WO1999027425A1 - Multiple scale signal processing and control system - Google Patents
Multiple scale signal processing and control system Download PDFInfo
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- WO1999027425A1 WO1999027425A1 PCT/US1998/023889 US9823889W WO9927425A1 WO 1999027425 A1 WO1999027425 A1 WO 1999027425A1 US 9823889 W US9823889 W US 9823889W WO 9927425 A1 WO9927425 A1 WO 9927425A1
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
- G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
- G05B13/04—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
- G05B13/042—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators in which a parameter or coefficient is automatically adjusted to optimise the performance
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B13/00—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion
- G05B13/02—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric
- G05B13/04—Adaptive control systems, i.e. systems automatically adjusting themselves to have a performance which is optimum according to some preassigned criterion electric involving the use of models or simulators
-
- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B17/00—Systems involving the use of models or simulators of said systems
- G05B17/02—Systems involving the use of models or simulators of said systems electric
Definitions
- the present invention relates to the field of signal processing and control systems. More particularly, the invention relates to the use of multiple time scale and /or space scale models for signal processing and control.
- Signal processing and the control of physical systems generally involves obtaining measurements from a physical system in the form of electrical signals and processing the signals in order to bring about a desired result.
- the control of a physical system typically involves obtaining measurements from the physical system, comparing the measurements with a predetermined control recipe, and adjusting the system inputs in response to the comparison to minimize variations between the measured values and recipe values.
- the signals to be processed or the variables to be controlled which ever the case may be, are not always directly available for observation and must be inferred from indirect and noisy measurements.
- the indirect measurements are generally obtained from embedded sensors which contain multiple pieces of information that are dynamically confounded. Extraction of the information of interest requires the use of complex and time consuming calibration procedures and the use of estimating techniques that result in high computation costs. Equipment setup costs are also high since diagnostic measurements must be taken to correlate the measured signal to the indirect measurements for each piece of equipment.
- measurements from a physical system are not always obtainable at a single time interval (time scale). For example, there may be a first measurement that is obtainable only at a first time scale, a second measurement that is only obtainable at a second time scale, a third measurement that is only obtainable at a third time scale, and so on.
- a measurement, or a set of measurements, taken from a physical system may not bear the same spatial relationship with the system as other measurements taken from the system. Even in instances where all measurements are available at a single high rate, the computation cost of indirect measurements at the high rate can be very high.
- the task of controlling a system involves not only the control of a single physical system, but the control of a family of physical systems. This situation is most prevalent in high volume manufacturing applications.
- the characteristics of a single physical system tend to change over time due to equipment degradation and other causes.
- the characteristics between a family of physical systems tend to differ from one physical system to another due to equipment-to-equipment variations. It is important to track these changes and to account for these differences so that the signal processing or control system may be updated accordingly. Otherwise, the accuracy of the signal processing or control system is compromised.
- One object of the present invention is to provide an accurate and cost efficient signal processing or control system.
- Another object of the present invention is to provide a method for rapidly calibrating one or more signal processing systems.
- Another object of the present invention is to optimize the performance of physical systems in which measurements are be obtained at different time scales.
- Another object of the present invention is to optimize the performance of physical systems in which measurements are be obtained at different space scales.
- Another object of the present invention is to accurately characterize the behavior of a physical system.
- a further object of the present invention is to develop multiple models that characterize the behavior of the physical system at different time scales and to employ online multi- variable control of the physical system based on the multiple time scale models.
- Another object of the present invention is to develop multiple models that characterize the behavior of the physical system at different space scales and to employ online multi-variable control of the physical system based on the multiple space scale models.
- Another object of the present invention is to control a family of physical systems in which measurements are obtained at different time scales.
- Another object of the present invention is to control a family of physical systems in which measurements are obtained at different space scales. 9/27425 _
- a further object of the present invention is to decrease equipment setup time.
- Another object of the present invention is to use diagnostic sensors to improve estimation quality in multi-scale systems.
- signals from the physical system are processed by: a) creating a first dynamic model at the first time scale that consists of a first set of parameters, a first set of states and a first set of inputs; b) creating a second dynamic model at the second time scale that consists of a second set of parameters, a second set of states and a second set of inputs, at least one of the first set of parameters in the first dynamic model being computed from the second set of states in the second dynamic model; c) creating a second estimator to produce estimates of the second set of states using the second dynamic model, measurements from the first physical system at the second time scale; and d) creating a first estimator to produce estimates of .the first set of states using the first dynamic model, measurements from the first physical system at the first time scale, and the estimates from the second estimator.
- Figure 1 illustrates an evaporator deposition system
- Figure 2 illustrates a control system for controlling the evaporator deposition system of Figure 1;
- Figure 3 illustrates a process for designing a dynamic model in one embodiment of the present invention
- Figure 4 illustrates the application of power test signals to the system while a synchronous response of the system is gathered
- Figure 5 is a flow chart of a method for processing signals from a physical system in accordance with one embodiment of the present invention
- Figure 6 is a flow chart of a method for controlling a family physical systems
- Figure 7A illustrates a side view of a conventional wafer processing furnace
- Figure 7B illustrates a fine scale model of the furnace shown in Figure 7A
- Figure 7C illustrates a coarse scale model of the furnace shown in Figure 7A.
- Figure 1 illustrates a deposition system 100 comprising a deposition chamber 102 containing a substrate 120 and one or more evaporation sources 104.
- the evaporation sources include raw materials 106 that are evaporated to produce a film 122 on a surface of substrate 120.
- Each evaporation source 104 is disposed in thermal exposure to a heating source 108 to evaporate the raw materials to be deposited onto substrate 120.
- Thermocouples 110 are used to monitor the temperature of the /27425 _ _
- deposition system 100 may be used in a variety of applications to produce particular film compositions on the surface of substrate 120.
- the deposition system is used to produce photovoltaic cells via a process of thin film deposition.
- multiple raw materials are evaporated, deposited, and reacted in the deposition chamber 102 to produce a desired film composition 122 on the surface of substrate 120.
- the surface temperature of raw material pools 106 are controlled by measuring the temperature of the raw materials at the bottom of the pools with thermocouples 110 at a first time scale (time interval), given by index k, and regulating the power to heaters 108 in response to the temperature measurements.
- substrate 120 is removed from chamber 100 and the composition of film 122 is measured at a second time scale, given by index j, to determine the product quality.
- the sample rate of the first time scale given by index k is faster than the sample rate of the second time scale given by index j.
- control system 200 for controlling the deposition system of Figure 1 is illustrated.
- the control system uses measurements from both the first and second time scales to create a controller 210 that optimizes the performance of the deposition system in order to produce a desired film composition 122 on the surface of substrate 120 in accordance with a predetermined process recipe or setpoint.
- Control system 200 includes a first dynamic model 202 that indicates the behavior of the deposition system 100 at the first time scale index k, and a second dynamic model 204 that indicates the behavior of the deposition system at the second time scale index j.
- the first dynamic model 202 is represented by the following set of model equations:
- xl is the thermal and chemical state of the system
- ul is the power input to evaporator heaters 108
- l are measurements from the system
- pn represents fixed system parameters
- pi 2 represents the source evaporation rate parameters for each of the raw materials 106.
- the evaporation rate parameters, p ⁇ 2 may change over time due to physical changes that are occurring within the evaporation chamber. Since the pi 2 parameters are subject to change, it is important that these parameters be updated or refined to ensure that the first dynamic model properly indicates the behavior of the system.
- the pn parameters may include, for example, the source-to-substrate distance, chamber volume, etc..
- the yl measurements consist of two sets of measurements; yll measurements, and yl2 measurements. The yll measurements are obtained from the evaporator thermocouples 110 (commonly known as production sensors) during the deposition process and represent the temperature of the bottom of raw material pools 106 during the 9/27425 _
- the yl2 measurements are obtained from diagnostic sensors that are not available during the production process.
- the second dynamic model 204 is represented by the following set of model equations:
- x2 is the state of the deposition system at the second time scale
- «2 are temperature setpoint offsets
- p 2 are fixed parameters of the system in the second time scale
- y2 is the end-of-run film composition measurements obtained at the end of the deposition process.
- equation (1) and/or (3) in models 202 and 204 may represent continuous-time dynamic models.
- the relationship between the pi2 parameters of the first dynamic model and the states of the second dynamic model (x2) may be characterized in the following manner.
- the pi2 parameters are chosen to represent evaporation rate offsets which contribute to variations in the end- of-run film compositions.
- ⁇ i2 is represented by the following equation:
- the second dynamic model is created using the following set of equations:
- ⁇ y is a stochastic drift process
- y2j is the measured evaporation offset
- zt2j is the temperature setpoint offsets (°C)
- .and y . is the measurement noise (A).
- Figures 3 and 4 illustrates a process for designing the first dynamic model 202.
- a set of heater power test signals 408 are created to exercise high bandwidth and low bandwidth dynamics on the system.
- Test signals 408 are then applied to heaters 108 by a test signal generator 402 to cause the raw materials 106 to evaporate.
- Diagnostic sensors 406, in the form of a Quartz Crystal Microbalances (QCMs) are positioned within chamber 102 to measure the evaporation rate of the raw materials 106.
- a response data acquisition unit 404 obtains measurement signals 410 and 412 from the diagnostic sensors 406 and thermocouples 110, respectively, in response to the test signals 408. The data acquired during this procedure is used to produce the first dynamic model 202.
- the first dynamic model 202 indicates the behavior of the system between the high bandwidth and low bandwidth dynamics at the first time scale index k.
- the first dynamic model is represented by both yll measurements and yl2 measurements.
- the yll measurements are obtained from thermocouples 110.
- the yl2 measurements (evaporation rates of the raw materials 106), however, are not directly available for observation during the deposition process so that they must be /27425
- thermocouples 110 The yll measurements obtained from thermocouples 110 are also noisy. For this reason, a first estimator 206 is created to produce estimates of the states and measurements of the first model and to predict the raw material evaporation rates (yl2 measurements) from the heater powers and thermocouple signals. The end- of-run film composition measurements (y2) are also noisy and for this reason a second estimator 208 is created to provide estimates of the states x2 and measurement inputs y2 of the second dynamic model.
- the second estimator 208 is represented by the following set of equations:
- estimator 208 is determined using all yllk measurements obtained at the first time scale in the last period of the second time scale as shown in equation (10) below. In such an instance, estimator 208 is represented by equations (8b) and (9b) below.
- yn j is represented by:
- n is the ratio of sample rate 1 to sample rate 2.
- the end-of-run film composition measurements acquired at the second time scale are used to refine the pn parameters of the first dynamic model in the first time scale.
- the first estimator 206 is, thus, created using the following set of equations:
- Construction of the first and second estimators 206 and 208 from models 202 and 204, respectively, are off-line activities.
- a controller 210 for controlling the deposition system 100 at the first time scale is then created using the estimates from the first estimator 206 and the second estimator 208.
- the controller 210 is written as: /27425
- w represents a predetermined process recipe or setpoint that will result in a desired film composition being deposited on the surface of substrate 120.
- the first and second estimators 206 and 208 may be created based on a variety of filtering techniques.
- Al, Bl, Cl, and Dl represent the linearization of i and gi in equations (1) and (2) and where Al is of dimension nsi x nsi, Bl is of dimension ns x n ⁇ , Cl is of dimension ny_ x ns ⁇ , .and Dl is of dimension nyi xnu ⁇ .
- Al is of dimension ns ⁇ is the number of states
- n i is the number of outputs
- the output measurement yl is divided into the measurable and the non-measurable parts as follows:
- the vector yllk corresponds to the measured temperatures from thermocouples 110 and is of dimension ny ⁇ x 1.
- the output matrix C is partitioned as
- multiple linearized models are obtained each with index i for different steady-state operating pints and the gain matrices L/ are obtained by solving steady-state Riccati equations using reduced order ARX model parameters as disclosed in column 8, line 22 through column 9, line 22 of United States patent no. 5,517,594.
- United States patent no. 5,517,594 entitled “Thermal Reactor Optimization” is hereby incorporated by reference.
- -17- estimators 206 and 208 may be created using a continuous-time extended Kalman filter (CTEKF) for state estimations in cases where equations (1) and /or (3) are continuous-time dynamic models, and in some instances may also be based on the diagnostic measurements, yl2.
- the estimators may also be created using other filtering techniques such as a discrete-time extended Kalman filter (DTEKF) for state estimation.
- DTEKF discrete-time extended Kalman filter
- the first estimator 206 is based on an extended Kalman filter (EKF) that uses discrete time measurements and integration. This method is described in co-pending United States patent application entitled "A Method for Real-Time Nonlinear System State Estimation and Control", filed by Sunil C. Shah and Pradeep Pandey on August 22, 1997 and hereby incorporated by reference.
- the discussion has thus been limited to controlling an evaporator deposition system, it is to be understood that the present invention is not limited to a specific type of system to be controlled, nor is it limited to a specific type of control system. In addition, it is appreciated that the present invention is not limited to a method of controlling a physical system that is characterized by only two time scales. Moreover, it is important to note that the scope of the present invention is not limited to control systems, but is also applicable to the field of signal processing in general.
- signals generated from any physical system may be processed pursuant to the method outlined in the flow chart of Figure 5.
- a first dynamic model is created that indicates a behavior of the physical system at a first time scale.
- a second dynamic model is created that indicates a behavior of the physical system at a second time scale.
- a second estimator is created to estimate the states of the second dynamic model using the second dynamic model and measurements from the physical system at the second time scale.
- a first estimator is created to estimate the states of the first dynamic model using the first dynamic model, measurements from the physical system at the first time scale, and estimates from the second estimator.
- Equations (1) through (4), (8), (9) and (11) through (13) generally represent the manner in which the dynamic models, estimators and controller are constructed in one embodiment of the invention.
- the deposition system is defined by a first set of parameters (fast parameters) that is changing at a fast rate and a second set of parameters (slow parameters) that is changing at a slow rate.
- the number of calculations required per time period to solve the combined set of parameters at a single fast time scale is represented by k(ns ⁇ +ns 2 ) ⁇ , where nsi is the number of states of the first model and ns 2 is the number of states in the second model.
- each deposition chamber within the family of chambers is manufactured so that all the chambers are identical.
- chambers-to-chamber variations will exist.
- the thermal characteristics of each of the chambers within the family may vary due to differences in the heater elements, insulation properties, emissivity variations, etc..
- FIG. 6 is a flow chart that outlines a method for controlling a family of systems consisting of a first system and a second system.
- a first dynamic model is created at a first time scale that /27425
- -20- indicates the behavior of the first system at the first time scale. This typically involves exciting the first system and capturing the response of the first system in a manner similar to that described above in Figures 3 and 4.
- the first dynamic model is represented by equations (1) and (2) above, wherein the p!2 parameters capture equipment-to-equipment variations between the first system and the second system.
- a second dynamic model is created at a second time scale that indicates the behavior of the of the first system at the second time scale.
- the second dynamic model is represented by equations (3) and (4) above.
- steps 604, 606, and 608 a first estimator, second estimator, and first controller are created in a manner similar to that described in the example above. Accordingly, equations (8) through (12) may be used to represent the first estimator, second estimator, and first controller for the first system.
- a second controller for optimizing the performance of the second system is then created by applying the first dynamic model to the second system to create a third dynamic model.
- the third dynamic model indicates the behavior of the second system at the first time scale and is represented by the following set of model equations:
- x3 is the state of the second system
- u3 are inputs to the second system
- y3 are measurements from the second system
- pn represents fixed parameters
- p32 represents refutable parameters, including those
- a fourth dynamic model is created to indicate the behavior of the second system at the second time scale and is represented by the following set of model equations:
- x4 is the state of the second system at the second time scale
- u4 inputs to the second system p 4 are fixed parameters of the second system at the second time scale
- y4 are measurements of the second system at the second time scale.
- a fourth estimator is created to estimate the states of the fourth dynamic model.
- the fourth estimator is created using the fourth dynamic model and measurements from the second system at the second time scale. In some instances, measurements from the second system at the first time scale are additionally used to create the fourth estimator.
- the • fourth estimator may then be represented by the following set of equations.
- a third estimator is created to estimate the states of the third dynamic model.
- the third estimator is created using the third dynamic model, measurements from the second system at the first time scale and the , scale modifier, modifier modifier, modifier modifier, modifier modifier, modifier modifier, modifier PCT/US98/2388 /27425
- a second controller for controlling the second system at the first time scale is created using estimates from the third and fourth estimators.
- the second controller maybe written as:
- the first dynamic model of the first system is applied to the second system in order to create the third dynamic model after it is initially created.
- the first dynamic model is first refined by implementing steps 602 through 610 before it is applied to the second system to create the third dynamic model.
- the ability to apply the first dynamic model of the first system to other systems alleviates the need to obtain diagnostic measurements from these systems during setup. As a result, the setup time and the costs associated with setting up each system is therefore reduced.
- a magnetic disk drive consist of a stack of circular disks having a thin magnetic coating rotating at high speed.
- Data is recorded on the disk surfaces using transducers mounted on read-write heads.
- the read-write heads are attached to actuator arms that are moved across the disk surfaces by a high-speed actuators that are under the control of a servo motor.
- the actual information is recorded in circumferential tracks on the disk surfaces. Reading the recorded information back involves sensing the magnetic transitions emanating from the surfaces of the magnetic disks, again using the transducers.
- the ability to store and read back information from each of the magnetic disks is affected by vibrations in the arm assemblies which affect the position of the read-write head transducers within the circumferential tracks. Magnetic modulation of the thin magnetic coatings will also affect the signal that is produced by the read-write head transducers. The read-write head transducer signals will thus consist of confounded information that is representative by both the vibration and magnetic modulation.
- Variations also exists between each of the read-write heads. These variations may be in the form of different read-write head transducer sensitivities, differences in the physical characteristics of the read-write heads, nominal tolerance differences, etc..
- the read-write signals may be processed by first creating a first model at a first time scale that indicates and takes into account the vibrational and magnetic modulation components of the magnetic disk drive.
- the first model may be represented by the following set of model equations:
- xl is the position .and magnetic states of the system
- wl is servo motor commands
- yl are measurements from taken from magnetic disk drive unit
- pil represents fixed system parameters
- pi2 represents head mass, offset and film sensitivity parameters.
- the pi2 parameters are subject to change and/or may vary from one magnetic disk/head assembly to another. Therefore, it is important that these parameters be updated or refined to ensure that the first model properly indicates the behavior of the disk drive unit.
- the pn parameters may include dynamics parameters, such as drag and inertia parameters.
- the yl measurements consist of two sets of measurements; yll measurements, and l2 measurements.
- the yll measurements include servo motor drive current, the read-write head sensor signal, actuator arm position, and servo motor velocity.
- the yl2 measurements may include read-write head positioning measurements that are obtained with laser positioning diagnostic sensors.
- a second model at a second time scale is also created which indicates how of each of the read-write heads, servo motor parameters, structural vibration parameters, friction and drag parameters change over time and from component to component.
- the second model also indicates how measurements of previously recorded data changes with drive and component parameters x2.
- the second model equations may be written as:
- x2 comprise head mass and transducer sensitivity states of the system
- 2 is the head position setpoint offsets
- p 2 are fixed parameters of the magnetic disk drive in the second time scale
- y2 is the measurement of previously recorded data.
- read-write signal processing is achieved by decomposing the magnetic disk drive into two separate models and updating the models in accordance with the method of Figure 5.
- Figure 7A exemplifies such a system.
- a furnace 702 for processing a plurality of wafers 704a-704d is shown.
- the furnace 702 includes a quartz jar 706 having a set of heating elements 708 that surround the quartz jar.
- a furnace controller may be created to control the temperature of the wafers by first determining a first dynamic model at a fine, space scale given by index 1, that consists of a first set of parameters, a first set of states, and a first set of inputs.
- the first dynamic model at the fine space scale may be written as:
- xl comprises wafer 704d temperatures
- ul is the heater powers
- yl are temperature measurements taken from the system
- pn is the thermal dynamics of the system
- pi2 represents the center and edge temperatures of wafer 704d.
- the yl measurements consist of two sets of measurements; yll measurements, and yl2 measurements.
- the yll measurements are obtained from production thermocouples within the furnace, whereas the yl2 measurements are obtained from diagnostic sensors that are not available during the production process.
- a second dynamic model at a coarse space scale given by index m is also created and consists of a second set of parameters, a second set of states, and a second set of inputs.
- the second dynamic model may be represented by the following equations:
- x2 is the center .and edge temperatures of wafers 704a-704d
- u2 is the heater powers
- p 2 represents the dynamics of the system at the coarse space scale
- y2 represents furnace production sensor measurements.
- a second estimator of the coarse model is created using the following set of equations:
- x2 represents estimates of the wafer center and edge temperatures and y2 represents estimates of the production thermocouple measurements.
- the center and edge wafer temperatures at the coarse space scale are used to refine the pi2 parameters of the first dynamic model in the fine space scale.
- a first estimator of the fine model is, thus, created using equations (40) and (41) below.
- a controller for controlling the furnace 702 at the fine space scale is created using the estimates from the first estimator and the second estimator.
- the controller is written as:
- w represents a predetermined process recipe or setpoint.
Abstract
Description
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AU14539/99A AU1453999A (en) | 1997-11-26 | 1998-11-10 | Multiple scale signal processing and control system |
DE69828995T DE69828995T2 (en) | 1997-11-26 | 1998-11-10 | SIGNAL PROCESSING AND CONTROL SYSTEM AT MULTIPLE LEVELS |
AT98958508T ATE289083T1 (en) | 1997-11-26 | 1998-11-10 | SIGNAL PROCESSING AND CONTROL SYSTEM ON MULTIPLE LEVELS |
EP98958508A EP1034459B1 (en) | 1997-11-26 | 1998-11-10 | Multiple scale signal processing and control system |
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US08/980,041 | 1997-11-26 | ||
US08/980,041 US6041172A (en) | 1997-11-26 | 1997-11-26 | Multiple scale signal processing and control system |
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EP (1) | EP1034459B1 (en) |
AT (1) | ATE289083T1 (en) |
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EP1034459A4 (en) | 2000-11-08 |
EP1034459B1 (en) | 2005-02-09 |
US6289508B1 (en) | 2001-09-11 |
EP1034459A1 (en) | 2000-09-13 |
DE69828995D1 (en) | 2005-03-17 |
US6167360A (en) | 2000-12-26 |
US6041172A (en) | 2000-03-21 |
AU1453999A (en) | 1999-06-15 |
DE69828995T2 (en) | 2006-01-19 |
ATE289083T1 (en) | 2005-02-15 |
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