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INDUSTRIAL AUTOMATION
Case Study
Industrial Automation and Control Systems
 
Case Study: Simulation software for hybrid systems: Chemical processing
 
 
The customer
A leading semiconductor processing equipment manufacturer based in USA producing a wide range of equipments covering the different stages of the silicon wafer processing.
 
Challenge
To solve Mission Critical Bugs on the actual factory-shop-floor on large code bases for different classes of wafer processing equipment.
To improve the efficiency and throughput of the distributed control system consisting of Process Chambers and cryo pumps, Robots, Pneumatic and Stepper motor based Lifters, Factory Interfaces, Motion Servers and Real Time Controllers.
To grasp and embed diversified technologies and domain knowledge in existing software.
To develop component based generic, scalable and modular software framework which simulates various classes of Equipments, devices, sensors, effect of device states on chamber parameters, interaction between chambers.
Development of Reusable components providing the product scalability and assistance in future development.
 
Solution

Developed a software with a user-friendly GUI and generic framework that can be extended to simulate any chip manufacturing machine.

The highlights of the development process were:
Elegant and effective use of object oriented, COM, STL methodologies along with use of Design Patterns
Achieved the balance between providing all the necessary interfaces and hiding internal implementation of framework so that the changes in the framework are backward compatible
Plug-able architecture for device modeling
Minimum effort for new equipment simulation
TCL scripting support for test automation
Time compression feature enables changing rate of updation of system parameters
Easy to configure for different machine baselines through configuration wizards
Communication with Devicenet, serial, socket devices
 
Benefits to Customer
Testing on real system costs in millions and time consuming. Testing on Simulator means just a desktop running a wafer cycle test. Thus Simulator provides faster testing cycles and huge cost benefit
Early to market solution provided customer with critical time-to-market advantage
Enabled complete automation of testing procedures at client site
Ability to create ‘Virtual’ equipment and test blueprint designs
Deployment in FABs for process testing before shipment of equipment
 
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  CASE STUDIES
Software development for control system of chemical processing and material handling equipment
Configuration tool development for distributed control system
Supervisory control system development for electroplating equipment
  More case studies

 
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