Patent Grant
10884435
The present invention relates to a pressure-type flow rate control device used in facilities such as semiconductor manufacturing facilities and chemical plants, and a flow rate calculation method and a flow rate control method thereof, and in particular relates to a pressure-type flow rate control device used for supplying a mixed gas that is a mixture of a plurality of types of gases, and a flow rate calculation method and a flow rate control method thereof.
The ability to supply gas accurately is required in facilities such as semiconductor manufacturing facilities or chemical plants. As one example of gas flow rate control devices, mass flow controllers (thermal mass flow rate controllers) are known.
As gas flow rate control devices having a simpler configuration than thermal mass flow rate controllers, based on a different principle, pressure-type flow rate control systems are known. For example, Patent Literatures 1 and 2 given below disclose pressure-type flow rate control devices that adjust the flow rate of input gas with a control valve and exhaust the gas through an orifice. These pressure-type flow rate control devices control a flow rate Q of gas by measuring an upstream pressure P1 of the orifice when the relationship between the upstream pressure P1 and a downstream pressure P2 of the orifice satisfies a predetermined condition. Assuming that the flow velocity of the gas when flowing out of the orifice reaches sound velocity at the gas temperature thereof, i.e., when the relationship between the upstream and downstream pressures P1 and P2 of the orifice satisfies a critical expansion condition P1/P2≥approx. 2, the flow rate Q is expressed as Q=FF·S·P1(1/T1)1/2 and is proportional to the upstream pressure P1, where FF is the flow factor (m3K1/2/kg sec) expressed as:
FF=(k/γs){2/(κ+1)}1/(κ−1)[κ/{(κ+1)R}]1/2.
Here, k is a constant (k=(2 g)1/2=4.429, where g is the acceleration of gravity (m/sec2)), Q(m3/sec) is the volume flow rate under standard conditions, S (m2) is the orifice cross section, P1 (kg/m2abs) is the upstream absolute pressure, T1 (K) is the upstream gas temperature, γs (kg/m3) is the gas density under standard conditions, κ (dimensionless) is the gas specific heat ratio, and R (m/K) is the gas constant.
Therefore, a desired flow rate can be obtained by measuring the upstream pressure P1 to calculate the flow rate Q and controlling the control valve such that the calculated flow rate Q becomes the desired flow rate.
Patent Literature 1: Japanese Patent Application Laid-Open No. H08-338546
Patent Literature 2: Japanese Patent Application Laid-Open No. 2000-322130
The control methods for obtaining a desired flow rate by measuring the upstream pressure P1 of the orifice to calculate the flow rate of the gas, disclosed in Patent Literatures 1 and 2, are applicable to a single type of gas, but cannot be applied to a mixed gas. This is because the flow factor FF includes characteristic values (density γs, specific heat ratio κ, and gas constant R) of each type of gases.
It is thus conceivable to obtain a value by weighting (hereinafter, also referred to as “multiplying”) the flow factor FF of each type of gases constituting the mixed gas at the ratio at which these types of gases are mixed and to use the obtained value as the flow factor FF of the mixed gas. For example, for a mixed gas consisting of gas A and gas B, it is conceivable to calculate the flow factor FF(AB) of the mixed gas by:
FF(AB)=X·FF(A)+(1−X)·FF(B)
and calculate the flow rate Q by:
Q=FF(AB)·S·P1(1/T1)1/2
where X (0≤X≤1) is the proportion of the gas A and (1−X) is the proportion of the gas B, i.e., the proportion of the gas A to the gas B is X:(1−X), and FF(A) and FF(B) are the flow factors FF of the gas A and the gas B, respectively. This method, however, has a problem in that the obtained results differ greatly from the actual measurement results.
It is an object of the present invention to solve the above-described problem, to provide a pressure-type flow rate control device for calculating a flow rate of a mixed gas with high accuracy and controlling the flow rate of the mixed gas to attain a desired value by using the calculated value, and to provide a flow rate calculation method and a flow rate control method thereof.
To achieve the above-described object, a pressure-type flow rate control device according to an embodiment of the present invention is a pressure-type flow rate control device for calculating a flow rate Q of a mixed gas that passes through an orifice from a flow factor FF, while an upstream pressure P1 of the orifice is maintained at approximately at least twice a downstream pressure P2 of the orifice, the mixed gas consisting of a first gas and a second gas and having a mixture ratio of X:(1−X) between the first gas and the second gas. The pressure-type flow rate control device includes a first processor calculating an average density ρAV, average specific heat ratio κAV, and average gas constant RAV of the mixed gas, respectively, by:
ρAV=X·ρ(A)+(1−X)·ρ(B),
κAV=X·κ(A)+(1−X)·κ(B), and
RAV=X·R(A)+(1−X)·R(B)
using a density ρ(A) of the first gas, a density ρ(B) of the second gas, a specific heat ratio κ(A) of the first gas, a specific heat ratio κ(B) of the second gas, a gas constant R(A) of the first gas, and a gas constant R(B) of the second gas, a second processor calculating the flow factor FF of the mixed gas by:
FF=(k/ρAV){2/(κAV+1)}1/(κAV−1)[κAV/{(κAV+1)RAV}]1/2
using the average density ρAV, the average specific heat ratio κAV, and the average gas constant RAV, where k is a constant, and a third processor calculating the flow rate Q of the mixed gas that is output from the orifice by:
Q=FF·S·P1(1/T1)1/2
using the flow factor FF of the mixed gas, where S is an orifice cross section, and T1 is a temperature of the gas on an upstream side of the orifice.
The above-described pressure-type flow rate control device further includes an adjuster disposed on the upstream side of the orifice and adjusting a supply amount of the mixed gas that is supplied to the orifice, and a controller controlling the supply amount adjusted by the adjuster such that the flow rate Q of the mixed gas that is calculated becomes a predetermined target flow rate Q0.
The above-described pressure-type flow rate control device further includes a storage storing a density, a specific heat ratio, and a gas constant for each of three or more types of gases, and a receiver receiving specification information that specifies the first gas and the second gas from external equipment. The first processor can read out the densities ρ(A) and ρ(B), the specific heat ratios κ(A) and κ(B), and the gas constants R(A) and R(B) of the gases that correspond to the specification information from the storage, and calculate the average density ρAV, the average specific heat ratio κAV, and the average gas constant RAV of the mixed gas.
A flow rate calculation method of a pressure-type flow rate control device according to an embodiment of the present invention is a flow rate calculation method of a pressure-type flow rate control device for calculating a flow rate Q of a mixed gas that passes through an orifice, while maintaining an upstream pressure P1 of the orifice at approximately at least twice a downstream pressure P2 of the orifice, the mixed gas consisting of a first gas and a second gas and having a mixture ratio of X:(1−X) between the first gas and the second gas. The flow rate calculation method includes a first step of calculating an average density ρAV, average specific heat ratio κAV, and average gas constant RAV of the mixed gas, respectively, by:
ρAV=X·ρ(A)+(1−X)·ρ(B),
κAV=X·κ(A)+(1−X)·κ(B), and
RAV=X·R(A)+(1−X)·R(B)
using a density ρ(A) of the first gas, a density ρ(B) of the second gas, a specific heat ratio κ(A) of the first gas, a specific heat ratio κ(B) of the second gas, a gas constant R(A) of the first gas, and a gas constant R(B) of the second gas, a second step of calculating the flow factor FF of the mixed gas by:
FF=(k/ρAV){2/(κAV+1)}1/(κAV−1)[κAV/{(κAV+1)RAV}]1/2
using the average density ρAV, the average specific heat ratio κAV, and the average gas constant RAV, where k is a constant, and a third step of calculating the flow rate Q of the mixed gas that is output from the orifice by:
Q=FF·S·P1(1/T1)1/2
using the flow factor FF of the mixed gas, where S is an orifice cross section, and T1 is a temperature of the gas on an upstream side of the orifice.
A flow rate control method of a pressure-type flow rate control device according to an embodiment of the present invention is a flow rate control method of a pressure-type flow rate control device that includes a flow rate adjuster disposed on an upstream side of an orifice through which a mixed gas passes. The flow rate control method includes the steps of calculating a flow rate Q of the mixed gas that passes through the orifice by the flow rate calculation method described above, and adjusting the flow rate adjuster such that the flow rate Q that is calculated becomes a predetermined target flow rate Q0.
With the pressure-type flow rate control device according to an embodiment of the present invention, the flow rate of the mixed gas can be calculated with high accuracy, and the flow rate of the mixed gas can be controlled with high accuracy to attain a desired value by using the calculated value.
Embodiments of a pressure-type flow rate control device according to the present invention will be described hereinafter with reference to the drawings. Note that the same or similar components are given the same reference numerals throughout all the figures and all the embodiments.
The mixed gas supply passage 2, the upstream flow passage 4, and the exhaust flow passage 6 may be formed by pipes, or may be formed inside a main block in which the control valve 3 and other components are mounted. As the control valve 3, a diaphragm, e.g., a direct-touch type metal diaphragm valve may be used. As the drive 9, for example, a piezoelectric element drive (piezoelectric actuator) may be used. The present invention is not limited thereto, and the drive 9 may also be a magnetostrictive drive, a solenoid drive, a motor drive, a pneumatic drive, or a thermal expansion drive.
The orifice 5 controls the flow rate of gas received from the upstream flow passage 4 while throttling the received gas, and outputs the gas to the exhaust flow passage 6 provided on the downstream side. The exhaust flow passage 6 is connected to a device (e.g., reactor) to which the gas is supplied. As the orifice 5, for example, a thin metal plate-like gasket with a hole formed by cutting may be used. Alternatively, an orifice with a hole formed in a metal film by etching or electrical discharge machining can be used. The orifice 5 further includes a flow rate limiter that reduces the aperture of its flow passage with a sonic nozzle or other elements. The flow rate of the gas depends on the orifice 5.
The pressure sensor 7 measures the pressure of the gas in the upstream flow passage 4. For example, a semiconductor strain pressure sensor may be used as the pressure sensor 7. The pressure sensor 7 is not limited thereto, and as the pressure sensor 7, any of other types of pressure sensor, such as a metal-foil strain pressure sensor, an electrical capacitance pressure sensor, or a magneto-resistive pressure sensor may be used.
The temperature sensor 8 measures the temperature of the gas in the upstream flow passage 4. For example, a thermistor is used as the temperature sensor 8. The temperature sensor 8 is not limited thereto, and as the temperature sensor 8, any of various types of commonly known temperature sensors such as a thermocouple temperature sensor or a resistance thermometer bulb temperature sensor may be used.
The controller 10 performs overall control of the pressure-type flow rate control device 1. Referring to
The CPU 20 implements functions of the pressure-type flow rate control device 1 by executing programs recorded on the ROM 21. The ROM 21 is, for example, a non-volatile electrically writable memory and stores predetermined programs and data (e.g., parameters) that are necessary to execute the programs. The RAM 22 is a volatile memory and is used as a work area used when the CPU 20 executes programs and temporarily stores the values of arithmetic operation results.
The I/O unit 23 serves as an interface for exchanging data with external equipment. The I/O unit 23 includes an A/D converter (not shown) for converting analog signals that are output from the pressure sensor 7 and the temperature sensor 8 into digital signals that can be handled by the CPU 20. The A/D converter generates digital signals in a predetermined cycle and stores the digital signals in a buffer (not shown). Thus, data in the buffer is updated in a predetermined cycle. The data stored in the buffer is read out by the CPU 20 at a predetermined timing and is used in arithmetic operations described later. Note that other components such as an amplifier (amp) for amplifying analog signals output from the pressure sensor 7 and the temperature sensor 8 to a predetermined level may be provided on the input side of the A/D converter. The I/O unit 23 may also output a control signal of the driver 9.
Although not shown, the I/O unit 23 may further include an interface for exchanging information with external equipment such as computers. In this case, programs and data can be written into the ROM 21 via the interface with external equipment. If the I/O unit 23 does not include any interface with external equipment, the ROM 21 may be configured to be detachable so that programs and parameters can be updated by replacing the ROM 21 with a new one. The data in the ROM 21 can also be updated using external equipment.
The bus 24 serves to support data exchange among the CPU 20, the ROM 21, the RAM 22, and the I/O unit 23. Although not shown in
This configuration allows the pressure-type flow rate control device 1 to calculate the flow rate Q of a mixed gas supplied from the outside through the mixed gas supply passage 2 and output through the control valve 3 and the orifice 5 to the exhaust flow passage 6, by using the pressure P1 of the mixed gas measured by the pressure sensor 7, and to adjust the control valve 3 by controlling the driver 9 such that the flow rate Q becomes a preset flow rate Q0, when the relationship between the upstream pressure P1 and downstream pressure P2 of the orifice 5 satisfies the critical expansion condition P1/P2≥approx. 2.
The operations of the pressure-type flow rate control device 1 will now be described more specifically with reference to the flowchart in
Here, the mixed gas supplied to the mixed gas supply passage 2 is assumed to be obtained by mixing two types of gases, namely gas A and gas B, at a ratio of X:(1−X). Here, Q=FF·S·P1(1/T1)1/2 is used as a calculation formula for the flow rate Q. As parameters necessary for calculating the flow rate Q, the ROM 21 stores the proportion X of the gas A, the respective densities ρ(A) and ρ(B) (kg/m3) of the gas A and the gas B, the gas specific heat ratios κ(A) and κ(B) (dimensionless), and the gas constants R(A) and R(B) (m/K). The ROM 21 also stores the orifice cross section S (m2) of the orifice 5.
In step 40, the mixture ratio X of the gas A, the target flow rate Q0, the respective densities ρ(A) and ρ(B), the respective gas specific heat ratios κ(A) and κ(B), and the respective gas constants R(A) and R(B) of the gas A and the gas B are read out from the ROM 21.
In step 41, the pressure sensor 7 measures the pressure of the mixed gas in the upstream flow passage 4, and the temperature sensor 8 measures the temperature of the mixed gas in the upstream flow passage 4. Specifically, the pressure P1 (kg/m2abs) and the temperature T1 (K), which are digital data obtained by A/D conversion of output from the pressure sensor 7 and the temperature sensor 8, are stored in the RAM 22.
In step 42, an average density ρAV, an average specific heat ratio κAV (or κAV), and an average gas constant RAV are calculated by the following equations:
ρAV=X·ρ(A)+(1−X)·ρ(B),
κAV=X·κ(A)+(1−X)·κ(B), and
RAV=X·R(A)+(1−X)·R(B).
In step 43, the flow factor FF of the mixed gas is calculated by:
FF=(k/ρAV){2/(κAV+1)}1/(κAV−1)[κAV/{(κAV+1)RAV}]1/2.
Then, the flow rate Q (m3/sec) is calculated by Q=FF·S·P1(1/T1)1/2, using the calculated flow factor FF, the orifice cross section S read out in step 40, and the pressure P1 and the temperature T1 acquired in step 41.
Here, k is a constant (k=4.429), and the flow factor FF and the flow rate Q are calculated using the average density ρAV, average specific heat ratio κAV, and average gas constant RAV of the mixed gas that are calculated in step 42.
In step 44, a difference D between the flow rate Q calculated in step 43 and the target flow rate Q0 read out in step 40 is calculated by D=Q−Q0.
In step 45, it is determined whether the absolute value of D calculated in step 44 is smaller than a predetermined threshold value D0. If the absolute value is smaller than D0, control returns to step 41, and if the absolute value is greater than or equal to D0, control transitions to step 46.
In step 46, a control value for controlling the control valve 3 is determined. The control value is determined according to the magnitude of D. The control value is determined according to the magnitude of D, such that the open/closed state of the control valve 3 is moved in the direction of closing the valve if D is a positive value and is moved in the direction of opening the valve if D is a negative value. Note that the control value can be determined according to the magnitude of D in an arbitrary manner as long as the direction of opening or closing the control valve 3 is correctly set according to whether D is positive or negative. For example, the control value can be changed by a large amount if D is a large value, and can be changed by a small amount if D is a small value. Alternatively, the control value can be changed by a predetermined amount every time, irrespective of the magnitude of D. In either case, the flow rate Q can be set to the target flow rate Q0 by repeating steps 41 to 46.
In step 47, the determined control value is output to the driver 9. Accordingly, the open/closed state of the control valve 3 is adjusted.
In step 48, it is determined whether an end instruction has been issued. If an end instruction has been received, control ends, and if not, control returns to step 41. For example, an end instruction is issued upon power-off.
In this way, the flow rate Q of the mixed gas output from the exhaust flow passage 6 of the pressure-type flow rate control device 1 can be adjusted to the target value Q0.
As the flow factor FF, a ratio (hereinafter, also referred to as a “relative FF”) of the flow factor FF of the mixed gas to the flow factor FF of reference gas (e.g., nitrogen (N2)) can also be used. In the case of using the relative FF, the actual flow rate of the mixed gas may be calculated by multiplying the calculated flow rate Q by the flow rate of the reference gas.
Although the case has been described above in which the mixture ratio of the mixed gas (specifically, the proportion X of the gas A that is mixed) is stored in the ROM 21, the present invention is not limited thereto. The mixture ratio may be input from external equipment to the controller 10 via the I/O unit 23.
Although the case has been described above in which parameters (gas densities, gas specific heat ratios, and gas constants) of two predetermined types of gases are stored in the ROM 21, the present invention is not limited thereto. Parameters (gas densities, gas specific heat ratios, gas constants) of three or more types of gases may be stored in the ROM 21. In that case, the flow rate can be controlled in a similar manner to that described above for a mixed gas that is obtained by mixing two arbitrary types of gases stored in the ROM 21 at an arbitrary mixture ratio, by inputting information on the type of mixed gas supplied from the outside and the mixture ratio thereof from external equipment to the controller 10.
The configuration of the controller 10 is not limited to the configuration illustrated in
Experimental results are hereinafter presented to show the effectiveness of the present invention.
A device with the same configuration as in
Table 1 shows the experimental results for various mixed gases.
The leftmost “Gas” column of Table 1 shows a first gas and the proportion thereof on the left side of the forward slash (/) and a second gas on the right side of the forward slash. The proportion (%) of the second gas is obtained by subtracting the proportion of the first gas from 100. For example, “5% B2H6/H2” represents a mixed gas that contains 5% B2H6 and 95% H2.
The “Calculation” column within the “FF” column shows the value of the flow factor FF calculated by the method according to the present invention. Here, FF refers to the relative FF. As described above, the average density ρAV, average specific heat ratio κAV, and average gas constant RAV of the mixed gas were calculated, and these values were used to calculate the relative FF by:
FF=(k/ρAV){2/(κAV+1)}1/(κAV−1)[κAV/{(κAV+1)RAV}]1/2.
The “Multiplication” column within the “FF” column shows the value calculated by FF(AB)=X·FF(A)+(1−X)·FF(B) using the relative FF in Table 2.
The “Range” column shows the rated flow rate and includes information for specifying the orifice cross section. The orifice cross section that corresponds to each rated flow rate was used to calculate the flow factor FF by the buildup method. Here, F600, F200, F1600, F5L, F130, and F20 each represents the flow rate of N2 gas. For example, F600 represents 600 SCCM.
The “N2” column shows the flow rate of nitrogen gas used as a reference gas. The “Actual Gas” column shows the measured value of the mixed gas obtained by the buildup method. The “Actually Measured FF” column shows the relative FF calculated from the actually measured values of the mixed gas.
The “Calculation” column within the “Error” column shows the value obtained by subtracting the value in the “Calculation” column of the “FF” column from the value in the “Actually Measured FF” column and dividing the subtraction value by the value in the “Actually Measured FF” column. Similarly, the “Multiplication” column within the “Error” column shows the value obtained by subtracting the value in the “Multiplying” column of the “FF” column from the value in “Actually Measured FF” column and dividing the subtraction value by the value in the “Actually Measured FF” column.
Comparison of these values indicates that, for every mixed gas, the relative FF calculated by the method according to the present invention has a smaller error, and the relative FF can be calculated with high accuracy. In particular, even if there is a large difference in relative FF between the two types of gases that are mixed, the relative FF was calculated with high accuracy. This verifies the effectiveness of the present invention.
Note that the types of gases to which the present invention is applicable are not limited to those shown in Tables 1 and 2.
While the present invention has been described above by describing embodiments thereof, the above-described embodiments are merely illustrative. The present invention is not limited to the above-described embodiments and can be implemented with various modifications.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2016-163883 | Aug 2016 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2017/030251 | 8/24/2017 | WO | 00 |
| Publishing Document | Publishing Date | Country | Kind |
|---|---|---|---|
| WO2018/038193 | 3/1/2018 | WO | A |
| Number | Name | Date | Kind |
|---|---|---|---|
| 20010004903 | Ohmi | Jun 2001 | A1 |
| 20070204702 | Melcer | Sep 2007 | A1 |
| 20140246097 | Smirnov | Sep 2014 | A1 |
| Number | Date | Country |
|---|---|---|
| H08-338546 | Dec 1996 | JP |
| 2000-322130 | Nov 2000 | JP |
| Entry |
|---|
| Engineering tool box (Gas Mixture Properties), May 2, 2006, retrieved from the internet <https://web.archive.org/web/20060502200956/https://www.engineeringtoolbox.conn/gas-mixture-properties-d_586.html> (Year: 2006). |
| Jim Buckley, (specific heat ratio of a gas mixture), May 7, 2009, retrieved from the internet <https://www.eng-tips.com/ viewthread.cfm?qid=244590> (Year: 2009). |
| International Search Report issued in PCT/JP2017/030251; dated Sep. 26, 2017. |
| Number | Date | Country | |
|---|---|---|---|
| 20190227577 A1 | Jul 2019 | US |
