A flexible polishing method for optical lenses
By employing a flexible polishing method to scientifically partition and monitor the lenses in real time, the polishing challenges of complex curved lenses have been solved, enabling high-precision, low-cost optical lens processing.
Patent Information
- Application Number
- CN202610870010.3
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2026-06-16
- Publication Date
- 2026-07-24
AI Technical Summary
Existing optical lens polishing technology is difficult to adapt to the curvature changes of complex curved lenses, resulting in uneven contact pressure distribution, problems such as over-polishing at the edges, central concavity, and local scratches. Furthermore, it cannot accurately repair local defects and surface errors on the lens surface, and the processing precision is difficult to meet the needs of high-end optical equipment.
The flexible polishing process is adopted. By scientifically dividing the lens surface into different zones and setting differentiated polishing parameters, a flexible polishing path adapted to the curved surface of the lens is generated. The parameters are corrected by combining the material removal rate model, and the polishing process is monitored and controlled in real time to achieve precise processing.
It achieves scientific partitioned and differentiated polishing of the lens surface, avoiding secondary damage caused by incomplete defect removal or over-polishing in traditional processing. It is suitable for lenses of different sizes and curvature types, reducing processing costs and improving processing efficiency and precision.
Smart Images
Figure CN122442485A_ABST
Abstract
Description
Technical Field
[0001] This invention relates to the field of optical lens processing technology, and in particular to a flexible polishing method for optical lenses. Background Technology
[0002] Optical lenses, as core components of optical systems, are widely used in many fields such as cameras, microscopes, telescopes, and laser equipment. Their surface quality and geometric accuracy directly determine the imaging effect, light transmission efficiency, and stability of the optical system. As optical technology develops towards higher precision, miniaturization, and complexity, more stringent requirements are placed on the surface roughness, surface shape error, edge quality, and surface defect control of optical lenses, especially for complex curved optical lenses, whose processing difficulty has increased significantly.
[0003] Currently, the polishing of optical lenses mainly employs rigid polishing and traditional flexible polishing methods. Rigid polishing uses a polishing head with a fixed shape, which is difficult to adapt to the curvature changes of complex curved lenses. This can easily lead to uneven distribution of contact pressure on the lens surface, resulting in problems such as over-polishing at the edges, central concavity, and localized scratches. Furthermore, it cannot accurately correct local defects and surface shape errors on the lens surface, and the processing precision is insufficient to meet the requirements of high-end optical equipment.
[0004] While traditional flexible polishing methods have improved contact compatibility to some extent, they still have many shortcomings: First, they do not scientifically divide the lens surface and use uniform polishing parameters to process the entire lens, which cannot take into account the curvature differences, error magnitudes, and defect distributions in different areas, making it difficult to achieve differentiated and precise processing; Second, the polishing path design does not fully incorporate the curved surface characteristics of the lens, which can easily lead to problems such as the trajectory not fitting the curved surface and abrupt changes in the processing of transition areas, affecting the uniformity of processing. Summary of the Invention
[0005] The purpose of this invention is to provide a flexible polishing method for optical lenses to solve the problems mentioned in the background art.
[0006] To achieve the above objectives, the present invention provides a flexible polishing method for optical lenses, comprising the following steps: S1. Perform surface cleaning, clamping and positioning, and initial state detection on the optical lens to be processed to obtain geometric morphology and surface defect information of the lens before processing. S2. Data processing, error analysis and region mapping are performed on the geometric morphology information and surface defect information to establish a flexible polishing processing model for the lens to be processed, and the surface of the lens to be processed is divided into zones. S3. Based on the partitioning results, generate a flexible polishing path and process parameter control scheme that adapts to the curved surface of the lens; S4. Based on the flexible polishing path and process parameter control scheme, the flexible polishing path, the regional processing sequence and the corresponding process parameters are imported into the flexible polishing equipment to drive the flexible polishing head to polish the optical lens. S5. During the polishing process, establish an online monitoring mechanism for the processing status, and collect, analyze and control the key process parameters and surface processing status in real time. S6. After polishing, perform post-processing, final inspection and necessary secondary finishing on the polished optical lens to confirm whether the final surface quality of the lens meets the requirements for delivery or use.
[0007] Preferably, S1 includes: S11. Remove dust, oil, and adhering particles from the upper and lower surfaces of the lens to be processed, and remove dust, fingerprints, processing residues, and other adhering impurities from the lens surface. S12. Install the cleaned lens into the testing fixture or processing clamping tool, and use the outer edge of the lens, the center hole, the reference plane or the preset positioning mark as the positioning reference to perform unified positioning of the lens in the axial, radial and orientation directions, so that the lens is in a stable and repeatable testing state. S13. Perform initial geometric detection on the surface of the lens after positioning to obtain the overall surface shape, local morphological deviation and curvature change characteristics of the lens; S14. Use surface imaging detection, scattering detection or microscopic visual detection methods to identify defects on the lens surface and obtain information on scratches, pits, microcracks, contamination spots, pinholes and local rough and abnormal areas. S15. The test results obtained in S13 and S14 are summarized in a unified manner to form an initial processing database for lenses.
[0008] Preferably, the initial processing database includes: lens size data, lens curvature distribution data, overall surface shape error data, local contour deviation data, surface defect type and location data, and processing priority data for each area.
[0009] Preferably, the initial geometry detection specifically includes: Overall surface shape error detection: The interferometer is used to scan the surface shape of the lens to obtain the wavefront error, surface shape deviation or height error distribution of the lens surface, which is used to determine whether there are shape problems such as warping, bulging or denting of the lens as a whole; Local surface contour detection: The lens surface is scanned point by point or line by line using a profilometer, 3D scanner or point displacement sensor to obtain information on local curvature changes, slope changes and height undulations in various areas of the lens, so as to identify high curvature areas, gradual change areas and transition areas. Edge and local feature detection: Focus on detecting the edge area, transition arc area or special curved surface area of the lens to obtain edge thickness changes, local step errors and boundary contour deviations, so as to avoid edge over-polishing or edge collapse during subsequent polishing.
[0010] Preferably, S2 includes: S21. Perform a unified coordinate transformation on the lens curvature distribution data, overall surface shape error data, local contour deviation data, and defect distribution data, so that they are mapped to the same lens surface coordinate system, forming a standardized surface data map that can be used for processing planning. S22. Based on the standardized surface data map, establish a flexible polishing processing model for the lens surface to characterize the geometric features, material removal characteristics and processing response relationship of different regions of the lens. S23. Based on the curvature variation, surface shape error distribution, and defect concentration of the lens surface, the surface to be processed is divided into multiple polishing areas. S24. For the different polishing areas obtained in S23, set the corresponding polishing target parameters to form a partitioned processing parameter table; S25. Associate the partitioning results of S23 with the target parameters of S24 to generate a flexible polishing partitioning processing strategy for the lens.
[0011] Preferably, the polishing areas include high curvature areas, low curvature areas, areas with large surface shape errors, areas with concentrated defects, and ordinary trimming areas; the polishing target parameters include polishing pressure, polishing speed, dwell time, feed path spacing, and polishing head posture angle; the processing strategy includes area number, area location range, area type, corresponding polishing parameters, area processing sequence, and area correction priority.
[0012] Preferably, S3 includes: S31. Based on the partitioning results, extract the spatial boundary, surface normal variation characteristics and region connection relationship of each polishing area, and divide the lens surface into several continuous processing units. S32. For each polished area, based on the local curvature distribution and surface normal change of that area, generate a scanning trajectory that fits the contour of the lens surface. S33. After generating the basic scanning trajectory, different error weights are assigned to different regions based on the size of the surface shape error, the degree of surface defects, and the priority of processing correction. The trajectory coverage density and repetition mode are adjusted accordingly. S34. Based on the curvature changes in different areas of the lens, the posture of the polishing head is dynamically preset so that the polishing head always maintains a reasonable contact angle and contact state during the movement. S35. Establish a material removal rate model, and based on the model, correct the path spacing, trajectory speed, residence time and number of repetitions to make the polishing path consistent with the actual removal effect. S36. Integrate the trajectory information, attitude information and parameter correction results obtained from S31 to S35 to form a flexible polishing path and process parameter control scheme that corresponds one-to-one with each polishing area of the lens.
[0013] Preferably, S4 includes: S41. The lens to be processed is mounted on the processing platform of the flexible polishing equipment, and the lens is repeatedly positioned by the positioning reference, clamping center or edge limiting structure. S42. Start the flexible polishing head, and slowly bring the polishing head closer to the lens surface at a preset initial height, and establish a stable and compliant contact state between the polishing head and the lens surface. S43. After the compliant contact is established, the flexible polishing head performs polishing motions on each area of the lens in sequence according to the partitioned polishing path generated in S3. S44. During the polishing process, adjust the contact pressure, movement speed, dwell time and attitude angle of the polishing head according to the area parameter table output by S3. S45. During the polishing process, the flexible polishing head relies on its own elastic deformation ability to compensate for the deformation of the local curved surface of the lens. S46. After polishing a single area, smooth the transition boundary between adjacent areas so that the polishing trajectory gradually transitions at the boundary between areas.
[0014] Preferably, S5 includes: S51. During the polishing process, the process data and status data of the polishing process are collected in real time by using sensors, encoders, temperature detection units and surface status recognition units installed on the flexible polishing equipment. S52. Input the collected process data and status data into the preset processing model, and compare them with the regional target parameters generated in S2 to S3 to determine whether the current actual processing status deviates from the preset target status. S53. When real-time processing data is detected to exceed the allowable threshold of the corresponding area, the abnormal area is located and classified to determine whether it belongs to the under-processed area or the over-processed area. S54. Generate parameter correction instructions for the corresponding area so that the polishing process can adaptively compensate for deviations. S55. Feed back the parameter correction command to the flexible polishing equipment so that the flexible polishing head can continue to perform local compensation processing according to the corrected parameters in the subsequent processing. S56. After performing parameter correction and compensation processing, continue to conduct online retesting of the corrected area, and compare the retest results with the target processing model again.
[0015] Preferably, S6 includes: S61. Clean the lens after polishing to remove residual polishing fluid, abrasive particles, debris and adhering contaminants from the lens surface; S62. After cleaning, the lens is dried to eliminate the influence of surface water film, cleaning solution residue and environmental humidity on the test results. S63. Perform a final quality inspection on the cleaned and dried lenses to determine whether the lenses meet the preset processing standards. S64. Compare the final inspection results obtained in S63 with the preset quality standards; S65. For lenses that fail the inspection, the non-compliant areas are located and analyzed based on the final inspection results to determine whether they belong to one or more of the following areas: surface shape error exceeding tolerance, roughness exceeding tolerance, defect residue, or optical performance abnormality. On this basis, a secondary compensation polishing strategy is regenerated for the non-compliant area. S66. According to the secondary compensation polishing strategy, the substandard areas that need to be corrected are returned to the corresponding steps in S2 to S5 for reprocessing. S67. After completing the second fine-tuning, perform the cleaning, drying and final inspection process on the lens again to repeatedly determine whether it meets the preset quality standards.
[0016] Therefore, the above-described flexible polishing method for optical lenses in this invention has the following beneficial effects: (1) The lens surface is scientifically divided into zones. Based on the curvature changes, surface errors and defect distribution of different zones, different polishing parameters are set to achieve precise processing of one zone, one strategy. A flexible polishing path that is compatible with the lens surface is generated. The parameters are corrected by combining the material removal rate model to ensure that the polishing trajectory fits perfectly with the surface contour.
[0017] (2) In the initial inspection stage, various inspection methods are used to accurately identify defects such as scratches, pits, and microcracks on the lens surface, and record detailed information such as the location, size, and depth of the defects; in the zoning processing stage, the defect concentration area is divided separately, and a low-pressure, low-speed, and progressive polishing strategy is set; in the path planning stage, the trajectory coverage method is adjusted for the defect concentration area, and multiple light coverages are used to achieve accurate removal of defects, avoiding secondary damage caused by incomplete defect removal or excessive polishing in traditional processing.
[0018] (3) Through the deformation compensation of the flexible polishing head, the zoned differentiated processing strategy and the adaptability path planning, it can flexibly adapt to optical lenses of different sizes and different surface types (including high curvature and complex transition surfaces). Whether it is a planar, spherical or aspherical lens, it can achieve precise polishing processing. At the same time, the processing parameters and paths can be adaptively adjusted according to the initial detection data of the lens. There is no need to redesign the entire processing scheme for different lenses, which reduces processing costs and improves processing efficiency.
[0019] The technical solution of the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Attached Figure Description
[0020] Figure 1 This is a flowchart of a flexible polishing method for optical lenses according to an embodiment of the present invention; Figure 2 This is a comparison curve showing the change in processing error with the number of polishing cycles in an embodiment of the present invention. Detailed Implementation
[0021] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some, not all, of the embodiments of the present invention. The components of the embodiments of the present invention described and shown in the accompanying drawings can generally be arranged and designed in various different configurations. Therefore, the following detailed description of the embodiments of the present invention provided in the accompanying drawings is not intended to limit the scope of the claimed invention, but merely to illustrate selected embodiments of the invention. All other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort are within the scope of protection of the present invention.
[0022] It should be noted that similar labels and letters in the following figures indicate similar items. Therefore, once an item is defined in one figure, it does not need to be further defined and explained in subsequent figures.
[0023] Example like Figure 1 As shown, the present invention provides a flexible polishing method for optical lenses, comprising the following steps: S1. Perform surface cleaning, clamping and positioning, and initial state detection on the optical lens to be processed to obtain geometric morphology and surface defect information of the lens before processing, providing basic data for setting subsequent flexible polishing parameters.
[0024] In this embodiment, S1 includes: S11. The upper and lower surfaces of the lens to be processed are treated to remove dust, oil, and adhering particles. It is preferred to use one or more of the following methods: dust-free airflow blowing, anhydrous ethanol wiping, or ultrasonic cleaning, to remove dust, fingerprints, processing residues, and other adhering impurities from the lens surface, so as to avoid affecting the detection accuracy or causing surface scratches due to foreign object interference during subsequent inspection and polishing.
[0025] S12. Install the cleaned lens into the testing fixture or machining clamping tool, and use the outer edge, center hole, reference plane, or preset positioning mark of the lens as the positioning reference to uniformly position the lens in the axial, radial, and orientation directions, so that the lens is in a stable and repeatable testing state. Among them, the clamping method preferably adopts a flexible support type or non-rigid contact clamping to reduce the impact of clamping stress on the original surface shape of the lens and avoid the distortion of the initial test results due to clamping deformation.
[0026] S13. Perform initial geometric inspection on the positioned lens surface to obtain the overall surface shape, local topographic deviations, and curvature variation characteristics of the lens. Specifically, this may include: Overall surface shape error detection: The interferometer is used to scan the surface shape of the lens to obtain the wavefront error, surface shape deviation or height error distribution of the lens surface, which is used to determine whether there are shape problems such as warping, bulging or denting of the lens as a whole; Local surface contour detection: The lens surface is scanned point by point or line by line using a profilometer, 3D scanner or point displacement sensor to obtain information on local curvature changes, slope changes and height undulations in various areas of the lens, so as to identify high curvature areas, gradual change areas and transition areas. Edge and local feature detection: Focus on detecting the edge area, transition arc area or special curved surface area of the lens to obtain edge thickness changes, local step errors and boundary contour deviations, so as to avoid edge over-polishing or edge collapse during subsequent polishing.
[0027] S14. Surface imaging detection, scattering detection, or microscopic visual inspection methods are used to identify defects on the lens surface, acquiring information on scratches, pitting, microcracks, contaminants, pinholes, and localized roughness anomalies. Defect detection can be enhanced by using ring lighting, oblique incidence lighting, or dark-field imaging to improve the visibility of surface micro-defects, thereby increasing the accuracy of defect identification. For defective areas, their coordinates, area range, depth, and distribution density can be further recorded for subsequent targeted polishing and repair.
[0028] S15. The test results obtained in S13 and S14 are summarized to form an initial processing database for the lens. The database includes at least: lens size data, lens curvature distribution data, overall surface shape error data, local contour deviation data, surface defect type and location data, and processing priority data for each area. Furthermore, the lens surface can be labeled with coordinate grids or area blocks to establish a "position-error-defect" correspondence, providing a basis for subsequent polishing path planning, pressure distribution, and residence time setting.
[0029] S2. Data processing, error analysis, and region mapping are performed on the geometric morphology and surface defect information to establish a flexible polishing processing model for the lens to be processed. The surface of the lens to be processed is divided into zones so that different regions correspond to different polishing strategies and processing parameters.
[0030] In this embodiment, S2 includes: S21. The lens curvature distribution parameters, overall surface shape error parameters, local contour deviation parameters, and defect distribution data obtained in S1 are uniformly transformed to map them to the same lens surface coordinate system, forming a standardized surface data map that can be used for processing planning. The standardization process includes: unifying the scale of data collected from different testing equipment; registering coordinates between different testing results; smoothing and filtering local noise data; and removing or correcting abnormal abrupt changes.
[0031] S22. Based on the standardized surface data map, establish a flexible polishing processing model for the lens surface to characterize the geometric features, material removal characteristics, and processing response relationship of different regions of the lens. The processing model includes at least: a local curvature model for each region of the lens, a surface shape error model for each region of the lens, a material removal rate model for the lens surface, a response relationship between polishing contact pressure and material removal amount, and a mapping relationship between the polishing trajectory and local removal uniformity.
[0032] S23. Based on the curvature variation, error deviation, and defect concentration of the lens surface, the surface to be processed is divided into multiple polishing areas. Each polishing area includes at least a high curvature area, a low curvature area, an area with significant surface shape error, a defect concentration area, and a general finishing area. Furthermore, based on the lens size, surface type, and processing requirements, each area can be divided into annular zones, sector blocks, or grids to improve the accuracy of area identification and parameter control.
[0033] S24. For the different polishing areas obtained in S23, set corresponding polishing target parameters to form a partitioned processing parameter table. The polishing target parameters include at least polishing pressure, polishing speed, dwell time, feed path spacing, and polishing head attitude angle. Specifically, the parameters corresponding to different areas can be set according to the following principles: reduce polishing pressure and path spacing and adjust polishing head attitude angle for high curvature areas; appropriately increase dwell time or number of repetitions for areas with large surface shape errors; reduce polishing pressure and speed for areas with concentrated defects and use a progressive finishing method to remove shallow defects; use uniform and continuous conventional parameters for processing low curvature areas and ordinary finishing areas.
[0034] S25. Associate the partitioning results of S23 with the target parameters of S24 to generate a flexible polishing partitioning processing strategy for the lens. The processing strategy includes at least the region number, region location range, region type, corresponding polishing parameters, region processing order, and region correction priority. Among them, regions with larger surface shape errors and regions with concentrated defects are marked first and are corrected first in subsequent polishing processes.
[0035] S3. After completing the lens surface partitioning and setting the target parameters for each region in S2, based on the geometric characteristics, error level and processing priority of each polishing region, a flexible polishing path and process parameter control scheme adapted to the lens surface are further generated to guide the subsequent polishing actuator to carry out differentiated processing for different regions.
[0036] In this embodiment, S3 includes: S31. Based on the partitioning results output by S2, extract the spatial boundaries, surface normal variation features, and region connectivity of each polishing region, dividing the lens surface into several continuous processing units. When extracting region boundaries, prioritize identifying high curvature boundaries, region transition boundaries, and defect concentration boundaries to avoid parameter abrupt changes when subsequent paths cross regions with different processing attributes.
[0037] S32. For each polished area, based on the local curvature distribution and surface normal variation of that area, a scanning trajectory that conforms to the contour of the lens surface is generated. The scanning trajectory can be generated through discrete sampling, smooth trajectory connection, and normal preservation. Short step distance and dense scanning trajectory are used for high curvature areas, and long step distance and continuous scanning trajectory are used for low curvature areas.
[0038] S33. After generating the basic scanning trajectory, different error weights are assigned to different regions based on the magnitude of surface shape error, the degree of surface defects, and the priority of processing correction. The trajectory coverage density and repetition mode are adjusted accordingly. For regions with large surface shape errors, the trajectory coverage density is increased, the spacing between adjacent trajectories is reduced, and the number of repeated scans is appropriately increased. For regions with concentrated defects, the intensity of a single trajectory action is reduced, and a gradual correction is performed using multiple light coverage methods. For ordinary correction areas, a uniform coverage trajectory is used. Gradual trajectory connection segments are set for edge or transition areas.
[0039] S34. Based on the curvature changes in different areas of the lens, the polishing head posture is dynamically preset to ensure that the polishing head maintains a reasonable contact angle and contact state throughout its movement. In high curvature areas, the deviation between the polishing head and the surface normal is reduced; transitional adjustments are made in areas of abrupt curvature changes; and a relatively stable posture is maintained in low curvature areas.
[0040] S35. Establish a material removal rate model and adjust the path spacing, trajectory speed, dwell time, and number of repetitions based on the model to ensure the polishing path matches the actual removal effect. When the material removal rate in a certain area is low, increase the dwell time or the number of repetitions in that area; when the material removal rate in a certain area is high, decrease the polishing pressure or increase the path spacing; when the surface defects in a region are shallow but densely distributed, use a low-pressure, low-speed, multiple-cycle correction method; when the surface shape error in a region is large and the removal volume requirement is high, appropriately increase the trajectory coverage density and extend the local processing time.
[0041] S36. Integrate the trajectory information, attitude information, and parameter correction results obtained from S31 to S35 to form a flexible polishing path and process parameter control scheme that corresponds one-to-one with each polishing area of the lens. The control scheme shall at least include the path start and end points, trajectory type, trajectory spacing, polishing speed, dwell time, polishing head attitude angle, number of repeated processing steps, and processing sequence and priority for each polishing area.
[0042] S4. After generating the flexible polishing path and parameter control scheme in S3, import the flexible polishing path, regional processing sequence and corresponding process parameters into the flexible polishing equipment, and drive the flexible polishing head to polish the optical lens in a zoned, graded and timed manner.
[0043] In this embodiment, S4 includes: S41. The lens to be processed is mounted on the processing platform of the flexible polishing equipment, and the lens is repeatedly positioned using a positioning reference, clamping center, or edge limiting structure to ensure that the processing center, rotation axis, and surface normal of the lens are consistent with the equipment coordinate system. Preferably, the lens clamping method uses a low-stress support or flexible limiting structure to avoid additional deformation of the lens before processing due to rigid clamping.
[0044] S42. Activate the flexible polishing head, slowly approaching the lens surface at a preset initial height, and establishing a stable, compliant contact between the polishing head and the lens surface. The flexible polishing head preferably includes a flexible substrate, a polishing working layer, and a buffer support layer. The flexible substrate has elastic deformation capabilities, enabling it to undergo appropriate deformation upon contact with the curved surface of the lens to compensate for contact differences caused by local curvature variations. The polishing working layer is used to directly contact the lens surface and remove material. The buffer support layer is used to disperse contact pressure and reduce local stress concentration.
[0045] S43. After establishing compliant contact, the flexible polishing head sequentially performs polishing motions on each area of the lens according to the partitioned polishing path generated in S3. The polishing motions include one or more of the following: reciprocating scanning motion, spiral circling motion, circular progressive motion, or localized dwell-and-finishing motion. Continuous scanning polishing motion is used for low-curvature areas; small-step, short-stroke, high-precision following polishing motion is used for high-curvature areas; localized repeated covering polishing motion is used for areas with large surface shape errors; and low-speed, multiple-pass finishing is used for areas with concentrated defects.
[0046] S44. During the polishing process, based on the area parameter table output by S3, adjust the contact pressure, movement speed, dwell time, and attitude angle of the polishing head in real time. Reduce the contact pressure and decrease the single feed rate in high curvature areas; appropriately increase the dwell time or number of repetitions in areas with large surface shape errors; reduce the polishing speed in areas with concentrated defects; and use stable and continuous standard parameters for uniform processing in ordinary finishing areas.
[0047] S45. During the polishing process, the flexible polishing head compensates for local surface curvature changes of the lens by relying on its own elastic deformation capability, thus maintaining a relatively stable contact area and contact pressure distribution when contacting areas with different curvatures. Through this flexible deformation compensation mechanism, problems such as excessive local contact pressure, over-polishing of edge areas, missed polishing of areas with abrupt curvature changes, surface scratches and edge chipping, and mismatch between the polishing trajectory and the actual surface can be effectively reduced.
[0048] S46. After polishing a single area, smooth the transition boundary between adjacent areas to ensure a gradual transition of the polishing trajectory at the area boundary, avoiding obvious steps or abrupt changes in processing. For areas that still have surface shape defects after the first polishing, the corresponding area parameters can be called again for secondary or multiple adjustments until the surface shape error, roughness, and defect status of the area meet the preset requirements.
[0049] S5. During the process of flexible polishing of optical lenses, an online monitoring mechanism for the processing status is established to collect, analyze and control the key process parameters and surface processing status in real time, so as to identify processing deviations in a timely manner and dynamically correct the polishing parameters, thereby keeping the actual processing process within the target processing range.
[0050] In this embodiment, S5 includes: S51. During the polishing process, sensors, encoders, temperature detection units, and surface condition recognition units installed on the flexible polishing equipment are used to collect process data and status data in real time. The collected data includes at least polishing pressure data, polishing head displacement data, spindle speed data, processing temperature data, and information on changes in the surface condition of the lens.
[0051] S52. Input the real-time processing data (process data and status data) collected in S51 into the preset processing model and compare it with the regional target parameters generated in S2 to S3 to determine whether the current actual processing state deviates from the preset target state. By dynamically comparing the real-time collected data with the target model, it can be determined whether there are abnormalities in the current processing, such as excessive or insufficient local pressure, the polishing head running trajectory deviating from the preset path, the spindle speed not matching the regional process requirements, abnormal local temperature rise, or the material removal rate being higher or lower than the set value.
[0052] S53. When real-time processing data is detected to exceed the allowable threshold of the corresponding area, the abnormal area is located and classified to determine whether it belongs to an under-processed area or an over-processed area. The under-processed area refers to the area where the amount of target material removed has not reached the preset value, the surface contour error is still greater than the allowable range, or the roughness improvement is not obvious; the over-processed area refers to the area where the amount of material removed exceeds the target value, the local surface shape shows an over-cutting trend, or the surface condition has undergone adverse changes.
[0053] S54. Generate parameter correction instructions for the corresponding area to enable the polishing process to adaptively compensate for deviations. Parameter correction includes at least adjusting polishing pressure, adjusting dwell time, adjusting polishing head attitude angle, adjusting trajectory repetition count, and adjusting local feed speed.
[0054] S55. Feedback the parameter correction command to the flexible polishing equipment, enabling the flexible polishing head to continue local compensation processing according to the corrected parameters in subsequent processing. Dynamic closed-loop compensation can be achieved by immediately performing local compensation on the current abnormal area, gradually transitioning parameters to adjacent transition areas, or using multiple rounds of small corrections instead of a single large correction for the same area.
[0055] S56. After performing parameter correction and compensation processing, continue to perform online retesting on the corrected area and compare the retest results with the target processing model again. If the retest results still do not meet the preset requirements, continue to perform parameter correction and compensation processing; if the retest results meet the requirements, restore the normal processing parameters of the area and proceed to the processing flow of the next area.
[0056] S6. After completing the partitioned flexible polishing process of the lens in S4, the polished optical lens is subjected to post-processing, final inspection and judgment and necessary secondary fine finishing to confirm whether the final surface quality of the lens meets the requirements for delivery or use.
[0057] In this embodiment, S6 includes: S61. Clean the lens after polishing to remove residual polishing fluid, abrasive particles, debris, and adhering contaminants from the lens surface, preventing residues from affecting subsequent test results. Cleaning can be performed using one or more of the following methods: ultrapure water rinsing, dust-free airflow purging, ultrasonic cleaning, and low-residue solvent cleaning.
[0058] S62. After cleaning, the lens is dried to eliminate the influence of surface water film, cleaning solution residue, and ambient humidity on the test results. Drying can be performed using one or more of the following methods: clean hot air drying at low temperature, nitrogen drying, or vacuum drying.
[0059] S63. Perform a final quality inspection on the cleaned and dried lenses to determine whether the lenses meet the preset processing standards. The final inspection includes at least surface roughness inspection, surface shape error inspection, transmission wavefront error inspection, and surface defect residue inspection. The final inspection can be performed using one or more of the following methods: interference inspection, contour inspection, scattering inspection, microscopic visual inspection, or optical performance testing.
[0060] S64. Compare the final inspection results obtained in S63 with the preset quality standards. The preset quality standards include at least the surface roughness threshold, surface shape error threshold, wavefront error threshold, and allowable residual defect level. If the inspection results meet all quality standards, the lens is deemed to be qualified and can proceed to the finished product packaging or subsequent assembly process. If any indicator in the inspection results fails to meet the preset standard, the lens is deemed to still require compensation and correction.
[0061] S65. For lenses that fail inspection, based on the final inspection results, the non-compliant areas are located and analyzed to determine whether they belong to one or more of the following areas: surface shape error exceeding tolerance, roughness exceeding tolerance, defect residue, or abnormal optical performance. Based on this, a secondary compensation polishing strategy is regenerated for the non-compliant area. The strategy includes at least the spatial location of the non-compliant area, the area to be processed secondary, the corresponding compensation pressure parameters, compensation dwell time, compensation trajectory density, compensation polishing times, and compensation polishing head attitude angle.
[0062] S66. Based on the secondary compensation polishing strategy generated in S65, the substandard areas that need correction are returned to the corresponding steps in S2 to S5 for further processing. Specifically, if it is necessary to re-identify the area attributes, return to S2 for local partition adjustment; if it is necessary to regenerate the path, return to S3 for local trajectory optimization; if it is necessary to re-execute polishing, return to S4 for secondary refinement; if it is necessary to correct while polishing, closed-loop compensation is performed during the processing in conjunction with the online monitoring results of S5.
[0063] S67. After completing the second fine-tuning, perform the cleaning, drying and final inspection process on the lens again to repeatedly determine whether it meets the preset quality standards.
[0064] Reference Figure 2 Under the same number of polishing cycles, the error of closed-loop correction decreases faster and can eventually control the error to a lower level. This shows that the method can detect and compensate for processing deviations in a timely manner, thereby improving processing accuracy and reducing over-polishing or under-polishing.
[0065] Therefore, the present invention adopts the above-mentioned flexible polishing method for optical lenses, which collects key data such as polishing pressure, rotation speed, temperature and lens surface condition in real time, and compares them dynamically with the preset processing model. This enables timely identification of processing deviations and location of abnormal areas. Closed-loop compensation processing is achieved through dynamic parameter correction, which effectively avoids the accumulation of processing errors and ensures that the actual processing process is always within the target range, significantly improving processing stability and consistency.
[0066] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.
Claims
1. A method for flexible polishing of optical lenses, characterized in that, Includes the following steps: S1. Perform surface cleaning, clamping and positioning, and initial state detection on the optical lens to be processed to obtain geometric morphology and surface defect information of the lens before processing. S2. Data processing, error analysis and region mapping are performed on the geometric morphology information and surface defect information to establish a flexible polishing processing model for the lens to be processed, and the surface of the lens to be processed is divided into zones. S3. Based on the partitioning results, generate a flexible polishing path and process parameter control scheme that adapts to the curved surface of the lens; S4. Based on the flexible polishing path and process parameter control scheme, the flexible polishing path, the regional processing sequence and the corresponding process parameters are imported into the flexible polishing equipment to drive the flexible polishing head to polish the optical lens. S5. During the polishing process, establish an online monitoring mechanism for the processing status, and collect, analyze and control the key process parameters and surface processing status in real time. S6. After polishing, perform post-processing, final inspection and necessary secondary finishing on the polished optical lens to confirm whether the final surface quality of the lens meets the requirements for delivery or use.
2. The flexible polishing method for optical lenses according to claim 1, characterized in that: S1 includes: S11. Remove dust, oil, and adhering particles from the upper and lower surfaces of the lens to be processed, and remove dust, fingerprints, processing residues, and other adhering impurities from the lens surface. S12. Install the cleaned lens into the testing fixture or processing clamping tool, and use the outer edge of the lens, the center hole, the reference plane or the preset positioning mark as the positioning reference to perform unified positioning of the lens in the axial, radial and orientation directions, so that the lens is in a stable and repeatable testing state. S13. Perform initial geometric detection on the surface of the lens after positioning to obtain the overall surface shape, local morphological deviation and curvature change characteristics of the lens; S14. Use surface imaging detection, scattering detection or microscopic visual detection methods to identify defects on the lens surface and obtain information on scratches, pits, microcracks, contamination spots, pinholes and local rough and abnormal areas. S15. The test results obtained in S13 and S14 are summarized in a unified manner to form an initial processing database for lenses.
3. The flexible polishing method for optical lenses according to claim 2, characterized in that: The initial processing database includes: lens size data, lens curvature distribution data, overall surface shape error data, local contour deviation data, surface defect type and location data, and processing priority data for each area.
4. The flexible polishing method for optical lenses according to claim 3, characterized in that: Initial geometry detection specifically includes: Overall surface shape error detection: The interferometer is used to scan the surface shape of the lens to obtain the wavefront error, surface shape deviation or height error distribution of the lens surface, which is used to determine whether there are shape problems such as warping, bulging or denting of the lens as a whole; Local surface contour detection: The lens surface is scanned point by point or line by line using a profilometer, 3D scanner or point displacement sensor to obtain information on local curvature changes, slope changes and height undulations in various areas of the lens, so as to identify high curvature areas, gradual change areas and transition areas. Edge and local feature detection: Focus on detecting the edge area, transition arc area or special curved surface area of the lens to obtain edge thickness changes, local step errors and boundary contour deviations, so as to avoid edge over-polishing or edge collapse during subsequent polishing.
5. The flexible polishing method for optical lenses according to claim 4, characterized in that: S2 includes: S21. Perform a unified coordinate transformation on the lens curvature distribution data, overall surface shape error data, local contour deviation data, and defect distribution data, so that they are mapped to the same lens surface coordinate system, forming a standardized surface data map that can be used for processing planning. S22. Based on the standardized surface data map, establish a flexible polishing processing model for the lens surface to characterize the geometric features, material removal characteristics and processing response relationship of different regions of the lens. S23. Based on the curvature variation, surface shape error distribution, and defect concentration of the lens surface, the surface to be processed is divided into multiple polishing areas. S24. For the different polishing areas obtained in S23, set the corresponding polishing target parameters to form a partitioned processing parameter table; S25. Associate the partitioning results of S23 with the target parameters of S24 to generate a flexible polishing partitioning processing strategy for the lens.
6. The flexible polishing method for optical lenses according to claim 5, characterized in that: The polishing areas include high curvature areas, low curvature areas, areas with large surface shape errors, areas with concentrated defects, and ordinary repair areas; the polishing target parameters include polishing pressure, polishing speed, dwell time, feed path spacing, and polishing head posture angle; the processing strategy includes area number, area location range, area type, corresponding polishing parameters, area processing sequence, and area correction priority.
7. The flexible polishing method for optical lenses according to claim 6, characterized in that: S3 includes: S31. Based on the partitioning results, extract the spatial boundary, surface normal variation characteristics and region connection relationship of each polishing area, and divide the lens surface into several continuous processing units. S32. For each polished area, based on the local curvature distribution and surface normal change of that area, generate a scanning trajectory that fits the contour of the lens surface. S33. After generating the basic scanning trajectory, different error weights are assigned to different regions based on the size of the surface shape error, the degree of surface defects, and the priority of processing correction. The trajectory coverage density and repetition mode are adjusted accordingly. S34. Based on the curvature changes in different areas of the lens, the posture of the polishing head is dynamically preset so that the polishing head always maintains a reasonable contact angle and contact state during the movement. S35. Establish a material removal rate model, and based on the model, correct the path spacing, trajectory speed, residence time and number of repetitions to make the polishing path consistent with the actual removal effect. S36. Integrate the trajectory information, attitude information and parameter correction results obtained from S31 to S35 to form a flexible polishing path and process parameter control scheme that corresponds one-to-one with each polishing area of the lens.
8. The flexible polishing method for optical lenses according to claim 7, characterized in that: S4 includes: S41. The lens to be processed is mounted on the processing platform of the flexible polishing equipment, and the lens is repeatedly positioned by the positioning reference, clamping center or edge limiting structure. S42. Start the flexible polishing head, and slowly bring the polishing head closer to the lens surface at a preset initial height, and establish a stable and compliant contact state between the polishing head and the lens surface. S43. After the compliant contact is established, the flexible polishing head performs polishing motions on each area of the lens in sequence according to the partitioned polishing path generated in S3. S44. During the polishing process, adjust the contact pressure, movement speed, dwell time and attitude angle of the polishing head according to the area parameter table output by S3. S45. During the polishing process, the flexible polishing head relies on its own elastic deformation ability to compensate for the deformation of the local curved surface of the lens. S46. After polishing a single area, smooth the transition boundary between adjacent areas so that the polishing trajectory gradually transitions at the boundary between areas.
9. The flexible polishing method for optical lenses according to claim 8, characterized in that: S5 includes: S51. During the polishing process, the process data and status data of the polishing process are collected in real time by using sensors, encoders, temperature detection units and surface status recognition units installed on the flexible polishing equipment. S52. Input the collected process data and status data into the preset processing model, and compare them with the regional target parameters generated in S2 to S3 to determine whether the current actual processing status deviates from the preset target status. S53. When real-time processing data is detected to exceed the allowable threshold of the corresponding area, the abnormal area is located and classified to determine whether it belongs to the under-processed area or the over-processed area. S54. Generate parameter correction instructions for the corresponding area so that the polishing process can adaptively compensate for deviations. S55. Feed back the parameter correction command to the flexible polishing equipment so that the flexible polishing head can continue to perform local compensation processing according to the corrected parameters in the subsequent processing. S56. After performing parameter correction and compensation processing, continue to conduct online retesting of the corrected area, and compare the retest results with the target processing model again.
10. The flexible polishing method for optical lenses according to claim 9, characterized in that: S6 include: S61. Clean the lens after polishing to remove residual polishing fluid, abrasive particles, debris and adhering contaminants from the lens surface; S62. After cleaning, the lens is dried to eliminate the influence of surface water film, cleaning solution residue and environmental humidity on the test results. S63. Perform a final quality inspection on the cleaned and dried lenses to determine whether the lenses meet the preset processing standards. S64. Compare the final inspection results obtained in S63 with the preset quality standards; S65. For lenses that fail the inspection, the non-compliant areas are located and analyzed based on the final inspection results to determine whether they belong to one or more of the following areas: surface shape error exceeding tolerance, roughness exceeding tolerance, defect residue, or optical performance abnormality. On this basis, a secondary compensation polishing strategy is regenerated for the non-compliant area. S66. According to the secondary compensation polishing strategy, the substandard areas that need to be corrected are returned to the corresponding steps in S2 to S5 for reprocessing. S67. After completing the second fine-tuning, perform the cleaning, drying and final inspection process on the lens again to repeatedly determine whether it meets the preset quality standards.