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基于计算机视觉的自动光学检测关键技术与应用研究
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摘要
随着近年来制造工业在我国的迅速发展,对于产品质量的要求也在不断提高,相应的对于产品质量检测技术的速度和检测准确率也提出了更高的要求,当前的人工检测方法已经不能满足工业生产需要。而计算机视觉技术的发展使得自动光学检测技术在工业质量检测的各个领域都得到了广泛的应用,包括半导体工业、电子电机工业、机械零件加工业、食品加工与包装业、汽车工业、金属加工业、印刷业、纺织皮革工业、农林产业等。但是国内科研机构在这方面的研究才刚刚起步,目前的技术在解决高速、高准确度以及缺陷分类的应用方面仍然存在不足。本文从自动光学检测相关的几个关键技术入手,在分析研究现有技术优缺点的基础上,针对工业生产的实际需求,对多种关键技术中的核心算法进行了研究与重新设计。并以晶圆缺陷检测为例,对自动光学检测设备的硬件结构和软件算法进行了研究,设计了一种具有快速、准确、具备缺陷分类能力等特点的晶圆缺陷检测设备。
     论文首先对自动光学检测中的图像质量进行了分析,对于成像质量最为相关的图像采集系统的各个组件性能进行了研究。在分析和总结了常用光源对于被测物体作用原理的基础上,提出了根据被测物体自身光学特性进行照明方案设计的原则。以大功率LED晶圆缺陷检测为例,分析了物体表面反光特性存在巨大反差下的成像特点,提出了一种基于明暗场同时照明的光源设计方案,解决了摄像机动态范围不足的问题。
     论文对图像分割算法进行了深入的研究,针对当前阈值分割、模板匹配等算法中存在的运行效率较低,容易受到外界环境变化干扰等问题,提出了一种新的基于压缩感知的自学习目标区域分割算法,解决了传统算法存在的问题。并根据晶圆缺陷检测的实际应用需求,设计了结合压缩感知分割算法和模板匹配算法的芯片分割方法,克服了基于压缩感知的目标区域分割算法只能对单一目标进行识别的缺点,在保证检测效率的前提下兼顾了定位的准确性。
     特征提取与缺陷分类是自动光学检测技术中重要的一环。对于晶圆缺陷特征的提取,传统的基于灰度值统计特性的特征提取算法能够提供的特征量较少、分类能力较低、且容易受到光照、噪声等因素的干扰。本文设计了一种改进型的基于相位一致性的线检测算法,提高了该算法的运行效率和检测精度。并在此基础上将该检测方法扩展到二维空间中实现了基于相位一致性的角点检测。此外本文针对传统的基于角点检测的特征提取算法只能实现定位功能,而无法直接对角点的形貌特性进行描述的缺点,将尺度空间原理与Harris角点检测算法相结合,提出了一种新的利用尺度空间信息对缺陷形状特征进行描述的方法。在使用BP神经网络分类器进行的分类实验中,以上算法体现了良好的分类准确度和抗干扰性。
     最后将本文的理论研究成果应用于实际的工业化设备开发中,研制了一种基于计算机视觉的晶圆缺陷自动检测系统并完成样机制作。使用该样机对文中提出的理论算法进行了实验验证和对比分析,结果显示这些算法都具有较好的实用价值。使用工业生产中的晶圆样片对样机进行测试,结果显示该系统完成单片晶圆检测时间小于12分钟,漏检率为O%,误检率小于10%,完全可以达到工业应用的要求。
Automated optical inspection (AOI) system has become more and more important in the field of wafer production. In order to be competitive in the semiconductor manufacturing industry, defect inspection becomes a critical issue. The goal of wafer defect inspection is to detect defective dies and discard them. However, these existing methods have limitations when dealing with the high speed and high accuracy applications. In this paper, the previous research works and literatures of the key algorithms in automated optical inspection. Some novel algorithms with high speed, high accuracy are proposed and the system of defect inspection is designed aims the existing method's shortages.
     This dissertation firstly analyzed the image used in an automated optical inspection system. The image acquirement system which is the most relevant factors to the image quality is analyzed. A novel bright-dark-field light source design is proposed based on the research of the previous light source design to solve the insufficient of camera dynamic range.
     The algorithms for image segmentation have been studied in details. The existing thresholding, geometric primitives and template matching methods have been summarized and compared. A novel image segmentation algorithm based on compressed sensing principle is proposed. This algorithm is efficient and robust. Then this algorithm is used in a wafer defect inspection system with template matching algorithm to get an efficient and accurate inspection result.
     The feature extraction and defect classification are the key technique of the automated optical inspection. For feature extraction of wafer defect, the traditional methods are low efficiency, poor classification, and sensitive to lighting and noise. In this paper, the line detection algorithm based on phase congruency is improved to get high efficiency and accuracy. This novel algorithm can be also used in corner detection. Then a new feature extraction algorithm based on scale-space principle and Harris corner detector is proposed. This algorithm has accuracy classification results in back-propagation neural network test.
     Finally, an automated wafer defect inspection system based on computer vision was presented. The algorithms and methods in this paper were verified and compared using this system. The experiment results have shown that the proposed algorithms and methods can inspect the wafer defect with high speed and accuracy. The inspection time of one wafer is12minutes, the missing rate is0%and the false rate is less than10%.
引文
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