Fast high-accuracy multi-dimensional pattern inspection

• US 6,985,625 B1
• Filed: 11/10/2003
• Issued: 01/10/2006
• Est. Priority Date: 11/26/1997
• Status: Expired due to Term

• Current Assignee: Cognex Corporation
• Original Assignee: Cognex Corporation
• Inventors: Wallack, Aaron, Silver, William, Wagman, Adam
• Primary Examiner(s): MARIAM, DANIEL G
• Application Number:
  US10/705,564
• Time in Patent Office: 792 Days
• Field of Search: 382/141, 382/151, 382/181, 382/190, 382/195, 382/197, 382/199, 382/284, 382/291
• US Class Current: 382/195
• CPC Class Codes: G06T 7/75 involving models
• CPC Class Codes: G06V 10/24 Aligning, centring, orientation detection or correction of the image
• CPC Class Codes: G06V 10/7515 Shifting the patterns to accommodate for positional errors

Abstract

A method and apparatus are provided for identifying differences between a stored pattern and a matching image subset, where variations in pattern position, orientation, and size do not give rise to false differences. The invention is also a system for analyzing an object image with respect to a model pattern so as to detect flaws in the object image. The system includes extracting pattern features from the model pattern; generating a vector-valued function using the pattern features to provide a pattern field; extracting image features from the object image; evaluating each image feature, using the pattern field and an n-dimensional transformation that associates image features with pattern features, so as to determine at least one associated feature characteristic; and using at least one feature characteristic to identify at least one flaw in the object image. The invention can find at least two distinct kinds of flaws: missing features, and extra features. The invention provides pattern inspection that is faster and more accurate than any known prior art method by using a stored pattern that represents an ideal example of the object to be found and inspected, and that can be translated, rotated, and scaled to arbitrary precision much faster than digital image re-sampling, and without pixel grid quantization errors. Furthermore, since the invention does not use digital image re-sampling, there are no pixel quantization errors to cause false differences between the pattern and image that can limit inspection performance.

Claims

1. A method for forming chains of edgelets, the edgelets being disposed within a two-dimensional array, each edgelet having a position and a direction, the method comprising:

for each edgelet, providing a data structure including data slots for storing;

edgelet position, edgelet direction, a right link to a right-neighboring edgelet, and a left link to a left-neighboring edgelet;

for each edgelet at a position in the two-dimensional array, examining neighboring positions in two phases so as to determine which neighboring positions contain a neighboring edgelet which can be connected to the edgelet at the position, a first phase for identifying a right-neighboring edgelet, and a second phase for identifying a left-neighboring edgelet, each phase including examination of an equal number of different neighboring positions; and

for each edgelet, storing from the first phase one of a right link and a null link in a first data slot of the data structure of the edgelet, and storing from the second phase one of a left link and a null link in a second slot of the data structure of the edgelet, thereby forming at least one chain of edgelets.

2. The method of claim 1, wherein each phase includes examination of four neighboring positions.

3. The method of claim 1, wherein each phase includes examination of the different neighboring positions in a particular order.

4. The method of claim 3, wherein the particular order is dependent upon the direction of the edgelet at the position in the two-dimensional array.

5. The method of claim 4, wherein the direction of the edgelet falls within east and north-east directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the first phase is:

north, west, north-west, north-east.

6. The method of claim 5, wherein the first neighboring edgelet found is deemed to be the left neighbor.

7. The method of claim 4, wherein the direction of the edgelet falls within north-east and north directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the first phase is:

west, north, north-west, south-west.

8. The method of claim 7, wherein the first neighboring edgelet found is deemed to be the right neighbor.

9. The method of claim 4, wherein the direction of the edgelet falls within east and north-east directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the second phase is:

south, east, south-east, south-west.

10. The method of claim 9, wherein the first neighboring edgelet found is deemed to be the left neighbor.

11. The method of claim 4, wherein the direction of the edgelet falls within north-east and north directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the second phase is:

east, south, south-east, north-east.

12. The method of claim 11, wherein the first neighboring edgelet found is deemed to be the right neighbor.

13. The method of claim 4, wherein the direction of the edgelet falls within a rotation of east and north-east directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the first phase is the rotation of:

north, west, north-west, north-east.

14. The method of claim 13, wherein the first neighboring edgelet found is deemed to be the left neighbor.

15. The method of claim 4, wherein the direction of the edgelet falls within a rotation of north-east and north directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the first phase is the rotation of:

west, north, north-west, south-west.

16. The method of claim 15, wherein the first neighboring edgelet found is deemed to be the right neighbor.

17. The method of claim 4, wherein the direction of the edgelet falls within a rotation of east and north-east directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the second phase is the rotation of:

south, east, southeast, south-west.

18. The method of claim 17, wherein the first neighboring edgelet found is deemed to be the left neighbor.

19. The method of claim 4, wherein the direction of the edgelet falls within a rotation of north-east and north directions from the position of the edgelet in the two-dimensional array, and consequently the particular order of examination of the different neighboring positions in the second phase is the rotation of:

east, south, south-cast, north-east.

20. The method of claim 19, wherein the first neighboring edgelet found is deemed to be the right neighbor.

21. The method of claim 3, wherein each phase includes examination of the different neighboring positions in a particular order that favors orthogonal neighbors over diagonal neighbors.

22. The method of claim 3, wherein each phase includes examination of the different neighboring positions in a particular order so as to provide a chain having a stair-step pattern for boundaries not aligned with grid axes of the two-dimensional array.

23. The method of claim 1, further comprising:

performing a consistency check for each edgelet in the at least one chain so-formed.

24. The method of claim 23, wherein performing a consistency check includes:

verifying that the right neighbor of an edgelet'"'"'s left neighbor is the edgelet itself.

25. The method of claim 24, wherein when the consistency check fails, both links are replaced by a null link.

26. The method of claim 23, wherein performing a consistency check includes:

verifying that the left neighbor of an edgelet'"'"'s right neighbor is the edgelet itself.

27. The method of claim 26, wherein when the consistency check fails, both links are replaced by a null link.

28. The method of claim 1, wherein the edgelets are disposed such that only one edgelet is disposed within each element of the two-dimensional array.

29. The method of claim 1, wherein the edgelets are disposed such that more than one edgelet is disposed within some elements of the two-dimensional array.

30. The method of claim 29, wherein one edgelet is selected within each element of the two-dimensional array having more than one edgelet.