Integrated Control and Monitoring for FOUP Stocker Systems
Introduction
The customer specializes in automation solutions for advanced cleanroom applications, including FOUP (Front Opening Unified Pod) stocker systems. FOUPs are widely used in semiconductor manufacturing to safely store, transport, and protect wafers throughout the production process. FOUP stockers serve as automated storage and transfer stations, helping ensure efficient material handling between process steps.
These stocker systems combine advanced robotics, motion control, and software to automate FOUP storage, retrieval, and tracking operations. In the customer’s original setup, integrating O-brand PLCs with third-party I/O modules resulted in recurring error codes and system reliability issues. To address these challenges, the customer turned to ICP DAS USA’s automation solution.
ICP DAS USA Automation Solution for FOUP Stockers
For this application, the customer developed a custom driver using the ICP DAS USA AXP-9051-IoT programmable automation controller (PAC). Operational data is exchanged between the PAC, the O-brand PLC, and customized ICP DAS USA CAN-205XD I/O modules via the Modbus TCP protocol.
This architecture enables reliable command transmission and control of the FOUP stocker system while eliminating the error code issues experienced with the previous solution.
The deployment includes two FOUP stocker models:
CAN-205XD DeviceNet Remote I/O Module
The CAN-205XD Series DeviceNet remote I/O slave module complies with DeviceNet Volume I/II Release 2.0 specifications, allowing users to configure settings and monitor DI/DO channel status through the standard DeviceNet protocol. The module also includes a standard EDS (Electronic Data Sheet) file, enabling fast and seamless integration with DeviceNet master devices from various manufacturers.
The CAN-205XD Series provides 8 or 16 channels of isolated digital inputs (DI) and outputs (DO), supporting PNP, NPN, TTL, and relay applications. In this FOUP stocker system, the DI channels receive control signals, while the DO channels operate key equipment, including solenoid valves, pressure control valves, speed control valves, pneumatic cylinders, and electric slide tables. The modules also support monitoring of pressure switches and positioning signals throughout the stocker system.
To meet the customer’s requirements, ICP DAS USA customized the CAN-205XD firmware and EDS files, eliminating the communication-related error codes experienced with the previous solution.
AXP-9051-IoT Programmable Automation Controller (PAC)
The AXP-9000-IoT Series PAC combines computing, control, and I/O capabilities in a single platform running Windows 10 IoT Enterprise. It supports Intel® Core™ i5-8365UE or Intel® Atom™ E3950 processors and offers multiple I/O expansion options to accommodate a wide range of automation applications.
The platform includes dual Gigabit Ethernet ports, VGA, HDMI, USB, RS-232, and RS-485 interfaces, providing flexible connectivity for industrial systems. Local expansion slots support ICP DAS USA I-9K, I-97K, and e-9K I/O modules, while remote expansion can be connected to Ethernet I/O modules or RS-485 I/O modules.
In this application, the customer uses the AXP-9051-IoT PAC to develop custom drivers and communicate with the O-brand PLC through Modbus TCP, enabling reliable control of the FOUP stocker system.
Benefits
ICP DAS USA’s One-Stop DeviceNet Solution
From compact DeviceNet remote I/O modules to high-performance PACs, ICP DAS USA provides a complete range of DeviceNet products for reliable machine automation and industrial control. With flexible communication options, easy integration, and customized engineering support, ICP DAS USA helps manufacturers improve system reliability, simplify deployment, and accelerate project implementation.
ICP DAS USA’s Complete DeviceNet Product Portfolio
Built on CAN bus technology, DeviceNet remains one of the world’s most widely used industrial automation networks. With decades of DeviceNet expertise, ICP DAS USA offers a comprehensive portfolio of DeviceNet products, including master devices, slave devices, I/O modules, gateways, PCI interface cards, and complete automation solutions.
In addition to its extensive product lineup, ICP DAS USA provides experienced technical support to help customers simplify integration, improve system performance, and overcome DeviceNet communication challenges.
I/O Modules and Expansion Units (Slave Devices)
The CAN-8×24 Series remote I/O units and CAN-2000D Series I/O modules make it easy to integrate sensors and actuators into a DeviceNet network. Both product families include standard EDS files for seamless compatibility with DeviceNet master devices.
Key differences include:
Gateways (Slave Devices)
The I-7000D and GW-7000D Series gateways enable communication between DeviceNet networks and equipment using different protocols. These gateways provide a fast and cost-effective way to connect existing devices to DeviceNet systems.
DeviceNet Master Solutions
ICP DAS USA offers a range of DeviceNet master products to support both PAC-based and PC-based automation systems.
For PAC applications, the I-8124W-G and I-87124-G DeviceNet master modules are designed for use with WinPAC, WinCon, LinCon, and I-8000 Series PACs.
For PC-based systems, ICP DAS USA provides the PISO-DNM100 Series DeviceNet master PCI boards and the I-7565-DNM USB-to-DeviceNet master converter. Equipped with an onboard 80 MHz 186 CPU, these products deliver reliable communication performance for demanding industrial applications.
Why Choose ICP DAS USA for DeviceNet?
Conclusion
ICP DAS USA’s automation solution for FOUP stocker systems simplifies the integration of equipment from multiple vendors while ensuring reliable and stable operation in semiconductor manufacturing environments.
With a broad portfolio of I/O modules, gateways, and industry-specific automation solutions, ICP DAS USA helps manufacturers connect, control, and monitor diverse systems through reliable industrial communication protocols. These solutions enable secure data exchange and seamless interoperability across modern IIoT environments.
For example, the GW-7663 PROFINET-to-Modbus TCP gateway enables PROFINET-based PLCs to communicate with Modbus TCP devices, while the ECAT-M801 Series EtherCAT multi-axis motion control card supports advanced motion control applications, including robotic systems used in high-precision industrial and research environments.
Beyond standard products, ICP DAS USA offers comprehensive OEM and ODM services, allowing customers to develop customized remote I/O modules and automation solutions tailored to their unique requirements. By working closely with customers, ICP DAS USA helps accelerate digital transformation and build more efficient, connected smart factories.
