CN116183623B - Intelligent wafer surface defect detection method and device - Google Patents
Intelligent wafer surface defect detection method and device Download PDFInfo
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Abstract
Description
技术领域Technical Field
本发明涉及晶圆缺陷检测技术领域,具体为一种晶圆表面缺陷智能检测方法、装置。The present invention relates to the technical field of wafer defect detection, and in particular to a method and device for intelligently detecting wafer surface defects.
背景技术Background technique
晶圆是指制作半导体电路所用的晶片,常用材料有硅、锗、砷化镓、碳化硅、氮化铝、氧化锌、金刚石、磷化铟、氮化镓等;通过向其中掺杂不同元素来获得相应的特性;以硅材料为例,高纯度的多晶硅溶解后掺入硅晶体晶种,通过提拉法完成硅棒的制备;硅晶棒在经过研磨、抛光、切片后,形成硅晶圆片,也就是晶圆;在晶圆制作过程中,化学气相沉淀、光学显影、化学机械研磨在拉单晶、切片、磨片、抛光、增层、光刻、掺杂、热处理以及划片等一系列工序和步骤;由于半导体晶圆加工工艺繁多,在加工工艺流程和搬运过程中,由于加工工序中仪器异常动作和工人操作不当等原因极易造成晶圆表面缺陷。A wafer refers to a chip used to make semiconductor circuits. Common materials include silicon, germanium, gallium arsenide, silicon carbide, aluminum nitride, zinc oxide, diamond, indium phosphide, gallium nitride, etc.; the corresponding properties are obtained by doping different elements into them; taking silicon material as an example, high-purity polycrystalline silicon is dissolved and then doped with silicon crystal seeds, and the preparation of silicon rods is completed by the pulling method; after grinding, polishing and slicing, the silicon crystal rods are formed into silicon wafers, that is, wafers; in the wafer production process, chemical vapor deposition, optical development, chemical mechanical grinding, single crystal pulling, slicing, grinding, polishing, layer addition, photolithography, doping, heat treatment and dicing are a series of processes and steps; due to the various processing techniques of semiconductor wafers, during the processing process and transportation process, wafer surface defects are very easy to cause due to abnormal operation of instruments and improper operation of workers in the processing process.
在搬运过程中造成的缺陷有吸盘在搬运晶圆时由于压力调节不当留在晶圆表面的吸盘印;由于夹取固定或加工晶圆过程中设备在晶圆上制造的爪裂、崩边、划道和蹭伤;由于在光刻胶涂敷后进行的光刻胶去除不干净而在晶圆表面产生的沾污、针孔和药液灼伤;在晶圆切割过程中由于切割不均匀而产生的去边不均缺陷。Defects caused during the handling process include suction cup marks left on the wafer surface due to improper pressure adjustment when transporting the wafer; claw cracks, edge collapse, scratches and abrasions caused by equipment on the wafer during clamping or processing of the wafer; stains, pinholes and chemical burns on the wafer surface due to unclean removal of photoresist after photoresist coating; and uneven edge removal defects caused by uneven cutting during wafer cutting.
上述缺陷会对缺陷晶圆之后的光刻工序造成更严重的缺陷;并且缺陷晶圆进入下一加工制造工序,会造成生产制造资源的浪费,影响后续晶圆加工良率和总体制造加工效率。The above defects will cause more serious defects in the subsequent lithography process of the defective wafer; and the defective wafer entering the next processing and manufacturing process will cause a waste of production and manufacturing resources, affecting the subsequent wafer processing yield and overall manufacturing efficiency.
随着工业图像传感器、计算机视觉和图像处理硬件算力的进步,逐渐发展并应用了借助光学检测设备和机器视觉来对晶圆表面缺陷进行检测并结合工艺分析缺陷造成原因,以改进制造工艺。目前已经有借助机器视觉和计算机视觉方法完成晶圆的缺陷检测的案例,大多都是固定打光方式,只能够检测单一、结构简单的晶圆表面缺陷;而实际晶圆检测行业的真实情况是晶圆产品更新迭代快,对于晶圆的检测工艺和材料变化越来越丰富并且缺陷种类多样的特性,固定打光方式不能满足越来越多类型的缺陷。上述的检测方式和方法存在拍摄方式单一,自动化程度较低,缺陷数据集难收集和通用性较差。With the advancement of industrial image sensors, computer vision, and image processing hardware computing power, the use of optical inspection equipment and machine vision to detect wafer surface defects and analyze the causes of defects in combination with process analysis has gradually developed and applied to improve the manufacturing process. At present, there are cases of wafer defect detection using machine vision and computer vision methods, most of which are fixed lighting methods, which can only detect single, simple-structured wafer surface defects; and the actual situation in the actual wafer inspection industry is that wafer products are updated and iterated quickly, and the inspection process and materials of wafers are becoming more and more diverse, and the types of defects are diverse. Fixed lighting methods cannot meet the increasing number of types of defects. The above-mentioned detection methods and methods have the disadvantages of single shooting methods, low degree of automation, difficulty in collecting defect data sets, and poor versatility.
发明内容Summary of the invention
本发明旨在至少在一定程度上解决相关技术中的技术问题之一。为此,本发明提供了一种晶圆表面缺陷智能检测方法、装置,通过高自由度的打光方式和自适应性强的检测算法完成准确高效的检测,是一种具有高通用性、强可靠性、高延展性的晶圆表面缺陷检测方法。The present invention aims to solve one of the technical problems in the related art to at least a certain extent. To this end, the present invention provides a method and device for intelligent detection of wafer surface defects, which can achieve accurate and efficient detection through a high degree of freedom lighting method and a highly adaptive detection algorithm, and is a wafer surface defect detection method with high versatility, strong reliability and high ductility.
为实现上述目的,第一方面,本申请提供了一种晶圆表面缺陷智能检测方法,包括:将晶圆片和晶圆视觉拍照模组分别安装在相应载体上;To achieve the above-mentioned purpose, in a first aspect, the present application provides a method for intelligent detection of wafer surface defects, comprising: mounting a wafer and a wafer visual camera module on corresponding carriers respectively;
控制晶圆片或晶圆视觉拍照模组移动至第一检测起始相对位置;Controlling the wafer or the wafer visual camera module to move to a first detection starting relative position;
利用晶圆视觉拍照模组在检测一模式下对晶圆表面图像进行采集,包括在检测一模式的预设检测路径下逐路径点进行拍照,循环至检测路径终点;Using the wafer vision camera module to collect wafer surface images in the detection mode, including taking pictures at each path point in the preset detection path of the detection mode, and looping to the end point of the detection path;
控制晶圆片或晶圆视觉拍照模组移动至第二检测起始相对位置;Controlling the wafer or the wafer visual camera module to move to a second detection starting relative position;
利用晶圆视觉拍照模组在检测二模式下对晶圆表面图像进行采集,包括在检测二模式的预设检测路径下逐路径点进行拍照,循环至检测路径终点;Using the wafer vision camera module to collect wafer surface images in the second detection mode, including taking pictures at each path point in the preset detection path of the second detection mode, and looping to the end point of the detection path;
对检测一模式和检测二模式下得到的所有拍摄图像进行图像检测处理,生成晶圆表面缺陷检测结果。Perform image detection processing on all the captured images obtained in the detection mode 1 and the detection mode 2 to generate wafer surface defect detection results.
优选地,所述检测一模式通过LED漫平行光源在不同的倾斜角度下进行对晶圆表面进行打光。Preferably, the detection mode illuminates the wafer surface at different tilt angles through an LED diffuse parallel light source.
优选地,所述检测二模式通过光照度大于第一阈值的高强度光源在不同的倾斜角度下进行对晶圆表面进行打光。Preferably, the second detection mode illuminates the wafer surface at different tilt angles through a high-intensity light source with an illumination greater than a first threshold.
优选地,所述检测一模式和检测二模式下在不同的倾斜角度下进行对晶圆表面进行打光均至少包括高打光角度范围和低打光角度范围,其中打光角度α为光源出射方向与晶圆表面法向夹角,所述高打光角度范围为α=0°°~30,所述低打光角度范围为α=60°°~90。Preferably, the lighting of the wafer surface at different tilt angles in the detection mode 1 and the detection mode 2 includes at least a high lighting angle range and a low lighting angle range, wherein the lighting angle α is the angle between the light source emission direction and the normal of the wafer surface, the high lighting angle range is α=0 °° ~30, and the low lighting angle range is α=60 °° ~90.
优选地,所述将晶圆片和晶圆视觉拍照模组分别安装在相应载体上,控制晶圆片或晶圆视觉拍照模组移动至第一检测起始相对位置包括,将待测晶圆片吸附在多自由度机器人的末端支架上的吸盘上,并将晶圆视觉拍照模组固定安装在模组支架上,控制多自由度机器人带动待测晶圆片移动至第一检测起始相对位置。Preferably, the wafer and the wafer vision camera module are respectively installed on corresponding carriers, and the wafer or the wafer vision camera module is controlled to move to the first detection starting relative position, including adsorbing the wafer to be tested on the suction cup on the end bracket of the multi-degree-of-freedom robot, and fixing the wafer vision camera module on the module bracket, and controlling the multi-degree-of-freedom robot to drive the wafer to be tested to move to the first detection starting relative position.
优选地,所述将晶圆片和晶圆视觉拍照模组分别安装在相应载体上,控制晶圆片或晶圆视觉拍照模组移动至第一检测起始相对位置包括,将晶圆视觉拍照模组安装在多自由度机器人的末端支架上,并将待测晶圆片放置在模组支架上,控制多自由度机器人带动视觉拍照模组移动至第一检测起始相对位置。Preferably, the wafer and the wafer vision camera module are respectively installed on corresponding carriers, and the wafer or the wafer vision camera module is controlled to move to the first detection starting relative position, including installing the wafer vision camera module on the end bracket of the multi-degree-of-freedom robot, and placing the wafer to be tested on the module bracket, and controlling the multi-degree-of-freedom robot to drive the vision camera module to move to the first detection starting relative position.
优选地,对检测一模式和检测二模式下得到的所有拍摄图像进行图像检测处理,生成晶圆表面缺陷检测结果包括对所有拍摄图像进行预处理后进行区域分割处理,以将晶圆图像剪切出来,并使用优化过的YOLOV5模型完成对晶圆图像的表面缺陷目标检测。Preferably, image detection processing is performed on all captured images obtained in detection mode 1 and detection mode 2 to generate wafer surface defect detection results, including pre-processing all captured images and then performing region segmentation processing to cut out the wafer images, and using the optimized YOLOV5 model to complete surface defect target detection of the wafer images.
第二方面,本申请提供了一种晶圆表面缺陷智能检测装置,包括:In a second aspect, the present application provides an intelligent detection device for wafer surface defects, comprising:
检测工作台、晶圆视觉拍照模组和多自由度机器人,所述晶圆视觉拍照模组和多自由度机器人均对称设置在所述检测工作台上,所述晶圆视觉拍照模组用于对晶圆表面缺陷进行图像拍摄,所述多自由度机器人用于带动晶圆片或晶圆视觉拍照模组进行位置移动变换。An inspection workbench, a wafer vision camera module and a multi-degree-of-freedom robot, wherein the wafer vision camera module and the multi-degree-of-freedom robot are symmetrically arranged on the inspection workbench, the wafer vision camera module is used to capture images of wafer surface defects, and the multi-degree-of-freedom robot is used to drive the wafer or the wafer vision camera module to move and transform its position.
优选地,所述晶圆视觉拍照模组包括工业相机一、工业相机二、高强度光源和LED漫平行光源,所述工业相机一和LED漫平行光源用于在检测一模式下对晶圆表面图像进行采集,所述工业相机二和高强度光源用于在检测二模式下对晶圆表面图像进行采集。Preferably, the wafer visual camera module includes industrial camera 1, industrial camera 2, a high-intensity light source and an LED diffuse parallel light source. The industrial camera 1 and the LED diffuse parallel light source are used to collect the wafer surface image in detection mode 1, and the industrial camera 2 and the high-intensity light source are used to collect the wafer surface image in detection mode 2.
与现有技术相比,本发明的有益效果是:Compared with the prior art, the present invention has the following beneficial effects:
本发明提供的晶圆表面缺陷智能检测方法通过高自由度的打光方式能够对晶圆表面多种缺陷完成准确高效的检测,通过不同检测模式的相互配合,能够完成对晶圆进行多角度、全尺寸、全种类表面缺陷检测的目标。The intelligent wafer surface defect detection method provided by the present invention can accurately and efficiently detect various defects on the wafer surface through a high-degree-of-freedom lighting method, and can achieve the goal of multi-angle, full-size, and full-type surface defect detection of the wafer through the mutual cooperation of different detection modes.
本申请的其他特征和优点将在随后的说明书阐述,并且,部分地从说明书中变得显而易见,或者通过实施本申请了解本申请的目的和其他优点可通过在所写的说明书、权利要求书、以及附图中所特别指出的结构来实现和获得。Other features and advantages of the present application will be described in the subsequent description, and in part will become apparent from the description, or it may be understood through the implementation of the present application that the objects and other advantages of the present application can be realized and obtained through the structures particularly pointed out in the written description, claims, and drawings.
附图说明BRIEF DESCRIPTION OF THE DRAWINGS
图1为本发明一种晶圆表面缺陷智能检测方法的流程图;FIG1 is a flow chart of a method for intelligently detecting wafer surface defects according to the present invention;
图2为本发明一种晶圆表面缺陷智能检测方法中高角度打光示意图;FIG2 is a schematic diagram of high-angle lighting in a wafer surface defect intelligent detection method of the present invention;
图3为本发明一种晶圆表面缺陷智能检测方法中低角度打光示意图;FIG3 is a schematic diagram of low-angle lighting in a wafer surface defect intelligent detection method according to the present invention;
图4为本发明一种晶圆表面缺陷智能检测装置的第一种实施例的结构示意图;FIG4 is a schematic structural diagram of a first embodiment of an intelligent device for detecting wafer surface defects according to the present invention;
图5为本发明一种晶圆表面缺陷智能检测装置的第二种实施例的结构示意图;FIG5 is a schematic structural diagram of a second embodiment of a wafer surface defect intelligent detection device according to the present invention;
图6为本发明一种晶圆表面缺陷智能检测装置中晶圆视觉拍照模组的结构示意图;FIG6 is a schematic diagram of the structure of a wafer visual camera module in a wafer surface defect intelligent detection device according to the present invention;
图7为本发明一种晶圆表面缺陷智能检测方法的网络结构图。FIG. 7 is a network structure diagram of a wafer surface defect intelligent detection method according to the present invention.
图中:1、模组支架;2、晶圆视觉拍照模组;3、晶圆片;4、吸盘;5、末端支架;6、多自由度机器人;7、检测工作台;8、晶圆支架;2-1、工业相机一;2-2、工业镜头一;2-3、工业相机二;2-4、工业镜头二;2-5、高强度光源;2-6、LED漫平行光源;2-7、传感器支架。In the figure: 1. Module bracket; 2. Wafer vision camera module; 3. Wafer; 4. Suction cup; 5. End bracket; 6. Multi-degree-of-freedom robot; 7. Inspection workbench; 8. Wafer bracket; 2-1. Industrial camera 1; 2-2. Industrial lens 1; 2-3. Industrial camera 2; 2-4. Industrial lens 2; 2-5. High-intensity light source; 2-6. LED diffuse parallel light source; 2-7. Sensor bracket.
具体实施方式Detailed ways
下面将结合本发明实施例中的附图,对本发明实施例中的技术方案进行清楚、完整地描述,显然,所描述的实施例仅仅是本发明一部分实施例,而不是全部的实施例。基于本发明中的实施例,本领域普通技术人员在没有做出创造性劳动前提下所获得的所有其他实施例,都属于本发明保护的范围。The following will be combined with the drawings in the embodiments of the present invention to clearly and completely describe the technical solutions in the embodiments of the present invention. Obviously, the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.
如图1所示,第一方面,本发明提供的第一种实施例,一种晶圆表面缺陷智能检测方法,包括:As shown in FIG1 , in a first aspect, the present invention provides a first embodiment, a wafer surface defect intelligent detection method, comprising:
将晶圆片3和晶圆视觉拍照模组2分别安装在相应载体上;The wafer 3 and the wafer vision camera module 2 are mounted on corresponding carriers respectively;
控制晶圆片3或晶圆视觉拍照模组2移动至第一检测起始相对位置;Control the wafer 3 or the wafer visual camera module 2 to move to a first detection starting relative position;
利用晶圆视觉拍照模组2在检测一模式下对晶圆表面图像进行采集,包括在检测一模式的预设检测路径下逐路径点进行拍照,循环至检测路径终点;Using the wafer vision camera module 2 to collect the wafer surface image in the detection mode 1, including taking pictures at each path point in the preset detection path of the detection mode 1, and looping to the end point of the detection path;
控制晶圆片3或晶圆视觉拍照模组2移动至第二检测起始相对位置;Control the wafer 3 or the wafer visual camera module 2 to move to a second detection starting relative position;
利用晶圆视觉拍照模组2在检测二模式下对晶圆表面图像进行采集,包括在检测二模式的预设检测路径下逐路径点进行拍照,循环至检测路径终点;Using the wafer vision camera module 2 to collect the wafer surface image in the second detection mode, including taking pictures at each path point in the preset detection path of the second detection mode, and looping to the end point of the detection path;
对检测一模式和检测二模式下得到的所有拍摄图像进行图像检测处理,生成晶圆表面缺陷检测结果。Perform image detection processing on all captured images obtained in detection mode 1 and detection mode 2 to generate wafer surface defect detection results.
本发明还配置有自适应性强的检测算法完成准确高效的检测,该方法通过计算平均灰度值和灰度分布均匀程度自动化识别图像类型,判断明暗场,针对明场使用直方图均衡化和使用动态双边滤波算法进行去噪锐化处理,针对暗场使用去除过爆图像的方法进行处理原始图像,使用动态阈值方法对图像进行滤波,之后通过改进YOLOV5加入一层针对缺陷对比度差的增强特征提取器对晶圆表面缺陷信息进行识别并提取,因此该自适应算法具有高通用性、强可靠性。The present invention is also equipped with a highly adaptive detection algorithm to complete accurate and efficient detection. The method automatically identifies the image type by calculating the average grayscale value and the uniformity of grayscale distribution, judges the bright and dark fields, uses histogram equalization and a dynamic bilateral filtering algorithm for denoising and sharpening for the bright field, uses a method for removing overexposure images for the dark field to process the original image, uses a dynamic threshold method to filter the image, and then improves YOLOV5 by adding a layer of enhanced feature extractor for defect contrast difference to identify and extract wafer surface defect information. Therefore, the adaptive algorithm has high versatility and strong reliability.
优选地,所述检测一模式通过LED漫平行光源2-6在不同的倾斜角度下进行对晶圆表面进行打光,检测一模式是晶圆表面平行光漫反射全尺寸检测模式。所述检测二模式通过光照度大于第一阈值的高强度光源2-5在不同的倾斜角度下进行对晶圆表面进行打光。所述检测一模式和检测二模式下在不同的倾斜角度下进行对晶圆表面进行打光均至少包括高打光角度范围和低打光角度范围,其中打光角度α为光源出射方向与晶圆表面法向夹角,所述高打光角度范围为α=0°°~30,所述低打光角度范围为α=60°°~90。Preferably, the detection mode 1 illuminates the wafer surface at different tilt angles through LED diffuse parallel light sources 2-6, and the detection mode 1 is a full-size detection mode of diffuse reflection of parallel light on the wafer surface. The detection mode 2 illuminates the wafer surface at different tilt angles through a high-intensity light source 2-5 whose illumination is greater than a first threshold. The illumination of the wafer surface at different tilt angles in the detection mode 1 and the detection mode 2 at least includes a high lighting angle range and a low lighting angle range, wherein the lighting angle α is the angle between the light source emission direction and the normal of the wafer surface, the high lighting angle range is α=0°°~30, and the low lighting angle range is α=60°°~90.
如图2和图3所示,分别为高角度打光和低角度打光的结构示意图,计算公式为hc=do×tan(α),其中hc为计算出的能够识别出的裂缝特征深度,do为当前裂缝宽度,α为光源相机夹角,统计当前检测硅片裂缝、划道缺陷,其孔深宽比分布在2.5左右,所以对于低角度打光需要将相机正对检测物,光源与相机呈夹角α。经过实验确认光源出射方向与晶圆表面法向夹角在α=60°°~90特征表现最佳。应用反射定律,高角度打光在硅片上获得更加均匀的光照效果,光源出射方向与晶圆表面法向夹角在α=0°°~30这个范围,通过实验确定其能够获得最均匀的光照效果。As shown in Figures 2 and 3, they are schematic diagrams of the structures of high-angle lighting and low-angle lighting, respectively. The calculation formula is h c = d o × tan (α), where h c is the calculated crack feature depth that can be identified, d o is the current crack width, and α is the angle between the light source and the camera. According to statistics, the hole depth-to-width ratio of the currently detected silicon wafer cracks and scratch defects is distributed around 2.5, so for low-angle lighting, the camera needs to be facing the object to be tested, and the light source and the camera form an angle α. Experiments have confirmed that the angle between the light source emission direction and the normal to the wafer surface is α = 60°°~90° for the best feature performance. Applying the law of reflection, high-angle lighting obtains a more uniform lighting effect on the silicon wafer. The angle between the light source emission direction and the normal to the wafer surface is in the range of α = 0°°~30°. It has been determined through experiments that it can obtain the most uniform lighting effect.
检测一模式下,低打光角度范围下,光源出射方向与晶圆表面法向夹角在α=60°°~90,此为检测一模式的低角度打光形态,由于低角度光源的入射光线经过被测物表面的漫反射光进入相机中,这也称为“浮雕图”打光方式;在当前形态下,采集到的图像能够凸显爪裂、划道、蹭伤等晶圆表面缺陷类型,增强缺陷区域和非缺陷区域的对比度,图像质量更好;光源出射方向与晶圆表面法向夹角在α=0°°~30时,此为检测一模式的高角度打光形态,光源的入射光线通过被测物表面后大部分通过镜面反射进入到相机当中,这也称为“黑白图”打光方式;当前形态下,采集的图像能够凸显出晶圆边缘图像的对比度,且晶圆图像灰度更加均匀。In the detection mode, in the low lighting angle range, the angle between the light source's emitting direction and the wafer surface normal is α=60°~90, which is the low-angle lighting form of the detection mode. Since the incident light of the low-angle light source enters the camera through the diffuse reflection light of the surface of the object to be measured, this is also called the "relief image" lighting method; in the current form, the collected image can highlight the types of wafer surface defects such as claw cracks, scratches, and abrasions, enhance the contrast between defective areas and non-defective areas, and have better image quality; when the angle between the light source's emitting direction and the wafer surface normal is α=0°~30, this is the high-angle lighting form of the detection mode. After passing through the surface of the object to be measured, most of the incident light of the light source enters the camera through mirror reflection, which is also called the "black and white image" lighting method; in the current form, the collected image can highlight the contrast of the wafer edge image, and the grayscale of the wafer image is more uniform.
在检测二模式下,高强度光源出射方向与晶圆表面法向夹角在α=60°°~90时,此为检测二模式的低角度打光形态,高强度光照射下,使得在低强度光下漫反射打光原理条件下不易突显的缺陷表现地更加锐利;当前形态下,采集的图像凸显出了沾污、针孔等晶圆表面缺陷区域呈现出亮斑汇聚,也意味着对于沾污和针孔这样的附着类缺陷取得较好的图像质量;在检测二模式下,高强度光源出射方向与晶圆表面法向夹角在α=0°°~30时。此为检测二模式的高角度打光形态,在此形态下,晶圆表面由于药液残留被灼伤的区域在高强度光照射下显像为亮面或阴影,更易于后续缺陷检测算法对其提取。In the detection mode 2, when the angle between the high-intensity light source and the normal to the wafer surface is α=60°°~90, this is the low-angle lighting form of the detection mode 2. Under high-intensity light irradiation, defects that are not easy to highlight under the diffuse reflection lighting principle under low-intensity light appear sharper; in the current form, the collected image highlights the contamination, pinholes and other wafer surface defect areas showing bright spot convergence, which also means that the adhesion defects such as contamination and pinholes have a better image quality; in the detection mode 2, when the angle between the high-intensity light source and the normal to the wafer surface is α=0°°~30. This is the high-angle lighting form of the detection mode 2. In this form, the area on the wafer surface burned by the residual liquid is imaged as a bright surface or shadow under high-intensity light irradiation, which is easier to extract by the subsequent defect detection algorithm.
如图4所示,本发明的提供的第一种实施例,所述将晶圆片3和晶圆视觉拍照模组2分别安装在相应载体上,控制晶圆片3或晶圆视觉拍照模组2移动至第一检测起始相对位置包括,将待测晶圆片3吸附在多自由度机器人6的末端支架5上的吸盘4上,并将晶圆视觉拍照模组2固定安装在模组支架1上,控制多自由度机器人6带动待测晶圆片3移动至第一检测起始相对位置。其中,多自由度机器人6为6自由度的智能晶圆检测协作机器人;As shown in FIG4 , the first embodiment provided by the present invention, wherein the wafer 3 and the wafer visual camera module 2 are respectively mounted on corresponding carriers, and the wafer 3 or the wafer visual camera module 2 is controlled to move to the first detection starting relative position, comprises: adsorbing the wafer 3 to be tested on the suction cup 4 on the end bracket 5 of the multi-degree-of-freedom robot 6, and fixing the wafer visual camera module 2 on the module bracket 1, and controlling the multi-degree-of-freedom robot 6 to drive the wafer 3 to be tested to move to the first detection starting relative position. Among them, the multi-degree-of-freedom robot 6 is a 6-degree-of-freedom intelligent wafer detection collaborative robot;
多自由度机器人6末端通过搭载由吸盘4和末端支架5组成的晶圆吸附末端执行模块,通过电磁阀控制可以完成对晶圆的插取和吸附;其中晶圆依次排列在晶圆盒中,晶圆之间存在一定间隙,相互独立不会接触。The end of the multi-degree-of-freedom robot 6 is equipped with a wafer adsorption end execution module composed of a suction cup 4 and an end bracket 5, and can complete the insertion and adsorption of the wafer through the control of the solenoid valve; the wafers are arranged in sequence in the wafer box, there is a certain gap between the wafers, and they are independent of each other and will not touch each other.
吸附晶圆时,多自由度机器人6搭载的晶圆吸附末端执行模块运动至待检晶圆与下一片晶圆的空隙中,沿平行于晶圆吸附末端执行模块的吸盘4面方向插入,调整姿态使吸盘4平面与晶圆平面平行并处于近乎接触的位置,当前位置是多自由度机器人6吸附晶圆上料的位置,多自由度机器人6到位并发送到位信号;上位机软件系统接收到机器人发送的信号,向运动控制器发送吸附指令,运动控制器控制电磁阀响应,末端吸盘4将晶圆吸附完成。When adsorbing the wafer, the wafer adsorption terminal execution module carried by the multi-degree-of-freedom robot 6 moves to the gap between the wafer to be inspected and the next wafer, and is inserted in a direction parallel to the suction cup 4 surface of the wafer adsorption terminal execution module, and the posture is adjusted so that the plane of the suction cup 4 is parallel to the plane of the wafer and is in a position close to contact. The current position is the position where the multi-degree-of-freedom robot 6 adsorbs the wafer for loading, and the multi-degree-of-freedom robot 6 is in place and sends an in-place signal; the upper computer software system receives the signal sent by the robot, sends an adsorption instruction to the motion controller, the motion controller controls the solenoid valve to respond, and the end suction cup 4 completes the wafer adsorption.
末端吸盘4吸附上一片待检测晶圆后,移动至检测区一,在到达检测起始位置后,机器人发送到位信号;上位机软件系统接收到信号后,控制晶圆检测平行光检测模块的光源开启,晶圆检测高强度光检测模块的光源关闭,检测系统进入检测一模式;末端吸盘4在检测结束前始终保持晶圆被吸附的状态,末端吸盘4搭载被测晶圆,按照预设好的位置路径进行运动;在检测一模式的检测过程中,上位机软件系统获取机器人实时发送的位置参数,判断机器人到位后,上位机软件系统控制触发相机拍照;拍照获得图像进入上位机软件系统中,通过晶圆表面缺陷检测算法进行处理,并输出结果至晶圆表面缺陷检测结果列表;之后逐路径点进行拍照检测并处理,依次循环至检测路径终点;After the end suction cup 4 absorbs a wafer to be inspected, it moves to the inspection area 1. After reaching the inspection starting position, the robot sends an in-position signal; after receiving the signal, the host computer software system controls the light source of the wafer inspection parallel light detection module to turn on, and the light source of the wafer inspection high-intensity light detection module to turn off, and the inspection system enters the inspection mode 1; the end suction cup 4 always keeps the wafer in the state of being adsorbed before the end of the inspection, and the end suction cup 4 carries the wafer to be inspected and moves according to the preset position path; during the inspection process of the inspection mode 1, the host computer software system obtains the position parameters sent by the robot in real time, and after judging that the robot is in place, the host computer software system controls the triggering of the camera to take pictures; the image obtained by taking pictures enters the host computer software system, is processed by the wafer surface defect detection algorithm, and the result is output to the wafer surface defect detection result list; then, the photo detection and processing are carried out at each path point, and it is cycled to the end of the inspection path in sequence;
末端吸盘4搭载被测晶圆移动至检测一模式的起始位置,在到达位置后,机器人发送到位信号;上位机软件系统接收到机器人到位信号后,关闭晶圆检测平行光检测模块的光源,并开启晶圆检测高强度光检测模块的光源,进入检测二模式;机器人搭载晶圆按照在检测区二的检测路径进行运动,在每一个拍摄位置点位处,上位机软件系统获取机器人实时发送的位置参数,判断机器人到位后,上位机软件系统控制触发相机拍照;拍照获得图像传入上位机软件系统的晶圆表面缺陷检测算法中,通过晶圆表面缺陷检测算法进行处理,输出结果至晶圆表面缺陷检测结果列表;之后,逐路径点进行拍照检测并处理,依次循环至检测路径终点;拍照过程结束,中控系统对晶圆表面缺陷检测结果列表进行遍历,判断当前的晶圆表面是否存在缺陷,将缺陷晶圆和正常晶圆分开放置进所对应的晶圆摆放仓内,检测结束。The end suction cup 4 carries the wafer to be tested and moves to the starting position of the first detection mode. After reaching the position, the robot sends an in-position signal; after receiving the robot in-position signal, the host computer software system turns off the light source of the wafer detection parallel light detection module, and turns on the light source of the wafer detection high-intensity light detection module, and enters the second detection mode; the robot carries the wafer and moves according to the detection path in the second detection area. At each shooting position, the host computer software system obtains the position parameters sent by the robot in real time. After determining that the robot is in position, the host computer software system controls the triggering camera to take pictures; the image obtained by taking pictures is transmitted to the wafer surface defect detection algorithm of the host computer software system, processed by the wafer surface defect detection algorithm, and the result is output to the wafer surface defect detection result list; after that, the photo detection and processing are performed at each path point, and the cycle is cycled to the end of the detection path; after the photo process is completed, the central control system traverses the wafer surface defect detection result list, determines whether there are defects on the current wafer surface, and separates the defective wafer and the normal wafer into the corresponding wafer placement bin, and the detection is completed.
如图5所示,本发明的提供的第二种实施例,与第一种实施例的不同之处在于,所述将晶圆片3和晶圆视觉拍照模组2分别安装在相应载体上,控制晶圆片3或晶圆视觉拍照模组2移动至第一检测起始相对位置包括,将晶圆视觉拍照模组2安装在多自由度机器人6的末端支架5上,并将待测晶圆片3放置在模组支架1上,控制多自由度机器人6带动视觉拍照模组移动至第一检测起始相对位置。具体的,在该实施例下,自动化上料模组末端吸盘4吸附上一片待检测晶圆后,将其放置在晶圆支架8的检测工位上,检测工位传感器检测到有新的待检晶圆被放上后,触发上料完成的信号。As shown in FIG5 , the second embodiment provided by the present invention is different from the first embodiment in that the wafer 3 and the wafer visual camera module 2 are respectively installed on the corresponding carriers, and the wafer 3 or the wafer visual camera module 2 is controlled to move to the first detection starting relative position, including installing the wafer visual camera module 2 on the end bracket 5 of the multi-degree-of-freedom robot 6, and placing the wafer 3 to be tested on the module bracket 1, and controlling the multi-degree-of-freedom robot 6 to drive the visual camera module to move to the first detection starting relative position. Specifically, in this embodiment, after the end suction cup 4 of the automatic loading module absorbs a wafer to be tested, it is placed on the detection station of the wafer bracket 8. After the detection station sensor detects that a new wafer to be tested is placed, it triggers a signal that the loading is completed.
优选地,所述对所有拍摄图像进行图像检测处理,生成晶圆表面缺陷检测结果包括对所有拍摄图像进行预处理后进行区域分割处理,以将晶圆图像剪切出来,并使用优化过的YOLOV5模型完成对晶圆图像的表面缺陷目标检测。其中,对所有拍摄图像进行预处理包括进行滤波和直方图均衡化处理。Preferably, the image detection processing of all captured images to generate wafer surface defect detection results includes preprocessing all captured images and then performing region segmentation processing to cut out the wafer image, and using the optimized YOLOV5 model to complete the surface defect target detection of the wafer image. Preprocessing all captured images includes filtering and histogram equalization processing.
原本的YOLOV5模型对于晶圆表面缺陷检测效果不好的一个原因是因为晶圆缺陷与背景对比度较弱且缺晶圆表面的陷较尺寸较小,而原始的YOLOV5的下采样倍数比较大,较深的特征图很难学习到小目标的特征信息,因此提出增加小目标检测层对较浅特征图与深特征图拼接后进行检测。One reason why the original YOLOV5 model is not effective for wafer surface defect detection is that the contrast between wafer defects and the background is weak and the size of the defects on the wafer surface is small. The original YOLOV5 has a large downsampling multiple, and it is difficult for deeper feature maps to learn the feature information of small targets. Therefore, it is proposed to add a small target detection layer to splice the shallower feature map with the deep feature map for detection.
在原先网络特征提取层后最后一次上采样后,继续对特征图进行上采样等处理,使得特征图继续扩大,同时将获取到的大小为152X152的特征图与骨干网络中第2层特征图进行concat融合,以此获取更大的特征图进行小目标检测。而对于原始的YOLOV5各个模型的网络结构,比如网络结构最复杂的YOLOV5-x只能在网络结构中重复多次CSP使用层数,看似网络结构加深,但是没有贴合对于晶圆这种特征和背景差异不明显,特征尺寸小的检测特点,检测效果不理想。配合前面的图像预处理算法,加入一层增强特征提取器,优化YOLOV5网络,可以将晶圆缺陷提取效果更好。After the last upsampling after the original network feature extraction layer, the feature map continues to be upsampled and other processes to expand the feature map. At the same time, the acquired feature map of size 152X152 is concat fused with the second layer feature map in the backbone network to obtain a larger feature map for small target detection. As for the network structure of each model of the original YOLOV5, for example, the YOLOV5-x with the most complex network structure can only repeat the CSP use layer multiple times in the network structure. It seems that the network structure is deepened, but it does not fit the detection characteristics of the wafer, where the difference between the feature and background is not obvious and the feature size is small, and the detection effect is not ideal. In conjunction with the previous image preprocessing algorithm, adding a layer of enhanced feature extractor and optimizing the YOLOV5 network can achieve better wafer defect extraction results.
如图7所示的网络结构图,相较于原始的YOLOV5模型,又加入了一个上采样,其对于晶圆表面缺陷特征的提取更加明显。As shown in the network structure diagram in Figure 7, compared with the original YOLOV5 model, an upsampling is added, which makes the extraction of wafer surface defect features more obvious.
第二方面,本申请提供了一种晶圆表面缺陷智能检测装置,包括:In a second aspect, the present application provides an intelligent detection device for wafer surface defects, comprising:
检测工作台7、晶圆视觉拍照模组2和多自由度机器人6,所述晶圆视觉拍照模组2和多自由度机器人6均对称设置在所述检测工作台7上,所述晶圆视觉拍照模组2用于对晶圆表面缺陷进行图像拍摄,所述多自由度机器人6用于带动晶圆片3或晶圆视觉拍照模组2进行位置移动变换。An inspection workbench 7, a wafer vision camera module 2 and a multi-degree-of-freedom robot 6, wherein the wafer vision camera module 2 and the multi-degree-of-freedom robot 6 are symmetrically arranged on the inspection workbench 7, the wafer vision camera module 2 is used to capture images of wafer surface defects, and the multi-degree-of-freedom robot 6 is used to drive the wafer 3 or the wafer vision camera module 2 to move and transform its position.
如图6所示,所述晶圆视觉拍照模组2包括工业相机一2-1、工业相机二2-3、高强度光源2-5和LED漫平行光源2-6,所述工业相机一2-1和LED漫平行光源2-6用于在检测一模式下对晶圆表面图像进行采集,所述工业相机二2-3和高强度光源2-5用于在检测二模式下对晶圆表面图像进行采集,其中,工业相机一2-1和工业相机二2-3上分别配备有工业镜头一2-2和工业镜头二2-4,工业相机一2-1和工业相机二2-3均固定安装在传感器支架2-7上。As shown in Figure 6, the wafer vision camera module 2 includes an industrial camera 1 2-1, an industrial camera 2 2-3, a high-intensity light source 2-5 and an LED diffuse parallel light source 2-6. The industrial camera 1 2-1 and the LED diffuse parallel light source 2-6 are used to collect wafer surface images in a detection mode 1, and the industrial camera 2 2-3 and the high-intensity light source 2-5 are used to collect wafer surface images in a detection mode 2. Among them, the industrial camera 1 2-1 and the industrial camera 2 2-3 are respectively equipped with an industrial lens 1 2-2 and an industrial lens 2 2-4, and the industrial camera 1 2-1 and the industrial camera 2 2-3 are both fixedly mounted on a sensor bracket 2-7.
本发明提供的晶圆表面缺陷智能检测方法通过高自由度的打光方式能够对晶圆表面多种缺陷完成准确高效的检测,通过不同检测模式的相互配合,能够完成对晶圆进行多角度、全尺寸、全种类表面缺陷检测的目标。The intelligent wafer surface defect detection method provided by the present invention can accurately and efficiently detect various defects on the wafer surface through a high-degree-of-freedom lighting method, and can achieve the goal of multi-angle, full-size, and full-type surface defect detection of the wafer through the mutual cooperation of different detection modes.
在本申请的上述实施例中,对各个实施例的描述都各有侧重,某个实施例中没有详述的部分,可以参见其他实施例的相关描述。In the above embodiments of the present application, the description of each embodiment has its own emphasis. For parts that are not described in detail in a certain embodiment, please refer to the relevant description of other embodiments.
本领域内的技术人员应明白,本发明的实施例可提供为方法、系统、或计算机程序产品。因此,本发明可采用完全硬件实施例、完全软件实施例、或结合软件和硬件方面的实施例的形式。而且,本发明可采用在一个或多个其中包含有计算机可用程序代码的计算机可用存储介质上实施的计算机程序产品的形式。其中,存储介质可以由任何类型的易失性或非易失性存储设备或者它们的组合实现,如静态随机存取存储器(Static RandomAccess Memory,简称SRAM),电可擦除可编程只读存储器(Electrically ErasableProgrammable Read-Only Memory,简称EEPROM),可擦除可编程只读存储器(ErasableProgrammable Read Only Memory,简称EPROM),可编程只读存储器(Programmable Red-Only Memory,简称PROM),只读存储器(Read-OnlyMemory,简称ROM),磁存储器,快闪存储器,磁盘或光盘。这些计算机程序指令也可存储在能引导计算机或其他可编程数据处理设备以特定方式工作的计算机可读存储器中,使得存储在该计算机可读存储器中的指令产生包括指令装置的制造品,该指令装置实现在流程图一个流程或多个流程和/或方框图一个方框或多个方框中指定的功能。Those skilled in the art will appreciate that the embodiments of the present invention may be provided as methods, systems, or computer program products. Therefore, the present invention may adopt the form of a complete hardware embodiment, a complete software embodiment, or an embodiment combining software and hardware. Moreover, the present invention may adopt the form of a computer program product implemented on one or more computer-usable storage media containing computer-usable program codes. Wherein, the storage medium may be implemented by any type of volatile or non-volatile storage device or a combination thereof, such as static random access memory (Static Random Access Memory, referred to as SRAM), electrically erasable programmable read-only memory (Electrically Erasable Programmable Read-Only Memory, referred to as EEPROM), erasable programmable read-only memory (Erasable Programmable Read Only Memory, referred to as EPROM), programmable read-only memory (Programmable Red-Only Memory, referred to as PROM), read-only memory (Read-Only Memory, referred to as ROM), magnetic memory, flash memory, disk or optical disk. These computer program instructions may also be stored in a computer-readable memory that can direct a computer or other programmable data processing device to work in a specific manner, so that the instructions stored in the computer-readable memory produce a manufactured product including an instruction device that implements the functions specified in one or more processes in the flowchart and/or one or more boxes in the block diagram.
在本申请所提供的实施例中,应该理解到,所揭露装置和方法,可以通过其它的方式实现。以上所描述的装置实施例仅仅是示意性的,例如,所述单元的划分,仅仅为一种逻辑功能划分,实际实现时可以有另外的划分方式,又例如,多个单元或组件可以结合或者可以集成到另一个系统,或一些特征可以忽略,或不执行。另一点,所显示或讨论的相互之间的耦合或直接耦合或通信连接可以是通过一些通信接口,装置或单元的间接耦合或通信连接,可以是电性,机械或其它的形式。In the embodiments provided in the present application, it should be understood that the disclosed devices and methods can be implemented in other ways. The device embodiments described above are merely schematic. For example, the division of the units is only a logical function division. There may be other division methods in actual implementation. For example, multiple units or components can be combined or integrated into another system, or some features can be ignored or not executed. Another point is that the mutual coupling or direct coupling or communication connection shown or discussed can be through some communication interfaces, and the indirect coupling or communication connection of devices or units can be electrical, mechanical or other forms.
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