Fig. 1. Experimental setup for on-machine measurement system
Fig. 2. System hardware-software framework diagram
Fig. 3. Schematic of point autofocus sensor. (a) Structure diagram; (b) defocus-voltage curves of the sensor
[21] Fig. 4. Temperature correlation verification. (a) Schematic of the experimental process; (b) 3D measurement result of optical plane; (c) spectrum analysis results for 2D profile averaged along the scanning direction and temperature
Fig. 5. Schematic of coordinate system for origin calibration of the measurement system
Fig. 6. Temperature compensation algorithm verification. (a) Original surface topography; (b) surface topography after temperature compensation; (c) comparison of mean topography along scanning direction before and after temperature compensation; (d) mean topography spectrum analysis before and after temperature compensation
Fig. 7. Measurement results of Fresnel structure. (a) Comparison of surface topography measured by conventional confocal sensor and point autofocus sensor; (b) cause analysis of central defect; (c) light intensity curve received by the equipment at the draft surface
Fig. 8. Schematic of spherical Fresnel workpiece and error evaluation. (a) Spherical Fresnel microstructure workpiece; (b) spherical Fresnel error evaluation process
Fig. 9. Error of Fresnel structure under different measuring equipments. (a) Offline white light interferometer; (b) offline point autofocus instrument; (c) on-machine point autofocus instrument without temperature compensation; (d) on-machine point autofocus instrument with temperature compensation
Parameter | Value |
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Probe model | Mitaka PF1S | Lateral measuring range | 100 μm | Feed measurement range | 200 μm | Movement speed | 0.2 mm/min | Scanning frequency | 50 Hz | Feed step | 1 μm | Objective magnification | 100 | Objective numerical aperture | 0.8 |
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Table 1. Parameters for temperature correlation verification
Item | Parameter | Setting |
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Standard sphere | Calibrated radius | 39977.540 μm | Calibrated length | 10000.000 μm | Scanning path | Scanning times | 10 | X-axis offset interval | 500.000 μm | Z-axis offset interval | 100.000 μm | Probe setting | Scanning frequency | 50 Hz | Optimization setting | Method | Interior point | Termination tolerance on X | 10-50 | Termination tolerance on function | 10-50 | Maximum iterations | Infinite |
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Table 2. Parameters for probe calibration
Parameter | Initial value of optimization | Maximum deviation |
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(0,0) | (100,100) | (100,-100) | (-100,-100) |
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/μm | 82.37166 | 81.93131 | 81.66810 | 80.27421 | 2.09745 | /μm | -289.60924 | -287.37639 | -303.12874 | -283.24341 | 19.88533 | /μm | 40434.69249 | 40434.68058 | 40434.53479 | 40434.61210 | 0.15771 | u | -0.00017 | -0.00004 | 0.00021 | 0.00037 | 0.00054 | v | 0.00310 | 0.00797 | -0.02607 | 0.01875 | 0.04482 | w | 1.00000 | 0.99997 | 0.99966 | 0.99982 | 0.00034 | Δx /μm | 193.85000 | 193.60421 | -195.46880 | -193.02804 | 389.31880 | Δy /μm | -206.61631 | -206.85537 | 205.38973 | 207.46654 | 414.32191 |
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Table 3. Optimization initial value and corresponding results for original optimization equation
Parameter | Initial value of optimization | Maximum deviation |
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(0,0) | (100,100) | (100,-100) | (-100,-100) |
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/μm | 82.89883 | 82.36304 | 82.68023 | 82.63738 | 0.53579 | /μm | -292.09877 | -289.60783 | -291.52141 | -291.72633 | 2.49094 | /μm | 40434.69146 | 40434.69235 | 40434.69615 | 40434.69442 | 0.00469 | u | -0.00016 | -0.00017 | -0.00023 | -0.00024 | 0.00008 | v | -0.00370 | 0.00317 | -0.00196 | -0.00164 | 0.00687 | w | 0.99999 | 0.99999 | 1.00000 | 1.00000 | 0.00001 | ρ0 /μm | 283.34333 | 283.31593 | 283.32717 | 283.32135 | 0.02740 | φ0 /(°) | -46.71952 | -46.82735 | -46.74763 | -46.75793 | 0.10783 |
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Table 4. Optimization initial value and corresponding results for optimization equation proposed in this work