Inspection System Fixed-Frequency Triggering for Variable Stage Speed
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Solution Overview
Problem
Existing inspection systems for electrical circuits face challenges in maintaining optimal image acquisition speed and overlap consistency due to speed variations of the mechanical stage, leading to suboptimal throughput and complex control requirements.
Innovation Solution
An inspection system that generates triggering pulses at a fixed frequency, providing location information, and compensates for overlap variations between images, allowing for speed variations and flexible movement patterns, including curved and hybrid paths, while synchronizing camera and strobe illumination independently of stage position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the stage moves at variable speeds to optimize throughput, then productivity increases, but image acquisition synchronization becomes complex and overlap consistency deteriorates
Solution Approach 1:
Instead of synchronizing camera triggers to stage position (traditional approach), the patent inverts the approach by using a fixed-frequency trigger source that operates independently of stage speed. The stage position is then measured and recorded for each captured image, allowing variable speed operation without synchronization complexity.
Solution Approach 2:
The patent replaces the mechanical coupling between stage position sensing and camera triggering with an electronic decoupling approach. A fixed-frequency electronic trigger source generates triggers independent of mechanical stage speed, while electronic position measurement systems record location data for each image, eliminating the need for complex mechanical synchronization mechanisms.
2Productivity
If the stage moves faster to increase throughput, then productivity improves, but image overlap consistency between consecutive images deteriorates
Solution Approach 1:
The patent implements feedback by continuously measuring stage position using encoders or other position sensing devices for each triggered image capture. This position information is recorded and used to calculate actual overlap between consecutive images, enabling post-acquisition verification and correction of overlap inconsistencies regardless of stage speed variations.
Solution Approach 2:
The system dynamically adapts to variable stage speeds by using a fixed-frequency trigger source that operates independently of mechanical speed variations. The position measurement and overlap calculation processes dynamically adjust to capture accurate location data at any stage speed, maintaining overlap consistency through computational correction rather than mechanical control.
3Manufacturing precision
If stage speed is reduced to maintain overlap consistency, then image acquisition quality improves, but throughput decreases
Solution Approach 1:
The patent inverts the traditional relationship by not tying trigger frequency to stage speed requirements. Instead of reducing speed to maintain overlap, the system maintains fixed trigger frequency and uses position measurement to calculate and correct overlap variations, allowing high-speed operation without sacrificing overlap consistency.
4Illumination intensity
If flash duration is extended to improve illumination, then image quality improves, but motion blur increases
Solution Approach 1:
The patent uses periodic flash illumination synchronized to fixed-frequency triggers, where each flash provides brief, intense illumination. The periodic nature of the triggering ensures consistent flash timing independent of stage speed, maintaining both adequate illumination and minimal exposure time to prevent motion blur.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables maximal throughput and simplified control by maintaining consistent image acquisition rates regardless of stage speed, allowing for faster and more flexible movement patterns without compromising image quality.
Implementation Method 1
a strobe illuminator for illuminating areas of the inspected object in response to the triggering pulses
Implementation Method 2
a camera for acquiring images of areas of the inspected object in response to the triggering pulses
Data Source
AI summary
Method and inspection system. The inspection system includes: (i) a stage, for supporting an inspected object and for moving the inspected object by a movement that is characterized by speed variations; (ii) a signal generator, for generating triggering pulses at a fixed frequency regardless of the speed variations; (iii) a stage location generator, for providing location information indicative of a location of the stage at points of time that are determined by the triggering pulses; (iv) a strobe illuminator for illuminating areas of the inspected object in response to the triggering pulses; (v) a camera for acquiring images of areas of the inspected object in response to the triggering pulses; wherein overlaps between the images of the areas of the inspected object are characterized by overlap variations; and (vi) a processor for associating location information to the acquired images.