Patent Description:
The present disclosure relates generally to microscopes with objective assembly crash detection and/or to methods of utilizing the microscopes.

Microscopes often are utilized, within probe systems, to collect, store, and/or display optical images. These optical images may be utilized in automated and/or in manually controlled probe systems to facilitate alignment of probes of the probe system with a device under test (DUT), such as to permit testing of the DUT by the probe system. Because of the high levels of optical magnification and the tight tolerances involved, the microscope, or an objective assembly of the microscope, may collide with the DUT, with the probes, and/or with another component of the probe system. Additionally or alternatively, components of the probe system may collide with the objective assembly. Such collisions may cause damage to the microscope, the probe system, and/or the DUT. Thus, there exists a need for microscopes with objective assembly crash detection and/or for methods of utilizing the microscopes with objective assembly crash detection.

Microscopes with objective assembly crash detection and methods of utilizing the same are disclosed herein and defined by independent claims <NUM> and <NUM>.

<CIT> and <CIT> disclose microscopes for examination of the interior of living organisms. <CIT> disclose another known microscope.

<FIG> provide examples of probe systems <NUM>, microscopes <NUM>, and/or methods <NUM>, according to the present disclosure. Elements that serve a similar, or at least substantially similar, purpose are labeled with like numbers in each of <FIG>, and these elements may not be discussed in detail herein with reference to each of <FIG>. Similarly, all elements may not be labeled in each of <FIG>, but reference numerals associated therewith may be utilized herein for consistency. Elements, components, and/or features that are discussed herein with reference to one or more of <FIG> may be included in and/or utilized with any of <FIG> without departing from the scope of the present disclosure.

In general, elements that are included in a particular embodiment according to the present invention are defined by the appended claims, irrespective of whether these elements are illustrated in solid or dashed lines. Further, electrical connections (wired or wireless) between components are illustrated in dotted lines, and different possible pieces and/or positions of components are illustrated in dash-dot lines.

<FIG> is a schematic illustration of a microscope <NUM> that may form a portion of a probe system <NUM>, according to the present disclosure. <FIG> provide additional examples of microscopes <NUM> and/or components thereof. For convenience, the components of probe system <NUM> are generally described sequentially in the description herein, such that a given component is substantially fully described before beginning description of a new component. Thus, a given component may be introduced and described as it is schematically illustrated in <FIG>, followed by a more detailed description of specific examples of the component as illustrated in one or more of <FIG>, before moving on to the next component. For this reason, <FIG> are discussed collectively herein, followed by a description of <FIG>.

In more detail, the <FIG> provide a specific example of an orientation detection circuit <NUM> that may be used to determine when a collision has occurred between microscope <NUM> and other components of probe system <NUM>. In the example of <FIG>, orientation detection circuit <NUM> includes a plurality of contacting structures <NUM> included in an objective assembly <NUM> and an objective assembly mount <NUM> of microscope <NUM>. <FIG> illustrate how the relative orientation between objective assembly <NUM> and objective assembly mount <NUM> may change during and/or after a collision, and how this change in orientation may cause two or more of the contacting structures <NUM> to come out of contact with one another.

<FIG> illustrate how this example orientation detection circuit <NUM> (i.e. one containing a plurality of contacting structures <NUM>) may be incorporated into objective assembly <NUM> and objective assembly mount <NUM>, and further illustrate additional optional structures/components of objective assembly mount <NUM> and objective assembly <NUM>. In particular, <FIG> illustrates an example objective assembly mount <NUM> that comprises one or more of contacting structure <NUM> and various other structures/components such as a levelling mechanism <NUM>, and <FIG> shows a bottom view of objective assembly <NUM>, and in particular, the bottom surface of a projecting region <NUM> of objective assembly <NUM> that directly interfaces with objective assembly mount <NUM>. This bottom surface of projecting region <NUM> may comprise one or more contacting structures <NUM> that interface with contacting structure <NUM> of objective assembly mount <NUM>. <FIG> and <FIG> further illustrate examples of objective assembly <NUM> and objective assembly mount <NUM> post-collision, where objective assembly <NUM> and objective assembly mount <NUM> are out of alignment. <FIG> shows an example method for detecting and/or mitigating a collision between objective assembly <NUM> and various components of probe system <NUM>.

As illustrated collectively by <FIG>, microscope <NUM> includes a microscope body <NUM> and an objective assembly <NUM> comprising an objective lens <NUM>. Microscope <NUM> also includes objective assembly mount <NUM> and an orientation detection circuit <NUM>. As illustrated in dashed lines in <FIG>, microscope <NUM> also may include a drive mechanism <NUM>.

As discussed, microscope <NUM> may be included in and/or may form a portion of probe system <NUM>. Probe system <NUM> may include a plurality of components, examples of which are illustrated in dashed lines in <FIG>. As an example, probe system <NUM> may include a chuck <NUM>. Chuck <NUM> may include and/or may define a support surface <NUM>, and support surface <NUM> may be sized, shaped, and/or configured to receive and/or to support a substrate <NUM>. Substrate <NUM> may include at least one device under test (DUT) <NUM>, and probe system <NUM> may be configured to test, to electrically test, and/or to optically test operation of the DUT. Examples of chuck <NUM> include a wafer chuck, an electrostatic chuck, and/or a temperature-controlled chuck.

As another example, probe system <NUM> may include a probe <NUM> that may be configured to communicate with DUT <NUM>. As an example, probe <NUM> may be configured to contact, or to electrically contact, DUT <NUM>, such as with a contact pad <NUM> of the DUT. As another example, probe <NUM> may be configured for wireless communication with DUT <NUM>. Examples of probe <NUM> include an electrical probe, an electrical conductor, a high frequency probe, a wireless probe, an antenna, and/or a near-field antenna.

As yet another example, probe system <NUM> may include a manipulator <NUM>. Manipulator <NUM> may be configured to operatively translate probe <NUM> relative to support surface <NUM> and/or relative to DUT <NUM>, such as to permit and/or facilitate alignment of the probe with the DUT. As an example, manipulator <NUM> may be utilized to electrically contact probe <NUM> with the contact pad of the DUT. This may include translation of probe <NUM> along the X, Y, and/or Z-axes of <FIG>. Examples of manipulator <NUM> include a mechanical manipulator, an electrical manipulator, a lead screw and nut, a ball screw and nut, a linear actuator, a stepper motor, and/or a piezoelectric actuator.

In other examples, probe <NUM> may form a portion of a probe card <NUM>. In these examples, probe system <NUM> may not include, or may not be required to include, manipulator <NUM>. An example of probe card <NUM> includes a card for testing electronic and/or optoelectronic devices and that includes a plurality of probes <NUM> that defines a fixed, or an at least substantially fixed, relative orientation therebetween.

As another example, probe system <NUM> may include a drive assembly <NUM>. Drive assembly <NUM> may be configured to selectively control a relative orientation between probe <NUM> and support surface <NUM> and/or DUT <NUM>. As examples, drive assembly <NUM> may be configured to operatively translate chuck <NUM> along the X, Y, and/or Z-axes of <FIG> and/or to rotate chuck <NUM> about the Z-axis. Examples of drive assembly <NUM> include a linear actuator, a rotary actuator, a lead screw and nut, a ball screw and nut, a stepper motor, and/or a piezoelectric actuator.

As yet another example, probe system <NUM> may include a signal generation and analysis assembly <NUM>. Signal generation and analysis assembly <NUM> may be configured to provide a test signal to DUT <NUM> and/or to receive a resultant signal from DUT <NUM>, such as via probe <NUM> and/or chuck <NUM>. Examples of signal generation and analysis assembly <NUM> include a function generator, an electric signal generator, a wireless signal generator, an optical signal generator, an electric signal analyzer, a wireless signal analyzer, and/or an optical signal analyzer.

As another example, probe system <NUM> may include a control system <NUM>. Control system <NUM> may be programmed to control the operation of at least a portion of probe system <NUM>, such as chuck <NUM>, manipulator <NUM>, drive assembly <NUM>, signal generation and analysis assembly <NUM>, and/or microscope <NUM>. This may include controlling the operation of probe system <NUM> according to any of the methods <NUM> that are disclosed herein. It is within the scope of the present disclosure that signal generation and analysis assembly <NUM> may be integrated into and/or may be integral with control system <NUM>. Alternatively, it also is within the scope of the present disclosure that signal generation and analysis assembly <NUM> may be distinct and/or separate from control system <NUM>. Examples of control system <NUM> are disclosed herein.

As yet another example, probe system <NUM> may include an enclosure <NUM>. Enclosure <NUM> may define an enclosed volume <NUM> that may house and/or contain at least support surface <NUM> and/or substrate <NUM>. Enclosure <NUM> may define an aperture <NUM>, and probes <NUM> and/or at least a portion of microscope <NUM> may extend through the aperture. In some examples, enclosure <NUM> may include a platen <NUM> that may define aperture <NUM> and/or that may support manipulator <NUM>, probe <NUM>, and/or probe card <NUM>.

During operation of probe system <NUM>, various components of probe system <NUM> purposefully may be moved relative to one another. As an example, drive mechanism <NUM> may be utilized to operatively translate microscope <NUM> along an optical axis <NUM> of objective lens <NUM>, such as to permit and/or facilitate focusing of microscope <NUM> on another component of probe system <NUM> and/or on DUT <NUM>. In some examples, the entire microscope <NUM>, including microscope body <NUM>, moves along optical axis <NUM> responsive to actuation by drive mechanism <NUM>. However, in other examples, only objective assembly <NUM> and objective assembly mount <NUM> move along optical axis <NUM>, and microscope body <NUM> remains in place. The drive mechanism may additionally be configured to operatively translate microscope <NUM> laterally (i.e. along a plane perpendicular to the optical axis of the objective lens). Thus, drive mechanism <NUM> may not only be configured to move the microscope up and down along optical axis <NUM>, but also may be configured to move microscope <NUM> sideways to different locations above DUT <NUM>.

Drive mechanism <NUM> may include and/or be any suitable structure that may, or that may be utilized to, operatively transition microscope <NUM> along optical axis <NUM>. Examples of drive mechanism <NUM> include a mechanical drive mechanism, an electrical drive mechanism, and/or a pneumatic drive mechanism. Additional examples of drive mechanism <NUM> include a linear actuator, a pneumatic cylinder, a linear motor, and/or a linear voice coil motor.

As another example, manipulator <NUM> may be utilized to operatively translate probe <NUM> relative to support surface <NUM> and/or relative to microscope <NUM>. As yet another example, drive assembly <NUM> may be utilized to translate and/or to rotate support surface <NUM> of chuck <NUM> relative to probe <NUM> and/or relative to microscope <NUM>.

During any and/or all of these relative motions, microscope <NUM> may be utilized to collect an image, or an optical image, of the other component of probe system <NUM> and/or of DUT <NUM>. Because of the relative motion, and under certain circumstances, objective assembly <NUM> may contact, may collide with, and/or may crash into DUT <NUM> and/or into another component of probe system <NUM>. As discussed, such collisions, if permitted to proceed, may damage the probe system and/or the DUT. Thus, it may be desirable to quickly detect such collisions and to cease relative motion before damage, or before significant damage, occurs.

Objective assembly <NUM>, according to the present disclosure, may be configured to mitigate the impact force of such collisions by, for example, moving relative to objective assembly mount <NUM> and/or microscope body <NUM> when the objective assembly makes contact with another object. Microscope <NUM>, according to the present disclosure, also may be configured to rapidly detect such collisions by detecting this relative motion between objective assembly <NUM> and microscope body <NUM> (e.g., pivoting of objective assembly <NUM> relative to objective assembly mount <NUM> and/or microscope body <NUM>). Microscope <NUM>, also may be configured to take corrective actions, such as ceasing relative motion of the colliding components and/or retracting the colliding objects from one another, to prevent and/or mitigate damage to the colliding components.

A collision, and the relative motion it may cause between objective assembly <NUM> and microscope body <NUM>, is illustrated in the transition between <FIG> and <FIG>. In <FIG>, objective assembly <NUM> is attached to microscope body <NUM> via objective assembly mount <NUM> and is oriented at a predetermined relative orientation <NUM> relative to microscope body <NUM>. In the example illustrated in <FIG>, predetermined relative orientation <NUM> is an orientation in which optical axis <NUM> of objective lens <NUM> is parallel to central axis <NUM> of microscope body <NUM>. However, in other examples, optical axis <NUM> may be at an angle to central axis <NUM> of microscope body <NUM> in predetermined relative orientation <NUM>. Microscope <NUM> also is illustrated translating along optical axis <NUM> and/or toward probe <NUM> in <FIG>, and orientation detection circuit <NUM> detects and/or indicates that the objective assembly is oriented at predetermined relative orientation <NUM>.

Subsequently, and as illustrated in <FIG>, objective assembly <NUM> contacts, or collides with, probe <NUM>, such as is indicated at <NUM>. This collision between the objective assembly and the probe may cause the relative orientation between the objective assembly and microscope body to change and/or to differ from predetermined relative orientation <NUM> of <FIG>. As an example, as illustrated in <FIG>, optical axis <NUM> of objective lens <NUM> and central axis <NUM> of microscope body <NUM> are no longer parallel to one another. Instead, they are at an angle with respect to one another. Thus, in <FIG>, objective assembly <NUM> has pivoted relative to microscope body <NUM> away from predetermined relative orientation <NUM> of <FIG>. In this way, objective assembly <NUM> may be configured to move and/or pivot relative to objective assembly mount <NUM>, optionally to permit the relative orientation between microscope body <NUM> and objective assembly <NUM> to differ from the predetermined relative orientation <NUM>.

Orientation detection circuit <NUM> detects this change in relative orientation, such as by detecting that microscope body <NUM> and objective assembly <NUM> are not in predetermined relative orientation <NUM> of <FIG>, thereby permitting and/or facilitating rapid response to the collision and decreasing a potential for damage. Orientation detection circuit <NUM> may include any suitable structure that may be adapted and/or configured to detect, determine, and/or indicate a change in relative orientation between objective assembly <NUM> and microscope body <NUM>. Additionally or alternatively, orientation detection circuit <NUM> may include any suitable structure that may be adapted and/or configured to detect, determine, and/or indicate when the relative orientation between microscope body <NUM> and objective assembly <NUM> differs from predetermined relative orientation <NUM>. As illustrated in <FIG>, orientation detection circuit <NUM> may comprise one or more electric circuits that may be configured such that, when the relative orientation between microscope body <NUM> and objective assembly <NUM> changes from predetermined relative orientation <NUM>, an electrical continuity of orientation detection circuit <NUM> changes, an electric current within orientation detection circuit <NUM> changes, and/or a voltage of orientation detection circuit <NUM> changes.

As an example, orientation detection circuit <NUM> may comprise an electric switch <NUM>. Electric switch <NUM> may be a normally closed switch that is configured to open (i.e. prevent and/or reduce current flow through the circuit) when the relative orientation between objective assembly <NUM> and microscope body <NUM> differs from predetermined relative orientation <NUM>. Alternatively, electric switch <NUM> may be a normally open switch that is configured to close (i.e. increase and/or permit current flow therethrough) when the relative orientation between objective assembly <NUM> and microscope body <NUM> differs from predetermined relative orientation <NUM>. In either example, the electrical continuity of electric switch <NUM> changes when the relative orientation between objective assembly <NUM> and microscope body <NUM> changes from predetermined relative orientation <NUM>.

In some examples, the change in the electrical continuity of electric switch <NUM> (e.g., the change from closed to open or vice versa) automatically stops and/or powers off drive mechanism <NUM> and/or other actuators of probe system <NUM>. However, in other examples, control system <NUM> and/or orientation detection circuit <NUM> may comprise a continuity detection circuit that actively monitors current flow through electric switch <NUM> and/or the circuit containing electric switch <NUM>. For example, the continuity detection circuit may comprise an ammeter, a volt meter, or the like. In such examples, control system <NUM> may estimate changes in the relative orientation between objective assembly <NUM> and objective assembly mount <NUM> and/or microscope body <NUM> based on output from the continuity detection circuit, and may adjust operation of one or more of the actuators responsive to this output.

In one example of electric switch <NUM>, electric switch <NUM> may comprise contacting structures <NUM>, as illustrated in <FIG> and <FIG>. In particular, contacting structures <NUM> may be arranged in corresponding pairs on objective assembly <NUM> and objective assembly mount <NUM>. In particular, objective assembly <NUM> may include an objective assembly contacting structure <NUM>, and objective assembly mount <NUM> may include an objective assembly mount contacting structure <NUM>. In particular, objective assembly contacting structure <NUM> may be operatively attached to objective assembly <NUM> and objective assembly mount contacting structure <NUM> may be operatively attached to objective assembly mount <NUM>. In addition, contacting structures <NUM> and <NUM> may be positioned such that, when objective assembly <NUM> and microscope body <NUM> are in predetermined relative orientation <NUM>, the contacting structures <NUM> and <NUM> are in electrical communication with each other. Such a configuration is illustrated in <FIG>, which illustrates two pairs of contacting structures <NUM>. Thus, objective assembly mount contacting structure <NUM> and objective assembly contacting structure <NUM> may include two or more contacting structures in some examples. In <FIG>, objective assembly mount contacting structure <NUM> is in contact, as indicated at <NUM>, with objective assembly contacting structure <NUM>.

In this example, the change in relative orientation caused by objective assembly <NUM> colliding with an object of probe system <NUM> may cause one or more pairs of contacting structures <NUM> to transition from being in contact with one another, as indicated at <NUM> (in <FIG>), to being out of contact with one another, as indicated at <NUM> (in <FIG>). Thus, when objective assembly <NUM> and microscope body <NUM> are not in predetermined relative orientation <NUM> or when the relative orientation between the objective assembly and the microscope body differs or changes from predetermined relative orientation <NUM>, at least one objective assembly contacting structure <NUM> and one objective assembly mount contacting structure <NUM> may transition to being out of contact with one another, as indicated in <FIG> at <NUM>. This transition may be detected, by orientation detection circuit <NUM> and/or by control system <NUM> of <FIG>, as a change in electrical continuity, and/or as a lack of electrical continuity, between the objective assembly mount contacting structure and the objective assembly contacting structure, thereby indicating that collision <NUM> has occurred. Probe system <NUM> and/or microscope <NUM> thereof may detect this lack of continuity, such as via a continuity detection circuit that is in electrical communication with each objective assembly contacting structure <NUM> and objective assembly mount contacting structure <NUM>. Probe system <NUM> and/or microscope <NUM> thereof then may interpret this lack of, or change in, continuity as an indication that objective assembly <NUM> has collided with the DUT and/or with another component of probe system <NUM> and may respond accordingly.

Contacting structures <NUM> may include and/or be any suitable structure that may permit and/or facilitate establishment of electrical communication between the corresponding pairs of contacting structures. As an example, the objective assembly contacting structure and/or the objective assembly mount contacting structure may include and/or be an electrically conductive surface and/or an electrically conductive flat surface. As another example, the objective assembly contacting structure and/or the objective assembly mount contacting structure may include and/or may be a spring-loaded electrically conductive contact, or pin, such as a Pogo Pin™. As yet another example, slots and surfaces may form and/or define the objective assembly contacting structure and/or the objective assembly mount contacting structure.

In another example, orientation detection circuit <NUM> may comprise a position sensor <NUM> configured to detect changes in the relative orientation between objective assembly <NUM> and microscope body <NUM> and/or objective assembly mount <NUM>. In some examples, the position sensor may include two or more position sensors. Position sensor <NUM> may include any suitable structure that may be adapted, configured, designed, and/or constructed to determine, to calculate, and/or to measure the relative positon and/or distance between objective assembly <NUM> and objective assembly mount <NUM>. In particular, position sensor <NUM> may be configured to convert changes in the relative orientation between the microscope body and the objective assembly into electrical signals that then may be communicated to control system <NUM>. Examples of position sensors <NUM> include a capacitance distance sensor, an optical distance sensor, an inductive distance sensor, a linear variable differential transducer (LVDT), an Eddy current sensor, a Hall effect sensor, an optical sensor, and/or an interferometer. Control system <NUM> may interpret these outputted electrical signals to determine if a collision has occurred.

As one such example, position sensor <NUM> may detect changes in the relative orientation between objective assembly <NUM> and microscope body <NUM> and/or objective assembly mount <NUM> by measuring a distance between objective assembly <NUM> and objective assembly mount <NUM> and/or microscope body <NUM>. As one example, a collision may cause objective assembly <NUM> to pivot relative to objective assembly mount <NUM> and/or microscope body <NUM>. Position sensor <NUM> may detect this pivoting because the distance between objective assembly <NUM> and objective assembly mount <NUM> and/or microscope body <NUM> may change due to the pivoting. In particular, some regions of objective assembly <NUM> may come closer to objective assembly mount <NUM>, and other regions may get farther away from objective assembly mount <NUM>, when objective assembly <NUM> pivots away from predetermined relative orientation <NUM> and/or to a different relative orientation.

Position sensor <NUM> may be contained, or fully contained, within either objective assembly <NUM> or objective assembly mount <NUM>, and may be spaced apart from the other of the two components in which it is not included. For example, position sensor <NUM> may be included in only objective assembly <NUM> and may be spaced apart from objective assembly mount <NUM>. In such a configuration, position sensor <NUM> may be configured to measure the distance between it and objective assembly mount <NUM>. Conversely, when position sensor <NUM> is included in only objective assembly mount <NUM>, the position sensor may be spaced apart from objective assembly <NUM>, and may be configured to measure the distance between it and objective assembly <NUM>.

However, in other examples, such as when position sensor <NUM> comprises a Hall effect sensor, the position sensor may comprise one or more components that are included in both objective assembly <NUM> and objective assembly mount <NUM>. For example, a sensing element of the Hall effect sensor may be included in objective assembly mount <NUM>, and a magnet of the Hall effect sensor may be included in objective assembly <NUM>, as just one example.

As illustrated by the dash-dot lines in <FIG>, orientation detection circuit <NUM> may be included at different positions within probe system <NUM> and/or may comprise multiple parts that may be positioned at different locations within and/or throughout probe system <NUM>. As an example, orientation detection circuit <NUM> may be at least partially included in both objective assembly <NUM> and objective assembly mount <NUM>. As one such example, and as described above, orientation detection circuit <NUM> may include contacting structures <NUM> and <NUM> that may be coupled to and/or included within objective assembly <NUM> and objective assembly mount <NUM> to form a type of switch.

However, in other examples, orientation detection circuit <NUM> may be wholly included in only one component of the microscope. For example, orientation detection circuit <NUM> may be included entirely within either objective assembly <NUM> or objective assembly mount <NUM>. As one such example, and as described above, orientation detection circuit <NUM> may comprise position sensor <NUM> that may be included in either objective assembly <NUM> or objective assembly mount <NUM>.

In still further examples, orientation detection circuit <NUM> may be positioned outside of objective assembly mount <NUM>, as illustrated by the dash-dot lines in <FIG>. As one such example, at least a portion or a part of orientation detection circuit <NUM> may be included in control system <NUM> and/or between control system <NUM> and microscope <NUM>. For example, orientation detection circuit <NUM> may be positioned outside (i.e. external to) objective assembly mount <NUM>, but may receive a signal (e.g., electrical, optical, wireless, etc.,) generated and/or collected within objective assembly mount <NUM>. As one such example, microscope <NUM> may include a sensor or other structure, such as position sensor <NUM>, that is positioned within the objective assembly mount <NUM> and is configured to measure the relative orientation between objective assembly <NUM> and objective assembly mount <NUM>. In particular, the sensor or other structure may be configured to generate a signal that is indicative of the relative orientation between objective assembly <NUM> and objective assembly mount <NUM>. When orientation detection circuit <NUM> is positioned outside of the objective assembly mount <NUM>, this signal may be transmitted from the sensor or other structure, outside the objective assembly mount <NUM>, to orientation detection circuit <NUM>. As just one example, an optical signal corresponding to the relative orientation between objective assembly <NUM> and objective assembly mount <NUM> may be transmitted by a fiber optic cable from within objective assembly mount <NUM> to the externally positioned orientation detection circuit.

Control system <NUM> may be in electrical communication (wired or wireless) with orientation detection circuit <NUM> for receiving an indication of the relative orientation between microscope body <NUM> and objective assembly <NUM> (e.g., based on electrical signals received from orientation detection circuit <NUM>). Based on detected changes in the relative orientation, control system <NUM> may determine that collision <NUM> has occurred. Responsive to determining that collision <NUM> has occurred, control system <NUM> may adjust movement of objective assembly <NUM>, probe <NUM>, and/or DUT <NUM> via the one or more actuators (e.g., drive mechanism <NUM>, drive assembly <NUM>, and manipulator <NUM>) to mitigate collision <NUM>. As one example, probe system <NUM> may cease relative motion among the various components involved in collision <NUM>, may cease motion of microscope <NUM>, may retract microscope <NUM>, and/or may retract one or more of the other components of probe system <NUM> involved in collision <NUM>, such as probe <NUM> and/or DUT <NUM>. Additionally or alternatively, probe system <NUM> may sound an alarm, display a dialog, and/or otherwise indicate, to a user of the microscope, that the collision has occurred.

In particular, control system <NUM> may be programmed to control various actuators of probe system <NUM> (e.g., drive mechanism <NUM>, manipulator <NUM>, drive assembly <NUM>, etc.) to control movement of probe <NUM>, DUT <NUM>, and microscope <NUM> (and therefore objective assembly <NUM>). When included, control system <NUM> may comprise a controller <NUM> (e.g., electric circuits). Controller <NUM> may include two or more controllers, in some examples. Each controller <NUM> may comprise a processing unit <NUM> and/or a memory unit <NUM>. Memory unit <NUM> may store computer-readable instructions (the software) and processing unit <NUM> may execute the stored computer-readable instructions to perform the various collision detection and mitigation techniques described herein.

In some examples, controller <NUM> may be at least partially included in signal generation and analysis assembly <NUM>. For example, processing unit <NUM> and/or memory unit <NUM> may be at least partially included in signal generation and analysis assembly <NUM>. When included, memory unit <NUM> may comprise non-volatile (also referred to herein as "non-transitory") memory <NUM> (e.g., ROM, PROM, and EPROM) and/or volatile (also referred to herein as "transitory") memory <NUM> (e.g., RAM, SRAM, and DRAM), in some examples. Processing unit <NUM> may comprise one or more integrated circuits including, but not limited to, one or more of: field-programmable gate arrays (FPGAs), application-specific integrated circuits (ASICs), digital signal processors (DSPs), microprocessors, microcontrollers, programmable array logic (PALs), and complex programmable logic devices (CPLDs).

Control system <NUM> may comprise controllers (e.g., electric circuits), located in different locations, and/or included in different devices, of probe system <NUM>. As one example, a corresponding controller <NUM> may be included in microscope <NUM>, and more specifically in microscope body <NUM>, as indicated by dash-dot lines in <FIG>. In some such examples, the corresponding controller <NUM> that may be fully included within microscope <NUM> and/or may be programmed to control the components of microscope <NUM>, such as to control drive mechanism <NUM> to adjust translation of microscope <NUM> along optical axis <NUM>. Said another way, microscope <NUM> may at least partially include control system <NUM> by including the corresponding controller <NUM> of control system <NUM>. In some further such examples, the corresponding controller <NUM> that may be fully included within microscope <NUM>, may be dedicated to just microscope <NUM>, and/or accordingly may be programmed to control only components of microscope <NUM>, such as drive mechanism <NUM>, and not manipulator <NUM> or drive assembly <NUM>.

Control system <NUM> may additionally or alternatively comprise one or more other controllers positioned outside microscope <NUM> that may be programmed to control the other actuators of probe system <NUM>, such as manipulator <NUM> and/or drive assembly <NUM>. In one specific example, control system <NUM> may include two controllers: one in microscope <NUM> for controlling operation of microscope <NUM>, and another outside of the microscope for controlling the various actuators of probe system <NUM> (e.g., manipulator <NUM>, drive assembly <NUM>, etc.). However, in other examples, control system <NUM> may include more than one controller outside of microscope <NUM>. As one such example, each of the actuators (e.g., manipulator <NUM>, drive assembly <NUM>, etc.) may include its own dedicated controller.

In still further examples, control system <NUM> may not include a controller within microscope <NUM> and may instead control operation of microscope <NUM> from an external controller that is positioned outside of microscope <NUM>. In a yet further example, control system <NUM> may include a single controller that is partially included in microscope <NUM> and partially positioned exterior to microscope <NUM>.

Control system <NUM> and/or controller <NUM> may include at least a part of, or all of, orientation detection circuit <NUM>, in some examples.

As will be described in greater detail below, control system <NUM> may be programmed to execute various methods, such as the methods schematically represented in <FIG>. In particular, control system <NUM> may be programmed to: <NUM>) detect collisions between objective assembly <NUM> and other components of probe system <NUM>; <NUM>) cease relative motion among the various components involved in the collision such as objective assembly <NUM>, probe <NUM> and/or DUT <NUM>; <NUM>) retract one or more of the various components involved in the collision; and/or <NUM>) sound an alarm, display a dialog, and/or otherwise indicate, to a user of the microscope, that the collision has occurred.

For example, a controller <NUM> included in microscope <NUM> may include computer-readable instructions stored in non-transitory memory <NUM> for controlling drive mechanism <NUM> to stop and/or reverse movement of microscope <NUM> responsive to orientation detection circuit <NUM> providing an indication that the relative orientation between microscope body <NUM> and objective assembly <NUM> differs from predetermined relative orientation <NUM>. Processing unit <NUM> may carry out these stored computer-readable instructions to control drive mechanism <NUM>. In particular, processing unit <NUM> may be in electrical communication with drive mechanism <NUM> and may be programmed to send a command signal to drive mechanism <NUM> to stop and/or reverse motion of microscope <NUM> responsive to the indication that the relative orientation between microscope body <NUM> and objective assembly <NUM> differs from predetermined relative orientation <NUM>.

In another example, control system <NUM> may include computer-readable instructions stored in non-transitory memory <NUM> for controlling one or more of the other external actuators positioned outside the microscope (e.g., manipulator <NUM> and drive assembly <NUM>). In particular, control system <NUM> may include computer-readable instructions stored in non-transitory memory <NUM> for controlling manipulator <NUM> and/or drive assembly <NUM>, to stop motion and/or reverse the direction of motion (i.e. retract) of probe <NUM> and/or support surface <NUM> of chuck <NUM>, respectively, responsive to orientation detection circuit <NUM> providing an indication that the relative orientation between microscope body <NUM> and objective assembly <NUM> differs from predetermined relative orientation <NUM>. In some examples, such as where probe system <NUM> includes multiple moving components, control system <NUM> may include computer-readable instructions for determining which probe system component (e.g. which probe <NUM>) has collided with objective assembly <NUM>, and control system <NUM> may only stop the motion of and/or retract that particular probe system component. However, in other examples, control system <NUM> may simply stop the motion of and/or reverse the direction of motion (i.e. retract) all of the probe system components when a collision occurs.

By detecting collisions and stopping and/or ceasing motion of microscope <NUM> and/or the external components of probe system <NUM> when a collision is detected, damage to the collided components of the probe system may be mitigated. The collided objects may additionally or alternatively be retracted from one another to further mitigate the impact of the collision, and/or to allow for quick inspection of the collided parts. Further, by allowing objective assembly <NUM> to pivot relative to microscope body <NUM> when a collision occurs, the forces generated during collisions between objective assembly <NUM> and components of probe system <NUM> may be dampened and/or decreased, thereby reducing the amount of damage done by such collisions before the motion of microscope <NUM> is stopped.

Microscope body <NUM> may include any suitable structure that may permit and/or facilitate the collection of images, or of optical images, by microscope <NUM>. These may include structures that may be conventional to microscopes, to optical microscopes, to electronic microscopes, and/or to microscopes that are configured to collect digital images. As examples, microscope body <NUM> may include one or more lenses, mirrors, charge coupled devices (CCDs), actuators, memory devices, electronic devices, electrical conductors, and/or logic devices such as corresponding controller <NUM>.

Objective assembly <NUM> may include any suitable structure that may include objective lens <NUM>. This may include structures that may be conventional to microscopes, to optical microscopes, to electronic microscopes, and/or to microscopes that are configured to collect digital images. It is within the scope of the present disclosure that objective assembly <NUM> may at least partially form and/or define orientation detection circuit <NUM>, as discussed in more detail herein.

As illustrated in <FIG> and <FIG>, objective assembly <NUM> may include a projecting region <NUM> that may extend away from optical axis <NUM>. Projecting region <NUM> may be shaped and/or sized to interface with objective assembly mount <NUM> and/or to retain objective assembly <NUM> within the objective assembly mount, as discussed in more detail herein. Projecting region <NUM> may include at least a portion of orientation detection circuit <NUM>. For example, if the orientation detection circuit comprises contacting structure <NUM> as illustrated in <FIG> and <FIG>, projecting region <NUM> may include one or more of contacting structures <NUM>.

Objective assembly mount <NUM> may include any suitable structure that may be configured to separably attach objective assembly <NUM> to microscope body <NUM>. As an example, and as illustrated in <FIG> and <FIG>, objective assembly mount <NUM> may define a receiving region <NUM> that may be shaped and/or sized to receive at least a portion of objective assembly <NUM>, such as projecting region <NUM> thereof. Further, receiving region <NUM> may define a restricted region <NUM> that may be sized to support projecting region <NUM> of objective assembly <NUM> and also to permit a portion of objective assembly <NUM> to pass therethrough.

As perhaps best illustrated in <FIG> and <FIG>, receiving region <NUM> may be oversized relative to projecting region <NUM> and/or may be sized to permit at least limited translation and/or rotation of objective assembly <NUM> while objective assembly mount <NUM> operably and/or separably attaches objective assembly <NUM> to microscope body <NUM>. In one example, receiving region <NUM> may be configured to permit objective assembly <NUM> to pivot relative to objective assembly mount <NUM> within receiving region <NUM>, such as may be responsive to collision <NUM>. In particular, receiving region <NUM> may be oversized relative to objective assembly <NUM> to permit objective assembly <NUM> to pivot relative to objective assembly mount <NUM>. Although objective assembly <NUM> may be configured to pivot relative to objective assembly mount <NUM> and/or microscope body <NUM>, objective assembly mount <NUM> may not be configured to pivot relative to microscope body <NUM>. That is, the relative orientation of objective assembly mount <NUM> and microscope body <NUM> may be fixed (i.e. not adjustable).

Such a configuration may permit and/or facilitate detection of contacts, collisions, and/or crashes by orientation detection circuit <NUM>, as discussed herein. Such a configuration additionally or alternatively may permit and/or facilitate separable attachment of objective assembly <NUM> to microscope body <NUM>, such as via insertion of projecting region <NUM> into receiving region <NUM> and/or removal of projecting region <NUM> from receiving region <NUM>.

According to the present invention, objective assembly <NUM> and objective assembly mount <NUM> are configured to utilize the force of gravity to bias the objective assembly toward the predetermined relative orientation. The objective assembly mount comprises a levelling mechanism <NUM> that defines a plane (e.g., x-y plane in <FIG>). In some such examples, this plane may be orthogonal to the force of gravity (z-axis in <FIG>). When microscope <NUM> is orientated such that the force of gravity acts along the negative z-axis of <FIG>, the force of gravity biases projecting region <NUM> toward and/or into contact with levelling mechanism <NUM> of objective assembly mount <NUM>. Because levelling mechanism <NUM> defines a substantially flat plane, levelling mechanism <NUM> in combination with the force of gravity biases objective assembly <NUM> into alignment with objective assembly mount <NUM> such that optical axis <NUM> of the objective assembly is parallel to central axis <NUM> of objective assembly mount <NUM> and microscope body <NUM>.

According to the present invention, levelling mechanism <NUM> includes a <NUM>-point mount <NUM> as illustrated in <FIG>. Three-point mount <NUM> may comprise three spaced-apart at least partially spherical surfaces <NUM> that may project into receiving region <NUM>. According to the claimed invention levelling mechanism <NUM> comprises a <NUM>-point kinematic mount. The tips of the at least partially spherical surfaces may define a flat plane on which objective assembly <NUM> may rest under the influence of gravity.

Further, objective assembly <NUM> and/or projecting region <NUM> thereof may include three slots and/or grooves <NUM>, as perhaps best illustrated in <FIG>. Surfaces <NUM> may be shaped and/or sized to be received within grooves <NUM> when projecting region <NUM> is received within receiving region <NUM> of objective assembly mount <NUM> and microscope body <NUM> and objective assembly <NUM> define predetermined relative orientation <NUM> therebetween. As discussed, microscope <NUM> may be oriented and/or positioned such that the force of gravity retains surfaces <NUM> within grooves <NUM> and/or such that the force of gravity retains microscope body <NUM> and objective assembly <NUM> in predetermined relative orientation <NUM>.

As illustrated in dashed lines in <FIG>, objective assembly mount <NUM> may include a biasing mechanism <NUM> that may be configured to bias the objective assembly towards predetermined relative orientation <NUM>. Biasing mechanism <NUM> may be configured to bias microscope body <NUM> and objective assembly <NUM> toward predetermined relative orientation <NUM> and/or to bias projecting region <NUM> toward restricted region <NUM>. Stated another way, biasing mechanism <NUM> may supplement the force of gravity in urging microscope body <NUM> and objective assembly <NUM> toward predetermined relative orientation <NUM>. Biasing mechanism <NUM> may comprise a magnetic assembly or other suitable assembly for biasing objective assembly <NUM> toward predetermined relative orientation <NUM>. For example, a magnetic assembly may include magnets in both projecting region <NUM> of objective assembly <NUM> and in receiving region <NUM> and/or restricted region <NUM> of objective assembly mount <NUM>.

Biasing mechanism <NUM> may decrease a potential for, or prevent, unwanted pivoting of objective assembly <NUM>. In particular, biasing mechanism <NUM> may help to ensure that objective assembly <NUM> stays in place during normal microscope operation and only moves relative to microscope body <NUM> when a collision occurs.

<FIG> is a flowchart depicting examples of methods <NUM> of detecting and/or mitigating a collision between a microscope, such as microscope <NUM> of <FIG>, and an object. As described above, control system <NUM> may be programmed to perform one or more of the methods <NUM>. In particular, control system <NUM> may include computer-readable instructions stored in non-transitory memory <NUM> for performing one or more of methods <NUM>. Methods <NUM> include moving the microscope and the object relative to one another at <NUM> and physically contacting an objective assembly of the microscope with the object at <NUM>. Methods <NUM> also include moving the objective assembly relative to a microscope body of the microscope at <NUM> and detecting a change in a relative orientation between the microscope body and the objective assembly at <NUM>. Methods <NUM> further may include responding to the change in relative orientation at <NUM>, aligning a probe with a device under test (DUT) at <NUM>, and/or testing the DUT at <NUM>.

Moving the microscope and the object relative to one another at <NUM> may include translating, pivoting, and/or rotating at least one of the microscope and the object relative to the other of the microscope and the object. The moving at <NUM> may produce, or result in, the physically contacting at <NUM>. Stated another way, the physically contacting at <NUM> may be a result of the moving at <NUM>, may be responsive to the moving at <NUM>, may be an undesired result of the moving at <NUM>, may be an unexpected result of the moving at <NUM>, or may be an unanticipated result of the moving at <NUM>.

The moving at <NUM> may be accomplished in any suitable manner. As an example, the moving at <NUM> may include moving the microscope with a drive mechanism, such as drive mechanism <NUM> of <FIG>. As another example, the object may include a probe of a probe system that includes the microscope and the moving at <NUM> may include moving the probe with a manipulator, such as manipulator <NUM> of <FIG>. As another example, the object may include the DUT and the moving at <NUM> may include moving the DUT with a drive assembly, such as drive assembly <NUM> of <FIG>.

Physically contacting the objective assembly of the microscope with the object at <NUM> may include bringing the objective assembly and the object into direct physical contact with one another and may be a result of the moving at <NUM>. Additionally or alternatively, the physically contacting at <NUM> may include applying a first force to the objective assembly with the object and/or applying a second force to the object with the objective assembly. The physically contacting at <NUM> may produce, generate, and/or result in the moving at <NUM>. Examples of the object include the probe, such as probe <NUM> of <FIG>, and/or the DUT, such as DUT <NUM> of <FIG>. Additional examples of the object include a cable of the probe system and/or a probe card of the probe system.

Moving the objective assembly relative to the microscope body of the microscope at <NUM> may include rotating, pivoting and/or translating the objective assembly relative to the microscope body and may be responsive to, or a result of, the physically contacting at <NUM>. Stated another way, the first force, which is applied to the objective assembly by the object during the physically contacting at <NUM> may cause relative motion between the objective assembly and the microscope body.

The moving the objective assembly relative to the microscope body may further comprise adjusting one or more of a voltage, current, and/or electrical continuity in an electric circuit (e.g., orientation detection circuit <NUM>) of the microscope. For example, in examples where the orientation detection circuit comprises an electric switch, the moving the objective assembly relative to the microscope body may comprise opening or closing the electric switch. The opening or closing the electric switch may comprise pivoting the objective assembly relative to the microscope body to separate the objective assembly from at least one electrical contacting structure of the objective assembly mount such that the objective assembly does not physically contact the at least one electrical contacting structure. This pivoting of the objective assembly relative to the microscope body may comprise pivoting the objective assembly away from a predetermined relative orientation.

As discussed, the objective assembly may be separably attached to the microscope body with, via, and/or utilizing an objective assembly mount, such as objective assembly mount <NUM> of <FIG> and <FIG>. As also discussed, the objective assembly mount utilizes the force of gravity and optionally also a supplemental force, which may be generated by a biasing mechanism, to retain the objective assembly and the microscope body in the predetermined relative orientation. As such, the first force, which is applied to the objective assembly during the physically contacting at <NUM> may be sufficient to overcome the gravitational force and optionally also the supplemental force, thereby causing the relative motion between the objective assembly and the microscope body and/or causing the objective assembly and the microscope body to transition away from the predetermined relative orientation and/or to a relative orientation that differs from the predetermined relative orientation.

Detecting the change in the relative orientation between the microscope body and the objective assembly at <NUM> may include detecting the change in relative orientation in any suitable manner. As an example, the microscope may include the orientation detection circuit, such as orientation detection circuit <NUM> of <FIG>, and the detecting at <NUM> may include detecting with, via, and/or utilizing the orientation detection circuit. As a more specific example, the detecting at <NUM> may include detecting a change in electrical continuity (e.g., opening and/or closing of an electric switch such as electric switch <NUM>) within the orientation detection circuit, such as between a contacting structure, such as contacting structures <NUM>, that is operatively attached to the objective assembly mount and another contacting structure that is operatively attached to the objective assembly. Detecting the moving of the objective assembly relative to the microscope body may additionally or alternatively comprise detecting a change in one or more of the voltage and current in the orientation detection circuit. In still further examples, the detecting the moving of the objective assembly relative to the microscope body may comprise detecting the moving at <NUM> with a position sensor and/or detecting a change in relative orientation produced by the moving at <NUM> with the position sensor.

Responding to the change in relative orientation at <NUM> may include performing at least one action responsive to detecting the change in relative orientation. In particular, the responding may comprise adjusting the moving of the microscope and/or one or more actuators outside of the microscope in the probe system, such as manipulator <NUM> and drive assembly <NUM>. As examples, the responding at <NUM> may include ceasing motion of the microscope (e.g., ceasing the moving at <NUM>), retracting the microscope away from the object, ceasing and/or reversing translation (i.e. retracting) of the probe, ceasing and/or reversing translation (i.e. retracting) of the DUT, and/or generating an alert that is indicative of physical contact between the objective assembly and the object.

Methods <NUM> may be utilized during operation of the probe system, such as to test the device under test. In such examples, methods <NUM> further may include aligning the probe with the device under test (DUT) at <NUM>. The aligning at <NUM> may include collecting one or more images of the probe and/or of the DUT with the microscope and/or utilizing the one or more images to align the probe with the DUT, to contact the probe with the DUT, and/or to contact the probe with a contact pad of the DUT.

When methods <NUM> are utilized during operation of the probe system, methods <NUM> further may include testing the DUT at <NUM>. The testing at <NUM> may include providing a test signal to the DUT and/or receiving a resultant signal from the DUT.

Claim 1:
A microscope (<NUM>) comprising:
a microscope body (<NUM>);
an objective assembly (<NUM>) comprising an objective lens (<NUM>);
an objective assembly mount (<NUM>) configured to separably attach the objective assembly (<NUM>) to the microscope body (<NUM>); and
an orientation detection circuit (<NUM>) configured to indicate when a relative orientation between the microscope body (<NUM>) and the objective assembly (<NUM>) differs from a predetermined relative orientation (<NUM>);
characterized in that the microscope further comprises
a levelling mechanism (<NUM>) that uses gravity to support the objective assembly (<NUM>) in the predetermined relative orientation (<NUM>), wherein the levelling mechanism (<NUM>) comprises a <NUM>-point kinematic mounting structure.