Application Background:
A wafer sorting machine is a key piece of equipment in semiconductor manufacturing, used to automatically classify and bin wafers according to predefined quality standards. It evaluates wafers based on visual inspection, electrical test results and other criteria, then automatically separates good wafers from the rest. The system typically integrates an advanced vision inspection unit and automated material handling, ensuring high inspection accuracy and high throughput at the same time. Wafer sorters are widely used in IC, optoelectronic and other electronic component production lines, helping increase automation, reduce human error and maintain consistent final product quality and reliability.

Solution Overview:

• Main controller: Siemens PLC

• Process segment: Wafer classification and sorting

• Project I/O configuration: 3RS-PN2 + 916DI + 916DO + 18AI

• Annual usage: Approx. 300,000 I/O points

Project Description:
This project adopts a Siemens S7-1200 PLC as the core controller, combined with multiple I/O modules to form an efficient and reliable wafer sorting control system. The PLC receives signals from various field sensors, including photoelectric sensors, displacement sensors, temperature sensors and decision results from the vision inspection system, to monitor wafer surface quality and environmental conditions in real time. Based on this data, the PLC precisely controls laser scanning devices, transfer robots and sorting actuators, achieving high-speed inspection, automatic binning and accurate unloading.

Through this intelligent monitoring and control system, the wafer sorter significantly improves sorting efficiency while ensuring the accuracy and repeatability of inspection results, providing strong support for stable mass production.

Application Advantages:

• Supports multiple wafer sizes and tray formats, offering flexible panel options;

• Modular I/O combination allows easy expansion according to line takt and station needs;

• High-precision inspection and stable sorting reduce manual intervention and missed defects;

• Centralized PLC management enables recipe-based process control and historical data logging for full quality traceability.