TWI806201B - Optical inspection system and method - Google Patents
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- G01N21/8851—Scan or image signal processing specially adapted therefor, e.g. for scan signal adjustment, for detecting different kinds of defects, for compensating for structures, markings, edges
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Abstract
Description
本揭露有關於能結合多個檢測站的資訊的光學檢測系統與方法。The present disclosure relates to optical inspection systems and methods that combine information from multiple inspection stations.
一般產品的製造過程中會經過多個製程,為了確保產品的規格符合要求,會設置多個檢測站來檢查產品在各個製程之前或之後是否符合要求。然而,在習知的做法中這些檢測站之間是獨立運作的,如何結合這些檢測站之間的資料,為此領域技術人員所關心的議題。Generally, the manufacturing process of products will go through multiple processes. In order to ensure that the product specifications meet the requirements, multiple inspection stations will be set up to check whether the products meet the requirements before or after each process. However, in the conventional practice, these detection stations operate independently, how to combine the data between these detection stations is a topic of concern to those skilled in the art.
本揭露的實施例提出一種光學檢測系統,包括多個檢測站與電腦系統。每一個檢測站依序對第一產品擷取第一檢測影像並且判斷第一產品是否符合規格要求以產生檢測結果。電腦系統通訊連接至檢測站,用以根據第一檢測影像與檢測結果訓練一機器學習模型。當其中一個檢測站擷取第二產品的第二檢測影像之後,電腦系統根據機器學習模型以及第二檢測影像判斷第二產品在後續的檢測站中是否符合規格要求。如果檢測站判斷第二產品不符合規格要求但電腦系統判斷第二產品在後續的檢測站中符合規格要求,電腦系統繼續後續的製程且不淘汰第二產品。如果檢測站判斷第二產品符合規格要求但電腦系統判斷第二產品在後續的檢測站中不符合規格要求,電腦系統停止後續的製程且淘汰第二產品。Embodiments of the present disclosure provide an optical inspection system, including a plurality of inspection stations and a computer system. Each inspection station sequentially captures a first inspection image of the first product and judges whether the first product meets the specification requirements to generate inspection results. The computer system is communicatively connected to the detection station for training a machine learning model according to the first detection image and detection results. After one of the inspection stations captures the second inspection image of the second product, the computer system judges whether the second product meets the specification requirements in the subsequent inspection station according to the machine learning model and the second inspection image. If the testing station judges that the second product does not meet the specification requirements but the computer system judges that the second product meets the specification requirements at a subsequent testing station, the computer system continues the subsequent manufacturing process without eliminating the second product. If the inspection station judges that the second product meets the specification requirements but the computer system judges that the second product does not meet the specification requirements in subsequent inspection stations, the computer system stops the subsequent manufacturing process and eliminates the second product.
在一些實施例中,檢測站判斷第二產品不符合規格要求但電腦系統判斷第二產品在後續的檢測站中不符合規格要求,電腦系統停止後續的製程且淘汰第二產品。In some embodiments, the inspection station determines that the second product does not meet the specification requirements but the computer system determines that the second product does not meet the specification requirements at subsequent inspection stations, and the computer system stops the subsequent manufacturing process and eliminates the second product.
在一些實施例中,如果檢測站判斷第二產品符合規格要求但電腦系統判斷第二產品在後續的檢測站中符合規格要求,電腦系統繼續後續的製程且不淘汰第二產品。In some embodiments, if the test station determines that the second product meets the specification requirements but the computer system determines that the second product meets the specification requirements at a subsequent test station, the computer system continues the subsequent process without eliminating the second product.
在一些實施例中,上述的機器學習模型為捲積神經網路。In some embodiments, the aforementioned machine learning model is a convolutional neural network.
在一些實施例中,上述的檢測結果包括第一產品在檢測站被檢測到的一瑕疵在第一檢測影像中的位置。電腦系統用以重疊第一檢測影像並根據瑕疵在其餘檢測站中是否依然被判斷為瑕疵來產生訓練資料。In some embodiments, the above-mentioned detection result includes a position of a defect detected by the first product at the detection station in the first detection image. The computer system is used to overlap the first inspection image and generate training data according to whether the defect is still judged as a defect in other inspection stations.
以另一個角度來說,本揭露的實施例提出一種光學檢測方法,適用於多個檢測站。此光學檢測方法包括:透過每一個檢測站依序對第一產品擷取第一檢測影像並且判斷第一產品是否符合規格要求以產生檢測結果;根據第一檢測影像與檢測結果訓練一機器學習模型;當檢測站擷取第二產品的第二檢測影像之後,根據機器學習模型以及第二檢測影像判斷第二產品在後續的檢測站中是否符合規格要求;如果檢測站判斷第二產品不符合規格要求但判斷第二產品在後續的檢測站中符合規格要求,繼續後續的製程且不淘汰第二產品;以及如果檢測站判斷第二產品符合規格要求但判斷第二產品在後續的檢測站中不符合規格要求,停止後續的製程且淘汰第二產品。From another point of view, the embodiments of the present disclosure provide an optical detection method applicable to multiple detection stations. The optical inspection method includes: sequentially capturing first inspection images of the first product through each inspection station and judging whether the first product meets specification requirements to generate inspection results; training a machine learning model according to the first inspection images and inspection results ; After the inspection station captures the second inspection image of the second product, judge whether the second product meets the specification requirements in the subsequent inspection station according to the machine learning model and the second inspection image; if the inspection station judges that the second product does not meet the specification requires but judges that the second product meets the specification requirements in the subsequent testing station, continues the subsequent process without eliminating the second product; Meet the specification requirements, stop the subsequent process and eliminate the second product.
在一些實施例中,上述的光學檢測方法還包括:如果檢測站判斷第二產品不符合規格要求但判斷第二產品在後續的檢測站中不符合規格要求,停止後續的製程且淘汰第二產品。In some embodiments, the above-mentioned optical inspection method further includes: if the inspection station judges that the second product does not meet the specification requirements but determines that the second product does not meet the specification requirements in subsequent inspection stations, stopping the subsequent process and eliminating the second product .
在一些實施例中,上述的光學檢測方法還包括:如果檢測站判斷第二產品符合規格要求但判斷第二產品在後續的檢測站中符合規格要求,繼續後續的製程且不淘汰第二產品。In some embodiments, the above-mentioned optical inspection method further includes: if the inspection station judges that the second product meets the specification requirements but judges that the second product meets the specification requirements in a subsequent inspection station, continue the subsequent process without eliminating the second product.
在一些實施例中,上述的檢測結果包括第一產品在檢測站被檢測到的瑕疵在第一檢測影像中的位置。光學檢測方法還包括:重疊第一檢測影像並根據瑕疵在其餘檢測站中是否依然被判斷為瑕疵來產生訓練資料。In some embodiments, the above-mentioned detection result includes the position of the defect detected by the first product at the detection station in the first detection image. The optical inspection method further includes: superimposing the first inspection image and generating training data according to whether the defect is still judged as a defect in other inspection stations.
透過上述的光學檢測方法與系統,可以結合多個檢測站的資訊,預測瑕疵是否會被放大或是消失,藉此降低過檢率以及漏檢率,提升瑕疵分類檢測率。Through the above-mentioned optical inspection method and system, the information of multiple inspection stations can be combined to predict whether the defect will be enlarged or disappeared, thereby reducing the over-inspection rate and missed-inspection rate, and improving the defect classification and detection rate.
關於本文中所使用之「第一」、「第二」等,並非特別指次序或順位的意思,其僅為了區別以相同技術用語描述的元件或操作。The terms "first", "second" and the like used herein do not specifically refer to a sequence or sequence, but are only used to distinguish elements or operations described with the same technical terms.
圖1是根據一實施例繪示光學檢測系統的示意圖。請參照圖1,光學檢測系統100包括多個檢測站121~123以及一電腦系統140。檢測站121~123可以包含影像感測器以及其他合適的感測器,例如溫度感測器、壓力感測器等,本揭露並不在此限。在這些檢測站121~123的之前或之後,產品110可進行產線上的一或多道製程。這些檢測站121~123依照產線的順序依序對產品110進行檢查,拍攝產品110的檢測影像以判斷產品110是否符合規格要求。舉例來說,檢測站121擷取了檢測影像131,檢測站122擷取了檢測影像132,而檢測站123擷取了檢測影像133。每個檢測站121~123會產生對應的檢測結果,這些檢測結果包含了產品110是否符合規格要求的資訊,也可包含所檢測到的瑕疵在對應檢測影像中的位置資訊。舉例來說,在檢測影像131可發現瑕疵151,在檢測影像132中可發現瑕疵152,而檢測影像133中發現了瑕疵153。也就是說,上述的檢測結果可以包含瑕疵151~153的位置。FIG. 1 is a schematic diagram illustrating an optical detection system according to an embodiment. Please refer to FIG. 1 , the
電腦系統140透過任意有線或無線的方式通訊連接至檢測站121~123。檢測站121~123會將檢測影像131~133以及上述的檢測結果傳送至電腦系統140,電腦系統140據此可以訓練一機器學習模型,此機器學習模型例如為捲積神經網路,在其他實施例中機器學習模型也可以是支持向量機或其他合適的機器學習模型。電腦系統140會重疊這些檢測影像151~153並根據某一個瑕疵在其餘檢測站中是否依然被判斷為瑕疵來產生訓練資料。舉例來說,請參照圖2,在檢測影像131中具有瑕疵151,在檢測影像132中對應的位置上也具有瑕疵152,但是在檢測影像133中對應的位置上並沒有瑕疵,這是因為有一些瑕疵可能會因為後續的製程而消失,例如在產品上的一個刮痕可能因為後續的鍍膜製程而消失。另一方面,在檢測影像133中具有瑕疵153,但在檢測影像131~132中對應的位置上卻沒有瑕疵,這可能是檢測影像151、152中的瑕疵很小(符合規格要求),但是在後續的製程中此瑕疵被放大了,導致了在後續的製程中產生了不符合規格要求瑕疵153。The
上述的訓練資料包含了機器學習模型的輸入與輸出。電腦系統140可以將某一個檢測站之前(包含目前檢測站)產生的檢測影像當作機器學習模型的輸入,而將後續檢測站產生的檢測結果當作機器學習模型的輸出。機器學習模型可以輸出瑕疵的位置,也可以輸出一個數值來表示有沒有不符合規格要求的瑕疵,或者機器學習模型也可以輸出一張影像,其中每個像素的值可用來表示該像素是否為瑕疵。據此,訓練好的機器學習模型便可以根據先前的檢測影像來預測在後續的檢測站中是否會有不符合規格要求的瑕疵(以及位置)。在一些實施例中,這樣的機器學習模型可以有多個,例如一個機器學習模型是根據前n-1個檢測站的檢測影像來預測第n個檢測站的檢測結果,此n可以是任意的正整數,若總共有N個檢測站,則在這樣的實施例中可以有(N-1)個機器學習模型。作者,機器學習模型可以根據第i個檢測站的檢測影像來預測第j個檢測站的檢測結果,其中i、j為正整數且j大於i,例如在一些實施例中j=i+1。或者,在一些實施例中機器學習模型也可以是遞歸神經網路(recurrent neural network,RNN),因此可以把檢測影像依序輸入至遞歸神經網路,每次輸入一個檢測影像都可以對應一個輸出(檢測結果),在這樣的例子中機器學習模型的個數也可以是1。本領域具有通常知識者當可根據上述揭示內容而設計出任意合適的機器學習模型。
The above training data includes the input and output of the machine learning model. The
圖3是根據一實施例繪示光學檢測方法的流程圖。請參照圖3,在步驟301中,產品經過一或多個製程以後進入一檢測站。在步驟302中,由目前的檢測站判斷產品是否符合規格要求。在一些實施例中,此規格要求是由客戶所決定,但本揭露並不在此限。如果步驟302的結果為是,則在步驟303中由電腦系統根據訓練好的機器學習模型以及目前檢測站的檢測影像(也可包含先前檢測站的檢測影像)判斷在後續的檢測站中是否符合規格要求。如果步驟303的結果為是,則表示沒有瑕疵,在步驟305中會繼續後續的製程且不淘汰產品。如果步驟303的結果為否,則表示雖然產品目前符合規格要求(瑕疵可能很微小),但此瑕疵會在後續的製程中被放大,因此在步驟304會停止後續的製程且淘汰該產品。另外,如果步驟302的結果為否,則進行步驟306,此步驟306相同於步驟303。如果步驟306的結果為是,這表示雖然目前的檢測站判斷產品不符合規格要求,但對應的瑕疵可能在後續的製程中消失不見,因此可以進行步驟305。如果步驟306的結果為否,則在步驟307中停止後續的製程且淘汰該產品。值得注意的是,圖3中各步驟可以實作為多個程式碼或是電路,本發明並不在此限。FIG. 3 is a flowchart illustrating an optical detection method according to an embodiment. Please refer to FIG. 3 , in
在上述的方法與系統中,可以結合多個檢測站的資訊以訓練一機器學習模型,此機器學習模型可以用來預測產品在後續檢測站的檢測結果,藉此可以提早淘汰產品,或者是保留符合規格要求的產品,可以降低過檢率以及漏檢率,提升瑕疵分類檢測率。In the above method and system, the information of multiple testing stations can be combined to train a machine learning model. This machine learning model can be used to predict the testing results of products at subsequent testing stations, thereby eliminating products early or keeping them. Products that meet the specification requirements can reduce the over-inspection rate and missed-inspection rate, and increase the rate of defect classification and detection.
雖然本發明已以實施例揭露如上,然其並非用以限定本發明,任何所屬技術領域中具有通常知識者,在不脫離本發明的精神和範圍內,當可作些許的更動與潤飾,故本發明的保護範圍當視後附的申請專利範圍所界定者為準。Although the present invention has been disclosed above with the embodiments, it is not intended to limit the present invention. Anyone with ordinary knowledge in the technical field may make some changes and modifications without departing from the spirit and scope of the present invention. The scope of protection of the present invention should be defined by the scope of the appended patent application.
100:光學檢測系統
110:產品
121~123:檢測站
131~133:檢測影像
140:電腦系統
151~153:瑕疵
301~307:步驟
100: Optical detection system
110:
為讓本發明的上述特徵和優點能更明顯易懂,下文特舉實施例,並配合所附圖式作詳細說明如下。 圖1是根據一實施例繪示光學檢測系統的示意圖。 圖2是根據一實施例繪示重疊多張檢測影像的示意圖。 圖3是根據一實施例繪示光學檢測方法的流程圖。 In order to make the above-mentioned features and advantages of the present invention more comprehensible, the following specific embodiments are described in detail together with the accompanying drawings. FIG. 1 is a schematic diagram illustrating an optical detection system according to an embodiment. FIG. 2 is a schematic diagram illustrating overlapping multiple detection images according to an embodiment. FIG. 3 is a flowchart illustrating an optical detection method according to an embodiment.
100:光學檢測系統
110:產品
121~123:檢測站
131~133:檢測影像
140:電腦系統
151~153:瑕疵
100: Optical detection system
110:
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Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
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