System and Technology Overview
DMC’s client was developing a machine for a custom wafer handling scenario. The machine included a robot for wafer handling, multiple TCP and Serial wafer processing components, customer specific processing modules, and a Beckhoff PLC. The client needed an application to monitor, maintain, and execute silicon wafer processing jobs.
DMC developed a PC desktop application in Windows Presentation Framework (WPF) that orchestrates wafer handling jobs by sending commands and reading statuses from all the devices in the machine. The application interfaces with the devices over EtherCAT, TCP, and several serial protocols. By using WPF and C# instead of one of the many automation HMI platforms, we were able to fully customize the application's appearance. This also allowed us to remove the complication of serial port communication and process orchestration from the PLC.
The application allows users to create, delete, and edit jobs; monitor job status, I/O, logs, and alarms; and perform manual commands to each individual device when maintenance is required. The robot’s position on the machine graphic updates live as the robot moves wafers through the process, enhancing user interaction. The job status screen also gives insight into wafer locations and the overall progress.
System Benefits
With an automated workflow, the user is free to focus on other initiatives instead of operational inefficiencies. Real-time monitoring allows users to be proactive instead of reactive in detecting issues. Troubleshooting is streamlined with centralized accessibility to job status, logs, and alarms. This means that problems can be identified and fixed faster and prevented in the future, reducing downtime.
Project Process
During development, DMC tested the application’s orchestrated workflow by simulating device drivers and their state reactions to commands. DMC also conducted numerous remote testing sessions that involved logging into the client’s PC to run the application and validate communication with the devices. Finally, DMC went to the client’s facility to commission and test the application.
Conclusion
DMC leveraged our expertise in C#, WPF, and PLC programming to deliver a high-quality application that reduced downtime and increased operational visibility to the client.
Learn more about DMC's custom application development expertise and contact us today for your next project.