Single freeform surface design for prescribed input wavefront and target irradiance

In beam shaping applications, the minimization of the number of necessary optical elements for the beam shaping process can benefit the compactness of the optical system and reduce its cost. The single freeform surface design for input wavefronts, which are neither planar nor spherical, is therefore of interest. In this work, the design of single freeform surfaces for a given zero-\'etendue source and complex target irradiances is investigated. Hence, not only collimated input beams or point sources are assumed. Instead, a predefined input ray direction vector field and irradiance distribution on a source plane, which has to be redistributed by a single freeform surface to give the predefined target irradiance, is considered. To solve this design problem, a partial differential equation (PDE) or PDE system, respectively, for the unknown surface and its corresponding ray mapping is derived from energy conservation and the ray-tracing equations. In contrast to former PDE formulations of the single freeform design problem, the derived PDE of Monge-Amp\`ere type is formulated for general zero-\'etendue sources in cartesian coordinates. The PDE system is discretized with finite differences and the resulting nonlinear equation system solved by a root-finding algorithm. The basis of the efficient solution of the PDE system builds the introduction of an initial iterate constuction approach for a given input direction vector field, which uses optimal mass transport with a quadratic cost function. After a detailed description of the numerical algorithm, the efficiency of the design method is demonstrated by applying it to several design examples. This includes the redistribution of a collimated input beam beyond the paraxial approximation, the shaping of point source radiation and the shaping of an astigmatic input wavefront into a complex target irradiance distribution.Comment: 11 pages, 10 figures version 2: Equation (7) was corrected; additional minor changes/improvement

Double freeform illumination design for prescribed wavefronts and irradiances

A mathematical model in terms of partial differential equations (PDE) for the calculation of double freeform surfaces for irradiance and phase control with predefined input and output wavefronts is presented. It extends the results of B\"osel and Gross [J. Opt. Soc. Am. A 34, 1490 (2017)] for the illumination design of single freeform surfaces for zero-\'etendue light sources to double freeform lenses and mirrors. The PDE model thereby overcomes the restriction to paraxiality or the requirement of at least one planar wavefront of the current design models in the literature. In contrast with the single freeform illumination design, the PDE system does not reduce to a Monge-Amp\`ere type equation for the unknown freeform surfaces, if nonplanar input and output wavefronts are assumed. Additionally, a numerical solving strategy for the PDE model is presented. To show its efficiency, the algorithm is applied to the design of a double freeform mirror system and double freeform lens system.Comment: Copyright 2018 Optical Society of America. One print or electronic copy may be made for personal use only. Systematic reproduction and distribution, duplication of any material in this paper for a fee or for commercial purposes, or modifications of the content of this paper are prohibite

Freeform illumination design in optical systems with partial differential equations

Zahlreiche Anwendungen in der Beleuchtung und Messtechnik erfordern das Design kompakter, energieeffizienter, nicht-abbildender optischer Systeme zur Generierung nichttrivialer Zielintensitätsverteilungen. Eine moderne Möglichkeit dieses Anforderungsprofil zu erfüllen bieten refraktive oder reflektive optische Flächen ohne jegliche Symmetrien, sogenannte Freiformflächen. Im Gegensatz zu klassischen Projektionsmethoden wie zum Beispiel der Durchlichtprojektion bieten Freiformen durch die geeignete Wahl ihrer lokalen Oberflächenkrümmung theoretisch die Möglichkeit beliebige Beleuchtungsmuster nahezu verlustfrei zu erzeugen. Für eine gegebene Lichtquelle und ein gewünschtes Muster besteht die Hauptschwierigkeit hierbei in der Berechnung der entsprechenden Freiformflächen, welche die Energieumverteilung realisieren. Dieses sogenannte inverse Problem der nicht-abbildenden Optik erfordert zum einen dessen mathematische Modellierung und zum anderen die numerische Lösung des Models. Das Ziel dieser Arbeit ist demzufolge die Entwicklung einer allgemeinen mathematischen Beschreibung des inversen Problems und dessen numerischer Lösung, sowie die Entwicklung anwendungsorientierter Freiformbeleuchtungskonzepte.Numerous applications in illumination and metrology require the design of compact, energy-efficient nonimaging optical systems for nontrivial irradiance or intensity distributions. A modern way to fulfill the profile of requirements are freeform surfaces, meaning refractive or reflective surfaces without any symmetries.In contrast to classical projection methods, for instance transmitted-light illuminators, freeform surfaces offer the possiblity to generate nearly arbitrary target distributions by an appropriate choice of the local surface curvature. For a given light source and a desired target distribution the main difficulty is thereby the computation of the freeform surfaces, which realize the required energy redistribution. This so-called inverse problem of nonimaging optics necessitates on the one hand a mathematical description and on the other hand the numerical solving of the corresponding model. Therefore, the goal of this thesis is to develop a general mathematical description of the inverse problem, the numerical solving of the corresponding model as well as the development of application oriented freeform illumination design concepts

From computer-aided to intelligent machining: Recent advances in computer numerical control machining research

The aim of this paper is to provide an introduction and overview of recent advances in the key technologies and the supporting computerized systems, and to indicate the trend of research and development in the area of computational numerical control machining. Three main themes of recent research in CNC machining are simulation, optimization and automation, which form the key aspects of intelligent manufacturing in the digital and knowledge based manufacturing era. As the information and knowledge carrier, feature is the efficacious way to achieve intelligent manufacturing. From the regular shaped feature to freeform surface feature, the feature technology has been used in manufacturing of complex parts, such as aircraft structural parts. The authors’ latest research in intelligent machining is presented through a new concept of multi-perspective dynamic feature (MpDF), for future discussion and communication with readers of this special issue. The MpDF concept has been implemented and tested in real examples from the aerospace industry, and has the potential to make promising impact on the future research in the new paradigm of intelligent machining. The authors of this paper are the guest editors of this special issue on computational numerical control machining. The guest editors have extensive and complementary experiences in both academia and industry, gained in China, USA and UK

Multiple-sensor integration for efficient reverse engineering of geometry

This paper describes a multi-sensor measuring system for reverse engineering applications. A sphere-plate artefact is developed for data unification of the hybrid system. With the coordinate data acquired using the optical system, intelligent feature recognition and segmentation algorithms can be applied to extract the global surface information of the object. The coordinate measuring machine (CMM) is used to re-measure the geometric features with a small amount of sampling points and the obtained information can be subsequently used to compensate the point data patches which are measured by optical system. Then the optimized point data can be exploited for accurate reverse engineering of CAD model. The limitations of each measurement system are compensated by the other. Experimental results validate the accuracy and effectiveness of this data optimization approach

Use of Graded Laser Scanning to Generate Efficient Boundary Element Meshes

This thesis presents an approach which combines a reverse engineering technique with boundary element stress analysis, by generating a graded mesh to improve the simulation efficiency. A rectangular metal plate, a bar of a circular cross section, a gas turbine blade and a steam turbine blade were scanned at different resolutions using a (non-contact) laser scanner measurement to obtain the point clouds. Meshes of each object were generated in Rapidform and directly used in a boundary element stress analysis. In addition, the steam turbine blade was scanned using different scanning resolutions. From this, a graded mesh model of the blade was generated and then efficient boundary element stress analyses were performed. An application of a freeform surface reconstruction of a blade surface is also given. Also, several Matlab programs were written to repair the edges and the cylindrical surface of the meshes

Holistic simulation of optical systems

For many years, the design of optical systems mainly comprised a linear arrangement of plane or spherical components, such as lenses, mirrors or prisms, and a geometric-optical description by ray tracing lead to an accurate and satisfactory result. Today, many modern optical systems found in a variety of different industrial and scientific applications, deviate from this structure. Polarization, diffraction and coherence, or material interactions, such as volume or surface scattering, need to be included when reasonable performance predictions are required. Furthermore, manufacturing and alignment aspects must be considered in the design and simulation of optical systems to ensure that their impact is not damaging to the overall purpose of the corresponding setup. Another important part is the growing field of digital optics. Signal processing algorithms have become an indispensable part of many systems, whereby an almost unlimited number of current and potential applications exists. Since these algorithms are an essential part of the system, their compatibility and impact on the completed system is an important aspect to con- sider. In principle, this list of relevant topics and examples can be further expanded to an almost unlimited extend. However, the simulation and optimization of the single sub-aspects do often not lead to a satisfactory result. The goal of this thesis is to demonstrate that the performance prediction of modern optical systems benefits significantly from an aggregation of the individual models and technological aspects. Present concepts are further enhanced by the development and analysis of new approaches and algorithms, leading to a more holistic description and simulation of complex setups as a whole. The long-term objective of this work is a comprehensive virtual and rapid prototyping. From an industrial perspective, this would reduce the risk, time and costs associated with the development of an optical system

Computer aided process planning for multi-axis CNC machining using feature free polygonal CAD models

This dissertation provides new methods for the general area of Computer Aided Process Planning, often referred to as CAPP. It specifically focuses on 3 challenging problems in the area of multi-axis CNC machining process using feature free polygonal CAD models. The first research problem involves a new method for the rapid machining of Multi-Surface Parts. These types of parts typically have different requirements for each surface, for example, surface finish, accuracy, or functionality. The CAPP algorithms developed for this problem ensure the complete rapid machining of multi surface parts by providing better setup orientations to machine each surface. The second research problem is related to a new method for discrete multi-axis CNC machining of part models using feature free polygonal CAD models. This problem specifically considers a generic 3-axis CNC machining process for which CAPP algorithms are developed. These algorithms allow the rapid machining of a wide variety of parts with higher geometric accuracy by enabling access to visible surfaces through the choice of appropriate machine tool configurations (i.e. number of axes). The third research problem addresses challenges with geometric singularities that can occur when 2D slice models are used in process planning. The conversion from CAD to slice model results in the loss of model surface information, the consequence of which could be suboptimal or incorrect process planning. The algorithms developed here facilitate transfer of complete surface geometry information from CAD to slice models. The work of this dissertation will aid in developing the next generation of CAPP tools and result in lower cost and more accurately machined components