FLOW CONTROL SYSTEM WITH BUILD-DOWN SYSTEM FLOW MONITORING
20170364099 ยท 2017-12-21
Inventors
- Masaaki Nagase (Osaka, JP)
- Atsushi Hidaka (Osaka, JP)
- Kouji Nishino (Osaka, JP)
- Nobukazu Ikeda (Osaka, JP)
Cpc classification
Y10T137/7737
GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
G01F1/36
PHYSICS
International classification
G01F15/00
PHYSICS
Abstract
To provide a flow control system with build-down system flow monitoring that realizes flow monitoring close to real-time monitoring by combining build-down system flow rate measurement with the upstream side of the flow control system without using a thermal type flow sensor by effectively utilizing high pressure fluctuation resistance characteristics of the flow control system, and can be significantly downsized and reduced in cost.
Claims
1-18. (canceled)
19. A method for controlling a flow rate by using a flow control system, the method comprising: providing the flow control system comprising: an upstream side valve that opens/closes distribution of a gas from a gas supply source having a desired gas supply pressure; a pressure type flow control device connected to a downstream side of the upstream side valve and including a control valve, an orifice or a critical nozzle, a pressure sensor P.sub.1, and a flow rate arithmetic and control unit; a build-down capacity being an internal volume of a passage connecting an outlet side of the upstream side valve and an inlet side of the pressure type flow control device; a temperature detection sensor arranged to detect a temperature of a gas distributed inside the build-down capacity; and a pressure sensor P arranged to detect the pressure of the gas distributed inside the build-down capacity; opening the upstream side valve to set a gas pressure inside the build-down capacity to a set upper limit pressure value or more and then closing the upstream side valve to drop the gas pressure from the set upper limit pressure value to a set lower limit pressure value; computing a monitoring flow rate Q by the following equation:
20. The method for controlling a flow rate according to claim 19, wherein the monitoring flow rate Q is computed at least once per second and the controlled flow rate is monitored successively.
21. The method for controlling a flow rate according to claim 19, further comprising opening the upstream valve once the gas pressure reaches the set lower limit pressure value.
22. The method for controlling a flow rate according to claim 19, wherein a bar piece is inserted to the inside of a gas flow passage between the upstream side valve and the pressure type flow control device so that a passage sectional area of the gas flow passage is changed to adjust the build-down capacity and linearize the gas pressure drop characteristic.
23. The method for controlling a flow rate according to claim 19, wherein a chamber with an appropriate internal capacity is interposed in the gas passage between the outlet side of the upstream side valve and the pressure type flow control device, and by changing the internal volume of the chamber, the volume of the build-down capacity is adjusted.
24. The method for controlling a flow rate according to claim 19, wherein the gas pressure drops to the set lower limit pressure value after a predetermined time of t seconds after setting the gas pressure to the set upper limit pressure value by opening the upstream side valve.
25. The method for controlling a flow rate according to claim 24, wherein the build-down capacity is set to 1.0 to 20 cc, the set upper limit pressure value is set to 400 to 200 kPa abs, the set lower limit pressure value is set to 350 kPa abs to 150 kPa abs, and the predetermined time t is set to be within 1 second.
26. The method for controlling a flow rate according to claim 24, wherein the build-down capacity is set to 1.78 cc, the set upper limit pressure value is set to 370 kPa abs, the set lower limit pressure value is set to 350 kPa abs, the pressure drop range P is set to 20 kPa abs, and the predetermined time t is set to be within 1 second.
27. The method for controlling a flow rate according to claim 19, wherein the upstream side valve is a fluid pressure-operated solenoid direct-mounting type motor-operated valve or solenoid direct-operated type motor-operated valve, and a recovery time of the gas pressure from the set lower limit pressure value to the set upper limit pressure value by opening of the upstream side valve is set to be shorter than the pressure drop time t.
28. The method for controlling a flow rate according to claim 19, wherein the flow rate arithmetic and control unit and a build-down monitoring flow rate arithmetic and control unit for computing the monitoring flow rate Q are integrally formed.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0120] Hereinafter, an illustrative embodiment of the present invention is described based on each example with reference to the drawings.
FIRST EXAMPLE
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[0122] The pressure type flow control system itself is known, therefore, detailed description thereof is omitted here. As a matter of course, the filter F can be omitted.
[0123] The arithmetic and control unit CP is formed by integrally combining a flow rate arithmetic and control unit CPa that controls opening/closing of the control valve CV of the pressure type flow control system FCS and computes a flow rate distributed through the orifice and a monitoring flow rate arithmetic and control unit CPb that computes the build-down system monitoring flow rate and controls opening/closing of the upstream side valve AV.
[0124] That is, the build-down system monitoring flow rate arithmetic and control unit CPb forming the essential portion of the present invention controls opening/closing of the upstream side valve AV, and computes and outputs a build-down system flow rate Q from the pressure sensor P.sub.0, the temperature detection sensor T, and the builddown capacity BC consisting of the inlet side passage L.sub.2 and the inlet side passage L.sub.3.
[0125] As described above, in the arithmetic and control unit CP, the arithmetic and control unit CPa that performs flow rate computation and flow control of the pressure type flow control system FCS portion, and the arithmetic and control unit CPb that performs computation of the flow rate measured value Q of the build-down system flow monitoring unit, measurement of the pressure drop rate P/t, and opening/closing control of the upstream side valve AV, etc., are integrally provided, and by inputs of a command signal and/or a setting signal into the arithmetic and control unit CP, the flow control system with build-down system flow monitoring outputs a gas fluid the flow of which is controlled to a predetermined flow rate value, and this flow rate value is monitored and displayed at least once per second.
[0126] The structures and control methods of the pressure type flow control system FCS and the build-down system flow rate measuring unit are known, therefore, detailed descriptions thereof are omitted here.
[0127] When a difference equal to or more than a set value occurs between the monitoring flow rate output (flow rate output from the monitoring flow rate arithmetic and control unit CPb) and the flow rate output of the pressure type flow control system FCS (flow rate output from the pressure type flow rate arithmetic and control unit CPa), a flow rate abnormality warning can be issued, or if necessary, so-called flow rate self-diagnosis of the pressure type flow control system FCS can be performed to identify the cause and the location of the flow rate abnormality.
[0128] Further, when a flow rate difference equal to or more than the set value occurs, zero-point adjustment, etc., of the pressure type flow control system FCS can be automatically performed as well.
[0129] In the present first example, a direct-operated type solenoid driving valve is used as the upstream side valve AV, and the build-down capacity BC is selected in the range of 1.78 to 9.91 cc. Further, the pressure drop range P is selected to be 20 kPa abs (350 to 320 kPa abs), and the monitoring flow rate is output at least once or more per second.
[0130] As the temperature detection sensor T, an outer surface-attaching type resistance temperature sensor is used, and it is also possible to use a thermostat type thermometer to be inserted into the body block V.sub.3.
[0131] The flow passages L.sub.2, L.sub.2, and L.sub.3 forming the build-down capacity BC are formed to have inner diameters of 1.8 mm to 4.4 mm, and by appropriately selecting their inner diameters and flow passage lengths, a desired build-down capacity BC is obtained.
[0132] The build-down capacity BC may be adjusted by using a chamber with a pressure sensor as in the case of the third example described later.
SECOND EXAMPLE
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[0134] In
[0135] In this second example, a short bar piece (length: approximately 1 to 3 mm) Cu shown in
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[0138] As is clear from comparison among
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THIRD EXAMPLE
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[0141] That is, in this third example, a small-sized pressure chamber CH is provided between the upstream side valve AV and the control valve CV of the pressure type flow control system FCS, and by adjusting the internal volume of the pressure chamber CH, the build-down capacity BC is adjusted.
[0142] This pressure chamber CH is formed into a double cylinder consisting of an outer cylinder CHa and an inner cylinder CHb, and a gap G between the inner and outer cylinders CHa and CHb is selected to be 1.8 mm in the present embodiment.
[0143] The internal volume of the pressure chamber CH is selected to be approximately 1.3 to 12 cc, and the pressure sensor P.sub.3 is attached to this pressure chamber CH.
[0144] In
[0145] In this third example, the volume of the pressure chamber CH can freely be selected, and the gas flow passages L.sub.5 and L.sub.3, etc., can be formed to have the same small diameter (for example, a diameter of 1.8 mm), so that the build-down capacity BC can be accurately and easily set to a predetermined capacity value.
[0146] In detail, as a chamber CH for testing, five kinds of chambers having the gaps G set to 1.8 mm and 3.6 mm and sized as shown in Table 3 were prepared, and the system shown in
[0147] In the investigation using the test equipment shown in
TABLE-US-00003 TABLE 3 Chamber A Chamber B Chamber C Gap 1.8 mm Gap 1.8 mm Gap 2.4 mm Height 14.0 mm Height 92.0 mm Height 92.0 mm Diameter 18.0 mm Diameter 18.0 mm Diameter 18.0 mm Chamber 1.58 cc Chamber 8.72 cc Chamber 11.15 cc Other 0.226 cc Other 0.226 cc Other 0.226 cc flow flow flow passage passage passage volume volume volume Actual 2.31 cc Actual 9.70 cc Actual 11.55 cc total total total volume volume volume Chamber D Chamber E Gap 3.0 mm Gap 3.6 mm Height 92.0 mm Height 92.0 mm Diameter 18.0 mm Diameter 18.0 mm Chamber 13.35 cc Chamber 15.31 cc Other 0.226 cc Other 0.226 cc flow flow passage passage volume volume Actual 13.91 cc Actual 15.45 cc total total volume volume
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[0149] As is also clear from
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[0151] As is clear from
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[0154] In this flow rate measurement accuracy reproducibility test, to stabilize the pressure drop gradient, the measurement was performed after a predetermined waiting time from closing of the upstream side valve AV, and the measurement was performed for a long period of time to obtain the reproducibility, however, the flow rate output time was set to be within 1 second in each case.
[0155] As is also clear from
[0156] Table 4 shows basic data used for preparing the diagrammatic drawing showing reproducibility of the flow rate measurement accuracy shown in
TABLE-US-00004 TABLE 4 Chamber A (BC = 2.31 cc) Flow rate sccm 1 2 3 5 10 20 30 50 Temperature C. 22.7 23.0 23.1 22.8 22.6 22.6 22.6 22.7 Gradient kPa/sec 0.8 1.6 2.4 4.0 7.9 16.1 23.4 39.2 Measurement kPa abs. 370 370 370 370 370 370 370 370 start pressure Measurement kPa abs. 368 365 365 363 355 350 350 350 end pressure Measurement kPa 2 5 5 7 15 20 20 20 pressure range: P Measurement sec 2.73 3.42 2.28 1.91 2.05 1.37 0.91 0.55 time: t Chamber B (BC = 9.47 cc) Flow rate sccm 5 10 20 30 50 100 200 300 400 Temperature C. 22.7 23.0 22.4 22.4 22.5 22.5 22.5 22.6 22.59 Gradient kPa/sec 0.9 1.9 3.8 5.7 9.4 18.9 37.7 57.3 77.204 Measurement kPa abs. 370 370 370 370 370 370 370 370 370 start pressure Measurement kPa abs. 368 367 365 360 350 350 350 350 350 end pressure Measurement kPa 2 3 5 10 20 20 20 20 20 pressure range: P Measurement sec 2.24 1.68 1.40 1.87 2.24 1.12 0.56 0.37 0.28 time: t * Measured by changing the time and pressure range so as not to exceed 10,000 data.
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[0159] A longitudinal and columnar pin 2 having a flange portion 2a on the upper end is inserted and fixed into the longitudinal slot 1 at the center of the inner cylinder CHb from the upper side, and the longitudinal slot is communicatively connected to the inside of the gap G forming the gas passage through a plurality of small holes 2b provided in the flange portion 2a, and the end portion of the gap G is communicatively connected to the gas outlet passage L.sub.5 of the chamber outlet side block.
[0160] That is, in the pressure chamber CH of this second instance, the gas flowed from the lower side toward the upper side of the inner cylinder CHb flows into the gap G between the outer cylinder CHa and the inner cylinder CHb from the upper end of the inner cylinder CHb.
[0161] The gap G between the outer cylinder CHa and the inner cylinder CHb of this chamber CH is selected to be 1 to 2 mm, the gap G.sub.1 between the longitudinal slot 1 and the columnar pin or screw body 2 is selected to be 0.4 to 0.8 mm, and the height of the inner cylinder CHb is selected to be 30 to 35 mm, and these are used mainly for the pressure chamber CH with an internal volume V=2 to 5 cc.
[0162] The form of the chamber CH used in the third example of the present invention can be changed as appropriate, and can be structured so that, for example, the outer peripheral surface of the inner cylinder CHb of the chamber CH shown in
[0163] Further, instead of the longitudinal slot 1 of the inner cylinder CHb and the columnar pin 2 shown in
[0164] It is also possible that the whole or the portion to project upward of the inner cylinder CHb shown in
INDUSTRIAL APPLICABILITY
[0165] The present invention is widely applicable not only to gas supply equipment for semiconductor manufacturing equipment but also to gas supply equipment for chemical goods production equipment as long as it is a pressure type flow control system using an orifice or a critical nozzle.
DESCRIPTION OF REFERENCE SYMBOLS
[0166] FCS: pressure type flow control system [0167] AV: upstream side valve [0168] BC: build-down capacity [0169] RG: pressure regulator [0170] N.sub.2: N.sub.2 supply source [0171] T: temperature detection sensor (resistance temperature detector) [0172] P.sub.1, P.sub.2, P.sub.3: pressure sensor [0173] CV: control valve [0174] OL: orifice [0175] V.sub.1, V.sub.2: inlet side valve block [0176] V.sub.3, V.sub.4: FCS main body block [0177] V.sub.5, V.sub.6, V.sub.8: outlet side block [0178] V.sub.7: gas outlet joint [0179] V.sub.g: chamber outlet side block [0180] CP: arithmetic and control unit [0181] CPa: flow rate arithmetic and control unit [0182] CPb: monitoring flow rate arithmetic and control unit [0183] E.sub.1: power supply for pressure type flow control system [0184] E.sub.2: power supply for arithmetic and control unit [0185] E.sub.3: power supply for solenoid valve [0186] ECV: electric drive unit [0187] NR: data logger [0188] S: signal generator [0189] PC: arithmetic and display unit [0190] L.sub.1: gas inlet side passage of upstream side valve AV [0191] L.sub.2, L.sub.2: gas outlet side passage of upstream side valve AV [0192] L.sub.3: inlet side passage of control valve CV [0193] L.sub.4: outlet side passage of control valve CV [0194] L.sub.5: gas passage of chamber outlet side block [0195] Cu: bar piece [0196] Q: build-down flow rate [0197] CH: chamber [0198] CHa: outer cylinder [0199] CHb: inner cylinder [0200] 1: longitudinal slot of inner cylinder [0201] 1a: gas passage [0202] 2: columnar pin or screw body [0203] 2a: flange portion [0204] 2b: small hole