Abstract:
A method for measuring phase shift to detect irregularities of a surface is described. Additionally, a system for measuring phase shift to detect irregularities of a surface is provided. Further, a non-transitory computer-readable storage medium having computer-executable instructions embodied thereon is described. The computer-executable instructions are for measuring phase shift to detect irregularities of a surface.

Description:
BACKGROUND 
       [0001]    The field relates generally to phase measurement, and more particularly to systems and methods for interferometric phase measurement using a Fourier transform. 
         [0002]    Some known systems and methods for performing interferometric phase measurement include taking a series of images at different phase shifts and then numerically estimating, from the images, a cosine and sine of the phase of each image from the tangent in each pixel. From the numerically-estimated cosine and sine, the phase is then determined by calculating an arctangent. More specifically, the known systems and methods involve numerically stepping through one full phase in small steps and taking fringe images, then using the fringe images to perform a Fourier transformation through phases of a phase-dependent fringe intensity. Resulting first order sine and cosine coefficients give the tangent value, from which then the phase is determined by calculating the arctangent. However, this solution is impractical because it requires significant time to take the images, and requires a significant amount of processing time. 
         [0003]    Some known systems and methods reduce image capture time and processing time by taking a reduced number of fringe images. However, such systems and methods have reduced numerical accuracy and are less effective at rejecting erroneous data resulting from noise and/or vibration. 
       BRIEF DESCRIPTION 
       [0004]    In one aspect, a method for measuring phase shift to detect irregularities of a surface is provided. The method is implemented with a camera, a computing device coupled to or within the camera, a light source, a surface disposed opposite the light source, a semi-reflective reference plane disposed between the light source and the surface, and a beam splitter disposed between the light source and the reference plane. The light source emits a light beam comprising a first portion and a second portion, wherein the first portion is reflected by the reference plane and the second portion is transmitted through the reference plane and reflected by the surface. The beam splitter directs the reflected first portion and the reflected second portion to the camera. The method includes generating a first image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along a distance between the surface and the beam splitter at a first phase sweep rate. The method additionally includes generating a second image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a second phase sweep rate. Additionally, the method includes generating a third image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a third phase sweep rate. Further, the method includes generating, by the computing device, a first Fourier transform image and a second Fourier transform image based on the first image, the second image, and the third image. Additionally, the method includes generating, by the computing device, a phase image based on the first Fourier transform image and the second Fourier transform image. 
         [0005]    In another aspect, a system for measuring phase shift to detect irregularities of a surface is provided. The system includes a camera, a computing device coupled to or within the camera, a light source, a surface disposed opposite the light source, a semi-reflective reference plane disposed between the light source and the surface, and a beam splitter disposed between the light source and the reference plane. The light source emits a light beam that includes a first portion and a second portion. The first portion is reflected by the reference plane and the second portion is transmitted through the reference plane and reflected by the surface. The beam splitter directs the reflected first portion and the reflected second portion to the camera. The system is configured to generate a first image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along a distance between the surface and the beam splitter at a first phase sweep rate. The system is additionally configured to generate a second image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a second phase sweep rate. Additionally, the system is configured to generate a third image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a third phase sweep rate. The system is also configured to generate a first Fourier transform image and a second Fourier transform image based on the first image, the second image, and the third image, and generate a phase image based on the first Fourier transform image and the second Fourier transform image. 
         [0006]    In another aspect, a non-transitory computer-readable storage medium having computer-executable instructions embodied thereon is provided. The computer-executable instructions are for measuring phase shift to detect irregularities of a surface in a system including a camera, a computing device coupled to or within the camera, a light source, a surface disposed opposite the light source, a semi-reflective reference plane disposed between the light source and the surface, and a beam splitter disposed between the light source and the reference plane. The light source emits a light beam that includes a first portion and a second portion. The first portion is reflected by the reference plane and the second portion is transmitted through the reference plane and reflected by the surface. The beam splitter directs the reflected first portion and the reflected second portion to the camera. When executed by the computing device, the computer-executable instructions cause the computing device to generate a first image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along a distance between the surface and the beam splitter at a first phase sweep rate. The computer-executable instructions additionally cause the computing device to generate a second image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a second phase sweep rate, generate a third image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a third phase sweep rate, generate a first Fourier transform image and a second Fourier transform image based on the first image, the second image, and the third image, and generate a phase image based on the first Fourier transform image and the second Fourier transform image. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a diagram of an example system for measuring phase shift to detect irregularities on a surface. 
           [0008]      FIG. 2  is a block diagram of an example computing device that may be used in the system of  FIG. 1 . 
           [0009]      FIG. 3  is a plot of phase versus time during a first exposure performed by the system of  FIG. 1 . 
           [0010]      FIG. 4  is a plot of phase versus time during a second exposure performed by the system of  FIG. 1 . 
           [0011]      FIG. 5  is a plot of phase versus time during a third exposure performed by the system of  FIG. 1 . 
           [0012]      FIG. 6  is a flowchart of an example process that may be implemented by the system of  FIG. 1  for measuring phase shift to detect irregularities on a surface. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]      FIG. 1  is a diagram of a system  100  for measuring phase shift to detect irregularities on a surface. System  100  includes a camera  102 , and a computing device  104  that is coupled to camera  102 . In other implementations, computing device  104  is included within camera  102 . System  100  additionally includes a light source  106  and a surface  108  that is disposed opposite light source  106 . Surface  108  may be a surface of any object for which surface irregularities are to be measured. For example, surface  108  may be a surface of a silicon wafer. A semi-reflective reference plane  110  is disposed between light source  106  and surface  108 . Additionally, a beam splitter  112  is disposed between light source  106  and semi-reflective reference plane  110 . During operation of system  100 , light source  106  emits a light beam  114 . Light beam includes a first portion  116  and a second portion  118 . First portion  116  is reflected by semi-reflective reference plane  110 . Second portion  118  is transmitted through semi-reflective reference plane  110  and reflected by surface  108 . Beam splitter  112  directs reflected first portion  116  and second portion  118  to camera  102  for imaging. 
         [0014]      FIG. 2  is a schematic diagram of computing device  104 . Computing device  104  may include a bus  202 , a processor  204 , a main memory  206 , a read only memory (ROM)  208 , a storage device  210 , an input device  212 , an output device  214 , and a communication interface  216 . Bus  202  may include a path that permits communication among the components of computing device  200 . 
         [0015]    Processor  204  may include any type of conventional processor, microprocessor, or processing logic that interprets and executes instructions. Main memory  206  may include a random access memory (RAM) or another type of dynamic storage device that stores information and instructions for execution by processor  204 . ROM  208  may include a conventional ROM device or another type of static storage device that stores static information and instructions for use by processor  204 . Storage device  210  may include a magnetic and/or optical recording medium and its corresponding drive. 
         [0016]    Input device  212  may include a conventional mechanism that permits computing device  104  to receive commands, instructions, or other inputs from a user, including visual, audio, touch, button presses, stylus taps, etc. Accordingly, input device  212  may include, for example, a microphone, one or more buttons, and/or a touch screen. Output device  214  may include a conventional mechanism that outputs information to the user, including a display (including a touch screen) and/or a speaker. Communication interface  216  may include any transceiver-like mechanism that enables computing device  104  to communicate with other devices and/or systems. For example, communication interface  216  may include mechanisms for communicating with another device, such as camera  102 . As described above, in some implementations, computing device  104  is included within camera  102 . 
         [0017]    As described herein, computing device  104  performs operations to facilitate measuring phase shift to detect irregularities in surface  108  ( FIG. 1 ). Computing device  104  may perform these and other operations in response to processor  204  executing software instructions contained in a computer-readable medium, such as memory  206 . A computer-readable medium may be defined as a physical or logical memory device and/or carrier wave. The software instructions may be read into memory  206  from another computer-readable medium, such as data storage device  210 , or from another device via communication interface  216 . The software instructions contained in memory  206  may cause processor  204  to perform processes described herein. In other implementations, hardwired circuitry may be used in place of or in combination with software instructions to implement processes consistent with the subject matter herein. Thus, implementations consistent with the principles of the subject matter disclosed herein are not limited to any specific combination of hardware circuitry and software. 
         [0018]    System  100  exposes camera  102  three times, each time accumulating a phase-dependent fringe intensity while a phase sweeps through 2π radians or a multiple of 2π radians.  FIG. 3  is a plot  300  of a phase versus time during a first exposure performed by system  100  ( FIG. 1 ). The rate of the sweep of the phase is constant during the first exposure, thereby enabling camera  102  to linearly accumulate a phase-dependent fringe intensity. The rate of the first phase sweep is given by Equation 1. 
         [0000]      Φ′ 1 =2π  (Equation 1)
 
         [0019]      FIG. 4  is a plot  400  of phase versus time during a second exposure performed by system  100  ( FIG. 1 ). The rate of a second sweep of the phase is controlled such that an accumulated phase-dependent fringe intensity during the second exposure is substantially the same as during the first exposure plus an equivalent of a first order cosine Fourier transform over the phase of the phase-dependent fringe intensity. The rate of the second phase sweep is given by Equation 2, wherein ξ is a modulation coefficient with a value of, for example, approximately 0.75, and Φ represents the phase. 
         [0000]      Φ′ 2 =2π(1+ξcos(Φ))  (Equation 2)
 
         [0020]      FIG. 5  is a plot  500  of phase versus time during a third exposure performed by system  100  ( FIG. 1 ). During the third exposure, the rate of a third sweep is controlled such that an accumulated phase-dependent fringe intensity during the third exposure is substantially the same as during the first exposure, plus an equivalent of a first order sine Fourier transform over the phase of the phase-dependent fringe intensity. The rate of the third phase sweep is given by Equation 3, wherein ξ is a modulation coefficient with a value of, for example, approximately 0.75, and Φ represents the phase. 
         [0000]      Φ′ 3 =2π(1+ξsin(Φ))  (Equation 3)
 
         [0021]    After the three phase sweeps and corresponding three exposures occur, as described above, memory  206  of computing device  104  includes pixel values for each of the three exposures. In other words, memory  206  contains, for each of the three exposures, a corresponding image. The pixel values of the first image, the second image, and the third image corresponding to the first exposure, the second exposure, and the third exposure are given by Equations 4, 5, and 6. In Equations 4, 5, and 6, Y is a pixel value at coordinates x and y, I is the phase-dependent fringe intensity, t is time, 1 is the phase, and D′ is the first derivative of the phase with respect to time (i.e., the phase sweep rate). 
         [0000]        Y   1 ( x,y )=∫ I ( x,y, Φ 1( t )) dt=∫I ( x,y, Φ 1( t ))/Φ′1( t ) dΦ   (Equation 4)
 
         [0000]        Y   2 ( x,y )=∫ I ( x,y, Φ 2( t )) dt=∫I ( x,y, Φ 2( t ))/Φ′2( t ) dΦ   (Equation 5)
 
         [0000]        Y   3 ( x,y )=∫ I ( x,y, Φ 3( t )) dt=∫I ( x,y, Φ 3( t ))/Φ′3( t ) dΦ   (Equation 6)
 
         [0022]    Based on Equations 4, 5, and 6, the first image, the second image, and the third image can be expressed as Equations 7, 8, 9, respectively, as follows: 
         [0000]        Y   1 ( x,y )=1/2π ∫I ( x,x,Φ ) dΦ   (Equation 7)
 
         [0000]        Y   2 ( x,y )=1/2π ∫I ( x,x, Φ )(1+ξcos(Φ))dΦ  (Equation 8)
 
         [0000]        Y   3 ( x,y )=1/2π ∫I ( x,x, Φ )(1+ξsin(Φ))dΦ  (Equation 9)
 
         [0023]    Computing device  104  additionally generates a first Fourier transform image by subtracting the first image, represented by Y 1  in Equation 7, from the second image, represented by Y 2  in Equation 8. Additionally, computing device  104  generates a second Fourier transform image by subtracting the first image, Y 1  in Equation 7, from the third image, Y 2  in Equation 9.The first Fourier transform image, F c , is represented by Equation 10 and the second Fourier transform image, F s , is represented by Equation 11, below. 
         [0000]        Fc ( x,y )= Y 2( x,y )− Y 1( x,y )=ξ/2 π∫I ( x,x , Φ)cos(Φ) dΦ   (Equation 10)
 
         [0000]        Fs ( x,y )= Y 3( x,y )− Y 1( x,y )=ξ/2 π∫I ( x,x , Φ)cos(Φ) dΦ   (Equation 11)
 
         [0024]    Computing device  104  additionally generates a phase image, P, according to Equation 12, below. 
         [0000]        P ( x,y )=arctan( Fs ( x,y )/ Fc ( x,y ))  (Equation 12)
 
         [0025]      FIG. 6  is a flowchart of an example process that may be implemented by system  100  ( FIG. 1 ) for measuring phase shift to detect irregularities on a surface. First, system  100  generates  602  a first image by exposing  102  camera to first portion  116  and second portion  118  of light beam  114  while translating reference plane  110  along a distance  120  between surface  108  and beam splitter  112  at a first phase sweep rate. Next, system  100  generates  604  a second image by exposing camera  102  to first portion  116  and second portion  118  of light beam  114  while translating reference plane  110  along distance  120  at a second phase sweep rate. Next, system  100  generates  606  a third image by exposing camera  102  to first portion  116  and second portion  118  of light beam  114  while translating reference plane  110  along distance  120  at a third phase sweep rate. Next, system  100  generates  608  a first Fourier transform image and a second Fourier transform image based on the first image, the second image, and the third image. Next, system  100  generates  610  a phase image based on the first Fourier transform image and the second Fourier transform image. In some implementations, computing device  104  performs one or more of steps  602 - 610 . As described above, in some implementations, computing device  104  is included within camera  102 . 
         [0026]    In an example implementation, camera  102  may include an analog to digital converter with a resolution of approximately 0.037 degrees and may allocate 12 bits to each pixel value. Further, computing device  104  may adjust pixel values such that the first image, Y 1 , has pixel values at about 2048. With the modulation coefficient at approximately 0.75, the digitizing error is at most 0.0373°, as shown in Equation 13. 
         [0000]      Digitizing error≦tan −1 (0.75*2048)=0.0373°  (Equation 13)
 
         [0027]    In subtracting the first image from the second image to generate the first Fourier transform image, and subtracting the first image from the third image to generate the second Fourier transform image, erroneous pixel values (i.e., “hot pixels”) are cancelled out. More specifically, hot pixel intensity offset is determined by exposure time only. Given that all three exposures have the same exposure time, hot pixels are cancelled out during generation of the first Fourier transform image and the second Fourier transform image. 
         [0028]    A technical effect of systems and methods described herein includes at least one of: (a) generating a first image by exposing a camera to a first portion and a second portion of a light beam while translating a reference plane along a distance between a surface and a beam splitter at a first phase sweep rate; (b) generating a second image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a second phase sweep rate; (c) generating a third image by exposing the camera to the first portion and the second portion of the light beam while translating the reference plane along the distance at a third phase sweep rate; (d) generating, by a computing device, a first Fourier transform image and a second Fourier transform image based on the first image, the second image, and the third image; and (e) generating, by the computing device, a phase image based on the first Fourier transform image and the second Fourier transform image. 
         [0029]    As compared to known systems and methods for performing interferometric phase measurement, the systems and methods described herein facilitate performing interferometric phase measurement with increased accuracy and speed. Accordingly, irregularities in the surface of an object may be detected faster and with improved reliability over previous systems and methods. 
         [0030]    This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims.