Method of Manufacturing Ball Array Devices Using an Inspection Apparatus having Two or More Cameras and Ball Array Devices Produced According to the Method

A method of manufacturing a ball array device having a plurality of leads, the method comprising:

• providing a fixed optical imaging system comprising at least two cameras;
• calibrating the fixed optical imaging system with a planar precision pattern disposed in a fixed focus position;
• obtaining a bottom view image comprising donut shaped reflections from the leads using the calibrated system;
• obtaining a side view image comprising crescent shaped reflections from the leads using the calibrated system;
• finding locations of the donut shaped reflections from the leads;
• finding locations of the crescent shaped reflections from the leads;
• calculating a Z value for each lead by combining information from the locations of the donut shaped reflections and the locations of the crescent shaped reflections;
• calculating a coplanarity value for the ball array device by using the Z value for each lead;
• and
• determining an inspection result by comparing the coplanarity value to a predetermined tolerance value;
• and
• selecting the ball array device based upon the inspection result.

A method of manufacturing a ball array device having a plurality of leads, the method comprising:

• providing an imaging system comprising at least two cameras;
• calibrating the imaging system with a planar precision pattern disposed in a fixed focus position;
• obtaining two differing views of the leads in at least one image using the calibrated imaging system;
• obtaining a donut shaped reflection from each lead and a crescent shaped reflection from each lead in the at least one image;
• finding at least two reference positions of each lead in the at least one image;
• calculating a Z value of each lead using the at least two reference positions of each lead;
• calculating a coplanarity value using information from the Z value of each lead;
• determining an inspection result by comparing the coplanarity value to a tolerance value;
• and
• selecting the ball array device as a manufactured product depending upon the inspection result.

A method of manufacturing a ball array device having a plurality of leads, the method comprising:

• providing an imaging system comprising two cameras, fixed optics, illumination, a processor and memory;
• calibrating the imaging system with a planar precision pattern in a fixed focus position;
• obtaining a single bottom view image of the leads using the calibrated imaging system;
• obtaining a single side view image of the leads using the calibrated imaging system;
• finding a subpixel location of a reflection from each lead in the single bottom view image;
• finding a subpixel location of a reflection from each lead in the single side view image;
• calculating a Z value for each lead by combining information from the subpixel location of a reflection from the lead in the single bottom view image and the subpixel location of the reflection from the same lead in the single side view image;
• calculating a coplanarity value for the ball array device by using information from the Z value of each lead;
• determining an inspection result by comparing the coplanarity value to a predetermined tolerance value;
• and
• sorting the ball array device based upon the inspection result.

A method of manufacturing a ball array device having a plurality of leads, the method comprising:

• providing an imaging system comprising two cameras, fixed optics, fixed illumination, a processor, memory and a planar precision pattern;
• calibrating the first camera with the planar precision pattern in a fixed focus position;
• calibrating the second camera with the planar precision pattern in a fixed focus position;
• obtaining a generally circular shaped reflection from each lead in a bottom view image using the first camera;
• obtaining a generally curvilinear shaped reflection from each lead in a side view image using the second camera;
• calculating a Z value for each lead using information from the bottom view image and the side view image;
• calculating a coplanarity value using information from the Z values;
• determining an inspection result by comparing the coplanarity value to a tolerance value;
• and
• sorting the ball array device as a manufactured product depending upon the inspection result.

A method of manufacturing a ball array device having a plurality of leads, the method comprising:

• providing an imaging system comprising a first camera, a second camera, fixed optics, fixed illumination, a processor, memory and a planar precision pattern;
• calibrating the imaging system with the planar precision pattern;
• obtaining a generally circular shaped reflection from each lead in a bottom view image using the first camera;
• obtaining a generally curvilinear shaped reflection from each lead in a side view image using the second camera;
• calculating a Z value for each of the leads using information from the bottom view image and the side view image;
• calculating a coplanarity value using information from the Z values of each of the leads;
• determining an inspection result by comparing the coplanarity value to a tolerance value;
• and
• selecting the ball array device as a manufactured product depending upon the inspection result.

A ball array device having a plurality of leads, the device being produced according to a process comprising:

• providing a fixed optical imaging system comprising at least two cameras;
• calibrating the fixed optical imaging system with a planar precision pattern disposed in a fixed position;
• obtaining a single bottom view image of the leads using the calibrated system;
• obtaining a single side view image of the leads using the calibrated system;
• calculating an inspection result by combining information from the single bottom view image and the single side view image;
• and
• selecting the ball array device as a manufactured product using the calculated inspection result.

A ball array device having a plurality of leads, the device being produced according to a process comprising:

• providing a fixed optical imaging system comprising at least two cameras;
• calibrating the fixed optical imaging system with a planar precision pattern disposed in a fixed focus position;
• obtaining a bottom view image comprising donut shaped reflections from the leads using the calibrated system;
• obtaining a side view image comprising crescent shaped reflections from the leads using the calibrated system;
• finding locations of the donut shaped reflections from the leads;
• finding locations of the crescent shaped reflections from the leads;
• calculating a Z value for each lead by combining information from the locations of the donut shaped reflections and the locations of the crescent shaped reflections;
• calculating a coplanarity value for the ball array device by using the Z value for each lead;
• and
• determining an inspection result by comparing the coplanarity value to a predetermined tolerance value;
• and
• selecting the ball array device based upon the inspection result.

A ball array device having a plurality of leads, the device being produced according to a process comprising:

• providing an imaging system comprising at least two cameras;
• calibrating the imaging system with a planar precision pattern disposed in a fixed focus position;
• obtaining two differing views of the leads in at least one image using the calibrated imaging system;
• obtaining a donut shaped reflection from each lead and a crescent shaped reflection from each lead in the at least one image;
• finding at least two reference positions of each lead in the at least one image;
• calculating a Z value of each lead using the at least two reference positions of each lead;
• calculating a coplanarity value using information from the Z value of each lead;
• determining an inspection result by comparing the coplanarity value to a tolerance value;
• and
• selecting the ball array device as a manufactured product depending upon the inspection result.

A ball array device having a plurality of leads, the device being produced according to a process comprising:

• providing an imaging system comprising two cameras, fixed optics, illumination, a processor and memory;
• calibrating the imaging system with a planar precision pattern in a fixed focus position;
• obtaining a single bottom view image of the leads using the calibrated imaging system;
• obtaining a single side view image of the leads using the calibrated imaging system;
• finding a subpixel location of a reflection from each lead in the single bottom view image;
• finding a subpixel location of a reflection from each lead in the single side view image;
• calculating a Z value for each lead by combining information from the subpixel location of a reflection from the lead in the single bottom view image and the subpixel location of the reflection from the same lead in the single side view image;
• calculating a coplanarity value for the ball array device by using information from the Z value of each lead;
• determining an inspection result by comparing the coplanarity value to a predetermined tolerance value;
• and
• sorting the ball array device based upon the inspection result.

A ball array device having a plurality of leads, the device being produced according to a process comprising:

• providing an imaging system comprising two cameras, fixed optics, fixed illumination, a processor, memory and a planar precision pattern;
• calibrating the first camera with the planar precision pattern in a fixed focus position;
• calibrating the second camera with the planar precision pattern in a fixed focus position;
• obtaining a generally circular shaped reflection from each lead in a bottom view image using the first camera;
• obtaining a generally curvilinear shaped reflection from each lead in a side view image using the second camera;
• calculating a Z value for each lead using information from the bottom view image and the side view image;
• calculating a coplanarity value using information from the Z values;
• determining an inspection result by comparing the coplanarity value to a tolerance value;
• and
• sorting the ball array device as a manufactured product depending upon the inspection result.

A ball array device having a plurality of leads, the device being produced according to a process comprising:

• providing an imaging system comprising a first camera, a second camera, fixed optics, fixed illumination, a processor, memory and a planar precision pattern;
• calibrating the imaging system with the planar precision pattern;
• obtaining a generally circular shaped reflection from each lead in a bottom view image using the first camera;
• obtaining a generally curvilinear shaped reflection from each lead in a side view image using the second camera;
• calculating a Z value for each of the leads using information from the bottom view image and the side view image;
• calculating a coplanarity value using information from the Z values of each of the leads;
• determining an inspection result by comparing the coplanarity value to a tolerance value;
• and
• selecting the ball array device as a manufactured product depending upon the inspection result.