光学自由曲面设计方法及应用研究
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摘要
光学自由曲面面型复杂、可控制自由度多，能实现传统光学面型不能实现的光学映射关系，但是由于自由曲面面型的特殊性，目前光学领域并没有提出一种普遍适用的自由曲面设计方法。因此，其设计方法的研究已经成为光学自由曲面发展的重要领域。随着超精密加工技术的发展，光学自由曲面的加工已成为可能，且在航空、医疗、民用、军事上都有越来越广泛的应用。
本文研究了光学自由曲面设计方法，并就其典型应用开展了深入研究。对不同应用需求使用相应的自由曲面设计方法，完成了光学自由曲面在成像和非成像中的典型应用实例，主要内容如下：
1.基于对现有光学自由曲面设计方法（SMS法和微分法）的研究，提出了一种三维自由曲面设计方法，即三维几何构造法，同时保证了光学要求和曲面光滑性的要求。并利用几何构造法设计了LED二次光学元件，验证了设计方法的正确性；
2.研究了光学自由曲面在典型非成像光学系统聚光光伏中的应用，采用几何构造法设计完成了三种类型聚光镜，完成了相应的超精密加工和光学实验。设计的Fresnel聚光镜可实现对任意大小光斑的会聚，二级聚光镜可有效提高到达电池片太阳光的均匀性；
3.基于聚光光伏系统的超薄轻型化设计需求，提出了一种超短聚焦聚光镜的新型设计方法，采用微分法和几何构造法相结合，并利用透镜阵列和自由曲面反射镜实现对光线的精确控制，将太阳能电池放置在聚光镜侧面，大幅度的降低聚光模组的整体厚度，可实现聚光镜的轻薄化；
4.为验证设计的聚光镜的性能，开展了太阳模拟器的研究，设计了由两片自由曲面反射镜组成的太阳模拟器，完成了反射型自由曲面阵列积分镜的设计和加工，实现了对入射光能量的均匀化作用；
5.研究了自由曲面在成像光学系统中的应用，利用三维几何构造法和光学仿真软件相结合，解决了成像光学系统中复杂自由曲面面型的设计，并通过短焦投影仪的设计验证了方法的正确性。
Freeform optical elements have complex surfaces so that more freedom can becontrolled during the design. It can achieve optical mapping relationship which cannot be done by the conventional optical surfaces. There is not a applicable method forall freeform optics in the optical field till now. Therefore, the study of the designmethod of freeform optics has become an important area of the development offreeform optics. At the same time, with the development of ultra-precision machiningtechnology, it is possible to realize the machining of freeform optics, and the freefromoptics has more and more widely used in the aviation and aerospace, medicaltreatment, civilian and military applications.
This paper studied the design methods of freeform optics, and made adevelopment in typical applications. It is proposed that using corresponding methodsfor different optical requirements, and realized the optical applications of freeformoptics in imaging and nonimaging optics, the main contents as follows:
1. Based on the study of existing optical freeform design methods (SMS anddifferential methods), three-dimensional Geometric Construction Method (GCM) wasproposed, which can ensure the optical requirements and surface smoothnessrequirements simultaneously. A secondary optics was designed for LED to verify thecorrectness of the design method.
2. Studied the freeform optics in photovoltaic concentrators of typicalnonimaging optical system applications, completed the design of three types ofconcentrators by GCM, and completed the ultra precision machining and opticalexperiments of them. The Fresnel concentrators can realize any size spot on the solarcell, and the secondary concentrators can effectively improve the uniform distributionof the sun light on the solar cell.
3. Based on the ultra-thin and ultra-light design demand of concentrators in CPVsystems, proposed a new design method of ultra-short focus concentrators which usedthe differential method and GCM. The concentrator used a lens array and a freeformreflector to achieve the control of light precisely. The solar cells were placed at theside of the concentrators, and greatly reduced the overall thickness of theconcentrators module, which can meet the requirements of light and thin ofconcentrators;
4. To verify the performance of the concentrators, made the study on the solar simulator, designed a solar simulator consisted of two freefrom reflectors to achieveuniform and collimated light. Beside, designed an off-axis optical reflective integratorwith faceted structure to transform a parallel beam into a uniform intensity beam witha rectangular cross section.
5. Studied the applications of the freeform optics in imaging optical system,designed freeform surface by3D Geometric Construction Methods and opticalsimulation software, which can solve the problem of the complex optical freeformdesign, and verified this method by the design of short focal projector.
本文研究了光学自由曲面设计方法，并就其典型应用开展了深入研究。对不同应用需求使用相应的自由曲面设计方法，完成了光学自由曲面在成像和非成像中的典型应用实例，主要内容如下：
1.基于对现有光学自由曲面设计方法（SMS法和微分法）的研究，提出了一种三维自由曲面设计方法，即三维几何构造法，同时保证了光学要求和曲面光滑性的要求。并利用几何构造法设计了LED二次光学元件，验证了设计方法的正确性；
2.研究了光学自由曲面在典型非成像光学系统聚光光伏中的应用，采用几何构造法设计完成了三种类型聚光镜，完成了相应的超精密加工和光学实验。设计的Fresnel聚光镜可实现对任意大小光斑的会聚，二级聚光镜可有效提高到达电池片太阳光的均匀性；
3.基于聚光光伏系统的超薄轻型化设计需求，提出了一种超短聚焦聚光镜的新型设计方法，采用微分法和几何构造法相结合，并利用透镜阵列和自由曲面反射镜实现对光线的精确控制，将太阳能电池放置在聚光镜侧面，大幅度的降低聚光模组的整体厚度，可实现聚光镜的轻薄化；
4.为验证设计的聚光镜的性能，开展了太阳模拟器的研究，设计了由两片自由曲面反射镜组成的太阳模拟器，完成了反射型自由曲面阵列积分镜的设计和加工，实现了对入射光能量的均匀化作用；
5.研究了自由曲面在成像光学系统中的应用，利用三维几何构造法和光学仿真软件相结合，解决了成像光学系统中复杂自由曲面面型的设计，并通过短焦投影仪的设计验证了方法的正确性。
Freeform optical elements have complex surfaces so that more freedom can becontrolled during the design. It can achieve optical mapping relationship which cannot be done by the conventional optical surfaces. There is not a applicable method forall freeform optics in the optical field till now. Therefore, the study of the designmethod of freeform optics has become an important area of the development offreeform optics. At the same time, with the development of ultra-precision machiningtechnology, it is possible to realize the machining of freeform optics, and the freefromoptics has more and more widely used in the aviation and aerospace, medicaltreatment, civilian and military applications.
This paper studied the design methods of freeform optics, and made adevelopment in typical applications. It is proposed that using corresponding methodsfor different optical requirements, and realized the optical applications of freeformoptics in imaging and nonimaging optics, the main contents as follows:
1. Based on the study of existing optical freeform design methods (SMS anddifferential methods), three-dimensional Geometric Construction Method (GCM) wasproposed, which can ensure the optical requirements and surface smoothnessrequirements simultaneously. A secondary optics was designed for LED to verify thecorrectness of the design method.
2. Studied the freeform optics in photovoltaic concentrators of typicalnonimaging optical system applications, completed the design of three types ofconcentrators by GCM, and completed the ultra precision machining and opticalexperiments of them. The Fresnel concentrators can realize any size spot on the solarcell, and the secondary concentrators can effectively improve the uniform distributionof the sun light on the solar cell.
3. Based on the ultra-thin and ultra-light design demand of concentrators in CPVsystems, proposed a new design method of ultra-short focus concentrators which usedthe differential method and GCM. The concentrator used a lens array and a freeformreflector to achieve the control of light precisely. The solar cells were placed at theside of the concentrators, and greatly reduced the overall thickness of theconcentrators module, which can meet the requirements of light and thin ofconcentrators;
4. To verify the performance of the concentrators, made the study on the solar simulator, designed a solar simulator consisted of two freefrom reflectors to achieveuniform and collimated light. Beside, designed an off-axis optical reflective integratorwith faceted structure to transform a parallel beam into a uniform intensity beam witha rectangular cross section.
5. Studied the applications of the freeform optics in imaging optical system,designed freeform surface by3D Geometric Construction Methods and opticalsimulation software, which can solve the problem of the complex optical freeformdesign, and verified this method by the design of short focal projector.
引文
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[2] Gong H, Fang F, Hu X, Cao LX, Liu J. Optimization of tool positions locallybased on the BCELTP for5-axis machining of free-form surfaces.Computer-Aided Design.2010,42(6):558-70.
[3] Fang F, Zhang X, Hu X. Cylindrical coordinate machining of optical freeformsurfaces. Optics express.2008,16(10):7323-9.
[4] Rodgers J M, Thompson K P. Benefits of freeform mirror surfaces in opticaldesign. Proceedings of the American Society of Precision Engineering2004winter topical meeting on freeform optics.2004,31:73-78.
[5]张效栋,房丰洲,程颖.自由曲面超精密车削加工路径优化设计.天津大学学报.2009,42(3):278-82.
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[7]李林.现代光学设计方法.北京理工大学出版社[等],2009.
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