CN102736247B - Method for optimizing surface type parameters of optical free-form-surface prism based on machining tolerance constraints - Google Patents
Method for optimizing surface type parameters of optical free-form-surface prism based on machining tolerance constraints Download PDFInfo
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Abstract
The invention belongs to the technical field of designing and manufacturing of optical free-form surfaces in the field of optics, and relates to a method for optimizing surface type parameters of an optical free-form-surface prism based on machining tolerance constraints. The method comprises the following steps of: sequentially traversing all initial structural parameters in a tolerance range at certain sampling intervals, changing the structure of the optical free-form-surface prism, and counting the variation trend of modulation transfer function (MTF) values in the process of changing all the structural parameters; determining structural parameters which have great influences on imaging quality through the variation trend of the MTF values; acquiring a series of optical free-form-surface prism systems with new structural parameters according to the maximum limit and the minimum limit of the variation of the structural parameters which have the great influences on the imaging quality, and performing comprehensive optimization design to ensure that the highest imaging quality at all positions can be reached by adjusting the surface type parameters; and acquiring final surface type parameter data of the optical free-form-surface prism. By the method, accurate surface type parameters of the optical free-form-surface prism can be acquired, and design accuracy can be improved.
Description
Affiliated technical field
The invention belongs to the freeform optics surface design and manufacture technical field of optical field, relate to a kind of freeform optics surface prism design method.
Background technology
Along with the development of optical design theory and Ultraprecision Machining, the application of freeform optics surface prism has caused more and more people's concern.He is little with volume, and structure is light and can have a plurality of fields such as being widely used Helmet Mounted Display, entertainment video glasses, analog simulation training, operation compared with large visual field.In view of the many merits of free curved surface prism, lot of domestic and international mechanism has carried out a large amount of research work for the design of freeform optics surface at present.1996, Canon company took the lead in proposing freeform optics surface prism (Free-Form surface, FFS) structure; 1999, it was 57.8 ° * 34.6 ° wedge shape free curved surface prisms that Olympus company has proposed field angle, but its emergent pupil is relatively little, only has 4mm.Beijing Institute of Technology, Shanghai University of Science and Technology etc. have also proposed the freeform optics surface prism design method of larger visual field.
Freeform optics surface prism design is the process that a face shape parameter optimization is calculated.At present, be mainly divided into two kinds of modes and solve: multi-parameters optimization, first determine the initial results of optical device, then, by repeatedly revising some parameter, often computation process is longer; Direct reflection method, in the situation that know light distribution and the target face Illumination Distribution of light source itself, that can accomplish without any letup designs required reverberator or lens, is generally that lighting problem is changed into the numerical solution to second order nonlinear equations.At present, main or completed by multi-parameters optimization method for the design of freeform optics surface, and existing optical design and analysis software are also all developed based on this mode.
Existing, freeform optics surface prism facets shape parameter is optimized in the method for design, machining tolerance is not carried out to labor, therefore, easily cause design proposal to there is relatively high requirement on machining accuracy, to such an extent as to the mismachining tolerance of trace all can be brought considerable influence to image quality, and design proposal can not be realized under existing processing conditions.For the problem in existing design proposal, need to just consider at first machining tolerance in design, make design proposal can adapt to the scope that tolerance allows, to guarantee to process the image quality of rear freeform optics surface prism.
Summary of the invention
The object of the invention is to overcome the above-mentioned deficiency of prior art, provide a kind of and can obtain freeform optics surface prism facets shape parameter more accurately, improve design accuracy, make the design of freeform optics surface prism can meet the face shape parameter optimization method of machining tolerance variation range.The present invention, analyzing on the basis of mismachining tolerance, finds and affect the larger error source of freeform optics surface prism imaging quality, thereby opposite shape parameter is optimized.Technical scheme of the present invention is as follows:
1. the data-optimized method of freeform optics surface prism facets type based on machining tolerance constraint, be applied in freeform optics surface prism design process, when primary design, first according to actual application demand, freeform optics surface prism is obtained having preferably prism facets shape parameter and the structural parameters of image quality, using this as primary face shape parameter and structural parameters, again in conjunction with the machining tolerance of determined processing technology, determine the machining tolerance scope of prism structure parameter, obtain greatest limit and least limit that each structural parameters changes; This face shape parameter optimization method comprises the following steps:
1) successively each initial structural parameters is carried out to the traversal of margin tolerance according to a fixed sample interval, carry out the change of freeform optics surface prism structure, obtain a series of freeform optics surface prism systems with new construction, add up the variation tendency of mtf value in each structural parameters change process;
2) by mtf value variation tendency, determine and affect the structural parameters that image quality is larger;
3) according to the greatest limit and the least limit that affect the structural parameters variation that image quality is larger, obtain again a series of freeform optics surface prism systems with new construction parameter, image space using these new systems as zoom system, pancreatic system, the optics software that employing has optical optimization design and analysis carries out Synthetical Optimization, by adjusting the face shape parameter of prism curved surface, make the image quality of each position reach best;
4) obtain the final face shape parameter data of freeform optics surface prism.
As preferred implementation, the data-optimized method of freeform optics surface prism facets type of the present invention, the 3rd) in step, the optics software in employing with optical optimization design and analysis carries out in Synthetical Optimization process, need to consider the different freeform optics surface prism systems with new construction parameter that different optimization weighted values is set, and weight in this process need in conjunction with above-mentioned flow process the 2nd) the TOLERANCE ANALYSIS result of step sets, wherein affect the structural parameters that image quality is larger, optimize weighted value larger, on the contrary little.
The data-optimized method of face type adopting in the freeform optics surface prism design that the present invention mentions, considers machining tolerance requirement, has avoided optical design can not meet the possibility of machining tolerance requirement, thereby has guaranteed that optical design obtains the processibility of result.The method that the present invention mentions is a kind of pervasive mentality of designing, is not only applicable to freeform optics surface prism design, can also be suitable for other freeform optics surface methods for designing, and therefore, the present invention has good using value.
For better explanation effect of the present invention, carried out the contrast test of one group of concrete design example of implementing.First adopt traditional design method to be optimized design to freeform optics surface prism, obtain the good structure of image quality and face shape parameter, as the initial value based on tolerance constrained optimization method.Table 13 shown three surperficial face shape parameter initial values and optimize after result, can find out by type after constrained optimization and slightly change.Freeform optics surface prism system after optimizing is carried out to TOLERANCE ANALYSIS again, and Fig. 6 and 7 has shown the variation tendency of system mtf value with angular deflection and surface displacement skew, and wherein angle variable quantity is ± 0.05 °, and surface location variable quantity is ± 10 μ m.From scheming, can find out through after Tolerance Optimization, the variation of each curve tends towards stability, and illustrative system image quality obviously weakens the dependence of the change in displacement on angle variation and surface.Meanwhile, also can find out that optimizing rear mtf value is all greater than 0.2, is also significantly improved than starter system.Illustrate after optimizing that the angle tolerance of system can reach ± 0.05 °, can reach ± 10 μ m of surface location tolerance, are easy to meet the requirement of current machining precision.
Table 1 prism facets 1 primary face shape parameter and optimize below shape parameter contrast
| Parameter | Optimize initial value | After optimization |
| c | -0.12188697 | -0.12165259 |
| k | -1.19438267 | -0.42342227 |
| C 01 | -0.10105311 | -0.10612253 |
| C 20 | -0.00336662 | -0.00416239 |
| C 02 | 0.00712328 | 0.00622436 |
| C 21 | 0.00107549 | 0.00108066 |
| C 03 | 0.00058948 | 0.00070033 |
| C 40 | -0.00006840 | -0.00002804 |
Table 2 prism facets 2 primary face shape parameters and optimize below shape parameter contrast
| Parameter | Optimize initial value | After optimization |
| c | -0.05920634 | -0.05834927 |
| k | 3.32927755 | 3.12927755 |
| C 01 | -0.04653369 | -0.05114776 |
| C 20 | -0.00141041 | -0.00199008 |
| C 02 | 0.00276209 | 0.00213386 |
| C 21 | 0.00015275 | 0.00017713 |
| C 03 | -0.00006627 | -0.00004777 |
| C 40 | -0.00000301 | 0.00000191 |
Table 3 prism facets 3 primary face shape parameters and optimize below shape parameter contrast
| Parameter | Optimize initial value | After optimization |
| c | -0.16594523 | -0.16905050 |
| k | -1.90218065 | -1.63482881 |
| C 01 | -0.26958458 | -0.26071419 |
| C 20 | 0.13495779 | 0.13937375 |
| C 02 | 0.08616580 | 0.09891773 |
| C 21 | -0.01590361 | -0.01645603 |
| C 03 | -0.00425198 | -0.01315915 |
| C 40 | -0.00227223 | -0.00277021 |
Accompanying drawing explanation
Fig. 1 design cycle of the present invention.
Fig. 2 freeform optics surface prism helmet display system architecture schematic diagram.
Fig. 3 mismachining tolerance kind.
Fig. 4 freeform optics surface prism imaging quality and surperficial angle variation relation.
Fig. 5 freeform optics surface prism imaging quality and surface location offset variation relation.
Image quality and surperficial angle variation relation after Fig. 6 optimal design.
Image quality and surface location offset variation relation after Fig. 7 optimal design.
Embodiment
Fig. 1 is the freeform optics surface prism design method flow that the present invention proposes.First, freeform optics surface prism is carried out to optical imagery design, obtain designing a model of image quality the best; Error to the final work flow of freeform optics surface prism is carried out labor, finds and affects the larger margin of error of freeform optics surface prism imaging quality; Determine the accessible margin tolerance of this margin of error in whole work flow, thereby determine the scope that rear its structure of freeform optics surface prism processing may change; According to freeform optics surface prism structure transformation range, by these structures while optimal design, effects on surface face shape parameter carries out complex optimum adjustment, makes each structure can reach best image quality.In the process of optimizing at the same time, for affecting the caused variation structural system of the margin of error that image quality is larger, adopt higher optimization weight.Even if guarantee that all structures in the freeform optics surface prism structure transformation range causing, can reach good image quality in the situation that mismachining tolerance exists.
Fig. 2 is the canonical schema of freeform optics surface prism application.The refraction of the image of micro projection screen by three free form surfaces of freeform optics surface prism and total reflection, in the virtual scene of human eye front projection, realize position with real object and merge.Free curved surface prism structure by three not the freeform optics surface of ipsilateral (face 1,2,3) form prism wedge, material can adopt engineering plastics PMMA or crystal for infrared use etc.The final free form surface equation adopting of general design is XY polynomial expression, and expression is as follows:
Wherein c is radius-of-curvature, and k is secondary aspherical constant,
c
mnfor the coefficient of different rank, p is polynomial high order power, meets 1≤m+n≤p, and time power x item of generally choosing spouse in design process guarantees the symmetry of whole type YOZ face.The polynomial introducing of XY has increased the degree of freedom of prism design greatly, and produced simultaneously non-rotating symmetrical structure has also greatly improved the image quality of prism.C wherein, K, c
mnbeing face shape parameter, is the optimized amount of paying close attention in freeform optics surface prism design.Relevant freeform optics surface prism specific design flow process can list of references (Cheng Dewen, Wang Yongtian, Chang Jun, Liu Yue, Xu's condition.The design of light-duty angular field free curved surface prism helmet display. infrared and laser engineering, 2007,36 (3): 309-311; Dewen Cheng, Yongtian Wang, Hong Hua, and M.M.Talha.Design of an optical see-through head-mounted display with a low f-number and large field of view using a freeform prism.SPIE.5May 2009.).Actual design process can complete by means of business optical design and analysis software (as CodeV, Zemax etc.).
Diamond turning is the effective ways of processing optical free form surface.The processing of freeform optics surface prism at present mainly relies on diamond turning technology to realize, and its main method has two kinds: a kind of is directly to carry out diamond turning method to realize prism processing; Another kind is to adopt diamond turning method to carry out the processing of free form surface core rod, then by injection molding technology, realizes the manufacture of whole prism.Freeform optics surface prism process can cause two class errors, i.e. face type error and structural failure.For diamond turning, face type error more easily guarantees.And all can there is larger structural failure in two kinds of job operations.Work in-process is directly realized free curved surface prism processing for diamond turning technology, because freeform optics surface prism has three free form surface surfaces, therefore, the processing of the whole prism that can not once be installed, need to realize each Free-Form Surface Machining successively.Being repeatedly installed like this will be introduced the more serious error that is installed, thereby causes three surperficial the relative position error.And also there is same problem for injection molding method, in injection molding process, also there is error in the position adjustment between core rod, equally also can cause processing the deviation of rear three free form surfaces surface relative position.
Here take direct diamond turning method as example, analyze the integrally-built mismachining tolerance that may bring in freeform optics surface prism process.Diamond turning is carried out respectively on three surfaces of freeform optics surface prism, and dismounting meeting repeatedly causes each surface may have the mismachining tolerance of two aspects, as shown in Figure 3, i.e. and the translational movement deviation of surface location and surperficial angular deviation.And concrete design just should be able to meet the variation in the system architecture that possible deviation brings, and meet machining tolerance.And generally there is greatest limit change location and least limit change location for the margin tolerance of some amounts, as shown in Figure 3.The ability of current work flow and processing technology of take is example, can reach ± 10 μ m of translational movement tolerance, angle control tolerance and can reach ± and 0.05 °.Optical transfer function (MTF) is the important evaluation method of evaluating freeform optics surface prism design result.In order to find, affect the margin of error that image quality is larger, can be to the margin tolerance of a certain amount according to a fixed sample interval to traveling through, and carry out the change of freeform optics surface prism structure according to this tittle, evaluate the mtf value variation tendency after each structural change, wherein the variation of mtf value curve is illustrated as image quality greatly and is subject to the impact of this margin of error larger, and vice versa.
Fig. 4 has shown in certain primary system design, when prism surface angle exists the mtf value that deviation causes, changes, and Fig. 5 has shown the mtf value variation that exists deviation to cause when prism surface displacement.From the result of analyzing, can obtain, the image quality of this prism system is more responsive for the angular error variation on surface 2 and 3 and the variation of translational movement, insensitive to other structural changes.Therefore, need in the design process in later stage, consider to reduce these dependence of responsive amount to optical quality by emphasis.It should be noted that, for different prism systems, the margin of error is also different on image quality impact, therefore, when each concrete system of research, need to carry out similar TOLERANCE ANALYSIS for concrete system architecture, obtain affecting the margin of error that image quality is larger, by the later stage, further optimize and reduce the impact of these errors on image quality.
This patent has proposed the Optimization Design based on tolerance constraint for this reason.Consider that the system architecture that all error sources cause changes, and according to the minimum and maximum extreme variations position of each error, set up a plurality of prism systems and optimize simultaneously, free form surface surface face shape parameter is is further optimized and revised, make optimization obtain face shape parameter and can in all prism system structures, all have good imaging effect, thereby expanded system tolerance, in the scope that makes to allow in processing technology ability, obtain the freeform optics surface prism of performance optimization.The optimization evaluation function of the Optimization Design based on tolerance constraint can be described as,
F wherein
j(v
i) be the system optimization evaluation function of j system when i visual field, suppose that the system architecture being caused by error changes n altogether, needs to consider m feature visual field; w
ijfor weighted value.In the process of optimizing at the same time, the larger weight of structure setting that consideration causes affecting the margin of error that image quality is larger, by great many of experiments, obtain each margin of error also different to the MTF influence degree of different visual fields, therefore, need, in multisystem while optimizing process, need give different optimization weight magnitudes to different system and the different visual fields of each system, therefore, weight setting need wherein affect the system architecture weight that image quality is larger large in conjunction with TOLERANCE ANALYSIS result, otherwise little.For carrying out the system of TOLERANCE ANALYSIS above, greatly, and by contrast, it is maximum that surperficial 2 offset deviations attract the system weight of structural change to the weight that changes the system architecture causing by surface 2 and 3 angular error and translational movement.And can be set to zoom system, pancreatic system by means of business optical design and a plurality of structures of analysis software (as CodeV, Zemax etc.) in actual design process, be optimized together, make the final face type of adjusting meet each system imaging quality and can reach best.
Claims (1)
1. the data-optimized method of freeform optics surface prism facets type based on machining tolerance constraint, be applied in freeform optics surface prism design process, when primary design, first according to actual application demand, freeform optics surface prism is obtained having preferably prism facets shape parameter and the structural parameters of image quality, using this as primary face shape parameter and structural parameters, again in conjunction with the machining tolerance of determined processing technology, determine the machining tolerance scope of prism structure parameter, obtain greatest limit and least limit that each structural parameters changes; This face shape parameter optimization method comprises the following steps:
1) successively each initial structural parameters is carried out to the traversal of margin tolerance according to a fixed sample interval, carry out the change of freeform optics surface prism structure, obtain a series of freeform optics surface prism systems with new construction, add up the variation tendency of mtf value in each structural parameters change process;
2) by mtf value variation tendency, determine and affect the structural parameters that image quality is larger;
3) according to the greatest limit and the least limit that affect the structural parameters variation that image quality is larger, obtain again a series of freeform optics surface prism systems with new construction parameter, image space using these new systems as zoom system, pancreatic system, the optics software that employing has optical optimization design and analysis carries out Synthetical Optimization, by adjusting the face shape parameter of prism curved surface, make the image quality of each position reach best, the optics software in employing with optical optimization design and analysis carries out in Synthetical Optimization process, need to consider the different freeform optics surface prism systems with new construction parameter that different optimization weighted values is set, and weight in this process need in conjunction with above-mentioned flow process the 2nd) the TOLERANCE ANALYSIS result of step sets, wherein affect the structural parameters that image quality is larger, optimize weighted value larger, otherwise little,
4) obtain the final face shape parameter data of freeform optics surface prism.
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