Inspection system and method for bond detection and validation of surface mount devices using sensor fusion and active perception
First Claim
1. A method for inspecting circuits by performing feature level sensor fusion using an active perception process, comprising the steps of:
- using a gross inspection station to determine global circuit features and rapidly detect defects in the global circuit features, the gross inspection station configured to receive data from at least two infrared (IR) sensors and a vision sensor, using a fine inspection station to generate local circuit features, fusing the local circuit features using active perception;
performing data level sensor fusion at the gross inspection station by determining a ratio of the outputs of the two IR sensors thus canceling effectively the effect of sensor emissivity and improving data reliability;
using an off-line learning process at the gross inspection station, the off-line learning process configured to perform feature ordering for active perception, the feature ordering performed using a distinguishability measure and the processing time required to extract each feature;
evaluating a cost function for each feature;
using a perceptron classifier at the gross inspection station to classify defects;
computing a degree of certainty index at the gross inspection station the degree of certainty index representing a confidence level associated with a classification result;
performing feature level sensor fusion at the fine inspection station using an active perception process, the active perception process configured to fuse information from the IR and vision sensors and also configured to minimize the processing time by controlling the information gathering process by aligning features optimally so that features requiring less processing time and providing greater distinguishability between failure classes are listed first in the ordering scheme;
using an on-line learning process at the fine inspection station, the on-line learning process configured to adapt the active perception process to changes and disturbances by fine tuning the feature ordering; and
monitoring the system changes and disturbances using a measure called feature effectiveness that optimizes on-line the feature utilization in the classification task.
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Accused Products
Abstract
A hybrid surface mount component inspection system which includes both vision and infrared inspection techniques to determine the presence of surface mount components on a printed wiring board, and the quality of solder joints of surface mount components on printed wiring boards by using data level sensor fusion to combine data from two infrared sensors to obtain emissivity independent thermal signatures of solder joints, and using feature level sensor fusion with active perception to assemble and process inspection information from any number of sensors to determine characteristic feature sets of different defect classes to classify solder defects.
43 Citations
15 Claims
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1. A method for inspecting circuits by performing feature level sensor fusion using an active perception process, comprising the steps of:
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using a gross inspection station to determine global circuit features and rapidly detect defects in the global circuit features, the gross inspection station configured to receive data from at least two infrared (IR) sensors and a vision sensor, using a fine inspection station to generate local circuit features, fusing the local circuit features using active perception;
performing data level sensor fusion at the gross inspection station by determining a ratio of the outputs of the two IR sensors thus canceling effectively the effect of sensor emissivity and improving data reliability;
using an off-line learning process at the gross inspection station, the off-line learning process configured to perform feature ordering for active perception, the feature ordering performed using a distinguishability measure and the processing time required to extract each feature;
evaluating a cost function for each feature;
using a perceptron classifier at the gross inspection station to classify defects;
computing a degree of certainty index at the gross inspection station the degree of certainty index representing a confidence level associated with a classification result;
performing feature level sensor fusion at the fine inspection station using an active perception process, the active perception process configured to fuse information from the IR and vision sensors and also configured to minimize the processing time by controlling the information gathering process by aligning features optimally so that features requiring less processing time and providing greater distinguishability between failure classes are listed first in the ordering scheme;
using an on-line learning process at the fine inspection station, the on-line learning process configured to adapt the active perception process to changes and disturbances by fine tuning the feature ordering; and
monitoring the system changes and disturbances using a measure called feature effectiveness that optimizes on-line the feature utilization in the classification task. - View Dependent Claims (2, 3, 4, 5)
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6. A system for inspecting circuits by performing feature level sensor fusion using an active perception process, comprising:
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means for determining global circuit features and rapidly detecting defects in the global circuit features, the determining means configured to receive data from at least two infrared (IR) sensors and a vision sensor;
means for generating local circuit features;
means for fusing the local circuit features using active perception;
means for performing data level sensor fusion at the gross inspection station by determining a ratio of the outputs of the two IR sensors thus canceling effectively the effect of sensor emissivity and improving data reliability;
means for performing an off-line learning process at the gross inspection station, the off-line learning process configured to perform feature ordering for active perception the feature ordering performed using a distinguishability measure and the processing time required to extract each feature;
means for evaluating a cost function for each feature;
means for classifying defects using a perceptron classifier at the gross inspection station;
means for computing a degree of certainty index at the gross inspection station the degree of certainty index representing a confidence level associated with a classification result;
means for performing feature level sensor fusion at the fine inspection station using an active perception process, the active perception process configured to fuse information from the IR and vision sensors and also configured to minimize the processing time by controlling the information gathering process by aligning features optimally so that features requiring less processing time and providing greater distinguishability between failure classes are listed first in the ordering scheme, means for using an on-line learning process at the fine inspection station the on-line learning process configured to adapt the active perception process to changes and disturbances by fine tuning the feature ordering; and
means for monitoring the system changes and disturbances using a measure called feature effectiveness that optimizes on-line the feature utilization in the classification task. - View Dependent Claims (7, 8, 9, 10)
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11. A computer readable medium having a program for inspecting circuits by performing feature level sensor fusion using an active perception process the medium comprising logic for performing the steps of:
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using a gross inspection station to determine global circuit features and rapidly detect defects in the global circuit features the gross inspection station configured to receive data from at least two infrared (R) sensors and a vision sensor;
using a fine inspection station to generate local circuit features;
fusing the local circuit features using active perception;
performing data level sensor fusion at the gross inspection station by determining a ratio of the outputs of the two IR sensors, thus canceling effectively the effect of sensor emissivity and improving data reliability;
using an off-line learning process at the gross inspection station the off-line learning process configured to perform feature ordering for active perception, the feature ordering performed using a distinguishability measure and the processing time required to extract each feature;
evaluating a cost function for each feature;
using a perceptron classifier at the gross inspection station to classify defects;
computing a degree of certainty index at the gross inspection station, the degree of certainty index representing a confidence level associated with a classification result;
performing feature level sensor fusion at the fine inspection station using an active perception process, the active perception process configured to fuse information from the IR and vision sensors and also configured to minimize the processing time by controlling the information gathering process by aligning features optimally so that features requiring less processing time and providing greater distinguishability between failure classes are listed first in the ordering scheme;
using an on-line learning process at the fine inspection station, the on-line learning process configured to adapt the active perception process to changes and disturbances by fine tuning the feature ordering; and
monitoring the system changes and disturbances using a measure called feature effectiveness that optimizes on-line the feature utilization in the classification task. - View Dependent Claims (12, 13, 14, 15)
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Specification