Miniaturized optics are main components in many different areas ranging from smart devices over medical products to the area of automotive and mobility. Thus several million if not billions of small lenses are merged into objectives. The optical function of these objectives can only be guaranteed, if all optical surfaces not only meet the form tolerances of the optical design but also have the right position with respect to another. To ensure this, a measurement method has been developed, that is able to measure the surface form and the centration of both functional surfaces of single micro optical polymer lenses. The method bases on Optical Coherence Tomography (OCT) so that due to the tomographic measurement principle both functional surfaces can be captured in one measurement. Key challenge is the reconstruction of the geometric form of the functional surface facing away from the measurement head since it is distorted due to the refraction of light on the functional surface that faces towards the measurement head. The distortion needs to be corrected by means of backwards ray tracing. The OCT-based characterization of the single optical elements allows an adaptive assembly of micro optical imaging objectives by feeding back the individual shape of every single optical component to the assembly process. This information can be used for either selective assembly or the compensation of individual component tolerances by matching components whose form and centration errors cancel each other out in the overall system.
Due to their short focal lengths, FAC lenses significantly influence the performance of high-power diode laser systems. In addition to the shape, coating and surface quality, high demands are placed on the assembly accuracy for these microoptical components. In order to optimally align and position the lenses despite varying properties (e.g. focal length), active alignment strategies are used. The automation of the active alignment process for production offers enormous potential. Compared to manual processes, the reproducibility and accuracy of the alignment is increased. For the automation of the active alignment process, a deep understanding of the system behaviour is necessary. To control a diversity of variants cost-effectively and robust, new approaches must be taken into account. Concepts of AI or machine learning are great for this kind of generalization and adoption and they have many advantages for the active alignment of systems like DOEs or free-form-optics, with a complex system behaviour. In this publication, we want to compare the performance of a classically model-based algorithm and a machine learning approach for the automated active alignment of FAC-lenses. The model-based algorithm uses a physical model of the metrology system (including the FAC to be aligned) to estimate a misalignment in 4-DOF. The machine learning algorithm consist of a deep neuronal network which was trained with image data.
Polarization maintaining fibers arrays are key enablers to process high bandwidth data, representing a powerful part within the photonic integrated chip technology. The different channels increase the information density and allow to multiple singles through one fiber bulk at the same time. Due to fiber’s small dimensions (ø125 μm) they can be integrated in existing infrastructure easily and are very flexible at the same time. However, the compact design together with the flexible material properties demands for new precise tools and technologies to reach the necessary precision during packing.
The Fraunhofer-Institute for Production Technology IPT develops, together with their partners Phix and Aixemtec, new handling and assembly tools, as well as processes as one of the leading companies in this field. In the self-developed assembly cell, the fiber handling tool-head operations automatically to pick up, manipulate and tack single fibers to a glass plate or fiber to chip. Each fiber is moved by a portal robot within the assembly cell with micrometer accuracy but also can be rotated with a repetition accuracy less than 0.01°. Advanced illumination units observation techniques allow to package fibers arrays much quicker and more robust than before. Therefore, additional camera systems and material characteristics are used to develop smart alignment routines. As a result, the observation of the orientation of the PM-fiber core as well as the fiber layout during the assembly process leads to high quality products within fast production cycles. Due to the flexible construction of the assembly call also PIC packaging and fiber-to-chip coupling is possible.
Fast axis collimator (FAC) to Chip in the assembly of High Power Diode Lasers (HPDL) systems is state of the art done in active alignment. Micro manipulators and (semi-) automated machines are available for purchase on the market. Neither the precision of the manipulation tools (step resolution < 10 nm) nor the measurement systems utilized in active alignment algorithms (alignment precision of ~50 nm) are the quality limiting factors but the bonding process is. This is due to the volumetric shrinkage of fast curing UV-adhesives in the curing process.
The objective of this work is to reduce the absolute volume of adhesives in optical systems by smart design of the glue glap so no significant misalignment while curing is expected.
The assertion is that the overall system quality is improved with the implementation of additional adhesive gaps if the amount of adhesive is reduced in this way. In high quality systems as HPDL this approach is state of the art with the implementation of FAC lens on Bottom tab. In other industries as automotive sensors that are drastically reducing component tolerances and improving system quality this approach is rather unknown.
Results of glue gap reduction for HPDL assembly is described in this work by combining active alignment of FAC to edge emitter with a tolerance compensated individualized FAC on bottom tab subassembly in a fully automated production process. The approach was described in the papers [SPIE 10086-28] and [SPIE 10514-38].
Furthermore the approach of systemizing the smart glue gap design is done.
Automated active alignment of optical components during the assembly process of optical systems is state of the art in today’s optics-production. With the increasing demand of optical systems in smart devices and automotive technologies, new methods and strategies have to be developed to guarantee rapid and goal-oriented development of active-alignmentalgorithms. A key approach to this is offline development via simulations. This paper presents and evaluates an efficient approach to generate a continuous data-feedback for the offline development of active-alignment-algorithms by interpolation of a discrete database. Dependent on the system-input the described procedure generates the raw, array-like output data of a CCD-chip from the existing data of the local neighborhood.
Injection moulding is key to fast mass production for smart devices, mobility and medical products, like micro-optics, covers and lab-on-a-discs respectively. For optics, several million if not billions of small lenses are merged into objectives. One characteristic type of objective holder is the lens barrel. The successful assembly of lenses with diameters of just a couple of millimetres into a lens barrel is an error-prone task antagonized with mass production and an optical inspection at the end of the assembly. Before the assembly and after the manufacture of the individual optics, the sprue separation takes place. This is a critical moment because even optics whose dimensions are within the target tolerance after manufacturing can be damaged by improper action. Common methods here are the separation by means of a blade, hot wire, laser or saw blade. Each of these methods has its advantages and disadvantages, but all have in common the introduction of stress and/or heat into the component. The Fraunhofer IPT investigates a much more elegant way removing the sprue from injection-moulded optics in an automated environment. Based on the ultrasound technology developed by IPT back in the 1980s, we use a high frequency generator to get an AC voltage and piezo crystal for the inverse piezoelectric effect. The crystal oscillates with a high frequency and low amplitude. Next, the λ/2 to λ/4 sonotrode amplifies the amplitude. The sonotrode is designed with a CAD model, simulated in ANSYS and the complete experimental verified on real lenses afterwards.
KEYWORDS: Adhesives, Laser systems engineering, Active optics, Optical alignment, High power diode lasers, Ultraviolet radiation, Collimators, Tolerancing, High power lasers, Semiconductor lasers
The quality of High Power Diode Laser (HPDL) systems highly depends on the assembly precision. Nowadays, neither the precision of the manipulation tools (step resolution < 10 nm) nor the measurement systems utilized in active alignment algorithms (alignment precision of ~50 nm) are the quality limiting factors but the bonding process is. This is due to the volumetric shrinkage of fast curing UV-adhesives in the curing process.
The objective of this work is to minimize the absolute volumetric shrinkage of the UV curing adhesives between edge emitter and bottom tab so no significant misalignment while curing is expected. The approach was first described in the paper [SPIE 10086-28] and aims for minimizing the glue gap and therefore the amount of adhesive through combining active alignment of fast axis collimators (FAC) to edge emitter with a tolerance compensated individualized FAC on bottom tab subassembly in a fully automated production process. With less adhesive the absolute volumetric shrinkage is reduced.
The expected benefits are the reduction of the misalignment through volumetric shrinkage and a 100% quality assessment without additional costs. Lens quality data such as smile, residual divergence and optical surface imperfections can be characterized. A permanent data collection provides feedback for all previous and following production systems and allows the improvement of the quality for the whole HPDL production chain. This paper presents the results gathered by implementing the individualized FAC on bottom tab process in an industrial production environment and compares it to the expected benefits to conventional HPDL production.
Miniaturized optics are main-components in many different areas ranging from smart devices over medical products to the area of automotive and mobility. Thus several millions if not billions of small lenses are merged into objectives. One characteristic type of objective holder is the lens barrel. The successful assembly of lenses with diameters of just a couple of millimeters into a lens barrel is an error-prone task antagonized with mass production and an optical inspection at the end of the assembly. Obviously, this process is neither time- nor cost-effective. Furthermore, the increasing imaging qualities demand for highly accurate aligned lens systems. The demand for high-quality optics in large quantities together with the small dimensions of the lenses make assembling a complex process. The Fraunhofer IPT investigates a much more elegant way inspecting the optical system during the fully automated assembly. In the assembly cell, our six-axis micromanipulator aligns the lens camera-led in the lens barrel. Next, the wavefront sensor analyses the imaging function of the lens and compares the actual status with the data from the optic model. This feedback loop between wavefront sensor and micromanipulator continues until the best position is found. We save this information as a digital twin and continue with the next lenses until the optics is completed. The observation of the optical function during the assembly process leads to high quality objectives produced in short cycle times. Moreover, our assembly cell is modular and this allows us to adopt the setup for new lens barrels easily.
Point-of-care (POC) testing attracts more and more attention in the medical health sector because of their specific property to perform the diagnostic close to the patient. The fast diagnosis right at the hospital or the doctor’s office improves the medical reaction time and the chances for a successful healing process. One of this POC test systems is a “Lab-on-a-Disc” (LoaD) which looks like a compact disc crisscrossed with microfluidic tubes and cavities. The fluid to be analysed is placed in the LoaD and an external device then rotates the LoaD. The cavities inside the LoaD and the centrifugal force ensure a clearly defined sequence of the analysis. Furthermore, we aim for an inexpensive manufacture of the medical product without neglecting its quality and functionality. Therefore, the Fraunhofer IPT works on an assembly cell to implement dissoluble films concisely into the disc. This dissoluble film demonstrates its successful usage as a gate for the fluid, which opens after a predefined moment in the cycle. Furthermore, we investigate to integrate a laser welding process into our gantry system and demonstrate its efficiency with the welding of polymer discs. This procedure is clinically safe because no further laser absorption material is needed in the sealing process, which might pollute the LoaD. Moreover, this process allows the alignment of several discs before the welding and therefore leads to precisely manufactured LoaDs in large quantities. All these methods together enable a fast, costefficient and reliable mass production to bring POC testing among the people.
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