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An incremental cluster based adaptive online solder joint inspection algorithm is proposed and demonstrated. First, the framework of an intelligent automated optical inspection (AOI) system is designed. Then, the initial solder joint classifier is established with the clustering algorithm. Finally, with a new incremental clustering algorithm, the AOI system can automatically adjust inspection parameters according to the feedback from the repair station. Experiments have shown that the proposed algorithm has a high inspection accuracy, and it is adaptive to environmental changes.