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研究生: 許文懷
Hsu, Wen-Huai
論文名稱: 基於歪斜光線追跡的系統化幾何光學式量測系統之數學建模方法與其在線性軸六自由度幾何誤差量測系統的應用
A Systematic Modeling Approach Based on Skew Ray Tracing for Optical Measurement Systems Using Geometrical Optics and Its Applications in a Six-DOF Geometrical Error Measurement System for Linear Stages
指導教授: 劉建聖
Liu, Chien-Sheng
學位類別: 碩士
Master
系所名稱: 工學院 - 機械工程學系
Department of Mechanical Engineering
論文出版年: 2024
畢業學年度: 112
語文別: 英文
論文頁數: 134
中文關鍵詞: 六自由度幾何誤差量測歪斜光線追跡誤差耦合誤差補償線性軸
外文關鍵詞: Six-DOF geometric errors measurement, Skew ray tracing, Error crosstalk, Error compensation, Linear axis
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  • 有著次微米精度的精密生產機具對先進產業與科技來說是不可或缺的。為了滿足此需求,校正這些機具的量測系統必須有著更優異的精度。觀察實際的誤差量測結果顯示,角度誤差會導致額外的平移誤差,即為阿貝誤差與布萊恩誤差。學者們針對此難題已提出多種光學式多自由度幾何誤差量測系統,其中六自由度幾何誤差量測系統通常由一組干涉儀與多組運用準直雷射的量測模組所組成。前者利用波動光學量測定位誤差,而後者則利用幾何光學量測剩餘的五自由度幾何誤差。儘管此方法已相當成熟,後者所使用的數學模型通常需要複雜的解析式推導,這使得設備供應商難以調整該系統並適用於其自有設備中。
    為了解決當前困難,本論文提出一套基於歪斜光線追跡的系統化幾何光學式量測系統之數學建模方法,經由此方法可運用數值方法來推導六自由度幾何誤差的解析模型,藉此改善繁瑣的符號表示式容易造成理解不清的問題。該方法經過模擬驗證後,將會應用於本論文所開發的六自由度幾何誤差量測系統中。藉由比較該系統與市售系統同時測量的六自由度誤差,結果顯示該系統在俯仰、偏擺、水平直度、垂直直度、翻滾與定位誤差的平均精度分別為 ±0.1 角秒、±0.1 角秒、±0.2 微米、±0.2 微米、±0.6 角秒與 ±0.20 微米,而相應的重現性分別為 ±0.5 角秒、±0.4 角秒、±0.6 微米、±0.6 微米、±1.8 角秒與 ±0.55 微米。這些結果不僅驗證了該量測系統的性能,也驗證了本論文所提出的系統化數學建模方法。

    Precision manufacturing machines with submicron accuracy are requisite for innovative industries and technologies. To meet this demand, the measurement systems utilized to calibrate these machines must possess superior accuracy. It has been observed that angular errors lead to additional parallel errors, known as Abbe and Bryan errors. To address this issue, researchers have proposed various multi-DOF geometric error (GE) measurement systems using optics. Among these systems, six-DOF GE measurement systems generally consist of an interferometer and multiple measurement modules utilizing a collimated laser. The former measures the positioning error using wave optics, while the latter measures the remaining five-DOF GEs using geometrical optics. Despite its maturation, the mathematical model used in the latter typically involves complex analytical derivations, making it challenging for equipment vendors to adapt this system to their own equipment.
    To resolve this difficulty, this thesis proposes a systematic modeling approach for multi-DOF GE measurement systems using geometrical optics. This model enables the derivation of a model for six-DOF GE analysis using numerical methods, circumventing the need for arduous symbolic expressions that can hinder comprehension. The models are initially validated through various simulations. Subsequently, they are applied to a six-DOF GE measurement system developed in this thesis. By comparing the six-DOF GEs of a linear stage measured simultaneously by the developed and commercial systems, the mean accuracy values of the developed measurement system are ±0.1 arcsec, ±0.1 arcsec, ±0.2 μm, ±0.2 μm, ±0.6 arcsec, and ±0.20 μm for pitch, yaw, horizontal straightness, vertical straightness, roll, and positioning errors, respectively. And the corresponding repeatability values are ±0.5 arcsec, ±0.4 arcsec, ±0.6 μm, ±0.6 μm, ±1.8 arcsec, and ±0.55 μm. These results validate not only the system performance but also the proposed systematic modeling approach.

    摘要 I Abstract II 誌謝 III Contents IV List of Tables VIII List of Figures IX List of Notations XIII Chapter 1 Introduction 1 1.1 Objectives 2 1.2 Organization of This Thesis 3 Chapter 2 Literature Review 4 2.1 Multi-DOF GEs Measurement Systems 4 2.1.1 Pitch and Yaw Errors 4 2.1.2 Positioning Error 6 2.1.3 Straightness Errors 8 2.1.4 Roll Error 9 2.1.5 Six-DOF GEs Measurement Systems 11 2.2 Effects of Various Error Sources in Multi-DOF GEs Measurement Systems Based on Geometrical Optics 13 2.2.1 Four-DOF Drifts of the Laser Source 13 2.2.2 Installation Errors in Optical Components 15 2.2.3 Air Disturbances 17 2.2.4 Crosstalk between Six-DOF GEs 19 2.3 Skew Ray Tracing 20 2.3.1 Source Ray 20 2.3.2 Spherical Boundary Surfaces 21 2.3.3 Points of Incidence on Spherical Boundary Surfaces 22 2.3.4 Directions of Reflected and Refracted Rays from Spherical Boundary Surfaces 23 2.3.5 Flat Boundary Surfaces 24 2.3.6 Points of Incidence on Flat Boundary Surfaces 25 2.3.7 Directions of Reflected and Refracted Rays from Flat Boundary Surfaces 25 2.3.8 Crosstalk Modeling 27 2.4 Jones Calculus 28 2.4.1 Jones Vectors 28 2.4.2 Jones Matrices 30 2.5 Interferometers for Positioning Error Measurement 33 2.5.1 Homodyne Interferometers 33 2.5.2 Heterodyne Interferometers 35 2.5.3 Nonlinearity in Homodyne Interferometers and the Compensation Methods 37 2.6 Summary 40 Chapter 3 Methodology 41 3.1 Systematic Modeling Approach Based on Skew Ray Tracing 41 3.1.1 Demonstration of the Recursive Calculation in Skew Ray Tracing 41 3.1.2 Derivation of the Inverse of the Recursive Calculation in Skew Ray Tracing 44 3.1.3 Demonstration of the Model for Six-DOF GE Analysis 47 3.2 A Combined Algorithm for Homodyne Interferometers 48 3.2.1 Implementation of the Pulse-counting Algorithm 48 3.2.2 Subdivision Using the Ellipse Fitting Algorithm 49 3.2.3 Verification of the Combined Algorithm 51 3.3 Simple Formula for the Refractive Index of Air 52 3.4 Summary 53 Chapter 4 Development of a Six-DOF GEs Measurement System for Long-travel Linear Stages 54 4.1 Design of the Optical Paths 54 4.2 Analysis of the Interference Signals 56 4.3 An Equivalent Model for Air Disturbances 57 4.4 Construction and Verification of the Skew Ray Tracing System 58 4.4.1 Verification of the SRT System 59 4.4.2 Sensitivity Analysis of the Six-DOF GEs Measurement System 61 4.4.3 Simplifications of the Model for Six-DOF GE Analysis 64 4.4.4 Strategies for Solving the Model for Six-DOF GE Analysis 65 4.4.5 Compensation for Installation Errors 67 4.4.6 Verification of the Model for Six-DOF GE Analysis 67 4.5 A Crosstalk Model for Combining the Interferometer and the SRT System 70 4.6 Design of the Measurement System 71 4.6.1 Design of the 3D Model 71 4.6.2 Selection of the PDs and PSDs 73 4.6.3 Selection of the Laser Source 73 4.6.4 Selection of the Linear Stage and Data Acquisition System for PDs 74 4.7 Construction of the PHT Module 75 4.8 Implementation of the User Interface for Verification Automation 76 4.9 Summary 77 Chapter 5 Construction and Verification of the Developed Six-DOF GEs Measurement System 78 5.1 Assembly of the Measurement System 78 5.1.1 Subassembly of the Optical Cage Module 78 5.1.2 Positioning the PSDs at the Focal Lengths of the Focusing Lenses 80 5.1.3 Completing the Assembly of the Measurement System 80 5.2 Calibrations of the Measurement System 82 5.2.1 PSD Readings 82 5.2.2 Abbe Errors 86 5.2.3 PHT Module 88 5.2.4 PD Readings 89 5.2.5 Installation Errors 91 5.2.6 Systematic Errors 93 5.3 Verification of the Measurement System 94 5.3.1 Comparisons with Commercial Measurement Systems 95 5.3.2 Effects of Compensating for Installation Errors 97 5.3.3 Effects of Compensating for Crosstalk 98 5.4 Summary 98 Chapter 6 Conclusions and Suggestions 100 6.1 Conclusions 100 6.2 Suggestions 101 References 103 Appendix A Expressions of the SGamma Motion Profile 113 Appendix B The Bill of Materials of the Six-DOF GEs Measurement System Developed in This Thesis 116 Appendix C The Specification of the High-precision Six-DOF Platform 118

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