Delivered Blackbox TLC Solution to Mitigate Supplier Obsolescence

Customer Background

Our client, a global leader in semiconductor equipment manufacturing, was experiencing frequent supply-chain disruptions due to the obsolescence of third-party temperature limit controllers. These legacy systems were often shipped with firmware locks, preventing any form of tuning or customization. This led to operational inflexibility and service delays, particularly for critical process tools like deposition and etching systems.

Project Overview

The objective was to design and develop a blackbox temperature limit controller to replace unreliable, locked-out supplier solutions. The controller needed to monitor critical temperature thresholds and execute safety interlocks in real time. The solution had to be plug-compatible, configurable, and long-term supportable—ensuring seamless integration into existing tool environments without depending on external OEM vendors.

Challenges Faced

Hardware Obsolescence: Frequent EOL (End-of-Life) notices for off-the-shelf controllers disrupted manufacturing support.

Firmware Locks: OEM firmware restrictions prevented reconfiguration or calibration.

Application Criticality: The controller was used on deposition and etching tools—requiring high accuracy and strict interlock reliability.

Environmental Stress: Units needed to perform reliably under elevated temperatures and continuous tool operations.

Our Comprehensive Approach

Requirements Engineering

Collaborated with the customer to define functional specifications, including input/output mapping, sensor interface protocols, fault response logic, and control thresholds
Captured mechanical boundary conditions and tool-level integration constraints to ensure drop-in replacement capability.

System Architecture & Hardware Design

Developed a detailed system block diagram outlining sensing, logic control, and interlock mechanisms.
Created schematic designs, selected robust components, and developed multi-layer PCBs with strict thermal and noise considerations.
Designed custom enclosure housing, ensuring mechanical protection, easy mounting, and thermal management.

Firmware Development

Built firmware from the ground up to handle real-time temperature monitoring, alarm thresholds, safety logic, and logging.
Designed the logic to support sensor calibration, fault diagnostics, and over-temperature interlock triggering.

Testing & Qualification

Executed a multi-level qualification plan including:
- Bench-level functional testing
- System integration with live tools
- Elevated temperature and reliability testing for long-term stress validation
Performed board-level diagnostics, including I/O response time, analog input calibration, and interlock trigger timing.

Deployment & Support

Produced pilot batch units, preloaded with final firmware versions for plug-and-play deployment.
Delivered engineering documentation and integrated firmware update utilities for future support.