Spiral Path Lens Machining for Precision Error Compensation
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Solution Overview
Problem
Conventional lens shape machining methods, such as lathe machining and spiral path machining, struggle to achieve high precision and efficiency in producing compact lens arrays, leading to shape errors and reduced production capacity due to limitations in measurement and compensation techniques, particularly in handling vertical and lateral asymmetries and micro lines that affect optical characteristics.
Innovation Solution
A lens shape machining method and device that utilize a spiral measurement path and machining path with an onboard measuring device to acquire shape data, interpolate errors, and determine compensated machining amounts, allowing for precise correction of shape errors along radial lines, thereby improving machining precision and capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If measurement is carried out along a linear raster path, then all machining surfaces can be measured, but line marks are left on the machining surface and manual labor hours increase due to escaping motions
Solution Approach 1:
The patent applies a spiral measurement path instead of linear raster paths, using curved continuous motion to measure all machining surfaces without leaving line marks. The spiral path smoothly covers the entire surface area while maintaining continuous probe contact, eliminating the harmful linear feeding lines that affect optical characteristics.
Solution Approach 2:
The spiral measurement path enables continuous measurement without escaping motions or path changes. The probe moves continuously along the spiral trajectory from the center outward, eliminating idle motions and reducing manual labor hours while maintaining complete surface coverage.
2Measurement precision
If cruciform section measurement is used, then vertical and lateral asymmetries can be comprehended, but other portions cannot be measured and compensation is inaccurate
Solution Approach 1:
The patent transitions from two-dimensional cruciform section measurement to three-dimensional spiral measurement that covers the entire surface. By adding the radial dimension and using spiral trajectories, the measurement system comprehends all portions of the machining surface including areas between radial lines, enabling accurate compensation throughout the entire lens array.
3Manufacturing precision
If lathe machining is used for lens metal mold, then machining can be performed, but production capacity is insufficient for compact lens arrays
Solution Approach 1:
The patent adopts spiral path machining instead of conventional lathe machining, using continuous curved tool paths to machine lens arrays. This approach maintains nanometer-level shape precision while significantly increasing production capacity by eliminating the need for repeated setup and positioning operations associated with traditional lathe machining.
Data Source
AI summary
A shape measurement data is acquired by measuring along a spiral measurement path a lens shape which is machined along a spiral machining path. An interpolated shape measurement data at intersecting points of a radial line passing through a center of the lens shape and the spiral measurement path is acquired by interpolating the shape measurement data, and a compensated machining amount for removing a machining error at each of the intersecting points (the machining points) is calculated from the interpolated shape measurement data by interpolation. Further, a machining point compensated machining amount at each of the machining points on the spiral machining path is calculated from the calculated compensated machining amount, and a compensated machining path is created on the basis of the machining point compensated machining amount.