SYSTEM AND METHOD FOR DIAGNOSING STATE OF MECHANICAL EQUIPMENT
20230057521 · 2023-02-23
Inventors
Cpc classification
G05B19/401
PHYSICS
G05B23/024
PHYSICS
International classification
Abstract
Provided are a system and a method for diagnosing a state of mechanical equipment. More particularly, provided are a system and a method for diagnosing a state of mechanical equipment, wherein a health index is calculated for various levels in the equipment using one or more sensor parameter values related to individual components of the equipment, and then a current state value of the equipment is finally derived.
Claims
1. A system for diagnosing a state of mechanical equipment, the system comprising: a detection part configured to sense parameter values of individual components; a state value derivation part configured to calculate a state value of the mechanical equipment in a time series manner from the parameter values; a database configured to store the state value; and a controller.
2. The system of claim 1, wherein the state value derivation part comprises: a health index derivation part configured to derive health indexes of individual parameter nodes in a parameter layer from the parameter values; a weighting derivation part configured to provide weightings for the individual parameter nodes in the parameter layer; and a health index calculation part configured to derive or calculate the state value of the mechanical equipment by multiplying the health indexes of the individual parameter nodes by the weightings.
3. The system of claim 2, wherein the health index derivation part is configured to derive or calculate each of the health indexes of the individual parameter nodes by dividing an overlapping area of a setting value and an analog value for a corresponding parameter within a set time interval and/or by a union of the setting value and the analog value.
4. The system of claim 3, wherein the health index derivation part is configured to omit a corresponding parameter value from the calculation of the health index of the parameter node when the corresponding parameter is in an off state.
5. The system of claim 2, wherein the weighting derivation part is configured to provide weightings for individual component nodes in a component layer and individual module nodes in a module layer, and the weighting derivation part comprises: an initial weighting setting module configured to divide into a number of individual child nodes connected to an individual parent node, and/or assign initial weightings to the individual child nodes; and a weighting update module configured to update the weightings from a previous time point for the individual child nodes into the weightings at a current time point.
6. The system of claim 5, wherein the weighting update module comprises: a variation calculation module configured to calculate variations in the health indexes of the individual child nodes for each period; an adjustment value calculation module configured to calculate adjustment values at the current time point using the variations in the health indexes of the individual child nodes; and a weighting calculation module configured to update the weightings for the individual child nodes connected to the individual parent node.
7. The system of claim 6, wherein each of the adjustment values is derived or calculated by adding the weighting at the previous time point for the individual child node to a value obtained by multiplying a hyperparameter by the variation in the health index between the previous time point and the current time point raised to the m-th power.
8. The system of claim 7, wherein the m is equal to or greater than 2.
9. The system of claim 6, wherein the weighting calculation module is configured to give a new weighting for each of the individual child nodes by dividing the adjustment value of each of the individual child nodes connected to the same parent node by a sum of the adjustment values of the individual child nodes connected to the same parent node.
10. The system of claim 9, wherein the health index calculation part is configured to derive or calculate new health indexes by multiplying the health indexes at the current time point of the individual parameter nodes by the weightings at the current time point resulting from update, and then to derive or calculate the state value of the mechanical equipment using a sum of values obtained by multiplying the new health indexes by the new weightings of the individual child nodes connected to the same parent node.
11. A method for diagnosing a state of mechanical equipment, the method comprising: deriving or calculating health indexes of individual parameter nodes from sensor parameter values; providing initial weightings for the individual parameter nodes, individual component nodes, and individual module nodes; updating the weightings for the individual parameter nodes, the individual component nodes, and the individual module nodes from an immediately previous time point; and deriving or calculating from the health indexes at a current time point of the individual parameter nodes connected to the individual component nodes, new health indexes at the current time point for the respective nodes.
12. The method of claim 11, wherein each of the health indexes of the individual parameter nodes is derived or calculated from a setting value and an actual measurement value for or of corresponding one(s) of the parameter values.
13. The method of claim 12, wherein in the deriving of the health indexes, each of the health indexes of the individual parameter nodes is derived from the setting value and the actual measurement value for or of the corresponding ones of the parameter values using an Intersection over Union (IoU) method.
14. The method of claim 11, wherein the initial weightings are provided to child nodes by proportionally dividing into a number of the child nodes connected to an individual parent node.
15. The method of claim 11, wherein updating the weightings comprises: calculating a variation for individual child nodes each period; and deriving or calculating new weightings of the individual child nodes from the variation.
16. The method of claim 15, wherein the updating of the weightings further comprises calculating adjustment values for the respective nodes from the corresponding variation each period.
17. The method of claim 16, wherein each of the adjustment values is derived or calculated by adding the weighting at the immediately previous time point for each of the individual child nodes to a value obtained by multiplying a hyperparameter by the variation in the health index between the immediately previous time point and the current time point raised to the m-th power.
18. The method of claim 16, wherein deriving the new weightings comprises dividing the adjustment value of each of the individual child nodes connected to a same parent node by a sum of the adjustment values of the individual child nodes connected to the same parent node.
19. The method of claim 17, wherein deriving the new health indexes comprises multiplying the health indexes at the current time point of the individual child nodes connected to an individual parent node by the new weightings at the current time point, and adding the new health indexes of the individual child nodes connected to the individual parent node to derive the new health index of the individual parent node.
20. The method of claim 17, further comprising deriving or calculating a state value of the mechanical equipment by adding the new health indexes of the individual child nodes connected to a mechanical equipment node.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The above and other objectives, features, and other advantages of the present disclosure will be more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:
[0046]
[0047]
[0048]
[0049]
[0050]
[0051]
[0052]
[0053]
[0054]
DETAILED DESCRIPTION OF THE INVENTION
[0055] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. It is noted that embodiments of the present disclosure may be changed to a variety of embodiments. The scope of the present disclosure should not be interpreted as being limited to the embodiments described hereinbelow, but should be interpreted on the basis of the descriptions in the appended claims. In addition, the embodiments of the present disclosure are provided for reference in order to fully describe the disclosure for those skilled in the art.
[0056] Unless otherwise mentioned in context, a singular noun or a singular noun phrase may have a plural meaning throughout the present specification. The terms “comprise” and/or “comprising” that are used in the present specification are intended to indicate that a shape, a number, a step, an operation, a member, an element, a group thereof, etc., are present, and do not to preclude the presence or addition of one or more other shapes, numbers, steps, operations, members, elements, groups thereof, etc.
[0057] In the present specification, according to need and/or design criteria, individual elements may be integral with each other or independent of each other. It should be noted that no specific limitation to such arrangements is imposed.
[0058] Hereinafter, a system 1 for diagnosing a state of mechanical equipment according to one or more embodiments of the present disclosure will be described in detail with reference to the accompanying drawings. Hereinafter, for convenience of description, semiconductor manufacturing equipment, which is one type of mechanical equipment, is described for illustrative purposes, but the scope of the present disclosure is not limited to a specific type and can be applied to various fields such as battery manufacturing equipment or other manufacturing equipment.
[0059]
[0060] Referring to
[0061] Furthermore, it is understood that the word “health indexes” refer to indexes for determining state values of the equipment, one or more modules thereof, components thereof, and one or more parameter layers useful for making a diagnosis of the equipment.
[0062]
[0063] Hereinbelow, a component may be the minimum unit of hardware configured to perform an independent function, and may refer to a part in a group of parts that constitute an individual module. A module may be a set of components that, taken together, may work as one unit to provide a larger function. In this regard, providing a description based on semiconductor manufacturing equipment as an example, components may include a plasma source, a mass flow controller (MFC), a pressure controller (e.g., adaptive pressure control; APC), a chuck for holding a semiconductor wafer, a baffle, etc. In addition, each module includes one or more components. Furthermore, in general, semiconductor manufacturing equipment/mechanical equipment comprises one or more modules. In addition, related parameter values in general semiconductor manufacturing equipment may include a lead value of source power, a chuck temperature, a gas flow rate, for example.
[0064] Referring to
[0065] Referring to
[0066] The detection part 10 comprises a sensor configured to detect or sense data related to each component, and may comprise a temperature sensor, a pressure sensor, a gas or chemical sensor, and/or an optical sensor, depending on or according to the function of a corresponding component, but is not limited thereto. The sensing data detected by the detection part 10 comprises time series data, and may be a parameter value such as a measurement value A, which will be described later. Furthermore, the sensing data related to each individual component detected by the detection part 10 is transmitted to the state value derivation part 30.
[0067]
[0068] Referring to
[0069]
[0070] Referring to
[0071] The health index derivation part 310 calculates a first health index H1 for each parameter node N1 from a setting value I and a measurement value A for each such parameter node N1 connected to each individual component node N2, wherein the measurement value A is actually sensed by the detection part 10. The setting value I is understood to mean a command value of the controller 70 for each parameter. Furthermore, as described above, the measurement value A and the setting value I for each parameter node N1 are understood to be included in the parameter values.
[0072] The measurement value A for each parameter node N1 in each individual component may show a slightly different value or pattern from the setting value I (that is, a command value/control value) with the passage of operation time. For example, referring to
[0073] Herein, the health index derivation part 310 derives, from an Intersection over Union (IoU), a first health index H1 of each individual parameter node N1 by using the setting value I and the measurement value A for each parameter node N1 (see
[0074] The first health index H1 may have any value that is equal to or greater than 0 and equal to or less than 1. When the aforementioned phase shift, vertical shift, and/or ripple/spike occur, the first health index may have a value between 0 and 1. Furthermore, when a component operates despite a non-operation command, the first health index may have a value of 0.
[0075] Each individual parameter node N1 may have a reference value. In this case, when the first health index H1 of each parameter node N1 is equal to or less than or the reference value, a worker (or equipment user) is notified that there may be a problem in performing the process (e.g., that the equipment performs during operation). For example, when the first health index H1 of each parameter node N1 is equal to or less than the reference value, an alarm such as a warning sound may be given. However, no limitation thereto is imposed. Furthermore, the first health index H1 for each period (e.g., of time) of each parameter node N1 may be classified by time and stored in the database 50 so that a worker or user can search the database.
[0076] As described above, the health index derivation part 310 derives a first health index H1 for each parameter node N1. Furthermore, the health index derivation part 310 may include a calculation exclusion selection module 311.
[0077] The calculation exclusion selection module 311 is a module for excluding an element (e.g., a parameter or an individual parameter node N1) when the component corresponding to the element is in an off state. For example, when a Gas1 valve and a Gas2 valve are closed during a specific period (e.g., of operation of the equipment including the Gas1 and Gas2 valves), the setting value I of the Gas1 valve and the setting value I of the Gas2 valve are 0, and the first health indexes H1 of the corresponding parameter nodes N1 are 0. Herein, when considering (e.g., calculating or determining) a weighting w and the second and third health indexes H2 and H3 (which will be described later), first health indexes H1 of the parameter nodes N1 having a 0 value (e.g., corresponding to the Gas1 valve and the Gas2 valve) may result in distortion of the weighting w and/or the health indexes H2 and/or H3. Therefore, the calculation exclusion selection module 311 omits the calculation of a first health index H1 of a parameter value corresponding to an element and/or component in a non-operating state. Afterward, when the element and/or component are operating (e.g., the Gas1 valve and/or the Gas2 valve is/are opened), the first health index H1 of the corresponding parameter node N1 may be considered.
[0078]
[0079] Referring to
[0080] To this end, the weighting derivation part 330 may include an initial weighting setting module 331, and a weighting update module 333.
[0081]
[0082] Referring to
[0083] As described above, the initial weighting setting module 331 sets an initial weighting w.sub.0 for each node considering (e.g., depending on) the number of child nodes connected to a corresponding parent node, thereby preventing intervention of potentially subjective personal bias.
[0084] Referring to
[0085] To this end, the weighting update module 333 may include a variation calculation module 3331, an adjustment value calculation module 3333, and a weighting calculation module 3335.
[0086] The variation calculation module 3331 calculates a variation d for each period (e.g., of time) for the health index of each individual child node. For example, in the parameter layer, when input values of the first health index H1 of a specific parameter node N1 are 0.70 at the time point t.sub.1, 0.71 at the time point t.sub.2, and 0.73 at the time point t.sub.3, the variation d between the time points t.sub.1 and t.sub.2 is 0.01. The variation calculation module 3331 calculates the health index variation d for all of the nodes in each layer.
[0087] The adjustment value calculation module 3333 is configured to calculate an adjustment value S at the current time point t from the variation d for each period (e.g., of time) for the health index of each of the individual child nodes. The adjustment value S is a value for adjustment of the weighting so that the sum of the weightings of a set of child nodes connected to a single parent node is 1. The adjustment value S of each individual node at the current time point t may be calculated by the following Equation
[0088] That is, the adjustment value S of a specific node may be derived or calculated by adding the weighting W.sub.t-1 of the node at the previous time point to a value obtained by multiplying a hyperparameter λ by the health index variation d between the previous time point t-1 and the current time point t raised to the m-th power. Herein, when the hyperparameter λ value is 0, the adjustment value S may have the same value as the weighting W.sub.t-1 at the previous time point. When λ > 0, however, the adjustment value S may change (e.g., be greater than the weighting W.sub.t-1 at the previous time point) because the new weighting wt will have a different value as a result of an update (e.g., to the weighting and/or due to the variation). For example, the hyperparameter λ may have value of 0 when the variation d is within an acceptable or predetermined variation limit or margin (e.g., when the gas valve is set at a flow rate of 50 sccm, the acceptable or predetermined variation limit may be ± 2.5 sccm, ± 5 sccm, etc.). However, the hyperparameter λ may have value > 0 when the variation d is outside of the acceptable or predetermined variation limit or margin. Alternatively, the hyperparameter λ may have value of 0 when the failure rate of the corresponding component (e.g., in other pieces of the same equipment) is 0, or is less than all of the other components (e.g., corresponding to the child nodes of a particular parent node). However, the hyperparameter λ may have value > 0 when the failure rate of the corresponding component > 0, or is not the smallest among all of the components (e.g., corresponding to the child nodes of a particular parent node). In addition, the variation d may improve the discrimination of the weighting wt at the current time point by adjusting the value of the exponent m. For example, preferably, the value of the exponent m is equal to or greater than 2.
[0089] The weighting calculation module 3335 is configured to update the weighting W.sub.t-1 at the previous time point for each child node into a weighting wt at the current time point. For example, the weighting wt at the current time point may be derived or calculated by dividing the adjustment value S for each individual child node connected to the same parent node by the sum of the adjustment values S of all of the child nodes connected to the same parent node.
[0090] The weighting calculation module 3335 may continuously update the initial weighting w.sub.0 (set by proportionally dividing 1 by the number of child nodes connected to the same parent node) periodically over time. Continuing the description of the above example, the variation d of a first health index H1 between the time point t.sub.0 and the time point t.sub.1 corrects the weighting w.sub.0 at the time point t.sub.0. Furthermore, the health index variation d at the current time point t corrects the weighting w.sub.t-1 at the previous time point (e.g., one time period earlier, t-1). In this way, continuous updates into a new weighting w are provided. Herein, the new weighting w resulting from each update depends on the health index variation d, rather than a value based on a user setting (e.g., a user-defined value), thereby reducing or eliminating individual user subjectivity, increasing or ensuring greater objectivity, and providing more accurate values over time.
[0091] Referring to
[0092] That is, a new first health index H1 of each parameter node N1 in the parameter layer is derived or calculated, and from the new first health index H1, a new second health index H2 of each component node N2 in the component layer is derived or calculated. Afterward, the new second health index H2 is used to derive or calculate a third health index H3 of each module node N3 in the module layer, and then a current state value H4 of the mechanical equipment connected to each module node may be derived or calculated.
[0093] Referring to
[0094] The controller 70 is configured to control the system 1 according to the present disclosure, but no limitation thereto is imposed.
[0095]
[0096] Hereinafter, the method S1 for diagnosing a state of mechanical equipment according to the present disclosure will be described in detail with reference to the accompanying drawings. The diagnosing method S1 may be implemented by the above-described diagnosing system 1, and a detailed description of each individual element of the system 1 will be omitted. In addition, it is noted that individual steps may be performed in a temporal order different from the described order, or may be performed substantially simultaneously.
[0097] First, referring to
[0098] Afterward, an initial weighting w.sub.0 for each individual parameter node N1, each individual component node N2, and each individual module node N3 are set in step S20. Step S20 may be performed by the initial weighting setting module 331. Specifically, an initial weighting w.sub.0 may be set by proportionally dividing the number 1 into the number of child nodes connected to a single parent node. For example, when five child nodes are connected to a specific parent node, each of the child nodes is given the initial weighting w.sub.0 of 0.2.
[0099] After step S20 is performed, a weighting w.sub.t-1 at a previous time point (e.g., at the end of the immediately previous time period or cycle) is updated to a weighting wt at the current time point in step S30. Step S30 may be performed using the weighting update module 333. From this, an initial weighting w.sub.0 may be updated to a weighting w.sub.1 at a following time point (e.g., at the end of the current time period or cycle).
[0100]
[0101] With reference to
[0102] Afterward, an adjustment value S for each individual node is calculated in step S330. In step S330, the adjustment value S may be derived or calculated by adding a weighting w.sub.t-1 at the previous time point for each node to a value obtained by multiplying a hyperparameter λ by the health index variation d between the previous time point t-1 and the current time point t raised to the m-th power. For details, see Equation (1) above. Step S330 may be performed by the adjustment value calculation module 3333. The adjustment value S is calculated periodically.
[0103] Next, a new weighting w.sub.t is derived or calculated in step S350. Specifically describing step S350, a weighting w.sub.t at the current time point may be derived or calculated by dividing the adjustment value S of each individual child node connected to the same parent node, by the sum of the adjustment values S of all of the individual child nodes connected to the same parent node.
[0104] Referring back to
[0105] After step S40, a state value of the mechanical equipment/mechanical equipment node based on the new health indexes H1, H2 and H3 of the individual nodes N1, N2, and N3 is derived or calculated in step S50. The state value in step S50 may also be derived or calculated in the same way as the new health indexes. For example, the state value H4 of the mechanical equipment may be derived or calculated by adding the individual new health indexes of the module nodes N3 connected to the mechanical equipment node N4.
[0106] When step S50 is finished, the process may be terminated (e.g., according to a user setting), or may proceed back to step S30 to update the weightings w.
[0107] The foregoing detailed description illustrates the present disclosure. In addition, the foregoing illustrates and describes one or more embodiments of the present disclosure. The present disclosure may be utilized in various other combinations, modifications and environments. That is, it is possible to make changes or modifications within the scope of the concept of the disclosure herein, within the scope of equivalents to the above described disclosure, and/or within the scope of the skill or knowledge of the art. The above-described embodiments are intended to describe one or more modes for carrying out the technical spirit of the present disclosure, and various modifications that may be advantageous for specific applications and/or uses of the present disclosure are possible. Accordingly, the foregoing detailed description is not intended to limit the present disclosure to the embodiment(s) disclosed.