Non-spatial Measurement Calibration via Misalignment Database
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Solution Overview
Problem
Conventional product inspection systems using non-spatial cameras require costly high-precision mechanical translation stages and reduced throughput due to the need for precise alignment of devices under test (DUTs) with the camera's field of view.
Innovation Solution
The development of a misalignment calibration database that stores calibration data for various misalignment positions, allowing product inspection systems to calibrate measurements taken by non-spatial cameras without the need for precise alignment, thereby reducing the reliance on expensive mechanical translation stages.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If precise alignment of DUT with camera field of view is required, then measurement accuracy is improved, but device complexity and cost increase due to high-precision mechanical translation stages
Solution Approach 1:
The system performs preliminary alignment by capturing an image of the DUT using the spatial camera, determining its position and orientation, and calculating the required adjustment angles before taking measurements. This preliminary action eliminates the need for complex real-time alignment mechanisms during measurement.
Solution Approach 2:
The patent replaces high-precision mechanical translation stages with a computational approach using spatial and non-spatial cameras. Instead of mechanically adjusting the DUT or camera position, the system uses image processing and coordinate transformation algorithms to achieve accurate measurements.
2Measurement precision
If precise alignment is required before measurement, then measurement accuracy is improved, but productivity decreases due to time-consuming alignment procedures
Solution Approach 1:
The system captures the DUT image and determines its position and orientation before measurement, performing all necessary alignment calculations in advance. This allows the actual measurement process to proceed without time-consuming alignment adjustments.
Solution Approach 2:
The patent enables continuous measurement by eliminating the need to stop and realign the DUT between measurements. Once the initial position and orientation are determined, multiple measurements can be taken continuously using the calculated alignment parameters.
3Measurement precision
If high-precision mechanical translation stages are used, then alignment accuracy is improved, but cost increases due to expensive mechanical equipment
Solution Approach 1:
The patent replaces expensive high-precision mechanical translation stages with a combination of spatial and non-spatial cameras along with computational algorithms. This substitution dramatically reduces hardware costs while maintaining or improving alignment accuracy through software-based coordinate transformation.
Solution Approach 2:
The system uses the spatial camera to create an image copy of the DUT's position and orientation, then uses this copied information to calculate alignment parameters for the non-spatial camera measurements, eliminating the need for direct mechanical positioning.
Data Source
AI summary
Systems and methods for calibrating non-spatial measurements of a device under test (DUT) for misalignment between the DUT and a non-spatial measurement device are disclosed herein. A system for generating a misalignment calibration database can include, for example, a non-spatial measurement device and a high-precision translation stage. The system can generate a misalignment calibration database by taking measurements of a DUT at multiple misalignment locations. A system for measuring a DUT can include, for example, a spatial measurement device, a non-spatial measurement device, a translation stage, and/or a carrier tray. The system can capture measurements of the DUT at a first position and calibrate the measurements for misalignment using calibration data corresponding to the first position. For example, the system can retrieve calibration data from a calibration misalignment system that was taken at the same and/or different locations proximate the position of the DUT.