PATENT DOCUMENT

Publication Number: US-8976250-B2
Application Number: US-201213597704-A
Country: US
Kind Code: B2

Title: Lens inspection system

Abstract:
A lens testing system may have a test pattern source that generates a test pattern of light. A lens may have a lens surface that reflects the test pattern of light. A digital camera system may capture an image of the reflected test pattern of light. Computing equipment may perform image processing operations to evaluate the captured image of the reflected test pattern. The test pattern may contain a known pattern of test elements such as a rectangular array of spots or test elements of other configurations. During image processing operations, the computing equipment may analyze the reflected version of the spots or other test elements to measure characteristics of the lens such as radius of curvature, whether the lens contains flat regions, pits, or bumps, lens placement in a support structure, and other lens performance data. The computing equipment may compare the measured lens data to predetermined criteria.

Claims:
What is claimed is: 
     
       1. A method of evaluating a lens having a lens surface, comprising:
 applying a temporary reflective coating to the lens; 
 with a test pattern source, generating a test pattern of light that reflects off of the temporary reflective coating; 
 with a camera system, capturing an image of the reflected test pattern; 
 with computing equipment, evaluating the lens by processing the captured image of the reflected test pattern; and 
 after capturing the image of the reflected test pattern, removing the temporary reflective coating from the lens. 
 
     
     
       2. The method defined in  claim 1  wherein generating the test pattern comprises generating a plurality of illuminated test elements with a dark background. 
     
     
       3. The method defined in  claim 1  wherein generating the test pattern comprises generating an array of light spots. 
     
     
       4. The method defined in  claim 1  wherein generating the test pattern comprises generating concentric rings of light. 
     
     
       5. The method defined in  claim 1  wherein generating the test pattern comprises generating an array of crosses. 
     
     
       6. The method defined in  claim 1  wherein generating the test pattern comprises generating a test pattern that has light spots, wherein the light spots have a first density in a first portion of the test pattern and have a second density in a second portion of the test pattern, and wherein the second density is different than the first density. 
     
     
       7. The method defined in  claim 1  wherein generating the test pattern comprises generating a circular pattern of test elements. 
     
     
       8. The method defined in  claim 1  wherein generating the test pattern comprises generating a plurality of illuminated rings. 
     
     
       9. The method defined in  claim 1  wherein generating the test pattern comprises generating a test pattern sufficiently large to cover the surface of the lens. 
     
     
       10. The method defined in  claim 1  wherein evaluating the lens by processing the captured image of the reflected test pattern comprises counting spots in the captured image. 
     
     
       11. The method defined in  claim 1  wherein evaluating the lens by processing the captured image of the reflected test pattern comprises determining a radius of curvature value for the lens. 
     
     
       12. The method defined in  claim 1  wherein evaluating the lens by processing the captured image of the reflected test pattern comprises measuring spot-to-spot distances. 
     
     
       13. The method defined in  claim 1  wherein evaluating the lens by processing the captured image of the reflected test pattern comprises measuring line curvatures. 
     
     
       14. The method defined in  claim 1  wherein evaluating the lens by processing the captured image of the reflected test pattern comprises processing the captured image to identifying flat portions of the lens surface. 
     
     
       15. The method defined in  claim 1  wherein evaluating the lens by processing the captured image of the reflected test pattern comprises processing the captured image to identify protrusions in the lens surface. 
     
     
       16. The method defined in  claim 1  wherein evaluating the lens by processing the captured image of the reflected test pattern comprises processing the captured image to identify recesses in the lens surface. 
     
     
       17. The method defined in  claim 1  wherein the test pattern includes an array of test elements and wherein evaluating the lens by processing the captured image of the reflected test pattern comprises processing the captured image to individually analyze the test elements in the array. 
     
     
       18. The method defined in  claim 1  further comprising determining whether the lens satisfies predetermined criteria using the processed captured image. 
     
     
       19. The method defined in  claim 1  further comprising:
 after removing the temporary reflective coating from the lens, assembling the lens into an electronic device. 
 
     
     
       20. A lens testing system for testing a lens having a lens surface, comprising:
 a test pattern source configured to generate a test pattern of light; 
 a camera system configured to capture an image of the test pattern reflected from the lens surface; 
 computing equipment configured to evaluate the lens by processing the captured image of the reflected test pattern, wherein the test pattern source comprises:
 a light source; and 
 an opaque mask containing a pattern of openings that allow the light to pass through the opaque mask to form the test pattern; and 
 
 a diffuser between the light source and the opaque mask. 
 
     
     
       21. The lens testing system defined in  claim 20  wherein the openings in the opaque mask are configured to form an array of spots.

Description:
This application claims the benefit of provisional patent application No. 61/640,872, filed May 1, 2012, which is hereby incorporated by reference herein in its entirety. 
    
    
     BACKGROUND 
     This relates to optical inspection, and, more particularly, to optical inspection systems for evaluating optical components such as lenses. 
     Electronic devices such as cellular telephones, computers, and other equipment are often provided with electrical components that use lenses. For example, proximity sensor modules and camera modules may contain lenses. 
     Compact lenses for components such as these may be manufactured in high volume using techniques such as plastic molding techniques. Due to manufacturing variations, not all lenses may be formed perfectly. Some lenses may contain flattened areas and other imperfections. These imperfections can be difficult or impossible to detect using conventional visual inspection techniques. As a result, there is a risk that defective lenses will be assembled into electrical components. If care is not taken, components may be fully assembled or even used in finished electronic devices before lens problems are detected, leading to waste and manufacturing inefficiencies. 
     It would therefore be desirable to be able to provide improved ways in which to evaluate lenses. 
     SUMMARY 
     A lens testing system may have a test pattern source that generates a test pattern of light. A lens may have a lens surface that reflects the test pattern. A digital camera system may capture an image of the reflected test pattern. Computing equipment may perform image processing operations on the captured image of the reflected test pattern to evaluate the lens. 
     The test pattern may contain a known pattern of test elements such as a rectangular array of spots or other test elements. For example, the test pattern may contain a series of parallel lines or crisscrossing lines that form a grid. Circular spots, rectangular spots, crosses, or test elements of other shapes may be used. Test elements may be arranged in a rectangular array, in a line, in a circle, or in other suitable patterns. Test patterns may contain circular features such as ring-shaped test elements. Ring-shaped test elements may be nested inside each other in a concentric fashion. Ring-shaped elements may also be arranged in a circular array pattern. 
     During image processing operations, the computing equipment may analyze the reflected version of the spots or other test elements in a test pattern to measure characteristics of the lens such as radius of curvature. The image processing operations may reveal whether the lens contains defects such as flat regions, pits, or bumps. Lens placement problems such as offsets from a desired location within a support structure may also be detected. Lens faults can be detected when spots in a test pattern are spaced differently than expected, when the number of counted spots in a captured image does not match an expected value, when reflected lines or spots have a different curvature than expected, and when reflected elements have shapes that deviate from expected shapes. Upon detection of a fault, the computing equipment may notify an operator, may create an entry in a data log, or may automatically take corrective action by adjusting manufacturing equipment. Satisfactory lenses may be incorporated into components for use in an electronic device. Faulty lenses may be discarded or reworked. 
     The testing system may be used to test structures that include plastic lenses, glass lenses, nano-lenses (e.g., lenses of the type that may be used in a field of microscopic lenses resting directly on an image sensor in a light field camera), nano-spheres, other optical structures, or other structures of interest. 
     Further features of the invention, its nature and various advantages will be more apparent from the accompanying drawings and the following detailed description of the preferred embodiments. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a diagram of an illustrative lens inspection system in accordance with an embodiment of the present invention. 
         FIG. 2  is a cross-sectional view of a lens inspection system in which a lens is being illuminated using a ring-shaped test pattern source in accordance with an embodiment of the present invention. 
         FIG. 3  is a top view of an illustrative lens inspection system showing potential locations within the system at which light sources and a camera may be placed relative to a lens under test in accordance with an embodiment of the present invention. 
         FIG. 4  is an illustrative lens test pattern having a rectangular array of circles in accordance with an embodiment of the present invention. 
         FIG. 5  is an illustrative lens test pattern reflected from the surface of a satisfactory lens in accordance with an embodiment of the present invention. 
         FIG. 6  is an illustrative lens test pattern reflected from the surface of a lens with an imperfection in accordance with an embodiment of the present invention. 
         FIG. 7  is an illustrative lens test pattern having a rectangular array of squares in accordance with an embodiment of the present invention. 
         FIG. 8  is an illustrative lens test pattern having a rectangular array of crosses in accordance with an embodiment of the present invention. 
         FIG. 9  is an illustrative lens test pattern formed from parallel lines in accordance with an embodiment of the present invention. 
         FIG. 10  is an illustrative lens test pattern having a grid of lines in accordance with an embodiment of the present invention. 
         FIG. 11  is an illustrative lens test pattern having concentric rings of light in accordance with an embodiment of the present invention. 
         FIG. 12  is an illustrative lens test pattern having an array of rings in accordance with an embodiment of the present invention. 
         FIG. 13  is an illustrative lens test pattern having a circular array of illuminated ring-shaped test elements in accordance with an embodiment of the present invention. 
         FIG. 14  is an illustrative lens test pattern having test elements that are distributed with an uneven density so as to concentrate test elements in areas of particular interest when testing a lens in accordance with an embodiment of the present invention. 
         FIG. 15  is a diagram showing how a lens test pattern may be configured to fit the curvature of an optimal lens so that its reflection off a good lens will present a rectangular array pattern of evenly-spaced spots to the inspection system in accordance with an embodiment of the present invention. 
         FIG. 16  is a diagram showing how an array of circular light spots or other test elements in a lens test pattern may be configured to partially cover the exposed surface of a lens under test in accordance with an embodiment of the present invention. 
         FIG. 17  is a diagram showing how an array of circular light spots or other test elements in a lens test pattern may be configured to illuminate an area that covers the entire exposed surface of a lens and additional surrounding areas in accordance with an embodiment of the present invention. 
         FIG. 18  is a cross-sectional side view of an illustrative lens that is characterized by a radius of curvature in accordance with an embodiment of the present invention. 
         FIG. 19  is a cross-sectional side view of an illustrative lens with imperfections that may be detected by an optical inspection system in accordance with an embodiment of the present invention. 
         FIG. 20  is a cross-sectional side view of an illustrative lens showing how an optical inspection system may detect whether the lens has been offset from its desired location in accordance with an embodiment of the present invention. 
         FIG. 21  is a flow chart of illustrative steps involved in evaluating a component such as a lens using an optical inspection system in accordance with an embodiment of the present invention. 
         FIG. 22  is a diagram of an illustrative test system having a display that may be used to generate test patterns in accordance with an embodiment of the present invention. 
         FIG. 23  is a flow chart of illustrative steps involved in using a test system of the type shown in  FIG. 22  in accordance with an embodiment of the present invention. 
         FIG. 24  is a diagram of an illustrative lens inspection system having test pattern generation equipment that includes an ancillary optical component to help direct light onto a lens surface during testing in accordance with an embodiment of the present invention. 
         FIG. 25  is a top view of an illustrative lens in a support structure with fiducials in accordance with an embodiment of the present invention. 
         FIG. 26  is a flow chart of illustrative steps involved in using a test system to process captured image data that includes information on fiducials in accordance with an embodiment of the present invention. 
         FIG. 27  is a diagram of an illustrative test system showing how test light may be applied to the front and rear of a lens and showing how camera systems or other detectors may be used in gathering front-side reflections, backside reflections, and transmitted light to determine whether a lens contains faults in accordance with an embodiment of the present invention. 
         FIG. 28  is a perspective view of a portion of an illustrative test system in which a test pattern generator has been formed using fiber optic structures in accordance with an embodiment of the present invention. 
         FIG. 29  is a diagram showing how an inspection system may be used to inspect a sheet of lenses in accordance with an embodiment of the present invention. 
         FIG. 30  is a cross-sectional side view of an illustrative lens showing how light of three different colors may be captured by a camera system during lens inspection operations in accordance with an embodiment of the present invention. 
     
    
    
     DETAILED DESCRIPTION 
     An optical inspection system of the type that may be used in inspecting components in an electronic device is shown in  FIG. 1 . As shown in  FIG. 1 , optical inspection system  10  may include an illuminated test pattern source such as illuminated test pattern source  12 . Test pattern source  12  may include a light source such as light source  14 , an optical diffuser such as diffuser  16 , and a patterned opaque mask such as mask  18 . Light source  14  may be a lamp, one or more light-emitting diodes, or other source of light. Light source  14  may be configured to produce infrared light, visible light, or ultraviolet light. 
     The light produced by light source  14  may be diffused using light diffuser  16 . Light diffuser  16  may be formed from frosted glass, translucent plastic, or other suitable light diffuser structures. 
     Patterned opaque mask  18  may include an opaque substrate such as opaque mask substrate  22 . Openings  20  may be formed in substrate  22 . Light may pass through the pattern formed by openings  20 . This light may serve as an illuminated test pattern for testing a structure under test in system  10  such as structure under test  24 . 
     Structure under test  24  may include an optical structure or other structures. As an example, structure under test  24  may include a lens such as lens  28  mounted in support structure  24 . Support structure  24  may be a test fixture for use during testing of lens  28  or may be a housing or other structure that is part of a component in which lens  28  is to be used. Lens  28  may, if desired, have a diameter that is less than 5 mm, less than 2 mm, less than 1 mm, less than 0.5 mm, or more than 3 mm (as examples). Lens  28  may be formed from molded plastic, glass, or other transparent materials. 
     Lens  28  may be a visible light lens that passes visible light (and that passes or blocks infrared light and/or ultraviolet light), an infrared (IR) light lens that passes infrared light while passing or blocking infrared light and/or ultraviolet (UV) light, or may be an ultraviolet light lens that passes UV light while allowing visible and/or infrared light to pass or while blocking visible and/or infrared light (as examples). 
     As shown in  FIG. 1 , light associated with light test pattern  32  (e.g., a lens test pattern of light produced by a lens test pattern generator such as lens test pattern generator  12  of  FIG. 1 ), may reflect off of exposed surface  30  of lens  28  and may be detected using camera system  34 . Camera system  34  may include a lens such as lens  36  and a digital image sensor such as sensor  38 . Using lens  36 , camera system  34  may view surface  30  of lens  28  or may otherwise capture an image of light reflected from the surface of the structures being tested by system  10 . Camera system  34  may be located to one side of structures under test  24 , as shown in  FIG. 1 , or may be located vertically above structures under test  24 , as shown by illustrative camera system  34 ′. 
     Computing equipment  40  may be used to perform digital image analysis on captured images from camera system  34  to determine whether lens  28  or other structures under test contain defects. Computing equipment  40  may include one or more computers, networked computers, an image processing board in a computer or computer network, an image processing integrated circuit, and/or other equipment for analyzing captured digital image data. If desired, image inspection operations may also be performed manually (e.g., by allowing a user to view a captured image from camera system  34  on a monitor or by providing a microscope through which the user can directly view surface  30 ). 
     Structures under test  24  may be any structures with a surface to be inspected. As an example, structures under test  24  may be a fully or partly assembled electronic device component such as a proximity sensor containing an infrared light source, an infrared lens through which infrared light from the infrared light source passes to illuminate an external object, an infrared light detector, and an infrared lens through which infrared light passes that has reflected from the external object. The infrared lenses in this type of component may have surfaces such as surface  30  to be inspected. The lenses may exhibit a transmittance that is larger at infrared wavelengths than visible wavelengths (as an example). This may help ensure that visible light that enters lens  28  will be absorbed by the bulk material that forms lens  28 , rather than being reflected back into camera system  34 , thereby reducing unwanted reflections from inside structures under test  24  that might potentially interfere with inspection of surface  30  of lens  28 . In configurations in which structures under test  24  contain lenses with other optical properties, the wavelength of light produced by light source  14  can be selected accordingly. For example, in configurations in which lens  28  transmits visible light, light source  14  may be configured to produce an out-of-band test pattern such as an ultraviolet test pattern or an infrared test pattern. 
     As shown in the illustrative configuration of  FIG. 2 , test pattern source  12  may have a ring-shaped configuration. With this type of arrangement, an opening such as opening  42  may be formed in the center of test pattern source  12 . Test pattern source  12  may be pointed downwards. Camera system  34  may be aligned with opening  42  above structures under test  24 . Light  32  from ring-shaped test pattern source  28  may illuminate surface  30  of lens  28  and, after passing through opening  42 , may be imaged by camera system  34 . Computing equipment  40  may analyze the reflected light (light  32 ) that is detected by camera system  34 . 
     Another illustrative configuration for system  10  is shown in  FIG. 3 .  FIG. 3  is a top view of system  10  showing how test pattern source  12  may be located in various angularly distributed positions around lens  28  (i.e., test pattern source  12  need not be located directly across from camera system  34 ). As shown in  FIG. 3 , illustrative positions that may be used for test pattern source  12  when illuminating lens  28  include positions  12 - 1 ,  12 - 2  (directly across from camera system  34  and raised vertically out of the page in dimension Z above the X-Y plane of lens  28  so that light reflects from surface  30  of lens  28  as shown in  FIG. 1 ), and  12 - 3 . In positions such as position  12 - 2  and, if desired, positions  12 - 1  and  12 - 3 , test pattern source  12  may be located slightly above lens  28  in dimension Z to help ensure that light  32  will reflect towards camera system  34  so that camera system  34  can capture images of the test pattern on surface  30  of lens  28 . 
     The pattern of light that is produced by patterned mask  18  of test pattern source  12  may form an array of spots of light or other illuminated test elements or may have other suitable patterns.  FIG. 4  is a diagram of an illustrative test pattern based on an array of spots. As shown in  FIG. 4 , test pattern  44  may include test elements such as circular spots  50  arranged in a rectangular array (i.e., an array containing rows  46  and columns  48  of spots  50 ). Test elements such as spots  50  are illuminated, whereas background region  52  of pattern  44  is dark. 
     During testing of lens  28 , test pattern source  12  may direct the light of test pattern  44  of  FIG. 4  onto surface  30  of lens  28 . While test pattern source  12  is illuminating surface  30  of lens  28  using test pattern  44  of  FIG. 4 , camera system  34  may capture an image of the test pattern reflecting from surface  30  for analysis by computing equipment  40 . 
     When test pattern  44  of  FIG. 4  reflects from a lens that is free of defects, the image captured by camera system  34  of surface  30  may appear as shown in captured pattern  54  of  FIG. 5 . Individual test elements such as circular spots  50  may appear distinct and evenly distributed over surface  30 . Rows and columns  58  and  60  may be resolved and the spacing between adjacent rows and adjacent columns may be smooth and regular. 
     In contrast, the reflected test pattern from a defective lens will contain artifacts. When, for example, test pattern  44  of  FIG. 4  is reflected from a lens that contains faults, camera system  34  may capture an image such as the image of  FIG. 6 . In captured pattern  62  of  FIG. 6 , the light spots of the original test pattern have been reflected unevenly, resulting in a defect-revealing row-to-row (column-to-column) spacing such as spacing  66 , reduced-intensity (or missing) spots such as spot  68 , smeared out and merged spots such as spots  64 , and test pattern features that are otherwise distorted by the surface imperfections of lens surface  30 . During image analysis by computing equipment  40 , the irregularities that are detected in the captured image of the test pattern may be analyzed to identify the nature of the lens imperfections. As an example, the type of each imperfection may be identified, the severity of each imperfection may be quantified, the location of each imperfection can be identified, the number of imperfections can be quantified, etc. 
     The rectangular array of circular spots that are used in the illustrative test pattern of  FIG. 4  is merely illustrative. In general, test pattern source  12  may generate any suitable test pattern of light.  FIG. 7  shows an example in which test pattern  44  includes rectangular (e.g., square) spots  50  in a rectangular array. Spots  50  of  FIG. 7  and the other illustrative test patterns described herein may each have the same intensity or may have different intensities (e.g., different known intensities). 
     To help identify localized imperfections such as small pits or bumps, it may be desirable to provide each test element in the test pattern with additional structure. As shown in  FIG. 8 , for example, test pattern  44  may include test elements  50  that have the shapes of crosses. During inspection operations, the shape of each reflected cross may be analyzed by computing equipment  40 . Well-shaped and properly positioned crosses in the captured image may be indicative of properly formed local regions of lens surface  30 . Ill-formed and improperly positioned crosses in the captured image may be used to identify the locations of individual surface defects. 
     In the example of  FIG. 9 , test elements  50  have the shape of parallel lines.  FIG. 10  is an example of a test pattern having both horizontal and vertical lines. As shown in  FIG. 10 , test pattern  44  of  FIG. 10  may have vertical lines  50 V that overlap and run perpendicular to horizontal lines  50 H to form a grid of lines. 
     In the example of  FIG. 11 , test pattern  44  includes test elements that have the shape of rings. As shown in  FIG. 11 , rings  50  may have different diameters, so that each ring may nest within the next to form a set of concentric rings. If desired, rings  50  in test pattern  44  of  FIG. 11  may be laterally offset from each other (i.e., rings  50  need not be concentric and may overlap each other). 
       FIG. 12  shows how test pattern  44  may include a rectangular array of ring-shaped test elements  50 . Rectangular arrays may have any suitable numbers of rows and columns of test elements. The use of configurations with three or four rows and three or four columns of test elements is merely illustrative. As an example, test pattern  44  may contain one, two, three or more, five or more, ten or more, twenty or more, forty or more, 80 or more, or 160 or more test elements  50  organized in a rectangular array, in a pseudo-random pattern, in a circular pattern, in a spiral pattern, in a pattern having a circular or oval outline, in a pattern having straight edges, in a pattern having a combination of straight and curved edges, or in other suitable patterns.  FIG. 13  shows an illustrative configuration in which test pattern  44  includes a set of ring-shaped test elements  50  organized in a circle. 
     Some portions of lens surface  30  (or other structures under test) may be of more interest than others. For example, central portions of lens surface  30  may have more impact on the performance of lens  28  than others. To ensure that the areas of most interest on lens  28  can be accurately evaluated, test pattern  44  may be provided with spots or other test pattern elements that are denser in some portions of pattern  44  than in others. As an example, test pattern  44  may have a layout of the type shown in  FIG. 14 . As shown in  FIG. 14 , the central portions of test pattern  44  may be provided with a greater concentration of spots  50  than the peripheral portions of test pattern  44 . In general, the density of spots  50  in test pattern  44  may be varied as a function of lateral position within pattern  44 , as a function of radial distance from the center of pattern  44 , as a function of angular position within pattern  44 , and/or as another function of position within pattern  44 . The configuration of  FIG. 14  in which spots  50  are unevenly distributed across test pattern  44  is merely illustrative. 
     Computing equipment  40  may use pattern recognition algorithms to evaluate pattern  44  on the surface of lens  28 . To facilitate pattern recognition operations and/or to make it easier for a test system operator to manually ascertain whether a lens is satisfactory, it may be desirable to pre-distort pattern  44  so that the version of pattern  44  that appears on surface  30  of lens  28  has a regular and recognizable pattern. An example of this type of arrangement is shown in  FIG. 15 . As shown in  FIG. 15 , mask  18  of test pattern source may contain a pattern of openings  22  in opaque mask layer  22  that are configured so that the light spots that are produced in the test pattern have the appearance of the rectangular array of spots  56  on surface  30  of lens  28  when viewed using camera system  34 . Other types of pattern distortion may be used, if desired. For example, pattern  44  may be configured so that a pattern of parallel lines is visible on lens surface  30 , so that a grid with perpendicular straight lines is reflected from lens surface  30 , so that a circular array of spots is produced on lens surface  30 , or so that other desired patterns are produced on lens surface  30 . By configuring pattern  44  at test pattern source  12  in this way, the process of acquiring and analyzing images of the test pattern on lens surface  30  may be simplified. For example, the ability of computing equipment  40  to implement spot counting algorithms, row spacing measurement algorithms, column spacing measurement algorithms, and other test pattern analysis algorithms may be enhanced. If desired, spots  50  may be preconfigured so that the spots in the reflected version of the spots all have the same intensity or have other regular patterns of intensities. 
     As shown in  FIG. 16 , the size of test pattern  44  can be configured so that test pattern  44  illuminates only a subset of the surface area of the surface to be tested. In the  FIG. 16  example, test pattern  44  includes a four-by-four array of circular spots, leading to a four-by-four array of corresponding spots  56  on lens surface  30 . The width and height of the array of spots  56  has been configured to fit within a central portion of the surface area of lens  30 . This type of arrangement may be useful to avoid complications that may arise when evaluating spots on peripheral portions of lens surface  30 , where spots may not land completely on surface  30  or may otherwise be difficult to detect. 
     If desired, test pattern  44  may be oversized to ensure that spots  50  will completely cover lens surface  30 . As shown in  FIG. 17 , for example, pattern  44  may be configured so that surface  30  is completely covered with spots  56 . Some spots such as spots  56 ′ will generally land outside of lens area  30  and may therefore not be imaged by camera system  34 . Because the area covered by spots  56 ′ and  56  is larger than necessary to cover lens area  30 , misalignment of lens  28  can be tolerated without reducing the number of spots that appear on lens surface  30 . 
     Using digital image processing, computing equipment  40  can evaluate the pattern of light that appears on surface  30  of lens  28  when illuminated with a test pattern from test pattern source  12 . Image analysis with computing equipment  40  may be used to gather information on the size, shape, and location of lens  28 . 
     As shown in  FIG. 18 , surface  30  of lens  28  may be characterized by a radius of curvature R (or other curvature metrics such as a more complex equation description or a surface described by a series of coordinates). During image processing operations with computing equipment  40 , captured test pattern data may be analyzed to ascertain the value of R (or other curvature data) for the lens under test. If the value of R (or other surface shape data) is different than desired (e.g., in terms of offset distance, offset slope, or other metrics), appropriate action may be taken. 
     Lens  28  in the example of  FIG. 19  contains three imperfections: recess (pit)  70 , flat area  72 , and protrusion (bump)  74 . During image processing operations with computing equipment  40 , the image data from camera system  34  may be evaluated to determine the location and area of pit  70 , the location and area of flat region  72 , and the location and area of bump  74 . Other information on surface defects such as recesses, flat regions, and protrusions may be gathered if desired (e.g., recess curvature, recess shape, recess depth, protrusion curvature, protrusion shape, protrusion height, etc.). 
       FIG. 20  shows how lens  28  may have a location that is offset in dimensions X, Y, and/or Z from its desired location (location  76 ) or may have a location (shown as location  28 TL) in which the lens is tilted at a non-zero angle A with respect to nominal horizontal axis  31  (i.e., the X-Y plane). Computing equipment  40  may perform image analysis operations on captured image data from camera system  34  to determine the magnitude of these lateral offsets and angular orientation deviations (i.e., non-zero lens tilts). In situations in which lens  28  and surface  30  are radially asymmetric, rotational angular offset information can be gathered. In situations in which lens  28  is nominally symmetric (i.e., when it is desired for lens  28  to be rotationally symmetric around its center), image analysis operations on the captured image data may be used to evaluate the degree of symmetry of lens  28  (e.g., to determine whether lens  28  is more asymmetric than desired). 
     Other lens parameters for lens  28  may be measured by using computing equipment  40  to perform image analysis on image data from camera system  34 , if desired. Moreover, other types of structures may be evaluated by projecting spots  50  or other light patterns in test pattern  44  onto structures under test  24 . Examples of other types of structures that may be evaluated in this way include other optical structures (e.g., camera windows, windows for sensors, status indicator light windows, optical port covers, display cover layers such as cover glass layers or layers of plastic in a display), device housing structures (e.g., a planar rear glass housing surface), device components (e.g., button members), glass portions of a track pad or mouse, plastic structures, ceramic structures, glass plates or other glass structures, or other device structures. 
     Illustrative operations involved in using a system such as test system  10  of  FIG. 1 ,  2 , or  3  to evaluate a structure under test such as lens  28  are shown in  FIG. 21 . 
     At step  78 , lens  28  may be illuminated with test pattern of light such as test pattern  44 . Test pattern  44  may contain an array of spots such as spots  50  or other test elements (e.g., lines, circles, rings, crosses, squares, etc.). Spots  50  or other test elements may be organized in an evenly spaced array (e.g., a rectangular array or evenly-spaced circular pattern), may be pre-distorted to produce a regular shape when imaged on surface  30  of lens  28 , may be distributed with an uneven density (e.g., so that portions of surface  30  that are relatively more important for proper lens functioning have a greater density of spots than portions of surface  30  that are relatively less important for proper lens functioning), may be configured to have desired intensity distributions, or may otherwise be distributed within pattern  44 . If desired, the light that makes up test pattern  44  may have an out-of-band wavelength (e.g., a wavelength that does not lie in the transmission band for lens  28  such as visible light when lens  28  transmits infrared light or ultraviolet or infrared light when lens  28  transmits visible light). This may help to reduce undesired scattered light. 
     At step  80 , while test pattern source  12  is producing test light for pattern  44  and while this test light is striking surface  30  of lens  28 , camera system  34  may capture reflected light from surface  30  to acquire an image of test pattern  44  as it appears when reflected from surface  30 . Captured image data from camera system  34  may be stored in storage in computing equipment  40 . The storage of computing equipment  40  may also be used to store operating system code and code for an image analysis program. When the image analysis program code is executed using processing circuitry in computing equipment  40 , computing equipment  40  may analyze the captured digital image data from camera system  34  to evaluate lens  28 . Pattern recognition operations, spatial frequency measurements, intensity measurements, wavelength measurements (spectral data), and other measurements may be made. 
     Examples of parameters that may be evaluated include the spot-to-spot spacing in the test pattern (e.g., the apparent distance between respective spots  50 ), the curvature of lens  28  (e.g., the radius of curvature of surface  30 ), the total intensity of reflected pattern  44 , the individual intensity of each reflected spot  50 , the flatness of flat regions such as region  72  of  FIG. 19 , the shape, location, and other parameters associated with recess  70 , the shape, location, and other parameters associated with protrusion  74 , the number of spots  50  that fall in a particular portion of lens surface  30 , the total number of distinct spots on surface  30 , the number of spots per unit area (spot density) in each region of lens surface  30 , the spacing between lines, crosses, rings, and other test elements, the straightness of reflected lines, and the concentricity of circular test elements in test pattern  44 . During the operations of step  82 , measured test pattern parameters may be processed to produce lens data. As an example, the spacing between spots may be used to compute a radius of curvature value for lens  28 . As another example, the number of spots that is counted can be used to identify whether there are any surface defects such as flat areas, pits, or bumps and can therefore be converted into a defect count or other metric that corresponds to the degree of imperfection of surface  30 . Multiple parameters may, if desired, be combined in ascertaining lens performance. For example, the number of spots counted and the statistical nature of the individual spot intensities can be analyzed together to determine whether or not any of the spots have merged (representing defects such as flat or recessed areas, etc.). 
     Following the data analysis operations of step  84 , computing equipment  40  may compare the gathered test pattern data (raw and/or analyzed data) to lens evaluation criteria and suitable actions may be taken. Examples of actions that may be taken in response to determining that a lens has exhibited characteristics that do not satisfy predetermined criteria include discarding the lens (e.g., discarding a lens before or after assembling the lens into a finished component or device), reworking a partly competed assembly, repairing the lens, notifying an operator, making an entry in a data log, adjusting plastic molding equipment and other fabrication equipment to ensure that subsequent parts satisfy desired evaluation criteria, etc. 
     As an example of an illustrative comparison that may be performed during the operations of step  84  is comparing the number of spots that are detected by camera system  34  to an expected number of spots. If the number of spots that is measured by computing equipment  40  using camera system  34  deviates from the desired amount (e.g., if the number of spots measured is less than expected), it can be concluded that lens  28  contains an imperfection (e.g., a surface defect that causes spots to merge). As another example, if test element lines or rows/columns of spots are wavy or otherwise deviate from their expected positions by more than a predetermined amount, it can be concluded that surface  30  does not have an appropriate shape and suitable action may be taken. Defects associated with rotational position, linear offset, asymmetry, flatness, radius of curvature, spot-to-spot spacing, spot shape (or other test element shape), and other imperfections can also be identified by comparing expected test pattern characteristics to those measured using camera system  34 . 
       FIG. 22  is a diagram of an illustrative test system having a display that may be used to generate test patterns. As shown in  FIG. 22 , system  10  may include a computer monitor or other display with an array of display pixels  102  that serves as test pattern generator  12 . Display pixels  102  may be liquid crystal display pixels, plasma display pixels, light-emitting diode display pixels (e.g., organic light-emitting diode display pixels), cathode ray tube display pixels, or other suitable display pixels. Display pixels  102  may be configured to generate test patterns at suitable wavelengths of interest (e.g., infrared test patterns, red light, green light, blue light, or other visible light test patterns, ultraviolet light test patterns, etc.). 
     During testing with a test pattern, computing equipment  40  in system  10  or an operator may detect defects or areas of interest for further investigation on lens surface  30 . Based on operator input or real time analysis by computing equipment  40 , the test pattern displayed by the array of display pixels  102  in test pattern generator  12  may be updated by computing equipment  40 . Computing equipment  40  may communicate with test pattern generator  12  via path  86 . Modifying the test pattern in this way may help system  10  to accurately identify defects. For example, system  10  may initially use a test pattern with an array of widely spaced spots. If testing with the widely spaced spot array reveals localized areas of potential imperfections, computing equipment  40  may direct display  12  to generate a fine-pitched pattern for testing the localized areas of interest. System  10  may analyze image data that is captured using the fine-pitched pattern to ensure that the localized areas are free of defects. 
     A flow chart of illustrative steps involved in using a test system of the type shown in  FIG. 22  is shown in  FIG. 23 . 
     At step  88 , a display-based test pattern generator such as display  12  of  FIG. 22  may project a test pattern for testing surface  30  of lens  28 . 
     At step  90 , computing equipment  40  may use camera system  34  to capture an image of the test pattern. 
     At step  92 , computing equipment  40  may analyze the captured image. During the operations of step  94 , computing equipment  40  can compare the captured image data to evaluation criteria (expected radius of curvature, expected number of spots, expected reflected line shape, etc.) to determine whether additional testing data is desired. If more data is to be captured, the test pattern that is to be used may be updated. For example, computing equipment  40  may (automatically, or in response to a determination that more detailed testing is desired) update the test pattern so that more finely pitched spots are used (globally and/or locally). Processing may then loop back to the operations of step  88 , as indicated by line  98 . 
     In response to a determination by computing equipment  40  at step  94  that sufficient lens data has been captured, computing equipment  40  may take a suitable action at step  100  based on a comparison of the acquired lens data to predetermined evaluation criteria (e.g., to discard or rework the lens if faulty, to incorporate the lens into a product if not faulty, etc.). 
     In some configurations, it may be challenging to direct light  32  directly onto surface  30  of lens  30  (e.g., in configurations in which camera system  34  has been positioned relatively close to surface  30 ). To help direct light  32  onto surface  30 , test pattern generator  12  may, if desired, include mirrors or focusing lenses to help direct light  32  onto lens  28 .  FIG. 24  is a diagram of an illustrative lens inspection system having test pattern generation equipment  12  that includes main portion  12 A for generating test pattern light  32 - 1  and that includes an ancillary optical component such as a mirror and/or lens system (component  12 B). Ancillary optical system  12 B may be used to redirect light  32 - 1  towards lens  28  (see, e.g., redirected light  32 - 2 ). Light  32 - 2  may reflect from surface  30  and may be passed to camera system  34  as reflected light  32 - 3 . 
     If desired, alignment marks such as fiducials  104  of  FIG. 25  may be incorporated into the structures under test (e.g., as part of a lens housing, part of a structure that is temporarily holding a test component, etc.). In the example of  FIG. 25 , fiducials  104  have been incorporated into support structures  26  (e.g., temporary or finished lens housing structures for lens  28 ). Computing equipment  40  may use camera system  34  to captured information on fiducials  104  to determine the location of support structure  26  relative to lens  28  (e.g., to produce lens offset information). 
       FIG. 26  is a flow chart of illustrative steps involved in using a test system to process captured image data that includes information on fiducials. 
     At step  106 , test pattern generator  12  may project a test pattern for testing surface  30  of lens  28 . 
     At step  108 , computing equipment  40  may use camera system  34  to capture an image of the test pattern that has reflected from lens surface  30  and may use camera system  34  to capture an image of fiducials  104  or other information on the position of structures  26 . 
     At step  110 , computing equipment  40  may analyze the captured image data. During the operations of step  110 , computing equipment  40  can compare the captured image data to evaluation criteria (lens characteristics such as expected radius of curvature, expected number of spots, expected reflected line shape, and offset characteristics such as the offset of fiducials  104  and therefore structures  26  from the center of lens  28  in dimensions X, Y, and Z). 
     At step  112 , computing equipment  40  may compare captured lens and fiducial information to evaluation criteria (e.g., to determine whether surface  30  of lens  28  contains imperfections and/or to determine whether lens  28  is offset by more than an acceptable amount relative to fiducials  104 ). In response to this comparison, suitable action may be taken at step  114  (e.g., to adjust the manufacturing process, to rework faulty components, to discard lens assemblies with faults, to accept for further use parts that pass testing, etc.). 
     As shown in  FIG. 27 , system  10  may include equipment for testing the front and rear of lens  28  and for testing for internal lens defects in lens  28 . System  10  may, for example, include test light generation equipment such as test pattern generator  12 A, test pattern generator  12 B, and test pattern generator  12 C (as examples). Camera equipment  34  may include one or more camera systems such as camera systems  34 A,  34 B, and  34 C for gathering light that has been reflected off of lens  28  and/or that has been transmitted through lens  28 . 
     To facilitate test measurements where light is being scattered off of a surface of lens  28 , test pattern generator equipment  12  may use a wavelength of light that is weakly transmitted by lens  28  (i.e., an out-of-band wavelength of light that is absorbed by lens  28 ). To facilitate test measurements where light is being transmitted through lens  28 , test pattern generator equipment  12  may use an in-band wavelength of light (i.e., a wavelength that is well transmitted though lens  28 ). 
     Light reflections may be made off of the exposed side of a lens surface and/or from the internal side of a lens surface. Combinations of lens surface reflection measurements and lens transmission measurements may be made in characterizing lens  28 . As an example, equipment  12 A may generate a test pattern that is captured by camera system  34 A for inspecting upper lens surface  30 T and/or lower lens surface  30 B. Equipment  12 C may generate a test pattern that is captured by camera system  34 C for inspecting lower lens surface  30 B of lens  28  and/or upper lens surface  30 T. Equipment  12 B may generate a test pattern (e.g., test light) that is captured by camera system  34 B. Light from equipment  12 B (and or light from other sources such as sources  12 A and  12 B) that passes through lens  28  and that is captured by a detector such as camera system  34 C may be used in analyzing lens transmission performance (e.g., to monitor for the presence of lens voids or other bulk defects in lens  28 ). Bulk defects may also be detected using camera systems  34 A and  34 C (e.g., by focusing on the middle of lens  28 ). 
     To facilitate image analysis on captured image data from camera systems  32  of  FIG. 27 , the wavelengths of light that are analyzed may be filtered (e.g., upon light transmission by test pattern generation equipment  12  and/or upon light detection using camera systems  32 ). As an example, consider a lens that transmits infrared light but only weakly transmits visible light. In this situation, surface defects can be analyzed by using camera system  32  to capture bluish visible light from the lens surface. Light at this wavelength tends to be absorbed by lens  28 , so that light reflections that travel through the bulk material of lens  28  are suppressed. Bulk defects can be detected by using camera system  32  (e.g., camera system  34 C to capture light emitted by sources such as sources  12 A and/or  12 B) to capture light at longer wavelengths (e.g., visible light at green wavelengths or longer visible wavelengths, infrared light, etc.), because this light passes through lens  28  readily. Digital image processing techniques may be used to discriminate between captured wavelengths. Sources  12  and camera system  34  may also use optical filtering or other filtering schemes to discriminate between light at different wavelengths. 
     If desired, a temporary coating may be added to lens  28  to help detect defects. As an example, a temporary light-absorbing or reflecting coating may be added to one or more lens surfaces such as surfaces  30 T and  30 B. The coating may be formed from a water-soluble or alcohol-soluble material (as examples). The presence of the coating may help separate interior lens reflections from surface lens reflections. Lens  28  may, if desired, have a permanent coating that may facilitate the separation of interior lens reflections from surface lens reflections. In response to a determination that the interior of lens  28  has too many voids (e.g., bubbles), further analysis may be halted and the lens may be discarded or reworked. 
     If desired, lens rear surfaces such as lens surface  30 B of  FIG. 27  may be examined by capturing an image with a front-side camera system. For example, light that is supplied to the interior of lens surface  30 B may be captured using a front-side camera system such as camera system  34 A. In this type of configuration, test pattern  44  may be preconfigured so that the pattern of spots or other test elements that is observed in the captured image data will have a regular rectangular array shape or other known shape to facilitate fault detection. 
     In general, camera systems  32  may focus on the front or rear of a given lens or may focus on the middle (bulk portions) of the lens. Camera system  32 A may, for example, focus on front surface  30 T to examine surface  30 T for defects, may focus on rear surface  30 B to examine surface  30 B for defects, and/or may focus in the middle of lens  28  between surfaces  30 T and  30 B to examine lens  28  for bulk defects (e.g., voids). 
       FIG. 28  is a perspective view of a portion of an illustrative test system in which a test pattern generator has been formed using fiber optic structures. As shown in  FIG. 28 , test pattern source  12  may include one or more optical fibers such as fibers  116 . Fibers  116  may be organized as a fiber bundle or may be implemented using one or more individual fibers. Fiber structures  116  may be used to form a pencil-shape source suitable for placement close to compact lenses. 
     As shown in  FIG. 29 , lenses  28  may be mounted in a support structure such as support sheet  26  (e.g., following an injection molding operation). Test system  10  may include computer-controlled positioning equipment such as positioning equipment  118  (e.g., positioners in robotic inspection equipment). Computing equipment  40  may be used to control the positions of system components such as test pattern source  12  and/or camera system  34  using positioners  118 . This may allow system  10  to inspect individual lenses on sheet  26  such as lens  28 ′ in the example of  FIG. 29 . System  10  may step through each lens on sheet  26  to test a batch of lenses. Sheet  26  may be a temporary support structure. Following testing using system  10 , lenses that pass inspection may be assembled into lens housings. Fiducials  104  may be arranged around lenses such a lens  28 ′ (e.g., as part of sheet  26 ). 
       FIG. 30  is a cross-sectional side view of an illustrative lens showing how light of different colors may be captured by a camera system during lens inspection operations. Test pattern source  12  may emit white light (as an example). The white light pattern from source  12  may reflect off of top surface  30 T of lens  28  and may be captured as white reflected light  32 W by camera system  34 . The bulk material of lens  28  may tend to absorb blue light, so that light such as light  32 G that is reflected from voids or other bulk defects may have a greenish color. Surface reflections from the inside of lower surface  30 B of lens  28  may be colored similarly or may be provided with a different color using a coating (e.g., a temporary coating) such as coating  120 . As an example, coating  120  may be configured to impart a red color to reflected light from test pattern source  12 , so that reflected light  32 R is red. 
     Using this type of scheme, camera system  34  may be able to discriminate between reflections from surface  30 T (which appear white), reflections form bulk material in lens (which appear green), and reflections from the inside of rear surface  30 B (which appear red). Other combinations of colors may be produced by using a different light spectrum for the emitted light from light source  12 , by using different bulk material for forming lens  28 , and/or by forming coatings with different spectral properties on one or more surfaces of lens  28 . The example of  FIG. 30  is merely illustrative. 
     The foregoing is merely illustrative of the principles of this invention and various modifications can be made by those skilled in the art without departing from the scope and spirit of the invention.

Metadata:
Filing Date: 20120829
Publication Date: 20150310
Grant Date: 20150310
Priority Date: 20120501
Inventors: ARMSTRONG-MUNTNER JOEL S.
DUDLEY JAMES J.
RUH RICHARD
RAI ANANT
Assignee: APPLE INC
CPC Classifications: [{"code": "G01M11/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01M11/02", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01M11/0278", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N21/958", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N2021/9583", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01N21/958", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01M11/0278", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01B11/25", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01N2021/9583", "inventive": false, "first": false, "tree": "[]"}, {"code": "G01M11/00", "inventive": true, "first": true, "tree": "[]"}, {"code": "G01M11/005", "inventive": true, "first": false, "tree": "[]"}, {"code": "G01M11/02", "inventive": true, "first": true, "tree": "[]"}]
Family ID: 49512253