Deterministic Optical Surface Polishing via Computerized Control
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Solution Overview
Problem
Current full-aperture grinding and polishing processes for optical surfaces lack determinism, requiring human intuition and frequent adjustments, leading to inconsistent and suboptimal surface shapes, which can result in optical elements that are not suitable for their intended purposes or may be damaged in high-energy applications.
Innovation Solution
A computerized method and system that calculates material removal and surface shape by integrating kinematic properties, friction coefficients, pressure distributions, and moment forces, allowing for deterministic control of the polishing process to achieve a desired surface shape.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional full aperture polishing techniques are used, then material removal and surface shaping can be performed, but the process lacks determinism and requires continuous human monitoring and adjustment
Solution Approach 1:
The patent applies parameter changes by systematically varying polishing parameters (pressure, velocity, slurry concentration, particle size) to control material removal rates and achieve deterministic surface shaping. The Preston equation is used to model and predict material removal based on these parameters, enabling automated control without human intervention.
Solution Approach 2:
The patent replaces the mechanical human optician's monitoring and adjustment system with a computerized control system that uses mathematical models (Preston equation) and automated feedback loops to control polishing parameters, achieving deterministic results without human intervention.
2Manufacturing precision
If human opticians monitor and adjust polishing techniques, then surface shape can be controlled, but the process becomes intermittent and less repeatable
Solution Approach 1:
The polishing system performs self-service through automated feedback control where the system continuously measures surface topology, compares it to the target shape, and automatically adjusts polishing parameters to correct deviations, eliminating the need for human opticians and enabling continuous, repeatable operation.
Solution Approach 2:
The patent implements feedback control by measuring surface topology during polishing, comparing measured values to target values, and using the difference to adjust polishing parameters in real-time, ensuring deterministic achievement of desired surface shapes with high repeatability.
3Manufacturing precision
If iterative polishing techniques are applied, then surface shape can be monitored and adjusted, but the process time increases and economic feasibility decreases
Solution Approach 1:
The patent applies preliminary action by pre-calculating the desired surface topology and using it to guide the polishing process from the beginning, rather than iteratively adjusting during the process. This allows the system to achieve target shapes more directly and reduces total polishing time.
Solution Approach 2:
Real-time feedback control allows the system to detect and correct surface shape deviations during polishing, preventing the accumulation of errors that would require extensive iterative corrections later, thereby reducing total process time while maintaining precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the deterministic shaping of optical surfaces, ensuring repeatability, reducing human intervention, and improving the economic feasibility of the process, while accurately predicting and controlling material removal and surface shape.
Implementation Method 1
The surface of the cerium oxide particle is cerium hydroxide, which condenses with the glass surface (silanol surface) to form a Ce-O-Si bond.
Implementation Method 2
The surface of the cerium oxide particle is cerium hydroxide, which condenses with the glass surface (silanol surface) to form a Ce-O-Si bond.
Implementation Method 3
calculating a friction force between the lap and the workpiece
Implementation Method 4
a first device configured to couple to the workpiece and place a first amount of pressure between the workpiece and the lap
Data Source
Figure 1~2B
Figure 3
Figure 4A~4B
AI summary
A polishing system configured to polish a lap includes a lap configured to contact a workpiece for polishing the workpiece; and a septum configured to contact the lap. The septum has an aperture formed therein. The radius of the aperture and radius the workpiece are substantially the same. The aperture and the workpiece have centers disposed at substantially the same radial distance from a center of the lap. The aperture is disposed along a first radial direction from the center of the lap, and the workpiece is disposed along a second radial direction from the center of the lap. The first and second radial directions may be opposite directions.