Redundantable robot assembly for workpiece transfer

Abstract

A redundantable robotic mechanism is disclosed for improving reliability of tranport equipment. The redundantable robot assembly typically comprises independent robots with separate controls, motors, linkage arms, or power, thus providing the capability of operation even if parts of the assembly are not operational or when parts of the assembly are removed for repair. The redundantable robot assembly can be also designed to allow in-situ servicing, e.g. servicing one robot when the other is running. The disclosed redundantable robot assembly provides virtual uninterrupted process flow, and thus greatly increases the yield for the manufacturing facility.

Claims

1. A method comprising: rotating a carousel stocker storage, wherein the carousel stocker storage is configured to support multiple workpieces, wherein the carousel stocker storage is rotated to present the multiple workpieces to a redundantable workpiece transfer mechanism having at least two independent workpiece transfer assemblies; and transferring the multiple workpieces using each of the at least two independent workpiece transfer assemblies of the redundantable workpiece transfer mechanism, wherein each of the at least two independent workpiece transfer assemblies is configured so as to take over and effect workpiece transfer operations of another of the at least two independent workpiece transfer assemblies based on inoperability of the other of the at least two independent workpiece transfer assemblies.

2. The method of claim 1 further comprising establishing a service area by restricting the movements of each of the at least two independent workpiece transfer assemblies surrounding the other of the at least two independent workpiece transfer assemblies.

3. The method of claim 1 further comprising establishing a service area by moving the other of the at least two independent workpiece transfer assemblies outside the movement ranges of each of the at least two independent workpiece transfer assemblies.

4. The method of claim 3 wherein moving the other of the at least two independent workpiece assemblies comprises coupling the other of the at least two independent workpiece transfer assemblies to a hinged door, wherein the hinged door is operable to move the other of the at least two independent workpiece transfer assemblies to the service area.

5. The method of claim 1 further comprising transferring an inoperative one of the at least two independent workpiece transfer assemblies to a service area.

6. The method of claim 5 wherein transferring the inoperative one of the at least two independent workpiece assemblies comprises ejecting the inoperative one of the at least two independent workpiece transfer assemblies to the service area.

7. The method of claim 5 wherein transferring the inoperative one of the at least two independent workpiece assemblies comprises sliding the inoperative one of the at least two independent workpiece assemblies transfer assemblies to the service area.

8. The method of claim 1 further comprising moving at least one of the at least two independent workpiece transfer assemblies inside the movement ranges of the other or the at least two independent workpiece transfer assemblies.

9. The method of claim 1 further comprising moving the other of the at least two independent workpiece transfer assemblies outside the movement ranges of each of the at least two independent workpiece transfer assemblies.

10. The method of claim 1 further comprising coordinating the movements of each of the at least two independent workpiece transfer assemblies for noninterference of the other of the at least two independent workpiece transfer assemblies.

11. The method of claim 1 further comprising restricting the movements of each of the at least two independent workpiece transfer assemblies for noninterference of the other of the at least two independent workpiece transfer assemblies.

12. The method of claim 1 further comprising, with a computer processing unit, sensing a malfunction of the other of the at least two independent workpiece transfer assemblies; coordinating movement of the other of the at least two independent workpiece transfer assemblies to a serviceable area; and coordinating or restricting each of the at least two independent workpiece transfer assemblies movement ranges for non-interference of the other of the at least two independent workpiece transfer assemblies.

13. A system comprising: a carousel stocker storage, wherein the carousel stocker storage is configured to support multiple workpieces; and a workpiece transfer mechanism having at least two independent workpiece transfer assemblies, each of the at least two independent workpiece transfer assemblies being configured so as to take over and effect workpiece transfer operations of another of the at least two independent workpiece transfer assemblies based on inoperability of the other of the at least two independent workpiece transfer assemblies, wherein the at least two independent workpiece transfer assemblies are robot assemblies.

14. The system of claim 13 wherein the robot assemblies are at least one robot.

15. The system of claim 13 wherein the robot assemblies have at least two robots side by side.

16. The system of claim 13 wherein the robot assemblies have at least two robots vertically stacked.

17. The system of claim 13 wherein the robot assemblies act independently of each other.

18. The system of claim 13 wherein the robot assemblies have a plurality of articulate joint arms.

19. The system of claim 18 wherein the plurality of articulate joint arms extend, retract, raise, lower and rotate.

20. The system of claim 18 wherein the plurality of articulate joint arms house at least one mechanism.

Description

BRIEF DESCRIPTIONS OF THE DRAWINGS

(1) FIG. 1A shows a top view of an exemplary redundantable robot assembly according to the present invention, comprising two robots positioned side by side.

(2) FIG. 1B shows a side view, respectively, of an exemplary redundantable robot assembly according to the present invention, comprising two robots positioned side by side.

(3) FIG. 2A shows a configuration of two robot assemblies according to an embodiment of the present invention, comprising two robots positioned side by side with offset.

(4) FIG. 2B shows a configuration of two robot assemblies according to an embodiment of the present invention, comprising two robots positioned on top of each other.

(5) FIG. 2C shows a configuration of two robot assemblies according to an embodiment of the present invention, comprising two robots positioned on top of each other, also inverted with offset.

(6) FIG. 3 shows a configuration of two robot assembly according to an embodiment of the present invention, comprising two robots having 4 arm segments with multiple degrees of freedom.

(7) FIG. 4 shows a configuration of two robot assembly where there is a blind area where a robot cannot reach if no rotational movement is permitted after radial movement.

(8) FIG. 5 shows a configuration of two robot assembly where the blind area is eliminated if rotational movement is permitted after radial movement.

(9) FIG. 6 shows a configuration of two robot assembly in application to a concentric array of workpiece stations.

(10) FIG. 7 shows a configuration of two robot assembly in application to linear arrays of workpiece stations.

(11) FIG. 8 shows an exemplary configuration where two robots of the redundantable robot assembly of the present invention are located facing a carousel stocker storage area.

(12) FIG. 9 shows an exemplary configuration where two robots of the redundantable robot assembly of the present invention are positioned on a linear track of front end assembly.

(13) FIGS. 10A and 10B show configurations where the robots can be moved linearly for servicing. FIG. 10A shows an operating configuration, and FIG. 10B shows a configuration where the right robot is moved for servicing.

(14) FIGS. 11A and 11B show configurations where the robots can be moved rotationally for servicing. FIG. 11A shows an operating configuration, and FIG. 11B shows a configuration where the right robot is moved for servicing.

(15) FIGS. 12A and 12B show a configuration for a stocker according to an embodiment of the present invention.

(16) FIG. 13 shows an exemplary computer system for the present invention.

(17) FIG. 14 shows an exemplary computer environment for the present invention.

DETAIL DESCRIPTIONS

(18) The present invention relates to an apparatus and method for improving reliability with moving equipment. The present invention involves a redundancy of the failure-prone parts, e.g. transferred robots, in an equipment to ensure continuous flow of workpieces for a fabrication facility. An exemplary redundancy of the robot assembly in an equipment comprises the duplicate of the robots, plus the redundancy abilities such as the ability to operate one robot when the other is broken, the ability of in-situ servicing the broken robot, the ability to calibrate the repaired robot, and the ability to return the repaired robot back into operation. Operation of the robot assembly includes tolerance on the position of the robot arms, to prevent hitting the other parts of the assembly, especially when the other parts are not operative, and thus cannot move out of the way.

(19) During the processing of semiconductor workpieces in the manufacture of microelectronics, different equipments are employed for several hundred processing steps. The process flow of a workpiece is essential serial, with most of the tools operate on the workpieces one at a time. The failure of any link in the fabrication process would severely disrupt the process flow, resulting in loss of manufacturing productivity. The present invention provides the handling or movement of workpieces in a manner which assured a continuous flow of workpieces within an equipment and within a fabrication facility, even in the event of part failures. The present invention discloses a redundancy mechanism for prevent equipment failure from affecting the process flow, by allowing the equipment to be functioned, and by allowing the in-situ servicing of the failure parts.

(20) The present invention thus provides, in an exemplary embodiment, multiple transport mechanisms, such as a plurality of robots, to perform essentially the same operations of moving workpieces. A station, such as a wafer or reticle stocker station, is centrally served by a pair of robots or workpiece transport mechanisms. Each transport is capable of axial motion along a member and pivotal or articulated motion of an arm. The axial motion is used to move workpieces between the stations and the carrier residing in a load lock, and the articulated arm is used for more constrained motions within the stations, such as swinging between stations.

(21) FIG. 1A and FIG. 1B show a top view and a side view, respectively, of an exemplary redundantable robot assembly according to the present invention. The robot assembly comprises two independent robots, located side by side. The robots as shown comprise a plurality of articulate joint arms, with a single blade end effector at the end. In other embodiment, an exemplary robot can include the linear r movement, e.g. extending and retracting, to receive a workpiece, the rotation theta movement of the articulate arm, and the vertical z movement of raising or lowering the workpieces. The robots can include several different mechanisms to perform the movement of the workpieces, such as linear track, multi-segmented articulated arms, frog arms, swivel arms, scissors and telescopic mechanism, four-bar linkage mechanism. The robot arm can comprise an end effector to receive a workpiece, such as using gravitation force, or edge grip force. The end effector might be single blade of double blade. The robot's movements, such as a combination of linear and rotational motions, are typically designed to avoid high accelerations.

(22) The transport mechanism includes a plurality of hands which are driven independently of each other. Thus the robot arm has high degree of freedom in movement, and can be able to reach many places. The robot can have double end effector. The arms of the transport mechanisms may each have a fork-like tip. The operations of the redundantable robot assembly are controlled by a computer system.

(23) A robot arm having the ability to handle two workpieces at the same time can be used to increase the efficiency of robot handling. The robot can have two carrier arms located at opposed ends of a support, which rotates about a pivot. Another robot configuration includes a central hub having two opposed arms, with a blade linked to the free ends of the arms. A second pair of arms can extend opposed from the first pair, and thus the opposed rotation of the arms in one direction extends the first arm while retracting the second arm. The arm can use two blades to increases throughput. Another robot configuration includes a multiple robot assembly including co-axial upper and lower robot assemblies, which operate independently of each other. The upper robot is typically stacked above the lower robot and the two robots may be mounted concentrically. The robot assembly can be constructed with motors such as servo motors with a synchronous device.

(24) FIGS. 2A-2C show various configurations of two robot assembly according to embodiments of the present invention. The two robots can be positioned side by side with offset, as shown in FIG. 2A. The two robots can be positioned on top of each other, as shown in FIG. 2B, or inverted with offset as shown in FIG. 2C. The particular positions of the robots depend on the system requirements.

(25) FIG. 3 shows an exemplary configuration for two robots with 4 arm segments and multiple degrees of freedom at each joint. The robot arm can move virtually in all directions with no constraints of r, theta and z as in linear arms.

(26) FIG. 4 shows an exemplary configuration of redundantable robot assembly with the robot having 3 articulate joint arms. If rotational can only performed before radial movement, the arm of one robot might have a blind area (cross hatched area) where the left robot cannot reach. If rotational movement is allowed after radial movement, it can reach the blind area as shown in FIG. 5. The robot can have only one motor control for the first arm, with the second arm depending on the movement of the first arm. The robot can also have two motor controls, one for rotating the first arm, and one for rotating the second arm. The second arm in this case can move independent of the first arm.

(27) FIGS. 6 and 7 show exemplary configurations of redundantable robot assembly for transferring workpieces. FIG. 6 shows a configuration with the stations located concentric around the robot assembly, and FIG. 7 shows a configuration with the stations located in linear arrays around the robot assembly.

(28) The present invention redundantable robot assembly can be used in a stocker. An embodiment of the invention comprises a stocker storage area, comprising workpieces arranged in an array. Two redundant transfer robots are installed at a front side of the stocker array for transfer the workpieces in and out of the stocker. The stocker station can interface with the tracks in the interbay multilevel track system. Another robot assembly moves the carriers between the stocker and interbay track system. When the transfer or handling capability is insufficient with only the first transfer robot, the storage of the lots in the stocker can be performed by using the second transfer robot as well. Thus the redundantable robot assembly can improve the throughput of the equipment. The capacity of the stocker can also be designed with the capacity of the two robots. Since a plurality of transport mechanisms are used, the substrates are transported efficiently, thereby improving the overall through put of the apparatus as a whole. FIG. 8 shows an exemplary configuration where two robots of the redundantable robot assembly of the present invention are located facing a carousel stocker storage area.

(29) The robot assembly can be used, in one embodiment, in the front end assembly to transfer workpieces between cassettes in a pod assembly. The front end assembly generally contains a horizontal motion robot assembly to move a workpiece to the front end module or to the central module. FIG. 9 shows an exemplary configuration where two robots of the redundantable robot assembly of the present invention are positioned on a linear track, traveling back and forth to transfer workpieces from the front end assembly to the loadlock of the equipment.

(30) FIGS. 10A and 10B show configurations where the robots can be moved for servicing. FIG. 10A shows a configuration where the two robots are in operation mode. The robots are connected to a linear guide, where the robots can slide through the guide. FIG. 10B shows a configuration where the robot on the right is inoperative, and has been moved to a servicing station. The left robot can be still operating, and thus, moving the inoperative robot out of the way help prevent disrupting the movement of the working robot, together with providing room for servicing the inoperative robot.

(31) FIGS. 11A and 11B show another configuration for servicing the redundantable robot assembly. The moving section comprises a hinge door, where an inoperative robot can be moved out. FIG. 11A shows a working configuration, and FIG. 11B shows that the right robot has been moved out for servicing. Other configurations for servicing also are possible.

(32) FIGS. 12A and 12B show a configuration for a stocker system. FIG. 12A shows a cross section along the cut line I-I of FIG. 12B, and FIG. 12B shows a top view of an exemplary stocker 10 along the cut line II-II of FIG. 12B, employing a redundantable robot assembly with two robots. The stocker 10 includes a stocker storage 12, which is configured to support multiple workpieces 32a, 32b, 32c, 32d, 32e, 32f, 32g, 32h, 32i, 32j, 32k, and 36a, 36b, 36c, 36d, 36e, arranged in circular configurations around an axis of rotation. The stocker storage 12 can be configured to rotate workpieces 32a-32k in direction 46, and to rotate workpiece 36a-36k in direction 48. As shown, carousel stocker storage 12 is rotated to present workpiece 36a to the robot.

(33) The robot assembly further comprises a plurality of sensors, such as workpiece positioning sensors, image sensing of position errors, RF electric field sensing, magnetic resonance sensing, laser scanning, sensing with photo detector arrays, motor operation sensing, arm position sensing, or any sensors related to the operation and service. Furthermore, the sensors provides the status and locations of the robot assembly, thus allowing the optimum utilization of the remaining operative part of the assembly, plus the alerting the operator for servicing the inoperative parts of the assembly.

(34) The present invention may also be embodied in a machine or computer readable format, e.g., an appropriately programmed computer, a software program written in any of a variety of programming languages. The software program would be written to carry out various functional operations of the present invention. Moreover, a machine or computer readable format of the present invention may be embodied in a variety of program storage devices, such as a diskette, a hard disk, a CD, a DVD, a nonvolatile electronic memory, or the like. The software program may be run on a variety of devices, e.g. a processor.

(35) With reference to FIG. 13, an exemplary environment 300 for implementing various aspects of the invention includes a computer 301, comprising a processing unit 331, a system memory 332, and a system bus 330. The processing unit 331 can be any of various available processors, such as single microprocessor, dual microprocessors or other multiprocessor architectures. The system bus 330 can be any type of bus structures or architectures, such as 12-bit bus, Industrial Standard Architecture (ISA), Micro-Channel Architecture (MSA), Extended ISA (EISA), Intelligent Drive Electronics (IDE), VESA Local Bus (VLB), Peripheral Component Interconnect (PCI), Universal Serial Bus (USB), Advanced Graphics Port (AGP), Personal Computer Memory Card International Association bus (PCMCIA), or Small Computer Systems Interface (SCST).

(36) The system memory 332 can include volatile memory 333 and nonvolatile memory 334. Nonvolatile memory 334 can include read only memory (ROM), programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable ROM (EEPROM), or flash memory. Volatile memory 333, can include random access memory (RAM), synchronous RAM (SRAM), dynamic RAM (DRAM), synchronous DRAM (SDRAM), double data rate SDRAM (DDR SDRAM), enhanced SDRAM (ESDRAM), Synchlink DRAM (SLDRAM), or direct Rambus RAM (DRRAM).

(37) Computer 301 also includes storage media 336, such as removable/nonremovable, volatile/nonvolatile disk storage, magnetic disk drive, floppy disk drive, tape drive, Jaz drive, Zip drive, LS-100 drive, flash memory card, memory stick, optical disk drive such as a compact disk ROM device (CD-ROM), CD recordable drive (CD-R Drive), CD rewritable drive (CD-RW Drive) or a digital versatile disk ROM drive (DVD-ROM). A removable or non-removable interface 335 can be used to facilitate connection.

(38) The computer system 301 further can include software to operate in environment 300, such as an operating system 311, system applications 312, program modules 313 and program data 314, which are stored either in system memory 332 or on disk storage 336. Various operating systems or combinations of operating systems can be used.

(39) Input devices 322 can be used to enter commands or data, and can include a pointing device such as a mouse, trackball, stylus, touch pad, keyboard, microphone, joystick, game pad, satellite dish, scanner, TV tuner card, sound card, digital camera, digital video camera, web camera, and the like, connected through interface ports 338. Interface ports 338 can include a serial port, a parallel port, a game port, a universal serial bus (USB), and a 1394 bus. The interface ports 338 can also accommodate output devices 321. For example, a USB port may be used to provide input to computer 301 and to output information from computer 301 to an output device 321. Output adapter 339, such as video or sound cards, is provided to connect to some output devices such as monitors, speakers, and printers.

(40) Computer 301 can operate in a networked environment with remote computers 324. The remote computers 324, shown with a memory storage device 325, can be a personal computer, a server, a router, a network PC, a workstation, a microprocessor based appliance, a peer device or other common network node and the like, and typically includes many or all of the elements described relative to computer 301. Remote computers 324 can be connected to computer 301 through a network interface 323 and communication connection 337. Network interface 323 can be communication networks such as local-area networks (LAN) and wide area networks (WAN). LAN technologies include Fiber Distributed Data Interface (FDDI), Copper Distributed Data Interface (CDDI), Ethernet/IEEE 1202.3, Token Ring/IEEE 1202.5 and the like. WAN technologies include, but are not limited to, point-to-point links, circuit switching networks like Integrated Services Digital Networks (ISDN) and variations thereon, packet switching networks, and Digital Subscriber Lines (DSL).

(41) FIG. 14 is a schematic block diagram of a sample computing system 440 with which the present invention can interact. The system 440 includes a plurality of client systems 441. The system 440 also includes a plurality of servers 443. The servers 443 can be used to employ the present invention. The system 440 includes a communication network 445 to facilitate communications between the clients 441 and the servers 443. Client data storage 442, connected to client system 441, can store information locally. Similarly, the server 443 can include server data storages 444.

(42) While the invention is amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.