The present patent application claims the priority benefit of French patent application FR13/53275 which is herein incorporated by reference.
The present disclosure generally relates to optical inspection systems and, more specifically, to three-dimensional image determination systems intended for the on-line analysis of objects, particularly of electronic circuits.
Optical inspection systems are generally used to verify the sound condition of an object before it is released to the market. They especially enable to determine a three-dimensional image of the object, which may be analyzed to search for possible defects. In the case of an electronic circuit comprising, for example, a printed circuit equipped with electronic components, the three-dimensional image of the electronic circuit may be used, in particular, to inspect the sound condition of the welds of the electronic components on the printed circuit.
An example of a three-dimensional image determination method comprises the acquisition of two-dimensional images of the circuit by digital cameras while images are projected on the circuit.
An embodiment provides an optical inspection system for an electronic circuit comprising sensors of images of the electronic circuit, at least two supports having two portions of the electronic circuit intended to rest thereon, and a device for modifying the position of each support, independently from each other.
According to an embodiment, the electronic circuit comprises a printed circuit, each support being intended to support a lateral edge of the printed circuit.
According to an embodiment, the system comprises a first conveyor capable of transporting the electronic circuit along a first direction, the supports extending parallel to the first direction.
According to an embodiment, the system comprises a second conveyor capable of transporting the image sensors along a second direction, non-parallel to the first direction, and, particularly, perpendicular to the first direction.
According to an embodiment, the device is capable of displacing each support, independently from each other, along a third direction, non-parallel to the first and second directions, and, particularly, perpendicular to the first and second directions.
According to an embodiment, the system comprises a device for locking the electronic circuit portions on the supports.
An embodiment also provides a method of optical inspection of an electronic circuit, at least two portions of the electronic circuit resting on two supports, the method comprising successive acquisitions of images of the electronic circuit by image sensors and the modification of the position of each support, independently from each other, between successive acquisitions.
According to an embodiment, the image sensors are displaced with respect to the electronic circuit at least from a first location to acquire images of a first portion of the electronic circuit to a second location to acquire images of a second portion of the electronic circuit, the supports being displaced to first positions when the image sensors are at the first location and to second positions, different from the first positions, when the image sensors are at the second location.
According to an embodiment, the first portion of the electronic circuit is in the focus area of the image sensors when the supports are in the first positions and the second portion of the electronic circuit is in the focus area of the image sensors when the supports are in the second positions.
According to an embodiment, when the supports are in the first positions, the second positions are determined based on the first positions and on an extrapolation of the shape of the second portion of the electronic circuit.
The foregoing and other features and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings, among which:
For clarity, the same elements have been designated with the same reference numerals in the various drawings and, further, the various drawings are not to scale. In the following description, unless otherwise indicated, terms “substantially”, “approximately”, and “in the order of mean “to within 10%”. Further, only those elements which are useful to the understanding of the present description have been shown and will be described. In particular, the means for conveying the printed circuit and the means for conveying the cameras and the projectors of the optical inspection system described hereafter are within the abilities of those skilled in the art and are not described in detail.
Electronic circuit Card to be inspected is placed on a conveyor 12, for example, a planar conveyor. Conveyor 12 is capable of displacing circuit Card along a direction X, for example, a horizontal direction, from a circuit introduction position to an inspection position and from the inspection position to a circuit recovery position. As an example, conveyor 12 may comprise an assembly of straps and rollers driven by a rotating electric motor, not shown. As a variation, conveyor 12 may comprise a linear motor displacing a carriage having electronic circuit Card resting thereon.
Optical inspection system 10 comprises a device of image projection on circuit Card comprising projectors P, four aligned projectors being, as an example, schematically shown in
Optical inspection system 10 enables to determine a three-dimensional image of electronic circuit Card. In the following description, three-dimensional image or 3D image designates a cloud of points, for example, comprising several million points, of at least a portion of the external surface of the circuit, where each point of the surface is tracked by its coordinates determined with respect to a three-dimensional space reference system. Further, two-dimensional image, or 2D image, is used to designate a digital image acquired by one of cameras C and corresponding to a pixel array. In the following description, unless otherwise indicated, term image refers to a two-dimensional image. Further, in the following description, field of view of projector-camera block 14 designates the portion of real space captured by cameras C during the image acquisition and enabling to determine a three-dimensional image.
Cameras C and projectors P are connected to an image processing computer system 16. Processing system 16 may comprise a computer or a microcontroller comprising a processor and memories of different types including a non-volatile memory having instructions stored therein, the execution thereof by the processor enabling processing system 16 to carry out the desired functions. As a variation, system 16 may correspond to a dedicated electronic circuit or to a combination of a plurality of processing units of different technologies. Processing system 16 is capable of determining a three-dimensional image of circuit Card by projection of images, for example, comprising fringes, on circuit Card to be inspected.
In order for the three-dimensional image to be accurately determined, the two-dimensional images acquired by cameras C should not be blurred. Circuit Card should thus be placed in the focus area of cameras C. To achieve this, circuit Card is brought by conveyor 12 at the level of a reference plane PREF having a known position relative to cameras C.
However, the printed circuit may comprise deformations, particularly a warping or a distortion. The depth of field of cameras C should thus be sufficiently large to ascertain that sharp images of the circuit can be acquired whatever the circuit deformations. This requires using expensive cameras and opto-mechanical systems enabling to obtain a large depth of field.
Further, the dimensions of circuit Card are generally greater than the field of view of cameras C. The determination of a three-dimensional image of the entire circuit Card is then obtained by bringing projector-camera block 14 along direction Y to a plurality of fixed positions relative to circuit Card, images being acquired by cameras C at each position of projector-camera block 14. Such positions are called image acquisition positions hereafter. To decrease the number of images to be acquired, the image acquisition positions are selected so that the portion of circuit Card in the field of view of cameras C at an image acquisition position covers as little as possible the portion of circuit Card in the field of view of cameras C at the next image acquisition position.
However, if the circuit has a convex shape facing projector-camera block 14, for example, locally, portions of circuit Card may remain outside of the fields of view of cameras C at the different image acquisition positions. It is thus necessary to provide a partial overlapping of the acquired images of the portions of circuit Card by cameras C at two successive image acquisition positions. This increases the duration of an operation of determining the three-dimensional image of the entire circuit Card.
Further, the cameras are arranged with respect to the projectors in order not to receive the direct reflection of the incident beams projected by the projectors on the circuit. To achieve this, a minimum angle should generally be provided between the optical axes of the cameras and the optical axes of the associated projectors. This angle is determined by considering that the circuit is flat. This angle is determined by different contradictory parameters. To decrease the mechanical bulk and improve the radiometric balance, it is desirable for this angle to be as small as possible. However, to avoid a dazzling of the cameras and improve the system accuracy, it is desirable for this angle to be as large as possible.
However, if circuit Card has a domed shape, the beams emitted by the projectors may be deviated with respect to the case where the circuit is flat and may reach cameras C. The determination of the angles between the optical axes of the cameras and the optical axes of the associated projectors may be difficult if the previously-described constraints and the possible deformations of circuit Card are desired to be taken into account.
Thus, an object of an embodiment is to overcome all or part of the disadvantages of previously-described optical inspection systems.
Another object of an embodiment is to compensate for the deformations of electronic circuits during an image acquisition by the cameras of the optical inspection system.
Another object of an embodiment is to decrease the depth of field of the cameras.
Another object of an embodiment is to decrease the overlapping of the visual fields of the cameras to two successive image acquisition positions.
Another object of an embodiment is to bring the cameras closer to the projectors.
Another object of an embodiment is to decrease the duration of an operation of determining a complete three-dimensional image of an electronic circuit.
Another object of an embodiment is for the correction method to be compatible with a use at an industrial scale.
According to an embodiment, the determination of a three-dimensional image of the entire circuit Card, possibly except for the edges of circuit Card which may not be intended to be inspected by optical inspection system 10, is performed by displacing projector-camera block 14 along direction Y at a plurality of positions relative to circuit Card, images being acquired by the cameras at each image acquisition position.
As an example, the general field of view of projector-camera block 14 has been schematically shown by two dotted lines R1, R2. Reference Cardi designates the portion of electronic circuit Card, a three-dimensional image of which may be determined by processing system 16 based on the images acquired by cameras C for a given image acquisition position of projector-camera block 14.
The three-dimensional images of an integer N of circuit portions Cardi, where i is an integer varying from 1 to N, should be acquired to determine the three-dimensional image of the entire circuit Card. As an example, N typically varies from 1 to 10. Each circuit portion Cardi comprises an initial edge BIi, which is the leftmost edge of
According to an embodiment, to decrease the number of images to be acquired to determine the three-dimensional image of the entire circuit Card, possibly except for the circuit edges, the image acquisition positions are selected so that the overlapping between circuit portion Cardi in the field of view of projector-camera block 14 at an image acquisition position and circuit portion Cardi+1 in the field of view of projector-camera blocks 14 at the next image acquisition position is smaller than 20% of the length of circuit portion Cardi measured along direction Y, and preferably substantially zero. This means that final edge BFi of circuit portion Cardi substantially corresponds to initial edge BIi+1 of the next circuit portion Cardi+1.
System 10 comprises a device 20, not shown in
According to an embodiment, device 20 comprises two supports 22, 24 which substantially extend along direction X. Support 22 comprises an upper end 23 which may bear against a lateral edge 26 of circuit Card and support 24 comprises an upper end 25 which may bear against the opposite lateral edge 28 of circuit Card. Ends 23 and 25 may contain straps, not shown, enabling to convey the electronic circuits. As an example, each end 23, 25 comprises a planar portion which extends across the entire width of circuit Card, along direction X. As an example, a strip of conveyor 12, not shown in
Device 20 is capable of modifying height Z1 of the top of support 22 and height Z2 of the top of support 24 independently from each other. As an example, device 20 comprises two motors 30, 32, for example, step-by-step rotary electric motors, each rotating a cam 34, 36 around an axis parallel to direction Y. Each cam 34, 36 is, for example, a cam with an external profile having a portion of the associated support 22, 24 resting thereon. Height Z1 depends on the angular position of cam 34 and height Z2 depends on the angular position of cam 36. Motors 30, 32 are controlled by processing system 16. As a variation, linear actuators which directly displace supports 22, 24 along direction Z may be used.
Device 20 further comprises a device 38 for locking edge 26 of circuit Card on support 22 and a device 40 for locking edge 28 on support 24. Each locking device 38, 40 follows the displacement of the associated support 20, 22 along direction Z. Locking systems 38, 40 are controlled by processing system 16 to maintain edges 26, 28 of circuit Card against supports 22, 24 after circuit Card has been displaced along direction X all the way to the position where the image acquisitions are performed. As an example, each locking device 38, 40 corresponds to a clamp actuated by an actuator controlled by processing system 16.
At step 50, processing system 16 determines the sharpness of images of circuit portion Cardi which would be acquired by cameras C of projector-camera block 14. According to an embodiment, step 50 is implemented with no acquisition of two-dimensional images of circuit portion Cardi by cameras C. According to a first example, a distance measurement device, for example, a laser range-finder, may be provided and connected to processing system 16. The processing system determines what the sharpness of images of circuit portion Cardi acquired by cameras C from the measurements provided by the range-finder would be. According to a second example, step 50 is implemented by the acquisition of two-dimensional images of circuit portion Cardi by image acquisition devices other than cameras C. According to another embodiment, step 50 is implemented by the acquisition of two-dimensional images of circuit portion Cardi by cameras C of projector-camera bock 14. Processing system 16 can then determine a three-dimensional image of circuit portion Cardi of the circuit. Processing system 16 determines whether circuit portion Cardi clearly appears on the two-dimensional images acquired by cameras C by analysis of the two-dimensional images or on determination of the three-dimensional image. In particular, processing system 16 is capable of determining whether circuit portion Cardi is partly or totally located in the focus area of cameras C, before the first sharp plane of cameras C or after the last sharp plane of cameras C. The method carries on at step 52.
At step 52, processing system 16 determines whether the sharpness of the two-dimensional images acquired by cameras C or which would be acquired by cameras C is sufficient to determine a three-dimensional image at the desired accuracy. If all or part of portion Cardi does not sharply appear on the pictures acquired or to be acquired by cameras C, the method carries on at step 54.
At step 54, processing system 16 determines heights Z1 and Z2 to be provided so that the entire circuit portion Cardi sharply appears on the images acquired or to be acquired by cameras C.
As an example, first circuit portion Card1 is close to edge 26, which has a known position. Indeed, edge 26 is initially maintained in reference plane PREF, which is part of the focus area of cameras C. In this case, height Z2 is modified so that final edge BF1 of circuit portion Card1 is taken back into reference plane PREF. The new value of height Z2 is for example determined based on the position of edge BF1 relative to plane PREF determined by analysis of the range-finder measurements, based on the images acquired by the image acquisition devices other than cameras C, on the images acquired by cameras C, and/or during the determination of the 3D image of circuit portion Card1.
As an example, for a circuit portion Cardi, edge BIi is located in plane PREF or at least in the focus area of cameras C after the settings of heights Z1 and Z2 at the previous cycle. In this case, heights Z1 and Z2 are modified so that initial edge BIi is maintained in reference plane PREF and that final edge BFi is taken back into reference plane PREF. The new values of height Z1 and Z2 are determined based on the position of edge BFi relative to plane PREF determined by analysis of the range-finder measurements, on the images acquired by the image acquisition devices other than cameras C, on the images acquired by cameras C, and/or during the determination of the 3D image of circuit portion Cardi. The method carries on at step 56.
At step 56, motors 30 and 32 are actuated by processing system 16 to take the tops of supports 22 and 24 respectively up to heights Z1 and Z2. The method carries on at step 50.
At step 52, if the entire portion Cardi sharply appears on the images acquired or to be acquired by cameras C, the method carries on at step 57.
At step 57, two-dimensional images of circuit portion Cardi are acquired by cameras C of projector-camera block 14 and processing system 16 determines a three-dimensional image of circuit portion Cardi of the circuit. However, if, at step 50, two-dimensional images have already been acquired by cameras C and a three-dimensional image has already been determined, step 57 is not present. If, at step 50, two-dimensional images have already been acquired by cameras C but there has been no determination of a three-dimensional image, the three-dimensional image is determined at step 57. The method carries on at step 58.
At step 58, processing system 16 determines the new values of heights Z1 and Z2 so that the entire circuit portion Cardi+1 sharply appears on the images which will be acquired by cameras C at the next position of projector-camera bock 14.
As an example, for a circuit portion Cardi, edge BIi is substantially located in plane PREF or at least in the focus area of cameras C after the settings of heights Z1 and Z2 at the previous cycle. In this case, heights Z1 and Z2 may be modified so that initial edge BIi+1 of portion Cardi+1, which substantially corresponds to final edge BFi of circuit portion Cardi, is maintained in reference plane PREF and that final edge BFi+1 of portion Cardi+1 is taken back into reference plane PREF. Since no image of circuit portion Cardi+1 has been acquired yet, the new values of heights Z1 and Z2 may be determined by extrapolation from the general shape of portion Cardi, for example, considering that circuit portion Cardi+1 has substantially the same shape as circuit portion Cardi, taking into account the curvature variation of the previous circuit portions Cardi, Cardi−1, Cardi−2, . . . , taking into account the profiles of the identical electronic circuits previously measured or by instantaneous measurement of circuit portion Cardi to be inspected, or by combination of these solutions. The method carries on at steps 60 and 62, which may be carried out independently from each other, for example, successively or at least partly simultaneously.
At step 60, motors 30 and 32 are actuated by processing system 16 to displace supports 22 and 24 to the new values of the heights, respectively Z1 and Z2. The method carries on at step 50.
At step 62, projector-camera block 14 is displaced to the next position along direction Y for the determination of the three-dimensional image of circuit portion Cardi+1. Step 62 may be carried out at least partly simultaneously at step 58 and/or at step 60. The method carries on at step 50.
It is generally necessary to provide a step of calibrating optical inspection system 10 and particularly cameras C. This may be performed by the use of tools adapted according to the parameters to be calibrated. As an example, in
According to an embodiment, calibration tool 64 is connected to support 22 and calibration tool 66 is connected to support 24. As an example, calibration tool 66 is rigidly assembled to support 24 and displaces parallel to support 24 along direction Z. As an example, support 22 comprises a finger 70 capable of bearing against calibration tool 64 to pivot calibration tool 64 according to an inclination which depends on height Z1 of support 22. Resilient return means, not shown, may be provided to permanently bring calibration tool 64 back to a position of equilibrium. This embodiment advantageously enables to use device 20 to displace calibration tools 64, 66. It is then no longer necessary to provide dedicated actuation means.
Specific embodiments have been described. Various alterations and modifications will occur to those skilled in the art. In particular, although previously-described system 10 is capable of implementing a method of determining a three-dimensional image of an object by image projection on the object, it should be clear that the three-dimensional image determination method may be different, for example, by implementing methods of analysis of images acquired by the cameras with no image projection onto the circuit.
Number | Date | Country | Kind |
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1353275 | Apr 2013 | FR | national |
Filing Document | Filing Date | Country | Kind |
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PCT/FR2014/050853 | 4/9/2014 | WO | 00 |