CN110031971B - Assembling method of wide-angle optical free-form surface lens - Google Patents

Assembling method of wide-angle optical free-form surface lens Download PDF

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CN110031971B
CN110031971B CN201910360159.7A CN201910360159A CN110031971B CN 110031971 B CN110031971 B CN 110031971B CN 201910360159 A CN201910360159 A CN 201910360159A CN 110031971 B CN110031971 B CN 110031971B
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form surface
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surface reflector
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CN110031971A (en
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不公告发明人
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Shenzhen Ruisi Huachuang Technology Co., Ltd.
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Shenzhen Ruisi Huachuang Technology Co ltd
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    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/0012Optical design, e.g. procedures, algorithms, optimisation routines
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B27/00Optical systems or apparatus not provided for by any of the groups G02B1/00 - G02B26/00, G02B30/00
    • G02B27/01Head-up displays
    • G02B27/0101Head-up displays characterised by optical features
    • GPHYSICS
    • G02OPTICS
    • G02BOPTICAL ELEMENTS, SYSTEMS OR APPARATUS
    • G02B5/00Optical elements other than lenses
    • G02B5/08Mirrors
    • G02B5/10Mirrors with curved faces

Abstract

The invention provides an assembling method of a wide-angle optical free-form surface lens. The assembling method comprises the following steps: firstly, processing a free-form surface reflector lens; secondly, constructing an imaging optical structure; thirdly, installing a free-form surface reflector lens; fourthly, installing a camera lens structure and image analysis software; fifthly, analyzing and calculating the MTF value of the stripe of the ROI with specific frequency corresponding to the free-form surface reflector sub-lens in parallel by image analysis software, and adjusting the 6-dimensional position of the free-form surface reflector sub-lens; and sixthly, splicing and fixing the plurality of free-form surface reflector lens pieces into an integral lens. The wide-angle optical free-form surface lens is formed by assembling a plurality of sub-lenses, greatly reduces the processing difficulty of the lens, saves the cost, and is suitable for an augmented reality head-up display optical system.

Description

Assembling method of wide-angle optical free-form surface lens
Technical Field
The invention relates to an optical display technology, in particular to an assembling method of a wide-angle optical free-form surface lens, which adopts an assembling technology, is easy to process and has low cost.
Background
The existing optical system for augmented reality head-up display of an automobile can realize head-up display of a larger view field angle mainly through a plurality of large-area free-form surface reflection lenses, so that a driver can see images of a larger transverse angle and a larger longitudinal angle without lowering head and turning head, and the optical system for head-up display mainly comprises an imaging device, a directional scattering sheet, a plurality of off-axis free-form surface reflection lenses, an automobile windshield and a human eye observation window.
At present, the processing difficulty of the large-area free-form surface lens is very high, and the lens needs to be processed by a machine with more than 5 shafts, so that the manufacturing cost is very high.
Disclosure of Invention
The invention aims to provide an assembling method of a wide-angle optical free-form surface lens aiming at the defects of high processing difficulty and high manufacturing cost of a large-area free-form surface lens of an optical system for augmented reality head-up display at present.
In order to solve the above-mentioned prior art problems, the technical scheme of the invention is as follows:
an assembling method of a wide-angle optical free-form surface lens comprises the following steps:
firstly, processing free-form surface reflector sub-lenses, firstly determining the design parameters of a large-area free-form surface reflector lens which meets the requirements, then dividing a plurality of free-form surface reflector sub-lenses which are distributed in an array according to the design parameters of the large-area free-form surface reflector lens, respectively determining the design parameters of the free-form surface reflector sub-lenses, and then respectively processing the free-form surface reflector sub-lenses according to the design parameters of the free-form surface reflector sub-lenses;
secondly, constructing an imaging optical structure, wherein the imaging optical structure is preferably a head-up display optical structure, the head-up display optical structure comprises an image input interface, a directional diffraction sheet, a first off-axis free-form surface reflector, a second off-axis free-form surface reflector, virtual image forming glass, a human eye observation window and a virtual image position, the directional diffraction sheet is used as a relay image surface, image light of the image input interface projects imaging light beams to the virtual image forming glass according to a designed angle through the first off-axis free-form surface reflector and the second off-axis free-form surface reflector, and then partial light is reflected to the human eye observation window through the virtual image forming glass, so that human eyes can see a virtual image in the front;
thirdly, mounting free-form surface reflector sub-lenses, replacing second off-axis free-form surface reflector sub-lenses in the imaging optical structure constructed in the second step with a plurality of free-form surface reflector sub-lenses in the first step, arranging the free-form surface reflector sub-lenses according to positions in design parameters of large-area free-form surface reflector lenses in the first step, and respectively connecting the free-form surface reflector sub-lenses with a precision motion mechanism, wherein the precision motion mechanism at least comprises an X-axis walking module, a Y-axis walking module, a Z-axis walking module, an X-axis rotating module with an X axis as a rotating shaft, a Y-axis rotating module with a Y axis as a rotating shaft and a Z-axis rotating module with a Z axis as a rotating shaft, and is driven by the precision motion mechanism, and the free-form surface reflector sub-lenses can be subjected to 6-dimensional spatial position adjustment;
fourthly, installing a camera lens structure and image analysis software, installing the camera lens structure at the position of a human eye observation window in the imaging optical structure constructed in the second step, wherein the camera lens structure is used for replacing human eyes to receive virtual images, the camera lens structure is connected with a computer through a data line, and the computer is provided with the image analysis software;
fifthly, adjusting the 6-dimensional position of the free-form surface reflector sub-lens, inputting a horizontal and vertical stripe image with a specific spatial frequency through an image input interface, wherein the horizontal and vertical stripe image comprises a plurality of horizontal and vertical stripe sub-images, the layout of the horizontal and vertical stripe sub-images is the same as that of the free-form surface reflector sub-lens, the horizontal and vertical stripe sub-images are respectively reflected by the free-form surface reflector sub-lens at corresponding positions to form a virtual image, the virtual image is received by a camera lens structure and is transmitted to a computer, image analysis is carried out on the virtual image by image analysis software, the image analysis software divides the virtual image into a plurality of ROs respectively corresponding to the free-form surface reflector sub-lens according to the display information of the virtual image and the position of the free-form surface reflector sub-lens, and then the image analysis software analyzes and calculates the MTF value of the stripe with the specific frequency, adjusting the 6-dimensional space position of the free-form surface reflector sub-lens according to the MTF values, and judging that the free-form surface reflector sub-lens is assembled in place when all the MTF values reach the design target value;
and sixthly, splicing and fixing the plurality of free-form surface reflector sub-lenses adjusted in the fifth step into an integral lens to obtain the spliced wide-angle optical free-form surface lens.
The technical principle of the fifth step is as follows:
the spatial positions and spatial angles of all the free-form surface reflector sub-lenses can influence the image quality loss of virtual images obtained by the free-form surface reflector sub-lenses in an imaging display structure, and the free-form surface reflector sub-lenses correspond to characteristic imaging areas.
The method for calculating the MTF value in the fifth step includes:
the scheme of the invention adopts physical theory to calculate, the assembly method also comprises a plurality of necessary image filtering processes, and the MTF calculation formula is as follows:
MTF= (Imax−𝐼𝑚𝑖𝑛)/(𝐼𝑚𝑎𝑥+𝐼𝑚𝑖𝑛);
the MTF mainly calculates the tolerance of the gray value of the virtual image, where Imax is the gray value corresponding to the bright stripe and the gray value corresponding to the dark stripe, and a stripe cycle includes a bright stripe, i.e., a white stripe, and a dark stripe, i.e., a black stripe.
In the first step, the number of the free curved sub-lenses is preferably 4, 6 or 9;
further, the fifth step includes acquiring MTF values of multiple ROIs for the stripes imaged by the single free-form surface sub-lens, that is, one free-form surface sub-lens is detected by the MTF values of the multiple ROIs, and then the 6-dimensional spatial position of the single free-form surface reflecting sub-lens is adjusted according to the characteristics of the MTF values distributed vertically, horizontally and diagonally, so as to further improve the precision of active alignment of the free-form surface reflecting sub-lens.
The assembled wide-angle optical free-form surface lens comprises a plurality of free-form surface sub-lenses distributed in an array manner, wherein the plurality of free-form surface sub-lenses are assembled into the wide-angle optical free-form surface lens by adopting the assembling technology;
furthermore, the wide-angle optical free-form surface lens forms a head-up display optical system, the head-up display optical system comprises one or two image input interfaces, a directional diffraction sheet, a first off-axis free-form surface reflector lens, a second off-axis free-form surface reflector lens, virtual image forming glass, a human eye observation window and a virtual image position, the directional diffraction sheet is used as a relay image surface, the first off-axis free-form surface reflector adopts the assembled wide-angle optical free-form surface lens, image light of the image input interface is projected to the virtual image forming glass through the first off-axis free-form surface reflector and the second off-axis free-form surface reflector according to the designed angle, and then reflected partial light is reflected to the human eye observation window through the virtual image forming glass, so that human eyes can see one or two virtual images in the front.
The invention relates to an assembled wide-angle optical free-form surface lens and an assembling technology thereof, and the assembled wide-angle optical free-form surface lens has the following beneficial effects:
1. the large-area free-form surface lens is divided into a plurality of free-form surface sub-lenses with relatively small areas to be processed, so that the processing difficulty of the free-form surface lens is greatly reduced, and the cost is saved;
2. due to the adoption of the assembling technology, the free-form surface lens with any large area can be assembled, and the wide-angle head-up display structure is suitable for the requirement of the wide-angle head-up display structure on the free-form surface lens with the large area;
3. and a 6-dimensional precision motion mechanism is adopted, so that the position assembling precision is high.
Description of the drawings:
fig. 1 is a schematic structural diagram of an imaging optical structure of a method for assembling a wide-angle optical free-form surface lens according to the present invention;
fig. 2 is a schematic view of an optical path between a camera lens structure and a free-form sub-lens (omitting an imaging optical structure) according to the method for assembling a wide-angle optical free-form lens of the present invention;
FIG. 3 is a schematic structural diagram of a wide-angle optical free-form surface lens according to a method for assembling the wide-angle optical free-form surface lens of the present invention;
FIG. 4 is a horizontal and vertical stripe image inputted by the assembling method of the wide-angle optical free-form surface lens according to the present invention;
fig. 5 is a virtual image of the horizontal and vertical stripe images input by the assembling method of the wide-angle optical free-form surface lens of the present invention;
FIG. 6 is a schematic diagram of a method of assembling a wide-angle optical free-form surface lens according to the present invention, in which multiple ROIs are collected from a single free-form surface sub-lens imaged fringe;
fig. 7 shows a fringe pattern collected by a camera according to the method for assembling a wide-angle optical free-form surface lens of the present invention.
The specific implementation mode is as follows:
the present invention will be further described with reference to the following examples.
Example (b):
in this embodiment, the wide-angle optical free-form surface lens is divided into four free-form surface sub-lenses to be assembled, and the assembling method specifically includes the following steps:
firstly, processing free-form surface reflector sub-lenses, firstly determining design parameters of a large-area free-form surface reflector lens meeting requirements, then dividing four free-form surface reflector sub-lenses which are distributed in an array according to the design parameters of the large-area free-form surface reflector lens, respectively determining the design parameters of the free-form surface reflector sub-lenses, and then respectively processing the free-form surface reflector sub-lenses 100a, 100b, 100c and 100d according to the design parameters of the free-form surface reflector sub-lenses;
secondly, constructing an imaging optical structure, as shown in fig. 1, wherein the imaging optical structure is a head-up display optical structure, the head-up display optical structure comprises an image input interface 1, a directional diffraction sheet 2, a first off-axis free-form surface reflection lens 3, a second off-axis free-form surface reflection lens 4, virtual image forming glass 5, a human eye observation window 6 and a virtual image position 7, the directional diffraction sheet is used as a relay image surface, image light of the image input interface projects imaging light beams onto the virtual image forming glass according to a designed angle through the first off-axis free-form surface reflection lens and the second off-axis free-form surface reflection lens, and partial light is reflected to a human eye observation window through the virtual image forming glass, so that human eyes can see a virtual image in front;
thirdly, mounting free-form surface reflector sub-lenses, replacing a second off-axis free-form surface reflector sub-lens 4 in the imaging optical structure constructed in the second step with four free-form surface reflector sub-lenses 100a, 100b, 100c and 100d in the first step, arranging the free-form surface reflector sub-lenses according to positions in design parameters of the large-area free-form surface reflector sub-lenses in the first step, and respectively connecting the free-form surface reflector sub-lenses with a precise motion mechanism, wherein the precise motion mechanism at least comprises an X-axis walking module, a Y-axis walking module, a Z-axis walking module, an X-axis rotating module with an X-axis as a rotating shaft, a Y-axis rotating module with a Y-axis as a rotating shaft and a Z-axis rotating module with a Z-axis as a rotating shaft, and is driven by the precise motion mechanism, and the free-form surface reflector sub-lenses can perform 6-dimensional (X, Y, Z, thetax and thet, θ z) is adjusted;
fourthly, installing a camera lens structure 8 and image analysis software, as shown in fig. 2, installing the camera lens structure at the position of the human eye observation window in the imaging optical structure constructed in the second step, wherein the camera lens structure is used for replacing human eyes to receive virtual images, the camera lens structure is connected with a computer 9 through a data line, and the computer is provided with the image analysis software;
fifthly, adjusting the 6-dimensional position of the free-form surface reflector sub-lens, inputting a horizontal and vertical stripe image with a specific spatial frequency through an image input interface, as shown in fig. 4, wherein the horizontal and vertical stripe image comprises a plurality of horizontal and vertical stripe sub-images, the layout of the horizontal and vertical stripe sub-images is the same as that of the free-form surface reflector sub-lens, as shown in fig. 5, the four horizontal and vertical stripe sub-images are respectively reflected by the free-form surface reflector sub-lens at corresponding positions and form a virtual image, the virtual image is received by a camera lens structure and is transmitted to a computer, image analysis is performed on the virtual image by image analysis software, the image analysis software divides the virtual image into four ROIs respectively corresponding to the free-form surface reflector sub-lens according to the display information of the virtual image and the position of the free-form surface reflector sub-lens, and then the image analysis software analyzes and calculates the MTF value of, adjusting the 6-dimensional space position of the free-form surface reflector sub-lens according to the MTF values, and judging that the free-form surface reflector sub-lens is assembled in place when all the MTF values reach the design target value;
and sixthly, splicing and fixing the plurality of free-form surface reflector sub-lenses adjusted in the fifth step into an integral lens to obtain the spliced wide-angle optical free-form surface lens.
The MTF calculation formula in the fifth step is as follows:
MTF= (Imax−𝐼𝑚𝑖𝑛)/(𝐼𝑚𝑎𝑥+𝐼𝑚𝑖𝑛);
and Imax is a gray value corresponding to the bright stripe and a gray value corresponding to the dark stripe, and one stripe period comprises one bright stripe, namely a white stripe, and one dark stripe, namely a black stripe.
Assuming that the camera is used for data acquisition with 8 bits, the maximum bright stripe corresponds to a gray level of Imax =255 and the maximum dark stripe corresponds to a gray level of Imin =0, so that the MTF value of an ideal stripe without image quality loss is obtained
In the case of = (Imax-Imin)/(Imax + Imin) = (255-0)/(255+0) =1, the contrast of the original image is theoretically 1, and the theoretical maximum value of the contrast is 1, which is generally less than 1 because of the loss in the image definition transmission process.
As shown in fig. 7, after the original fringe pattern is transmitted through the lens, the fringe gray scale curve of a certain ROI of the image is as follows:
we can calculate the contrast to this ROI, by noise filtering calculation, assuming we get I _ max =115, I _ min =82 contrast = (I _ max-I _ min)/(I _ max + I _ min) = (115-82)/(115+82) = 0.168.
The fifth step is specifically adjusted as follows:
if the MTF of the ROI corresponding to the free-form surface mirror 100a is smaller than the set target value, the position of the free-form surface mirror 100a is adjusted, for example, the X-axis position is adjusted, and the process is as follows: increasing X-axis coordinate values, then calculating MTF values, if the MTF values are reduced, reducing the X-axis coordinate values, and thus finding the X-axis coordinate values when the MTF values are maximum through multiple adjustments; adjusting the coordinate values of the Y axis, the Z axis, the X axis angle, the Y axis angle and the Z axis angle in the same way; when the 6-dimensional position is adjusted, the maximum MTF value is obtained;
and (ii) setting the maximum MTF value in the step (i) as a target value, and similarly adjusting the 6-dimensional positions of the free-form surface mirror pieces 100b, 100c, and 100 d.
As shown in fig. 6, the fifth step further includes acquiring MTF values of multiple ROIs for the stripes imaged by the single free-form surface sub-lens, that is, one free-form surface sub-lens is detected by the MTF values of the multiple ROIs, and then the 6-dimensional spatial position of the single free-form surface reflecting sub-lens is adjusted according to the characteristics of the MTF values distributed vertically, horizontally and diagonally, so as to further improve the precision of active alignment of the free-form surface reflecting sub-lens.
Referring to fig. 3, an assembled wide-angle optical free-form surface lens 100 includes four array-distributed free- form surface sub-lenses 100a, 100b, 100c, 100d, which are assembled by the assembling technique as described above to form the wide-angle optical free-form surface lens;
further, by wide angle optics free-form surface lens constitutes new line display optical system, new line display optical system includes an image input interface, and directional diffraction piece, and first off-axis free-form surface mirror piece, and second off-axis free-form surface mirror piece, and becomes virtual image glass, and people's eye observation window and virtual image position, directional diffraction piece is as relaying image plane, first off-axis free-form surface mirror piece adopts the wide angle optics free-form surface mirror piece that the assembly becomes, image input interface's image light is through first off-axis free-form surface mirror piece, second off-axis free-form surface mirror piece according to the angle projection formation of image beam to becoming virtual image glass on, through becoming virtual image glass reflection part light to people's eye observation window again, makes people's eye can see a virtual image in the front.
The head-up display optical system can realize a view field angle of more than 20 degrees through 2 large-area free-form surface reflectors, and the sizes of the first off-axis free-form surface reflector and the second off-axis free-form surface reflector are 200mmx100mm and 420mmx200mm respectively.
The image input interface can be a micro high-speed vibration reflector shaped by a laser light source, or a Miro-LED, OLED, LBS, LCD and other display chips.
The present invention has been described in detail, and it should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.

Claims (7)

1. An assembling method of a wide-angle optical free-form surface lens is characterized by comprising the following steps:
firstly, processing a free-form surface reflector lens;
secondly, constructing an imaging optical structure;
thirdly, mounting free-form surface reflector sub-lenses, mounting the free-form surface reflector sub-lenses in the optical path of the imaging optical structure constructed in the second step, and respectively connecting the free-form surface reflector sub-lenses with a precise movement mechanism, wherein the precise movement mechanism at least comprises an X-axis walking module, a Y-axis walking module, a Z-axis walking module, an X-axis rotation module taking an X-axis as a rotating shaft, a Y-axis rotation module taking the Y-axis as the rotating shaft and a Z-axis rotation module taking the Z-axis as the rotating shaft;
fourthly, installing a camera lens structure and image analysis software;
fifthly, adjusting the 6-dimensional position of the free-form surface reflector sub-lens, inputting a horizontal and vertical stripe image with a specific spatial frequency through an image input interface, wherein the horizontal and vertical stripe image comprises a plurality of horizontal and vertical stripe sub-images, the layout of the horizontal and vertical stripe sub-images is the same as that of the free-form surface reflector sub-lens, the horizontal and vertical stripe sub-images are respectively reflected by the free-form surface reflector sub-lens at corresponding positions to form a virtual image, the virtual image is received by a camera lens structure and is transmitted to a computer, image analysis is carried out on the virtual image by image analysis software, the image analysis software divides the virtual image into a plurality of ROs respectively corresponding to the free-form surface reflector sub-lens according to the display information of the virtual image and the position of the free-form surface reflector sub-lens, and then the image analysis software analyzes and calculates the MTF value of the stripe with the specific frequency, adjusting the 6-dimensional space position of the free-form surface reflector sub-lens according to the MTF values, and judging that the free-form surface reflector sub-lens is assembled in place when all the MTF values reach the design target value;
and sixthly, splicing and fixing the plurality of free-form surface reflector sub-lenses adjusted in the fifth step into an integral lens to obtain the spliced wide-angle optical free-form surface lens.
2. The method of assembling a wide-angle optical free-form surface lens as claimed in claim 1, wherein the first step comprises: the method comprises the steps of firstly determining design parameters of a large-area free-form surface reflection lens which meets requirements, then dividing a plurality of free-form surface reflection sub-lenses which are distributed in an array according to the design parameters of the large-area free-form surface reflection lens, respectively determining the design parameters of the free-form surface reflection sub-lenses, and respectively processing the free-form surface reflection sub-lenses according to the design parameters of the free-form surface reflection sub-lenses, wherein the number of the free-form surface reflection sub-lenses is 4, 6 or 9.
3. The method of assembling a wide-angle optical free-form surface lens as claimed in claim 1, wherein the second step comprises: the imaging optical structure is a head-up display optical structure, the head-up display optical structure comprises an image input interface, a directional diffraction sheet, a first off-axis free-form surface reflector, a second off-axis free-form surface reflector, virtual image forming glass, a human eye observation window and a virtual image position, the directional diffraction sheet is used as a relay image surface, image light of the image input interface projects imaging light beams to the virtual image forming glass according to a designed angle through the first off-axis free-form surface reflector and the second off-axis free-form surface reflector, and partial light is reflected to the human eye observation window through the virtual image forming glass, so that human eyes can see a virtual image in front;
the third step further comprises: and replacing a second off-axis free-form surface reflector in the imaging optical structure constructed in the second step with a plurality of free-form surface reflector sub-lenses in the first step, wherein the free-form surface reflector sub-lenses are arranged according to positions in the design parameters of the large-area free-form surface reflector lens in the first step and are driven by a precise movement mechanism, and the free-form surface reflector sub-lenses can be adjusted in 6-dimensional space positions.
4. The method of assembling a wide-angle optical free-form surface lens as claimed in claim 3, wherein the fourth step comprises: and installing a camera lens structure at the position of a human eye observation window in the imaging optical structure constructed in the second step, wherein the camera lens structure is used for replacing human eyes to receive virtual images, the camera lens structure is connected with a computer through a data line, and the computer is provided with image analysis software.
5. The method for assembling a wide-angle optical free-form surface lens as claimed in claim 1, wherein the fifth step is performed according to the following technical principles:
the spatial positions and spatial angles of all the free-form surface reflector sub-lenses can influence the image quality loss of virtual images obtained by the free-form surface reflector sub-lenses in an imaging display structure, the free-form surface reflector sub-lenses correspond to characteristic imaging areas, the image quality loss degree of an imaging system of the free-form surface reflector sub-lenses is judged by the assembling method through MTF values, when the MTF values meet requirements and are consistent, the image quality loss degree of the free-form surface reflector sub-lenses is judged to be consistent, at the moment, the spatial positions and the spatial angles of the free-form surface reflector sub-lenses are consistent with the positions of the free-form surface reflector sub-lenses before the large-area free-form surface reflector sub-lenses are divided in the first step, and then all the free-form surface reflector sub-.
6. The assembly method of claim 1, wherein the calculating of the MTF value in the fifth step comprises:
the assembly method is calculated by adopting a physical theory, the assembly method further comprises a plurality of necessary image filtering processes, and the MTF calculation formula is as follows:
MTF= (Imax−𝐼𝑚𝑖𝑛)/(𝐼𝑚𝑎𝑥+𝐼𝑚𝑖𝑛);
and the MTF calculates the tolerance of the gray value of the stripes of the virtual image, wherein Imax is the gray value corresponding to the bright stripes and the gray value corresponding to the dark stripes, and one stripe period comprises one bright stripe, namely the white stripe, and one dark stripe, namely the black stripe.
7. The assembly method of claim 1, wherein the fifth step further comprises collecting MTF values of multiple ROIs for the strips imaged by a single free-form surface mirror sub-lens, that is, one free-form surface mirror sub-lens is detected by the MTF values of multiple ROIs, and then adjusting the 6-dimensional spatial position of the single free-form surface mirror sub-lens according to the characteristics of the MTF values distributed vertically, horizontally and diagonally, thereby further improving the precision of active alignment of the free-form surface mirror sub-lens.
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