ALIGNER DEVICE AND METHOD FOR CORRECTING POSITIONAL MISALIGNMENT OF WORKPIECE
20210300690 · 2021-09-30
Inventors
Cpc classification
B65G47/90
PERFORMING OPERATIONS; TRANSPORTING
H01L21/67259
ELECTRICITY
International classification
Abstract
An aligner device includes a robot hand, a lifting mechanism, sensors, a misalignment calculating unit, an x-y misalignment correcting unit, and a θ misalignment correcting unit. The robot hand includes vertically aligned hand members each configured to hold a planar workpiece. The lifting mechanism moves planar workpieces transported by the robot hand up from and down to the hand members, respectively. Each of the sensors, vertically spaced apart from each other, has a downward sensor surface to capture the outline of a planar workpiece brought close to the sensor surface by the workpiece lifting mechanism. The misalignment calculating unit calculates, by using the images of the captured outline shapes of the planar workpieces, an amount of positional misalignment of each planar workpiece with a reference position in X, Y and θ directions. The X-Y misalignment correcting unit corrects the misalignment of each planar workpiece in the X and Y directions based on the amount of X-Y direction misalignment calculated by the misalignment calculating unit. The θ misalignment correcting unit corrects the misalignment of each planar workpiece in the θ direction based on the amount of θ misalignment of the planar workpiece.
Claims
1. An aligner device comprising: a robot hand including a plurality of vertically aligned hand members each of which is configured to hold a planar workpiece placed thereon; a workpiece lifting mechanism that moves a plurality of planar workpieces transported by the robot hand up from and down to the plurality of hand members, respectively; a plurality of sensors vertically spaced apart from each other by a predetermined distance, each of the plurality of sensors having a sensor surface that faces downward and being configured to capture an outline shape of a planar workpiece that is brought into proximity to or into contact with the sensor surface by the workpiece lifting mechanism; a positional misalignment calculating unit that calculates, by using an image of an outline shape of a planar workpiece captured by each of the plurality of sensors, an amount of positional misalignment of the planar workpiece with a reference position in X, Y and θ directions; an X-Y direction positional misalignment correcting unit that corrects positional misalignment of each planar workpiece in the X and Y directions based on an amount of X-Y direction positional misalignment of the planar workpiece calculated by the positional misalignment calculating unit; and a θ direction positional misalignment correcting unit that corrects positional misalignment of each planar workpiece in the θ direction based on an amount of θ direction positional misalignment of the planar workpiece calculated by the positional misalignment calculating unit.
2. The aligner device according to claim 1, further comprising a control unit that controls the X-Y direction positional misalignment correcting unit and the θ direction positional misalignment correcting unit.
3. An aligner device comprising: a robot hand including a plurality of vertically aligned hand members each of which is configured to hold a planar workpiece placed thereon; a workpiece lifting mechanism that moves a plurality of planar workpieces transported by the robot hand up from and down to the plurality of hand members, respectively; a plurality of sensors vertically spaced apart from each other by a predetermined distance, each of the plurality of sensors having a sensor surface that faces downward and being configured to capture an outline shape of a planar workpiece that is brought into proximity to or into contact with the sensor surface by the workpiece lifting mechanism; a positional misalignment calculating unit that calculates, by using an image of an outline shape of a planar workpiece captured by each of the plurality of sensors, an amount of positional misalignment of the planar workpiece with a reference position in X, Y and θ direction; an X-Y direction positional misalignment correcting unit that corrects positional misalignment of each planar workpiece in the X and Y directions based on an amount of X-Y direction positional misalignment of the planar workpiece calculated by the positional misalignment calculating unit; a θ direction positional misalignment correcting unit that corrects positional misalignment of each planar workpiece in the θ direction based on an amount of θ direction positional misalignment of the planar workpiece calculated by the positional misalignment calculating unit; and a control unit that controls the X-Y direction positional misalignment correcting unit and the θ direction positional misalignment correcting unit, wherein the workpiece lifting mechanism includes a pin that supports a planar workpiece from under, the X-Y direction positional misalignment correcting unit corrects positional misalignment of the planar workpiece supported on the pin by moving the pin in the X-Y direction based on the amount of X-Y direction positional misalignment, and the θ direction positional misalignment correcting unit corrects positional misalignment of the planar workpiece supported on the pin by rotating the pin in the θ direction based on the amount of θ direction positional misalignment.
4. A method for correcting positional misalignment of a planar workpiece by using an aligner device, the aligner device including: a robot hand including a plurality of vertically aligned hand members each of which is configured to hold a planar workpiece placed thereon; a workpiece lifting mechanism that moves each of a plurality of planar workpieces transported by the robot hand up from and down to the plurality of hand members, respectively; a plurality of sensors vertically spaced apart from each other by a predetermined distance, each of the plurality of sensors having a sensor surface that faces downward and being configured to capture an outline shape of a planar workpiece that is brought into proximity to or into contact with the sensor surface by the workpiece lifting mechanism; a positional misalignment calculating unit that calculates, by using an image of an outline shape of a planar workpiece captured by each of the plurality of sensors, an amount of positional misalignment of the planar workpiece with a reference position in X, Y and θ direction; an X-Y direction positional misalignment correcting unit that corrects positional misalignment of each planar workpiece in the X and Y directions based on an amount of X-Y direction positional misalignment of the planar workpiece calculated by the positional misalignment calculating unit, and a θ direction positional misalignment correcting unit that corrects positional misalignment of each planar workpiece in the θ direction based on an amount of θ direction positional misalignment of the planar workpiece calculated by the positional misalignment calculating unit; and a control unit that controls the X-Y direction positional misalignment correcting unit and the θ direction positional misalignment correcting unit, wherein the workpiece lifting mechanism includes a plurality of pins each of which supports a planar workpiece from under, the X-Y direction positional misalignment correcting unit corrects positional misalignment of the planar workpiece supported on the pin by moving the pin in the X-Y direction based on the amount of X-Y direction positional misalignment, and the θ direction positional misalignment correcting unit corrects positional misalignment of the planar workpiece supported on the pin by rotating the pin in the θ direction based on the amount of θ direction positional misalignment, the method comprising: a planar workpiece transferring step of moving the robot hand so that a plurality of planar workpieces on the plurality of hand members are transferred to be positioned at respective alignment reference positions above the plurality of sensors; a planar workpiece lifting step of raising the plurality of pins to lift the plurality of planar workpieces up from the hand members to bring the planar workpieces into proximity to or into contact with the corresponding sensors; an outline shape capturing step of capturing the outline shape of each of the planar workpieces by the corresponding sensor; a positional misalignment calculating step of calculating an amount of positional misalignment of each of the plurality of planar workpieces with a reference position in the X, Y and θ directions, by using the captured outline shape; a θ direction position correcting step of lowering the plurality of pins of the workpiece lifting mechanism to move each of the planar workpieces down to a position above the corresponding hand member, and subsequently rotating each of the plurality of pins based on the calculated amount of positional misalignment in the θ direction; an X-Y direction position correcting step of moving the plurality of pins of the workpiece lifting based on the calculated positional misalignment in the X, Y and θ directions to align each of the planar workpieces with a reference position on the corresponding hand member; and an after-alignment-placing step of lowing the plurality of pins of the workpiece lifting mechanism to place the aligned planar workpieces onto the corresponding hand members.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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EMBODIMENTS
[0042] The following describes preferred embodiments of the present disclosure, with reference to the drawings.
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[0044] As shown in
[0045] The robot hand 1 includes a support 12 and a plurality of hand members 131, 132, 133 . . . . The support 12 is provided at an end arm (not shown) of an articulated robot, for example. The hand members 131, 132, 133 . . . are configured to hold workpieces (e.g., semiconductor wafers) Wa, Wb, Wc . . . on their upper surfaces. The vertical intervals between the adjacent hand members 131, 132, 133 . . . may or may not be adjustable. The robot hand 1 controls a manipulator (not shown) to at least achieve the function of moving each of the hand members 131, 132, 133 . . . in the horizontal direction (X-Y direction) while keeping the hand members horizontal. As shown in
[0046] The sensors 31, 32, 33 . . . are contact or non-contact proximal sensors having the function of capturing an image of the outline of a target object. In the example shown in the figures, each of the sensors 31, 32, 33 . . . is configured to sense the planner (two-dimensional) outline of a target object located underneath the sensor. As shown in
[0047] In the example shown in the figures, the sensors 31, 32, 33 . . . capture the outline shapes of the semiconductor wafers Wa, Wb, Wc . . . . The planar shape of each sensor 31, 32, 33 . . . is not specifically limited as long as it allows for a margin of positioning error of the semiconductor wafer Wa, Wb, Wc . . . in the X-Y direction to reliably to capture the outline shape of the semiconductor wafer. For examples, the sensors 31, 32, 33 . . . may be have a circular shape as in
[0048] As shown most clearly in
[0049] Typically, each of the semiconductor wafers Wa, Wb, Wc . . . has the shape of a circular disc as shown in
[0050] The positional misalignment calculating unit 6 determines the amounts of positional misalignment of the semiconductor wafers Wa, Wb, Wc . . . in the X-Y direction and the θ direction relative to the respective reference positions, based on the shapes of the images of the semiconductor wafers Wa, Wb, Wc . . . captured by the sensors 31, 32, 33 . . . . Specifically, the center of the captured image of each semiconductor wafer is determined as shown in
[0051] The aligner device A1 having the configuration described above may operate in the following manner.
[0052] As shown in
[0053] Next, as shown in
[0054] are raised to lift the semiconductor wafers Wa, Wb, Wc . . . up from the hand members 131, 132, 133 . . . until the semiconductor wafers Wa, Wb, Wc . . . are placed near the undersurfaces the sensors 31, 32, 33 . . . . Note that the semiconductor wafers Wa, Wb, Wc . . . need to be kept out of contact with the sensors 31, 32, 33 . . . to avoid possible contamination of the wafer surfaces. When the semiconductor wafers Wa, Wb, Wc . . . are lifted up from the hand members 131, 132, 133 . . . by the pins 51, 52, 53 . . . , the hand members 131, 132, 133 release the suction on the semiconductor wafers Wa, Wb, Wc . . . , and the pins 51, 52, 53 . . . exert suction on the semiconductor wafers Wa, Wb, Wc . . . . In this state, the sensors 31, 32, 33 . . . acquire image data representing the outline shapes of the semiconductor wafers Wa, Wb, Wc . . . as described above. The positional misalignment calculating unit 6 receives the image data and calculates the amounts of positional misalignment of each semiconductor wafer Wa, Wb, Wc . . . relative to the reference position C1 and also to the reference position N1. More specifically, the amounts of X direction misalignment δxa, δxb, δxc . . . , the amounts of Y direction misalignment δya, δyb, δyc . . . , and the amounts of θ direction misalignment δθa, δθb, δθc . . . are calculated for the respective semiconductor wafers Wa, Wb, Wc . . . (
[0055] Subsequently, as shown in
[0056] are lowered by a predetermined distance. In this state, the semiconductor wafers Wa, Wb, Wc . . . are spaced above the hand members 131, 132, 133 . . . . Subsequently, as shown in
[0057] After the correction by the amounts of θ direction misalignment δθa, δθb, δθc . . . , the positions of the semiconductor wafers Wa, Wb, Wc . . . are adjusted to correct the misalignment in the X-Y direction. Note that the amounts of misalignment in the X-Y direction at this stage (after the correction of θ directions) are not the same as the initial amounts of misalignment δxa, δxb, δxc . . . and δya, δyb, δyc . . . shown in
[0058] Subsequently, as shown in
[0059] Subsequently, the robot hand 1 retracts from the frame 4 to transfer the semiconductor wafers Wa, Wb, Wc . . . to the locations for the subsequent processing, while keeping the semiconductor wafers Wa, Wb, Wc . . . on the hand members 131, 132, 133 in alignment with the reference position in the X-Y direction.
[0060] As has been described above, the aligner device A1 can capture the outline shapes of the planar workpieces (semiconductor wafers) Wa, Wb, Wc . . . by using the sensors 31, 32, 33 . . . having planner sensor surfaces 311, 321, 331 . . . . The aligner device A1 can also calculate the amounts of positional misalignment of the semiconductor wafers Wa, Wb, Wc . . . with the reference position by using the captured image of the outline shapes. According to the aligner device A1, the units for determining the amounts of positional misalignment of the semiconductor wafers Wa, Wb, Wc . . . can be made thinner in profile.
[0061] With the low-profile positional misalignment detecting units, the positional misalignment of a plurality of semiconductor wafers Wa, Wb, Wc . . . can be detected simultaneously and corrected simultaneously. Therefore, the aligner device A1 can reduce the transfer takt time of a plurality of semiconductor wafers Wa, Wb, Wc . . . , including the time for correcting positional misalignment in a semiconductor process.
[0062] The present disclosure is not limited to the embodiments described above and intended to cover any modification that can be derived from the scope of each appended claim.
[0063] In the embodiments described above, the semiconductor wafers Wa, Wb, Wc . . . are kept out of contact with the sensors 31, 32, 33 . . . to avoid possible contamination of the surfaces of the semiconductor wafers Wa, Wb, Wc . . . . In an embodiment where contamination of the wafer surfaces does not pose problems, the sensors 31, 32, 33 . . . may be brought into contact the semiconductor wafers Wa, Wb, Wc . . . .