Patent Grant
7599075
1. Field of the Invention
Embodiments of the present invention generally relate to techniques for inspecting objects and, more particularly, to an automated optical inspection technique and system utilizing multiple objectives per camera.
2. Description of the Related Art
Automated optical inspection (AOI) systems are used to inspect a wide variety of objects, such as semiconductor wafers and printed circuit boards (PCBs), for defects. Such systems typically utilize one or more image acquisition or “microscope” modules to capture images that cover the entire surface area of the object that is to be inspected. These images are then fed to some type of computer system for processing using various types of algorithms design to identify defects in the object.
Typically, each image scanning module includes an illumination source to illuminate the portion of the article under inspection, some type of front lens assembly (referred to as an objective) that guides light back to an image capture device, such as a charge-coupled device (CCD) camera. One common type of AOI system utilizes a scanning approach, whereby the inspected article is divided into (e.g., horizontal) strips and a single image scanning module is moved back and forth, collecting images for successive strips on each pass. This approach may work well in some applications, for example, where the total surface area being inspected is relatively small and the total processing throughput requirements are relatively low. However, for applications requiring higher throughput, such as web inspection, which may have relatively large surface areas to inspect (e.g., with horizontal dimensions of several feet), a scanning approach may take too much time.
These higher throughput applications typically require multiple image scanning modules, with a camera and objective per module, allowing multiple images to be processed in parallel leading to increased throughput. In general, the number of image scanning modules utilized depends on various system requirements, as well as the individual image scanning module specifications. For example, the number of image scanning modules required is generally proportional to the total surface area to inspect and the required throughput of the system, and inversely proportional to the field of view (FOV) of each objective and pixel rate of the camera. Unfortunately, high resolution cameras with high pixel rates tend to be expensive, often costing many times more than the objectives. As a result, while systems utilizing multiple image scanning modules may achieve higher throughput than systems that scan with a single module, the cost of multiple high resolutions cameras may render such systems cost prohibitive.
Accordingly, a need exists for a system and technique for automated optical inspection resulting in high throughput relative to conventional scanning systems and low cost relative to systems that utilize a single objective per camera.
The present invention generally provides systems and methods for automated optical inspection utilizing multiple objectives per camera.
One embodiment provides an automated optical inspection system. The system generally includes at least one camera and at least one image scanning module. The image scanning module generally includes, a plurality of objective modules arranged to each have a field of view covering a portion of the article during inspection and an image selection mirror mechanism movable to sequentially transfer images from the field of view (FOV) from each objective module to the camera.
Another embodiment provides an automated optical inspection system for inspecting article. The system generally includes at least one camera and at least one image scanning module. The image scanning module generally includes a plurality of objective modules with fields of view covering a portion of the article during inspection and an image selection mirror mechanism movable to sequentially transfer images from the fields of view to the camera. For some embodiments, the objective modules in each image scanning module may be arranged in a circle or an arc, allowing a distance between the objective modules and an illumination source to be substantially constant. Arranging the modules in an arc may also allow a single mirror mechanism to be used for each objective module. The image scanning modules may be positioned relative to each other so that the FOVs of the objective modules cover the entire inspected article width with at least some partial overlap.
Another embodiment provides a method for optically inspecting an article with at least one image scanning module. The image scanning module generally includes a camera, scanning mechanism, illumination source, and multiple objective modules. The method generally includes sequentially transferring images of portions of the article within fields of view (FOVs) of the multiple objective modules to the camera. The scanning mechanism may be manipulated to sequentially direct light from the illumination source to the individual objective modules and images from the individual objective modules to the corresponding camera shared by the objective modules. The images captured with the shared camera may be processed to detect defects in the article.
So that the manner in which the above recited features of the present invention can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to embodiments, some of which are illustrated in the appended drawings. It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
The present invention generally provides apparatus and techniques for automated optical inspection (AOI) utilizing image scanning modules with multiple objectives for each camera. A scanning mechanism includes optical components to sequentially steer optical signals from each of the multiple objectives to the corresponding camera. By freezing individual field of view images, motion accuracy requirements of the translation system used to move the inspected article may be greatly reduced when compared to scanning systems, such as “flying spot” laser scanning systems or systems based on constant illumination and linear imaging devices, for example, charge coupled devices (CCDs) or time delay and integrate (TDI) CCDs that require accurate motion control.
Various control functions of the system 100, such as control of the conveyer 120, may be performed by a controller 150. The controller 150 may include any suitable computing and interface equipment, such as computers or programmable logic controllers (PLCs) with video capture cards to perform the control steps described herein. In some cases, an operator may control various aspects of the system 100 (e.g., conveyer speed, detection parameters, and the like) via a user interface, such as a touch screen 140 (or a conventional keyboard/mouse and display) coupled with the controller 150. In some cases, the controller 150 may display inspection results/reports or one or more images for manual inspection (e.g., by the operator) on the screen 140.
The controller 150 may also control the image scanning modules 110 to synchronize the capture of images with the movement of the article 130 under the image scanning modules 110. In general, the collective fields of view (FOVS) of the image scanning modules 110 should cover the entire article with acquired images. To account for possible inaccurate motion of the article 130 and finite accuracy of relative position of objectives modules used in the image scanning modules 110, the objective modules and image scanning modules 110 may be arranged to ensure at least some partial overlap between each.
For some embodiments, the system 100 may include a sensor (not shown) or some other means, such as detectable markings, to detect the location of the article 130 relative to the image scanning modules 110 to allow coarse synchronization between the mirror position and image acquisition commands to the article location. Increasing the accuracy of synchronization of image acquisition with conveyor movement may reduce the amount of overlap between modules and increase the system efficiency.
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Further, for some embodiments, the objective lenses 211 may be infinitely conjugate (i.e., the objective lenses 211 may be located a focal length f away from the inspected article 130) so that the rays coming from the inspected article 130 are propagating parallel to each other after passing through the objective lenses 211, and do not diverge. This may allow a relatively long distance between an objective lens 211 and the tube lens 205 which, in conjunction with the objective lens 211, creates the image of the FOV onto the camera 206.
If reflected illumination is used (e.g., if the inspected article 130 is reflective), the image selection mirror 208 may also be used to illuminate the field of view (FOV) 224 for each objective 202 by directing light from the illumination source 209 to the FOV 224. By aligning the objective modules 202 in arcs 112, a constant distance between each objective module 202 and the illumination source 209 may be preserved. By preserving this constant distance, it is possible to image light from the illumination source onto an aperture of each objective module 202 (and fulfill the condition for Kohler illumination) which may provide uniform illumination of the objective FOV of each objective module 202.
For some embodiments, the illumination source 209 may be a pulsed source, such as a flash lamp, pulsed LED or laser. For other embodiments, the illumination source 209 may be a continuous illumination source such as an arc lamp, filament lamp, continuous LED array or continuous laser. If the mirrors 208 scan continuously a light pulse can be used to freeze the image. The image may also be frozen in an effort to remove or reduce the influence of vibrations of the article or system. If continuous illumination is used, electronic or mechanical shutters for the camera 206 may also be used to freeze the image. If the mirrors 208 scan and settle at each FOV, the light integration by the camera can extend as long as the mirror is stable and as long as needed to integrate a suitable amount light.
For some embodiments, multiple images can be acquired for each FOV at different illumination and imaging configurations. The multiple images may be acquired simultaneously in the case of a continuous image selection mirror and short pulses of light, or consecutively in time in the case of scan and settle with long exposures. Various combinations of multiple illumination levels, imaging wavelengths, darkfield and brightfield, reflection and transmission levels, polarization states, focal planes, phase contrast, Diffractive Interference Contrast (DIC) and the like may be used to achieve greater contrast and enhance defect detection. These microscope illumination and imaging parameters may be varied to enhance the contrast of the defects relative to the background.
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Those skilled in the art will recognize that many different arrangements of optical components (lenses, mirrors, optical relays, and prisms) may be used to divert the optical path from multiple objective modules 202 to a single camera 206. Various corrective mechanisms, such as speckle reduction modules, spatial filters, auto-focus modules, and the like, may also be utilized. For some embodiments, rather than using mirrors, prisms (not shown) may be used to divert the optical path from an objective module 202 to the camera 206. However, prism based systems may suffer from wavelength dispersion and optical distortion at the edges of the FOV. Therefore, prism based systems may include optical components to compensate for such dispersion and distortion.
Those skilled in the art will also recognize that the exact optical properties of the illustrated components will vary with different embodiments, for example, to meet the needs of a particular application (e.g., to achieve a desired resolution or throughput). As an example, however, for some embodiments, the objective lenses 211 may have a rectangular field of view between 3 mm×3 mm to 8 mm×8 mm, an NA in the range of 0.03-0.06, a focal length in the range of 70-125 mm, and an approximate magnification in the range of 1-2. The camera 206 may have any number of pixels, and, for some embodiments, may be in a common range between 600×400 to 2000×2000 pixels, with a pixel size in the range of 7-15 micron. The illuminating source 207 may generate broadband light in the visible wavelength range and may be controlled to ensure the detected light (reflected by or transmitted through the inspected article 130) saturates the camera 206, which may be any suitable type of image sensing device, such as a CCD camera or CMOS sensor. Those skilled in the art will recognize that multiple wavelengths may also be utilized. Utilizing components with such properties, an image scanning module 110 may have an image acquisition time (the time required to obtain an image from each objective) in the range of 5-50 us. Those skilled in the art will recognize that greater resolution may be achieved by varying any number of the parameters described above, for example, by increasing the NA of the lenses, decreasing the field of view, and/or increasing the pixel size of the camera. Further, for some embodiments, in an effort to improve throughput, multiple cameras may be utilized per image scanning module (e.g., at least one camera for each arc).
In order to ensure full coverage of the inspected article 130, the total number of objective modules 202 may, at a minimum, be the total width of the article 130 to be inspected (WI) divided by the individual FOV 224 of each objective module 202 minus an overlap area between FOVs (to allow for some tolerance in objective placement and/or movement of the article 130). As shown in
As illustrated, the inspected region 132 may be conceptually divided into adjacent columns 134, with any four adjacent columns (e.g., 1341-1344) being covered by a FOV 224 of an objective module 202 in a different arc 112. For example, FOVs of objective modules 2021 and 2022 in arcs 112, and 1122, respectively, of the image scanning module 110A may cover first and second columns 1341 and 1342. Similarly, FOVs of objective modules 2023 and 2024 in arcs 1123 and 1124, respectively, of the image scanning module 110B may cover third and fourth columns 1343 and 1344. The remaining objectives 202 in each arc 112 may be arranged in a similar manner to ensure each column of the entire width WP of region 132 is covered, with at least some overlap.
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Another example of an alternative arrangement of objective modules 202, illustrated in
For some embodiments, an objective arrangement may include partially overlapping arcs of objective modules, with the radius of each arc and distance between the objective mirror and front lens for the corresponding objective modules varied to maintain a consistent optical path length. Maintaining a consistent optical path length may allow a common optical design (utilizing common optical components) to be used in the multiple arcs.
Those skilled in the art will also recognize that, while arranging objectives 202 in arcs 112 may facilitate uniform illumination by preserving a constant distance between the illuminating source and objective lens, objective modules may be arranged in other patterns, such as linear rows of objective modules 202 offset from each other to provide at least partially overlapping coverage of an inspected portion of an article.
In the objective arrangements described herein, the distance between the objective lenses 211 and the camera 206 and illumination source 209 may be relatively large when compared to conventional microscopes used for similar purposes. This distance may grow with the number of objectives scanned per camera. As previously described, to enable such long distances, the objective lenses 211 may be infinitely conjugate such that the rays from a single field points are collimated at the exit of the objective lens, or another lens may be put along the optical pass. In some cases, the practical limitations on this distance and hence on the number of objectives and the length of the optical path may come from the field span of the rays (the angular divergence of beams from the extreme field points), which may be limited by the practical size of the image selection mirror.
The operations 600 begin, at step 602, by resetting the scanning mechanism for an image scanning module 110 to direct a field of view of a first objective to a corresponding camera. For example, referring to
At step 608, a loop of operations 610-614, to be performed for each of the remaining objectives in the module, is entered to capture image portions therefrom. At step 610, the scanning mechanism is adjusted to direct the field of view of the next objective to the camera. At step 612, the field of view is illuminated and, at step 614, the image is captured. Once the operations 610-614 have been performed for each of the remaining objectives, the operations may return, to step 602, to again reset the scanning mechanism to direct the field of view of the first objective to the camera, in preparation of scanning the row again, to capture images of the portion of the inspected article 130 that has now traveled between the objectives. In an effort to ensure the entire portion of the article to be inspected is scanned, this cycle of operations may be performed synchronized with the article translation mechanism. In other words, the image selection mirror and translation mechanism may be controlled such that these operations may be performed in the same amount of time it takes for the inspected article is to travel one length of the FOV (the dimension parallel to the media travel direction) minus some pre-determined overlap between the FOV. The amount of this overlap may be determined by the tolerance in the travel of the inspected article.
For some embodiments, in order to detect defects, images from different rows may be pieced or “stitched” together to form a larger, more complete image of the article which is then processed. For other embodiments, however, the individual FOV images obtained from each objective may be sufficient for defect detection. This may be the case when the scale of such a defect allows the entire defect to be contained within a single FOV and the objectives are arranged to ensure the entire width of the inspected article 130 is covered with at least some partial overlap.
In any case, various image processing techniques may be utilized to detect defects based on captured images. For example, captured image portions may be compared against known good images (e.g., stored in a database), against images captured from a known good (or “golden”) article, or “statistical” images with/without defects of interest, or by comparison of one pattern in the article to an identically designed pattern (e.g., a “die to die” or “cell to cell” comparison.
Embodiments of the present invention provide high throughput optical inspection with moderate cost by reducing the number of cameras and illumination sources when compared to conventional multi-microscope systems utilizing a camera and illumination source for each microscope. Further, by freezing individual field of view images, the translation system (e.g., conveyer) motion accuracy requirements may be greatly reduced when compared to scanning systems (e.g., “flying spot laser scanning systems”). Inaccuracies in the coverage of the article by the multiple objectives may also be compensated for by at least partially overlapping fields of view.
While the foregoing is directed to embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.
This application is a continuation of U.S. patent application Ser. No. 11/047,435 filed Jan. 31, 2005 now U.S. Pat. No. 7,355,689, which is herein incorporated by reference in its entirety.
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| Number | Date | Country | |
|---|---|---|---|
| 20080186556 A1 | Aug 2008 | US |
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11047435 | Jan 2005 | US |
| Child | 12099709 | US |
