Panel inspection device having first, second and third mirrors, and method for inspecting a panel
12517337 ยท 2026-01-06
Assignee
Inventors
Cpc classification
G01N21/95
PHYSICS
International classification
Abstract
An inspection device for inspecting a panel, in particular a display, or a PCB, includes a first mirror, a second mirror, a third mirror, and a sensor. The first mirror, the second mirror, and the third mirror are arranged to display a section of the panel to be inspected on the sensor with a magnification factor greater than one. At least two of the group of the first mirror, the second mirror, and the third mirror, have both a first type of curvature, and a remaining mirror has a second type of curvature, opposite to the first type of curvature. The first mirror, the second mirror, and the third mirror form a telecentric system which is telecentric on a panel facing side and/or on a sensor facing side.
Claims
1. An inspection device for inspecting a panel, comprising: a first mirror, a second mirror, a third mirror, and a sensor, wherein the first mirror, the second mirror, and the third mirror are arranged to display a section of the panel to be inspected on the sensor with a magnification factor M, where M>1, and wherein at least two of the group of the first mirror, the second mirror, and the third mirror, have both a first type of curvature, and a remaining mirror has a second type of curvature, opposite to the first type of curvature, and the first mirror, the second mirror, and the third mirror form a telecentric system which is telecentric on a panel facing side and/or on a sensor facing side, wherein: a first vertex of the first mirror, a second vertex of the second mirror, and a third vertex of the third mirror, all lie on a common optical axis; a first aperture of the first mirror, and a third aperture of the third mirror are decentered relative to the common optical axis; and a second aperture of the second mirror remains symmetric, and non-decentered about the common optical axis.
2. The inspection device according to claim 1, wherein the first type of curvature is concave, and the second type of curvature is convex.
3. The inspection device according to claim 1, wherein at least one of the group of the first mirror, the second mirror, and the third mirror, is spherical.
4. The inspection device according to claim 1, wherein the first mirror and the third mirror are aspheric and the second mirror is spherical or aspheric.
5. The inspection device according to claim 1, wherein: the first mirror comprises the first aperture, and the third mirror comprises the third aperture; and the first mirror and the third mirror are arranged so that: the first aperture of the first mirror comprises a first offset with the common optical axis, and the third aperture of the third mirror comprises a third offset with the common optical axis.
6. The inspection device according to claim 1, wherein the second mirror, comprises the second aperture, and wherein a second centre of the second aperture coincides with the common optical axis and a chief ray.
7. The inspection device according to claim 1, wherein; the first mirror has a focal length f.sub.1, the second mirror has a focal length f.sub.2, and the third mirror has a focal length f.sub.3; and |f.sub.1|>|f.sub.2|, |f.sub.1||f.sub.3|, for f.sub.1 of the first mirror, and |f.sub.2|<|f.sub.1|, |f.sub.2|<|f.sub.3|, for f.sub.2 of the second mirror.
8. The inspection device according to claim 1, wherein the sensor comprises a line sensor.
9. The inspection device according to claim 8, wherein the line sensor has a line sensor length of at least 57 mm.
10. The inspection device according to claim 1, wherein a radius R.sub.1 of the first mirror, and a radius R.sub.3 of the third mirror are chosen in a ratio of R.sub.3/R.sub.1 being equivalent to the magnification factor M.
11. The inspection device according to claim 10, wherein a Seidel aberration of an image of the panel detected by the sensor is reduced according to an arrangement of the first mirror with an object distance D between the panel and the first mirror equal to or on the order of R.sub.1.
12. The inspection device according to claim 1, further comprising: a first planar fold mirror and/or a second planar fold mirror, wherein the first planar fold mirror is arranged before the first mirror, and wherein the second planar fold mirror is arranged after the third mirror.
13. The inspection device according to claim 1, further comprising: a camera unit to which the first mirror, the second mirror, and the third mirror are mounted, and further comprises X/Y-stage being adapted to receive the panel, wherein the X/Y-stage is movable in an X/Y-plane in accordance with a main plane of the panel and relative to the camera unit, so that images of different sections of the panel can be captured depending on a relative position of the X/Y-stage relative to the camera unit.
14. The inspection device of claim 2, wherein the first mirror and the third mirror are of the first type of curvature, the second mirror is of the second type of curvature, the inspection device is arranged so light coming from the section of the panel is reflected towards the first mirror, light from the first mirror the light is reflected to the second mirror, light from the second mirror is reflected towards the third mirror, light from the third mirror is reflected towards the sensor, and an image of the section of the panel is displayed on or reflected towards the sensor so the image of the section is displayed in the sensor with a magnification factor M.
15. A method of inspecting a panel, comprising the steps of: providing a first mirror, a second mirror, a third mirror, and a sensor, wherein the first mirror, the second mirror, and the third mirror have a combined magnification factor M greater than one and are arranged to convey an image of a section of the panel to be inspected on the sensor, and wherein at least two of the group of the first mirror, the second mirror, and the third mirror, have both a first type of curvature, and the remaining mirror has a second type of curvature, opposite to the first type of curvature; capturing the image of the section of the panel with the sensor; and visually displaying the section of the panel on the sensor with a magnification factor M greater than one, wherein: a first vertex of the first mirror, a second vertex of the second mirror, and a third vertex of the third mirror, all lie on a common optical axis; a first aperture of the first mirror, and a third aperture of the third mirror are decentered relative to the common optical axis; and a second aperture of the second mirror remains symmetric, and non-decentered about the common optical axis.
16. The method of claim 15, wherein the panel comprises a display or a printed circuit board.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
DETAILED DESCRIPTION
(10) The following definitions are useful for interpreting terms applied to features of the embodiments disclosed herein, and are meant only to define elements within the disclosure.
(11) As used within this disclosure, inspection device may refer to a piece of equipment or a mechanism designed to serve checking or testing of a specific object. The object may be a panel. The term panel may refer to a thin, and usually rectangular board. In particular, the panel may be a display, a PCB, or any other flat board which may require to be checked with a machine vision application. The features or structures to be detected on the panel may be as small as a few m or even smaller.
(12) The term mirror may refer to a polished or smooth surface (as of glass) that forms images by reflection.
(13) The term sensor may refer to a device that responds to a physical stimulus, in this case light, and transmits a resulting impulse, in this case, electronic signals. Here, the sensor may transmit an electronic impulse for measurement of the panel. Depending on its dimensions, the sensor may be called a surface sensor when having the shape of an area, or may be called a line sensor when having the shape of a line, which may be a pixel line.
(14) As used within this disclosure, machine vision refers to the technology and methods used to provide imaging-based automatic inspection and analysis for such applications as automatic inspection, process control, and robot guidance, usually in industry.
(15) As used within this disclosure, the expression to display a section of the panel to be inspected on the sensor with a magnification factor M greater than one may refer to an enlarged representation of a part or section of the panel on the sensor. The enlarged representation, or section of the panel, may correspond to the sensor. If the sensor is a surface sensor the shape of the section of the panel may be an area in XY-plane. If the sensor is a line sensor the shape of the section of the panel being displayed may be a line, or a pixel line.
(16) As used within this disclosure, the term curvature may refer to a measure or amount of curving. A curved surface, or a curved mirror in this case may reflect an image of the section of the panel on the sensor either enlarged or reduced in size. There may be two types of curvature: convex and concave. For example, in the embodiments described below two mirrors may be concave or convex wherein the third mirror may have the opposite type of curvatures being convex or concave, respectively.
(17) As used within this disclosure, the expression concave curvature may refer to an object being hollowed or rounded inward like the inside of a bowl. The expression convex curvature may refer to an object being curved or rounded outward like the exterior of a sphere. As an example, the first mirror, and the third mirror may be concave and the second mirror may be convex.
(18) As used within this disclosure, the term spherical may refer to a globular body describing an object that is bounded by a surface consisting of all points at a given distance from a point constituting its center. For example, for the inspection device according to an exemplary embodiment, at least one of the group of the first mirror, the second mirror, and the third mirror, may be spherical.
(19) As used within this disclosure, the term aspherical may refer to a form departing slightly from the spherical form, especially in order to correct spherical aberration.
(20) As used within this disclosure, the expression symmetric may refer to having, involving, or exhibiting symmetry. In particular, each of the mirrors may be symmetric to a central point (or vertex). The term aperture may here refer to a limitation of a mirror so that only a defined area of the mirror reflects the light.
(21) As used within this disclosure, the system stop defines the numerical aperture of the system. According to an exemplary embodiment of the inspection device a system stop is located directly on or close to the second mirror.
(22) As used within this disclosure, the term telecentric may refer to an objective or imaging system by which the image magnification is independent of the object's distance or position in the field of view. Telecentric lenses produce an orthographic view of the object, which is desired in many machine vision applications.
(23) As used within this disclosure, the expression planar folded mirror may refer to an optical system having mirrors arranged to bend the beam to change the common optical path to reduce the size of the system.
(24) Reference will now be made in detail to embodiments of the present invention, examples of which are illustrated in the accompanying drawings. Wherever possible, the same reference numbers are used in the drawings and the description to refer to the same or like parts. Exemplary embodiments of the present invention described herein address specific machine vision applications where a strict control of chromatic aberrations is essential. As shown in
(25) The exemplary embodiments produce a diffraction limited image of the panel 180 in machine vision applications. The panel 180, is inspected with high resolution. A broad wavelength spectrum may be applicable to inspect different features of the object. By using only mirrors longitudinal and transverse colour defects are avoided. Based on a so called Offner approach or Offner system (see U.S. Pat. No. 3,748,015, entitled Unit Power Imaging Catoptric Anastigmat), aberrations may be reduced or disappear, and a magnification range may be extended as well by using an additional third mirror 103. The aberrations may be formally deduced from the so-called Seidel formalism. Using a special arrangement of the three mirrors, almost any of the Seidel aberrations can be made zero or may remain very small. Higher aberrations may be corrected by appropriate aspherization of the mirrors. In particular, the Petzval sum can be kept close to zero by choosing appropriate radii of the mirrors.
(26) In order to inspect the larger areas of the object simultaneously, line sensors may be used which may be, for example, up to 82 mm long, or longer. For example, the line sensor may have a length of 57 mm with 16 K pixels and a 3.5 m pixel size. The panel 180 to be inspected may be moved perpendicular to a line axis of the scanner to provide continuous scanning.
(27) Using mirrors, the longitudinal and lateral chromatic aberrations may be significantly reduced as compared with a telecentric lens made of glass elements. In general, the shapes of the first mirror 101, the second mirror 102, and the third mirror 103 may be chosen freely in order to appropriately magnify the section 182 of the panel 180. The first mirror 101 may be aspherical or may be spherical. The third mirror 103 may be aspherical or may be spherical. The second mirror 102 may be spherical or may be aspherical. One or more of the mirrors may also have special shapes, for example but not limited to a hyperbolic shape or a parabolic shape. For example, the first mirror 101 and the third mirror 103 aspherical, and the second mirror 102 may be spherical or aspherical.
(28) The first mirror 101 and the third mirror 103 may be aspherical concave, and the second mirror 102 may be spherical or aspherical convex and may have the highest refractive power of the three mirrors. A first vertex of the first mirror 101, a second vertex of the second mirror 102, and a third vertex of the third mirror 103 may all lie on a common optical axis, wherein a first aperture of the first mirror 101, and a third aperture of the third mirror 103 may be decentred relative to the optical axis, and wherein a second aperture of the second mirror 102 remains symmetric, and non-decentred about the optical axis.
(29) The first mirror 101, the second mirror 102, and the third mirror 103 may all have their vertex (or their center of the radius of curvature, respectively) on the same common axis, hereinafter referred to as the optical axis. In order to avoid vignetting, the object (and hence the image in turn) may be shifted perpendicularly to the optical axis. In addition, the apertures of the first mirror 101 and the third mirror 103 are decentred while their vertex is still lying on the optical axis. The aperture of the second mirror 102 remains symmetric (non-decentred) about the optical axis.
(30) A ray emanating from the shifted on-axis point of the object that hits the center of the system stop defines the (on axis) chief ray 140m of the system. In a conventional rotationally symmetric optical system, this on-axis chief ray 140m coincides with the optical axis. When the object is shifted, the chief ray 140m may not coincide with the optical axis.
(31) The first mirror 101 may have a first decentred aperture, and the third mirror 103 may have a third decentred aperture, wherein the first mirror 101 and the third mirror 103 are arranged so that the first aperture of the first mirror 101 has a first offset with the common optical axis, and the third aperture of the third mirror 103 has a third offset with the common optical axis.
(32) The first aperture may be decentred, so that the first aperture has a first offset in relation to the common optical axis. The first offset may be formed between the common optical axis and the on axis chief ray 140m on the first mirror 101. Further, the third aperture may be decentred, so that the third aperture has a third offset in relation to the common optical axis. The third offset may be formed between the common optical axis and the on axis chief ray 140m on the third mirror 103.
(33) Alternatively, the first mirror 101 may have a first decentred aperture, and the third mirror 103 has a third decentred aperture, wherein the first mirror 101 and the third mirror 103 are arranged so the chief ray 140m may not intersect the vertex of the first mirror 101 or the vertex of the third mirror 103, respectively.
(34) An exemplary embodiment of the inspection device includes the second mirror 102 with a second aperture, where a second centre of the second aperture coincides with the common optical axis and with the chief ray 140m.
(35) According to an exemplary embodiment of the inspection device, the first mirror 101 has a focal length f.sub.1, the second mirror 102 has a focal length f.sub.2, and the third mirror 103 has a focal length f.sub.3, and wherein |f.sub.1|>|f.sub.2|, |f.sub.1||f.sub.3|, for f.sub.1 of the first mirror 101, and |f.sub.2|<|f.sub.1|, |f.sub.2|<|f.sub.3|, for f.sub.2 of the second mirror 102.
(36) The expression focal length may refer to the distance of a focus from the surface of a lens or curved mirror. As usual, the focal length may be defined in similar way for mirrors with curvatures like the focal length is defined for lens types being converging or diffusion lenses.
(37) According to an exemplary embodiment of the inspection device, the first mirror 101, the second mirror 102, and the third mirror 103 form a telecentric system that is telecentric on the side of the panel 180 and/or on the side of the sensor 130.
(38) The inspection device may be telecentric towards the panel 180 (object) and/or the sensor 130 (image). A telecentric system has the entrance pupil and/or the exit pupil at infinity. In particular, the imaging system may be telecentric towards the object (panel 180). The telecentricity towards the object may be ensured by proper placing of the system stop. However, the imaging system may be telecentric towards the panel 180 and towards the sensor 130. The imaging system may be telecentric towards the sensor 130 only.
(39) According to an exemplary embodiment of the inspection device, a radius R.sub.1 of the first mirror 101, a radius R.sub.2 of the second mirror 102, and a radius R.sub.3 of the third mirror 103 result in a field curvature being equal to zero or close to zero.
(40) The expression field curvature may refer to a lens aberration where the sharpest focus of the lens is on a curved surface in the image space rather than a plane. Objects in the center and edges of the field are usually not in focus simultaneously. By choosing the radii of the first mirror 101, the second mirror 102, and the third mirror 103 to result in small or even zero field curvature, this type of aberration may be avoided. The so-called Petzval-Sum may be nearly completely corrected with an appropriate choice of the radii of the mirrors.
(41) According to an exemplary embodiment of the inspection device the radius R.sub.1 of the first mirror 101, and the radius R.sub.3 of the third mirror 103 are chosen in a ratio of R.sub.3/R.sub.1 being equivalent or close to the magnification factor M.
(42) Generally, an aspherization of the mirrors may allow for correcting off-axis image errors. Further, the aspherization of the mirrors may help to correct the residual error of the spherical aberration. However, the spherical aberration may already be well corrected by the choice of radii and distances.
(43) In a preferred embodiment, the first mirror 101 with a radius of R.sub.1 may be located at a distance D being equal to or on the order of R.sub.1=2f.sub.1 relative to the panel 180, i.e., the object, or the section 182 of the panel 180, respectively. However, the object distance D may vary. A feasible value for the variation of the object distance may be obtained from the assumption that the rays emerging from the first mirror 101 towards the second mirror 102 should not diverge. Likewise, the rays emerging from the second mirror 102 and hitting the third mirror 103 should not converge. In case the rays from the first to the second mirror 102 diverge, the second mirror 102 should be larger than the first mirror 101, and a decentring of the apertures to avoid vignetting becomes very difficult. The same holds true if the rays from the second mirror 102 towards the third mirror 103 converge. A reasonable threshold for the object distance variation is hence that the rays are parallel either from the first to the second mirror 102 or from the second to the third mirror 103. The two limiting cases are depicted in the lower part of
(44)
(45) For example, in a design for minimizing in residual Seidel-aberrations, the object is located in a distance D=R.sub.1. In this specific setup, the spherical aberration at the first mirror is zero and the overall spherical aberration is very small. The second mirror 102 may be smaller than the first mirror 101 and the third mirror 103. Alternatively, the spherical aberration may be corrected by choosing the appropriate conical constants.
(46) The overall distortion may be correctable even if the mirror apertures are decentred. Specifically the distortion arising from the second mirror 102 may be entirely corrected if the aperture lies very close to the mirror or is exactly on the second mirror 102. Further, astigmatism may be corrected if the mirror apertures are not decentred. However, the astigmatism may also be correctable to a high degree if the mirror apertures are decentred.
(47) As shown in
(48) The inspection device may further include a camera unit to which the first mirror 101, the second mirror 102, and the third mirror 103 are mounted, and further includes an X/Y-stage adapted to receive the panel 180, where the X/Y-stage is movable in an X/Y-plane in accordance with a main plane of the panel 180 and relative to the camera unit, so that images of different sections 182 of the panel 180 may be captured depending on the relative position of the X/Y-stage relative to the camera unit. In particular, the camera unit may be stationary and the panel 180 may be movable.
(49) The expression X/Y-stages may refer to a mechanical system generally constraining a motion in one plane, and here to a plane defined by extending in an X/Y-plane. That is, with the X/Y-stage the imaging system may allow for displaying a panel 180 being too large for the sensor 130 with one take or image. By shifting the relative position of the panel 180 and the camera unit comprising the first, second, and third mirrors 101-103, with every chosen relative position a different part or a different section of the panel 180 may be displayed on the sensor 130.
(50) The inspection device illumination may be coupled into the optical path. In particular, the illumination may be coupled into the optical path between a last mirror (which may be the first mirror 101 or the first planar fold mirror 111) and the panel 180 to be inspected. For coupling the illumination into the optical path, a semi-transparent mirror may be used.
(51) A wavefront aberration may be expressed by Fringes-Zernike also showing non-rotationally symmetrical components on the sensor 130 axis. An aspherical formula is given by Eq. 3 applying to the height of the sagitta z parallel to the optical axis over the height h perpendicular to the optical axis:
(52)
where r0 [mm] refers to the radius of curvature of the vertex, k is the conical constant, and a4, a6, . . . , a16 are aspherical coefficients.
(53) A definition of the Zernike-Fringe polynomial Pi for the coefficient Zi may be given in accordance with Tab. 1B-Tab. 4B, shown below, where p is the normalized pupil coordinate and A the azimuth angle. Eq. 4 applies to the wavefront error W in the exit pupil:
(54)
The normalized pupil coordinate p has no unit and can assume values between 0 and 1. The wavefront error Wand thus the coefficients Ziare given in units of wavelength.
(55)
(56) The optical path 140 may be free of any shading or vignetting which could occur between the first planar fold mirror 111 and the second mirror 102, so the optical path 140 has a first free passage 145a between the first planar fold mirror 111 and the second mirror 102. Further, the optical path 140 may have a second free passage 145b between the first mirror 101 towards the third mirror 103.
(57) Due to a magnification factor of 1 or higher and a greater extension of the panel 180 compared to the sensor 130, at any moment in time the area which may be inspected may only be a section 182 (a part) of the complete panel 180.
(58) According to the exemplary embodiment shown in
(59) TABLE-US-00001 TABLE 1A Optical data for embodiment No 1, magnification 2x, double telecentric Focal length f Close to (double telecentric) magnification 2X Numerical aperture 0.1 Sensor size 23 23 mm.sup.2 (area sensor) Surface conical No Element Radius r0 constant distance Tilt 0 Object plane 75.000 1 Fold infinity 45 mirror 1 0.0000 93.667 2 EVENASPH M1 194.5213 2.6474 97.1048 0 3 STANDARD M2 130.1010 0.0000 0.0000 0 4 STO infinity 0.0000 189.753 0 5 EVENASPH M3 383.461 3.2386 230.000 0 6 Fold mirror 2 infinity 0.0000 254.139 45 7 Image plane Surface No a4 a6 a8 a10 a12 a14 a16 2 4.7273E08 1.9567E13 4.3868E18 0 0 0 0 5 6.6868E09 2.5486E14 0 0 0 0 0
(60) For a specific embodiment of
(61) TABLE-US-00002 TABLE 1B Zernike coefficients for embodiment 1 Z 2 0.000: (p) * COS (A) Z 3 0.039: (p) * SIN (A) Z 4 0.013: (2p{circumflex over ()}2 1) Z 5 0.041: (p{circumflex over ()}2) * COS (2A) Z 6 0.000: (p{circumflex over ()}2) * SIN (2A) Z 7 0.000: (3p{circumflex over ()}2 2) p * COS (A) Z 8 0.021: (3p{circumflex over ()}2 2) p * SIN (A) Z 9 0.084: (6p{circumflex over ()}4 6p{circumflex over ()}2 + 1) Z 10 0.000: (p{circumflex over ()}3) * COS (3A) Z 11 0.008: (p{circumflex over ()}3) * SIN (3A) Z 12 0.021: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * COS (2A) Z 13 0.000: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * SIN (2A) Z 14 0.000: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * COS (A) Z 15 0.001: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * SIN (A) Z 16 0.001: (20p{circumflex over ()}6 30p{circumflex over ()}4 + 12p{circumflex over ()}2 1) Z 17 0.009: (p{circumflex over ()}4) * COS (4A) Z 18 0.000: (p{circumflex over ()}4) * SIN (4A) Z 19 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * COS (3A) Z 20 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * SIN (3A) Z 21 0.001: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * COS (2A) Z 22 0.000: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * SIN (2A) Z 23 0.000: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * COS (A) Z 24 0.000: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * SIN (A) Z 25 0.000: (70p{circumflex over ()}8 140p{circumflex over ()}6 + 90p{circumflex over ()}4 20p{circumflex over ()}2 + 1)
(62) Spherical aberration of the lowest order (Z9) and some astigmatism (Z5 and Z12) and KOMA (Z8) may occur. Other aberrations are corrected, and the Zernike coefficients starting from Z13 on are virtually zero.
(63)
(64) According to the inspection device shown in
(65) TABLE-US-00003 TABLE 2A Optical data for embodiment No 2, magnification 2x, object side telecentric Focal length f 918 mm (object side telecentric) magnification 2X Numerical aperture 0.1 Sensor size 23 23 mm.sup.2 Surface conical No Element Radius r0 constant distance Tilt 0 Object plabe 198.433 2 EVENASPH 224.635 3.484 111.533 0 M1 3 STANDARD 141.933 0.0000 0.0000 0 M2 4 STO 0.0000 166.148 0 5 EVENASPH 377.369 3.403 500.000 0 M3 6 Image plane Flche a4 a6 a8 a10 a12 a14 a16 2 3.9369E08 4.7331E13 1.3131E17 0 0 0 0 5 7.1357E09 3.3049E14 0 0 0 0 0
(66) For a specific embodiment of
(67) TABLE-US-00004 TABLE 2B Zernike coefficients for embodiment 2 Z 2 0.000: (p) * COS (A) Z 3 0.004: (p) * SIN (A) Z 4 0.007: (2p{circumflex over ()}2 1) Z 5 0.037: (p{circumflex over ()}2) * COS (2A) Z 6 0.000: (p{circumflex over ()}2) * SIN (2A) Z 7 0.000: (3p{circumflex over ()}2 2) p * COS (A) Z 8 0.001: (3p{circumflex over ()}2 2) p * SIN (A) Z 9 0.011: (6p{circumflex over ()}4 6p{circumflex over ()}2 + 1) Z 10 0.000: (p{circumflex over ()}3) * COS (3A) Z 11 0.001: (p{circumflex over ()}3) * SIN (3A) Z 12 0.038: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * COS (2A) Z 13 0.000: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * SIN (2A) Z 14 0.000: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * COS (A) Z 15 0.002: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * SIN (A) Z 16 0.000: (20p{circumflex over ()}6 30p{circumflex over ()}4 + 12p{circumflex over ()}2 1) Z 17 0.011: (p{circumflex over ()}4) * COS (4A) Z 18 0.000: (p{circumflex over ()}4) * SIN (4A) Z 19 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * COS (3A) Z 20 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * SIN (3A) Z 21 0.001: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * COS (2A) Z 22 0.000: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * SIN (2A) Z 23 0.000: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * COS (A) Z 24 0.000: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * SIN (A) Z 25 0.000: (70p{circumflex over ()}8 140p{circumflex over ()}6 + 90p{circumflex over ()}4 20p{circumflex over ()}2 + 1)
(68) Spherical aberration is better corrected compared to Tab. 1B (or
(69) Further,
(70) In a third exemplary embodiment, the magnification factor M=2.8, showing an extension to larger magnifications. A numerical aperture (on the object side) is 0.15 and an image size chosen is 2436 mm.sup.2, which corresponds to a full frame sensor. The system is double telecentric.
(71) Assuming a blue LED at 460 nm we obtain a resolution of about 300 lp/mm on the object side. The optical data of the embodiment shown in
(72) TABLE-US-00005 TABLE 3A Optical data for embodiment No 3, magnification 2.8x, double telecentric Focal length f Close to (double telecentric) magnification 2.8X Numerical aperture 0.15 Sensor size 24 36 mm.sup.2 Surface conical No Element Radius r0 constant distance Tilt 0 Object plane Plan 90.000 1 Fold mirror 1 0.0000 80.138 45 2 EVENASPH 204.490 4.820 102.245 0 M1 3 EVENASPH 152.727 1.374 0.0000 0 M2 4 STO 0.0000 273.785 0 5 EVENASPH 558.388 0.338 200.000 0 M3 6 Fold mirror 2 0.0000 614.46 45 7 Image plane Flche a4 a6 a8 a10 a12 a14 a16 2 7.2939E08 2.1298E12 1.1481E16 3.359E21 3.484E26 0 0 3 7.3134E08 3.5623E12 1.0794E13 3.946E16 0 5 4.9104E10 9.9568E16 2.1724E22 1.588E25 0
(73) TABLE-US-00006 TABLE 3B Zernike coefficients for embodiment 3 Z 2 0.000: (p) * COS (A) Z 3 0.013: (p) * SIN (A) Z 4 0.005: (2p{circumflex over ()}2 1) Z 5 0.076: (p{circumflex over ()}2) * COS (2A) Z 6 0.000: (p{circumflex over ()}2) * SIN (2A) Z 7 0.000: (3p{circumflex over ()}2 2) p * COS (A) Z 8 0.011: (3p{circumflex over ()}2 2) p * SIN (A) Z 9 0.003: (6p{circumflex over ()}4 6p{circumflex over ()}2 + 1) Z 10 0.000: (p{circumflex over ()}3) * COS (3A) Z 11 0.026: (p{circumflex over ()}3) * SIN (3A) Z 12 0.170: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * COS (2A) Z 13 0.000: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * SIN (2A) Z 14 0.000: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * COS (A) Z 15 0.015: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * SIN (A) Z 16 0.010: (20p{circumflex over ()}6 30p{circumflex over ()}4 + 12p{circumflex over ()}2 1) Z 17 0.058: (p{circumflex over ()}4) * COS (4A) Z 18 0.000: (p{circumflex over ()}4) * SIN (4A) Z 19 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * COS (3A) Z 20 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * SIN (3A) Z 21 0.003: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * COS (2A) Z 22 0.000: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * SIN (2A) Z 23 0.000: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * COS (A) Z 24 0.005: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * SIN (A) Z 25 0.019: (70p{circumflex over ()}8 140p{circumflex over ()}6 + 90p{circumflex over ()}4 20p{circumflex over ()}2 + 1)
(74) A fourth embodiment specifically uses a large line sensor, which lies perpendicularly to the symmetry plane of the three mirrors. For an exemplary fourth embodiment, the line can be as long as 82 mm. This is a typical large line sensor used in line scan applications. The line may consist of only one pixel row, or it can be a TDI sensor with up to 256 separate pixel lines. The pixel size of the sensor is typically 5 m.
(75) According to the inspection device under the fourth embodiment, the focal length is 793 mm, and the system is telecentric on the object side. The magnification factor M=1.67, a numerical aperture (on the object side) is 0.09. The resolution attained on the object side is about 170 lp/mm. The optical data of the embodiment is given in Table 4A and the Zernike coefficients are listed in Table 4B.
(76) TABLE-US-00007 TABLE 4A Optical data for embodiment No 4, magnification 1.67x, object side telecentric Focal length f 793 mm (object side telecentric) magnification 1.67X Numerical aperture 0.09 Sensor size Line sensor length 82 mm Surface conical No Element Radius r0 constant distance Tilt 0 Object plane Plan 80.000 1 Fold mirror 1 0.0000 86.613 45 2 EVENASPH M1 184.098 0.286 92.05 0 3 STO 1.69 0 4 Standard M2 108.375 0.0000 112.22 0 5 EVENASPH M3 256.58 0.041 95.00 0 6 Fold mirror 2 0.0000 218.53 45 7 Image plane Flche a4 a6 a8 a10 a12 a14 a16 2 4.581E09 9.631e15 3.044e18 1.189e20 2.359e24 0 0 5 1.571e09 3.939e14 4.601e18 7.649e23 0 0 0
(77) TABLE-US-00008 TABLE 4B Zernike coefficients for embodiment 4 Z 2 0.000: (p) * COS (A) Z 3 0.007: (p) * SIN (A) Z 4 0.006: (2p{circumflex over ()}2 1) Z 5 0.008: (p{circumflex over ()}2) * COS (2A) Z 6 0.000: (p{circumflex over ()}2) * SIN (2A) Z 7 0.000: (3p{circumflex over ()}2 2) p * COS (A) Z 8 0.003: (3p{circumflex over ()}2 2) p * SIN (A) Z 9 0.007: (6p{circumflex over ()}4 6p{circumflex over ()}2 + 1) Z 10 0.000: (p{circumflex over ()}3) * COS (3A) Z 11 0.000: (p{circumflex over ()}3) * SIN (3A) Z 12 0.026: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * COS (2A) Z 13 0.000: (4p{circumflex over ()}2 3) p{circumflex over ()}2 * SIN (2A) Z 14 0.000: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * COS (A) Z 15 0.001: (1Op{circumflex over ()}4 12p{circumflex over ()}2 + 3) p * SIN (A) Z 16 0.000: (20p{circumflex over ()}6 30p{circumflex over ()}4 + 12p{circumflex over ()}2 1) Z 17 0.003: (p{circumflex over ()}4) * COS (4A) Z 18 0.000: (p{circumflex over ()}4) * SIN (4A) Z 19 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * COS (3A) Z 20 0.000: (5p{circumflex over ()}2 4) p{circumflex over ()}3 * SIN (3A) Z 21 0.001: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * COS (2A) Z 22 0.000: (15p{circumflex over ()}4 20p{circumflex over ()}2 + 6) p{circumflex over ()}2 * SIN (2A) Z 23 0.000: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * COS (A) Z 24 0.000: (35p{circumflex over ()}6 60p{circumflex over ()}4 + 30p{circumflex over ()}2 4) p * SIN (A) Z 25 0.000: (70p{circumflex over ()}8 140p{circumflex over ()}6 + 90p{circumflex over ()}4 20p{circumflex over ()}2 + 1)
(78)
(79) Within the inspection device 100, the sensor 130, the first mirror 101, the second mirror 102, the third mirror 103, the first planar fold mirror 111, and the second planar fold mirror 112 may be fixedly arranged to each other. By a movement in X-direction 141, and by a movement in Y-direction 142 of the panel 180 relative to the sensor 130, the section 182 changes its position on the panel 180. This may allow for a stepwise scan of the panel 180 in order to achieve a whole inspection image of the panel 180. The whole inspection image may include images of the sensor 130 for different (or shifted in Y-/Y-direction) positions for the section 182 on the panel 180.
(80)
(81)
(82)
(83) The camera unit 410 has a camera housing 411 in which the sensor 130, the first mirror 101, the second mirror 102, the third mirror 103, the first planar fold mirror 111, and the second planar fold mirror 112 are arranged. The camera housing 411 may, in particular, include a core housing 411a for the first mirror 101, the second mirror 102, the third mirror 103. Further, the camera housing 411 may have an ocular tube 411b for the sensor 130 and may include an end tube 411c having an opening 411d. A vision spot of the end tube 411c and/or the opening 411d, respectively, is directed perpendicularly to the panel 180 and may coincide with the position of the section 182 from which an image may be taken. There may be a certain distance between the opening 411d and the panel 180, or the section 182, respectively. The camera housing 411a, the ocular tube 411b, and the end tube 411b may be fixedly and detachably mounted to each other, so that the sensor 130, the first mirror 101, the second mirror 102, the third mirror 103, the first planar fold mirror 111, and the second planar fold mirror 112 are fixedly arranged to each other.
(84) The illumination unit 420 may include an illumination housing 421, a light source 422, and a fold mirror 423. The light source 422 and the fold mirror 423 may be fixedly arranged in the illumination housing 421. A beam splitter 424 may be arranged inside the camera housing 411, and between the first planar fold mirror 111 and the opening 411d. However, functionally, the beam splitter 424 may be regarded as a component of the illumination unit 420. Light being generated by the light source 422 may be reflected from the fold mirror 423 towards the beam splitter 424 which then reflects the light at least partially towards the section 182 to illuminate it. The illuminated section 182 of the panel 180 then may reflect light back towards the beam splitter 424 which in turn may at least partially pass the light towards the first planar fold mirror 111, so that eventually an image of the section 182 may be captured by the sensor 130 at the end of the optical path 140 (see
(85) The X-/Y-stage of the inspection device 100 may be adapted to receive the panel 180 and allow for the relative movement of the panel 180 relative to the opening 411d, or the camera unit 410, respectively. By this relative movement in X-direction 141 and/or Y-direction 142, the panel 180 may be stepwise scanned so images of different sections 182 corresponding to different positions of the panel 180 relative to the camera unit 410 may be captured. The computer 430 may then assemble the captured images for an evaluation of the complete panel 180.
(86)
(87)
(88)
(89)
(90)
(91) A sensor 130, a first mirror 101, a second mirror 102, a third mirror 103, are provided, as shown by block 710. At least two of the group of the first mirror 101, the second mirror 102, and the third mirror 103, have both a first type of curvature, and the remaining mirror has a second type of curvature, opposite to the first type of curvature. The first mirror 101, the second mirror 102, and the third mirror 103 are arranged to convey a section 182 of the panel 180 to be inspected on the sensor 130 with a magnification factor M greater than one, as shown by block 720. An image of the section 182 of the panel 180 is captured with the sensor 130, as shown by block 730. The section 182 of the panel 180 on the sensor 130 is displayed with a magnification factor M greater than one, as shown by block 740.
(92) It will be apparent to those skilled in the art that various modifications and variations can be made to the structure of the present invention without departing from the scope or spirit of the invention. In view of the foregoing, it is intended that the present invention cover modifications and variations of this invention provided they fall within the scope of the following claims and their equivalents.