in a unit process that requires high image quality and a unit process that does not require high image quality, the imaging video data captured without using the optical zoom is used as the monitoring video data as it is, it is necessary to always capture images with high image quality according to the process that requires high image quality. As a result, even in the process that does not require high image quality, monitoring is required to perform an image process with monitoring video data of high image quality. By enlarging and capturing the imaging region with an optical zoom in a process that requires high image quality, an amount of monitoring video data may be reduced as compared to always capturing the entire image with high image quality and the processing load of the computer may be reduced. Further, in the above-described configuration, since a computer process for adjusting the image quality may be omitted, it is more useful for reducing the processing load of the computer as compared with the first embodiment.

The monitoring condition changing unit138may change the generation condition by combining at least one of the process of changing the number of pixels per unit area, the process of changing the number of frames, and the process of selecting the target region IR according to the first embodiment with the process of changing the zoom magnification of the imaging apparatus110according to the second embodiment.

In the liquid process including the developing process in the liquid processing unit U1of the processing module14, the control apparatus100may monitor the process of the wafer W in the same manner as in the first embodiment and the second embodiment described above. In this case, in the drying process, the liquid processing unit U1may form a puddle of developer on the surface Wa while the wafer W to which the developer is applied (supplied) on the surface Wa is stopped. For example, the monitoring apparatus20may monitor whether the puddle is properly formed.

The substrate to be processed is not limited to a semiconductor wafer, and may be, for example, a glass substrate, a mask substrate, or a flat panel display (FPD).

DESCRIPTION OF SYMBOLS

1: substrate processing system2: coating/developing apparatus20: monitoring apparatus30: rotation holding unit40: processing liquid supply unit100: control apparatus136: monitoring data generation unit138: monitoring condition changing unit140: reference condition storage unit142: monitoring condition generation unit148: monitoring condition storage unit150: process determination unit152: storage data recording unit154: storage condition changing unitU1: liquid processing unit