USABILITY IMPROVEMENT WITH SAFETY NETWORK AND

APPLICATION TO SEMICONDUCTOR MANUFACTURING EQUIPMENT

1 1 1 1
TAKAYOSHI SHIMIZU * , MASAO DOHI * , HITOSHI IWAKURA * , NAKANO TADASHI * ,
1 2 2
MASAHIKO KAWAKAMI * , JUNJI HASHIYAMA * , MINORU SUZUKI* ,
2 2 1
ATSUSHI SHIMAJI * , AKIYOSHI ITO * , TOSHIHIRO FUJITA *
1
* : IDEC CORPORATION
1-7-31, Nishimiyahara, Yodogawa-ku, Osaka City, Osaka Prefecture, 532-8550, Japan
2
* : FUJITSU VLSI Corporation
1-1, Yata, Hachiya Cho, Minokamo City, Gifu Prefecture, 505-0009, Japan
[email protected], [email protected], [email protected],
[email protected], [email protected], [email protected]

Abstract
In manufacturing industries using robots and various machines, systems have to employ many safety
components to comply with international standards such as ISO 12100, IEC 60204, and related standards.
Emergency stop switches and door interlock safety switches are required so that, in case of an emergency,
a hazard can be shut down. Since failure of control systems should not affect safety control systems,
these systems were designed and installed separately. Open network technology, which greatly reduces
wiring and maintenance cost, could not be connected to safety equipment. Recent technology has allowed
for development of network systems that can be used with safety control components. We have examined
these safety networks and established a safety control system by implementing AS-Interface Safety at
Work (AS-i SAW) [1] to the semiconductor manufacturing equipment industry. This paper reports on the
performance of a new safety control system in which general control and safety control are compatible.
Introduction
In factory automation (FA) and process automation (PA) areas, where attention is mostly paid to the
enhancement of operation efficiency, the importance of an operators’ safety is becoming more and more
important [2, 3]. Because the number of industrial accidents that cause damage to both machines and
operators is increasing, international standards such as ISO 12100 (Safety of machinery - Basic concepts,
general principles for design) and IEC 60204 (Safety of machinery - Electrical equipment of industrial
machines) were issued to raise the awareness of the importance of safety. Semiconductor manufacturing
equipment and other automatic assembly lines using robots are, in order to ensure safety, required to

Door interlock Standardized control

(Safety switch) panel
Beacon lamp
Enabling device
(Grip switch)

Enabling device Emergency Off

(Grip switch) switch

Pendant device
(Enabling switch built-in)
Safety relay module Emergency Off
(inside the panel) switch

Figure 1. Example of the Semiconductor Manufacturing Equipment

 Beacon lamp
E-Stop E-Stop
Pushbutton switch Pushbutton switch

Sliding door
Door interlock device
(Safety switch)

Enabling device
(Grip switch)

Teaching pendant Standardized control Safety relay module

(Enabling switch built-in) panel (inside the panel)

Figure 2. Model of the Manufacturing system with Robots

mount emergency stop switches, safety switches, and a number of other safety components as shown in
figure 1 and 2. A system of safety components is needed to be constructed separately from standard
control systems, to maintain performance, and therefore the design, manufacturing, and maintenance
requires a great deal of labor. Therefore improvements in operational efficiency and safety have long been
considered mutually incompatible. As a result, improving the usability of a safety system has been a major
issue that has faced the manufacturing industry.
Manufacturing industries around the world are gradually introducing safety networks in which safety
components such as emergency stop switches and safety switches can be connected to a network,
complying with IEC 61508 (Functional safety of electrical/electronic/programmable electronic
safety-related systems) [4]. In this paper, we report an overview of the benefits of safety networks, and
also provide an analysis of improvement when applying AS-i SAW to semiconductor manufacturing
equipment. [5]
Safety System Establishment in FA
Figure 3 shows an automatic assembly line using robots, in which we compare a conventional system
shown in Figure 3 (a) and networked safety system shown in Figure 3 (b). In the conventional system, the
control system and safety system are structured separately. The control system consists of pushbuttons,
pilot lights and other I/O devices, while the safety system is comprised of safety components such as
emergency stop switches, safety switches, and light curtains. A safety relay module is used to shut the
power to hazardous sources such as robots and motors. A separate structure is intended to ensure safety,
because the failure of control system does not affect the operation of the safety system. In the control
system of the conventional system, PLCS, pushbuttons, and pilot lights are hard-wired, requiring as many
as 30 wires to connect 16 pushbuttons and 8 pilot lights shown with an “X”. In a safety system, safety
relay modules, emergency stop switches, safety switches and light curtains are hard-wired as well, but
require only 17 wires as shown with a “Y”. Wiring a control system necessitates a great deal of labor for
the wiring itself, checking the wiring, and maintenance, thereby resulting in increased costs.
In factory automation (FA), process automation (PA), and building automation (BA), the number of
pushbuttons, illuminated pushbuttons, pilot lights and other low-level components surpass that of other
levels. Although components require complicated wiring, little attention has been paid to their usability
related to manufacturers and maintenance operators. To solve this problem, we have developed a
wire-saving network, SwitchNet, which exhibits excellent performance for manufacturers and maintenance
operators. With SwitchNet, wiring work can be simplified without impairing operability [6-8].
Figure 4 shows a comparison between conventional wiring and SwitchNet wiring. Figure 4 (a) shows an
operational control panel, on which 40 control units such as pushbuttons and pilot lights are installed.
Figure 4 (b) shows the back of the same control panel, which is structured with conventional wiring, while
the control panel shown in Figure 4 (c) is
designed with using SwitchNet. As the
Host computer
figures show, wiring with SwitchNet is
much simpler and organized, proving that
SwitchNet provides superior connection Switch/ Display Light
methods and reduced installation time,
costs, and area. The network technology
that achieved both wire- and labor-saving,
as well as an improvement in safety
technology, made it possible to connect E-Stop
control equipment and safety equipment X Switch
in one network. This is safety network
technology. Controller
Standard Network
Figure 3 (b) shows a system concept in
which a safety network is installed.. As Light Curtain
Y
illustrated, control-related components
Safety Relay Module
(pushbuttons, pilot lights) and
safety-related components (emergency Safety Switch
stop switches, safety switches) are
connected to a safety controller without (a) Conventional safety system
any constraints. This system can also be
connected to a host computer seamlessly,
and high-speed data communication
(sending an enormous amount of data) is Host computer
achieved over just one network. With this
new technology, the entire system
including both control and safety signals Switch/ Display Light
can reduce wiring, labor, costs, and also
improve in usability.
As manufacturing plants are increasingly
evolving, along with information
E-Stop
technology and remote control systems,
Switch
requirements for open-networking of
control components and safety Safety
components is becoming greater, and Safety Network
Controller
various safety networks have been Light Curtain
developed in many countries. Table 1
shows examples of safety networks,
which comply with IEC 61508 and satisfy
Safety Switch
high safety integrity level (SIL) by (b) System using the safety network
reducing failure rates and introducing
Figure 3. Safety Network Systems
safety life cycles. AS-i SAW is one of the
major networks in the world of this type.

Features of AS-Interface Safety at Work

For semiconductor manufacturing equipment to comply with international standards such as ISO 12100,
IEC 60204-1, and also SEMI standards (which offer guidelines for the semiconductor industry), it needs to
undergo a risk assessment. This risk assessment is not only for normal operations, but is also on system
setup, teaching, system change-over, and maintenance. Many safety components, as shown in Figure 1,
must be installed on semiconductor manufacturing equipment. For example, emergency OFF (EMO)
switches and door interlock safety switches are required to be installed on the system so that in case of an
emergency, a hazard can be shut down. We have provided a Human Machine Interface (HMI)
environment with the necessary safety components [9-11].
 (a) Operation control panel

(b) Field-end components connected

(c) Field-end components
by the conventional wiring connected by the wiring of
SwitchNet
Figure 4. Comparison between the conventional wiring and the wiring of SwitchNet

AS-i SAW is one of the most popular open networks in Japan, North America and Europe, and was
developed to connect the safety components to an AS-Interface network, which complies with IEC
62026-2. The AS-i SAW achieves an integration of control signals and safety signals [12], and has been
approved by TÜV (Technischer Ürberwachungs Verein), a third-party certification organization, to be in
compliance with IEC 61508-1 to 7, SIL 3, and the highest safety category 4 of EN954-1 [13].

Table1. Comparison of Safety Networks

Safety-related field
AS-i Safety at work CC-Link Safety DeviceNet Safety INTERBUS Safety ProfiSafe SafetyBUS p
network
AS-International ProfiBus
Consortium CLPA ODVA INTERBUS Club SafetyBUS p Club
Association International

Based fIeld network AS-Interface CC-Link DeviceNet INTERBUS ProfiBus −

AS-International Omron, Allen

Original developer Mitsubishi Phoenix Contact Siemens Pilz
Association Bradley, and Sick

Topology master/slave master/slave master/slave master/slave master/slave multi-master

Maximum number of
31 nodes 64 nodes 64 nodes 512 nodes 122 nodes 64 nodes
slaves
Speed (bit rate) 167kbps Max.10 Mbps 500 kbps 500 kbps Max.12 Mbps Max.500 kbps
100m (10Mbps)
400m (between 100m (500kbps)
100m (167kbps) 160m (5Mbps) 500m (125kbps) 100m (12Mbps)
Maximum cable slaves) 500m (125 kbps)
300m (167kbps with 400m (2.5Mbps) 250m (250kbps) 200m (1.5Mbps)
length 12.8km (total 1000m (50kbps)
Repeaters) 900m (625kbps) 100m (500kbps) 1000m (187kbps)
length） 3000m (20kbps)
1200m (156kbps)
Control field network
and safety-related
Yes Yes Yes Yes Yes No
field network on one
topology

Note: Networks are listed in alphabetical order.

As Figure 5 shows, AS-i SAW makes it possible to establish a safety network by simply connecting the
general control system (containing an AS-Interface master, standard slaves, SwitchNet, AS-i power
supply), the safety input component (safety slave), and safety output and network monitoring component
(safety monitor) to an existing AS-Interface network. Wiring of components is easy and simple, by just
connecting to the existing AS-I cable. This process requires little labor time. Wiring SwitchNet can also be
completed easily just by connecting a branch connector to the AS-i cable and connecting two wires in
series. The operating condition of a safety output is programmed by PC software and the data can be
downloaded to a safety monitor. When compared to the conventional development of a logic circuit by
hardwiring, the savings in time and labor become evident. Moreover, a safety system can be configured to
suit various requirements and operating conditions, providing more flexibility

PLC & - Power Supply Safe related devices corresponding to

AS-i
AS-i master AS-Interface Safety at Work

Safety Safety
Monitor Slave

AS-i
Standard slave SwitchNet

Sensor
Motor E-Stop Door interlock device
Pushbutton switch (Safety switch)

Figure 5. AS-Interface Safety at Work Basic Configuration

Application to Semiconductor Manufacturing Equipment

Figure 6 shows a wafer etching system, a type of semiconductor manufacturing equipment. Cutting-edge
safety technologies have been introduced to this system to achieve inherent safety, complying with
various safety standards such as SEMI-S2. The usage of AS-i SAW has greatly contributed to the
achievement of a high level of safety.
Comparison of conventional systems and AS-i SAW
systems
Figure 7 shows the comparison of safety-related control
systems, one conventionally configured and the other
using AS-i SAW. In the conventional system, shown in
figure 7 (a-1), the safety system and the control system
are separately designed. The safety system, as shown in
figure 7 (a-2), is configured using interlock relays and is
hardwired. In the control system, a network has been
introduced to centrally control the controllers achieving
some degree of wire saving. However, the safety system
involves wiring over 100 points, requiring a great deal of
labor and cost. Because the system is hardwired and
designed using a proprietary relay interlock board,
considerable amount of labor and expenses are required
for system modification and improvement or when
debugging the system at start-up, or system changeover Figure 6. Wafer Etching System
to specific users’ request. Furthermore, labor and expenses are also necessary when applying for
certification by a third-party organization.
In the system employing the AS-i SAW, shown in figure 7 (b-1), the safety system is configured using only
one AS-i cable, and the control system is also simply designed with SwitchNet connected to the same
network, achieving wire-savings and improved usability [14]. In addition, while the conventional safety
system needed a proprietary interlock relay board (requiring labor and expense for system development
and modification), using AS-i SAW, which is approved for safety certification, greatly simplifies the process
of basic designing and certification procedures for international standards.

Controlled Devices Safety System

Distribution Panel Control Box

Interlock Relay Board

Relays
R Door SW

R Cover
High
R Pressure
Voltage
Power Vacuum Processing
R
Gauge Chamber
Supply
R Cooling Water

24V
Power
R Gas Valves
R

R Pump

EMO R

Safety Relay
EMO
Module EMO

Start Switch

Power Control I/O Node I/O Node Driving Power

Distribution Unit Controller for Wire-saving system for Gas Valves
for devices device-control

10 wires 80 to 100 wires Control System

(a-1) Conventional system configuration (a-2) Inside control panel

Control Safety System

Distribution Panel Control Box Controlled Devices

Safety Slave
Pump

Cover
Door SW
Pressure
Vacuum Processing
Gauge Chamber
Safety Slave
Cooling Water

Safety
Monitor Standard Slave

High
Voltage Gas Valves
Start Switch
Power
（SwitchNet)
Supply
EMO EMO EMO
Safety Safety Safety
Slave Slave Slave
AS-Interface

Safety
Monitor Safety Monitor R

Power
Distribution Unit Controller for AS-I
for devices device-control Master Driving Power
for Gas Valves

1 wire 1 wire (b-2) Inside control panel

(b-1) System configuration using AS-Interface Safety at Work

Figure 7. System Comparison between the (a) Conventional System and (b) AS-Interface
Safety at Work System Control System Unit
 EMO SwitchNet
Safety Monitor

EMO

AS-i Cable
SwitchNet

Safety Slave

(a) Operation Panel (b) The Inside of Operation Panel (c) Power Supply of System
Figure 8. Operation Panel and Internal Unit of Wafer Etching System

The system using AS-i SAW consists of a control box, controlled devices, a distribution panel, and an
operation panel. The operation panel, shown in figure 8 (a), houses the operation display, SwitchNet
components, and an emergency stop switch (EMO). In the operation panel, the control-related SwitchNet
components and safety-related emergency stop switch are connected via a safety slave as shown in
figure 8 (b). The network inside the operation panel is configured simply with an AS-i cable and a two-wire
parallel cable. In the power supply box, shown in figure 8 (c), a safety monitor is installed in the center,
which works in conjunction with the emergency stop switch and controls the main power supply. The
SwitchNet components on the operation panel control the startup and restarting of the devices.

Evaluation of AS-i SAW Usability

Figure 9 compares the usability of safety-related control systems, used in semiconductor manufacturing
equipment, evaluating on design, production, installation, and maintenance. Figure 9 (a) shows the
evaluation of a conventional system, while figure 9 (b) shows the analysis of the system in which AS-i
SAW is being used. As clearly illustrated, the safety-related control system with AS-i SAW excels in all
evaluation points, proving superiority in basic design, wiring, system changeover, maintenance, and
certification process.
Because semiconductor manufacturing equipment is large in size, flexibility and speed are needed in
developing and changing systems in order to respond to the users’ needs and safety requirements. AS-i
SAW provides flexibility to the system by facilitating the processes of increasing and changing of safety
slaves, safety monitoring standard slaves, and also software settings. By using AS-i SAW, semiconductor
manufacturing equipment has been enhanced in design and usability, and prove to be the highly superior
equipment by the use of state-of-the-art safety technology.

System Changeover System Changeover

• Difficult to change system layouts • Easy to change system layouts
• Difficult to add safety equipment • Easy to add safety equipment
Maintenance
Maintenance Certification Process • Least maintenance parts Certification Process
• Many parts need
maintenance. • Certification is needed • Monitoring function for failed • No boards (no need for
• Difficult to find failed parts separately for board modules. parts certification of module)
• Difficult to replace safety • Easy replacement
relays

Wiring
Basic design
Wiring Basic design • Reduces hard wirings
• Much hard wiring • No need for control boards
• Needs control boards significantly
• An immense wiring • Reduction of wiring material • Flexible setting of safety
• No flexibility in safety
material keeps environment. category
category setting

(a) Conventional Safety-related Control System (b) New Safety-related Control System using
AS-Interface Safety at Work
Figure 9. Usability Comparison of Semiconductor Manufacturing Equipment
Future Research and Development
As the application of AS-i SAW to semiconductor manufacturing equipment has revealed, AS-i SAW is an
optimum choice for improvement of usability in aspects of both safety and control. Manufacturing
industries around the world are now working hard on critical issues; international standardization, open
networks, saving, and safety. An AS-i SAW network system solves all these issues, and achieves
integration of information and safety. While the application of AS-i SAW to other machine systems is
expected to increase, we are committed to continue research and development of this technology for
increased usability.

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