On-tool mass flow controller diagnostic systems and methods
View Patent ↗Mass flow controllers with on-tool diagnostic capabilities and methods for on-tool diagnosis of mass flow controllers are disclosed herein. One disclosed method includes providing current to two heating-sensing elements of a mass flow sensor and modifying current through at least one of the heating-sensing elements. Reference data is obtained that characterizes proper operation of the mass flow sensor, and one or more flow sensor signals from the mass flow sensor are analyzed in connection with the reference data to assess whether the mass flow sensor is operating properly.
1. A method for on-tool diagnosis of a mass flow controller comprising:
providing current to two heating-sensing elements of a mass flow sensor;
modifying current through at least one of the heating-sensing elements;
obtaining reference data that characterizes proper operation of the mass flow sensor;
analyzing one or more flow sensor signals from the mass flow sensor in connection with the reference data to assess whether the mass flow sensor is operating properly; and
wherein modifying current includes:
modifying current through a first of the two heating-sensing elements then modifying current through a second of the two heating-sensing elements so current of only one of the heating-sensing elements is modified at a time.
2. The method of claim 1 , wherein modifying current includes providing current with a current source.
3. The method of claim 1 , wherein the reference data includes response data selected from the group consisting of rise time, delay, undershoot, and overshoot, wherein the response data characterizes responses of the mass flow sensor to changes in current through at least one of the heating-sensing elements when the mass flow sensor is operating properly, and wherein analyzing includes comparing a response of the one or more flow sensor signals from the mass flow sensor to the response data.
4. A method for on-tool diagnosis of a mass flow controller comprising:
providing current to two heating-sensing elements of a mass flow sensor;
modifying current through at least one of the heating-sensing elements;
obtaining reference data that characterizes proper operation of the mass flow sensor;
analyzing one or more flow sensor signals from the mass flow sensor in connection with
the reference data to assess whether the mass flow sensor is operating properly;
applying step-like-current-increases to a first of the heating-sensing elements;
obtaining a first transient curve from the one or more flow sensor signals from the mass flow sensor;
applying the step-like current increases to a second of the heating-sensing elements;
obtaining a second transient curve from the one or more flow sensor signals of the mass flow sensor; and
comparing the first and second transient curves to determine whether the two heating-sensing elements are similarly responding to the step-like current increases.
5. A method for on-tool diagnosis of a mass flow controller comprising:
providing current to two heating-sensing elements of a mass flow sensor;
modifying current through at least one of the heating-sensing elements;
obtaining reference data that characterizes proper operation of the mass flow sensor;
analyzing one or more flow sensor signals from the mass flow sensor in connection with the reference data to assess whether the mass flow sensor is operating properly; and
wherein the reference data includes transient response curves that characterize responses of the mass flow sensor when the mass flow sensor is operating properly, and wherein analyzing includes comparing the transient response curves from the reference data with response curves obtained from the one or more flow sensor signals of the mass flow sensor.
6. A mass flow controller with on-tool diagnostics capability comprising:
a main flow path for a fluid;
a control valve to control a flow rate of the fluid;
a mass flow sensor coupled to the main flow path including two heating-sensing elements for measuring a mass flow rate of the fluid;
a control component coupled to the mass flow sensor and the control valve to control a position of the control valve based upon a set point; and
a sensor analysis component including:
a diagnostic signal generator that modifies current through one or both of the two heating-sensing elements, wherein the diagnostic signal generator includes two current sources, each of the two current sources modifies current through a corresponding one of the two heating-sensing elements;
memory configured to store reference data that characterizes proper operation of the mass flow sensor; and
a diagnostic analysis component that analyzes one or more flow sensor signals from the mass flow sensor in connection with the reference data to assess whether the mass flow sensor is operating properly.
7. A mass flow controller with on-tool diagnostics capability comprising:
a main flow path for a fluid;
a control valve to control a flow rate of the fluid;
a mass flow sensor coupled to the main flow path, the mass flow sensor including a sensor-current-source and two heating-sensing elements to provide a measure of a mass flow rate of the fluid through the main flow path;
a control component coupled to the mass flow sensor and the control valve to control a position of the control valve based upon a set point and the measure of the mass flow rate of the fluid;
memory configured to store reference data that characterizes proper operation of the mass flow sensor;
a sensor analysis component including:
a diagnostic signal generator that modifies current through one or both of the two heating-sensing elements;
a diagnostic analysis component that analyzes one or more flow sensor signals from the mass flow sensor in connection with the reference data to assess whether mass flow sensor is operating properly, the diagnostic analysis component including:
a non-transitory, tangible processor readable storage medium, encoded with processor executable instructions to perform a method for on-tool diagnosis of the mass flow controller, the method comprising:
providing current from the sensor-current-source to the two heating-sensing elements of a mass flow sensor;
modifying current through at least one of the heating-sensing elements to generate modified current, wherein modifying current includes modifying current through a first of the two heating-sensing elements then modifying current through a second of the two heating-sensing elements so current of only one of the heating-sensing elements is modified at a time;
obtaining the reference data that characterizes proper operation of the mass flow sensor in response to the modified current; and
analyzing a response of the one or more flow sensor signals from the mass flow sensor to the modified current in connection with the reference data to assess whether mass flow sensor is operating properly.
8. The mass flow controller of claim 7 , wherein the diagnostic signal generator includes one or more current sources to modify current through one or more corresponding heating-sensing components.