M.Sc.

Zontar, Daniel

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  • Publication
    Automated sensor-guided packaging of diamond tools
    ( 2020)
    Ehret, Susanne
    ;
    Saunders, Gordon D.
    ;
    Hillmer, Nils
    ;
    Müller, Tobias
    ;
    Hoeren, Maximilian
    ;
    Zontar, Daniel
    ;
    Brecher, Christian
    Automated, ultra-precise packaging strategies reduce production time and costs while increasing yield, quantity, and precision, making them one of the main research and development questions in the field of production technology. Fraunhofer IPT develops sensor-guided assembly solutions for packaging and testing of optical and non-optical components to meet the demand. In this paper, we present a prototypical process for the automated, ultra-precise passive alignment using the assembly of a diamond engraving tool as an example. The challenge is to place a diamond measuring three millimetres in its largest dimension into a groove of similar size and to position the tip of the diamond within tolerances of a few micrometres and arcminutes. This six dimensional assembly problem is tackled by feeding live camera data to an image processing algorithm and by aligning the diamond using Fraunhofer IPT's ultra-precise micromanipulator, collectively forming an automated, closed-loop assembly process. Thus, a fully automated packaging process with very high accuracy and reliability is proven to be technically possible.
  • Publication
    Automated PM-fiber array assembly with high-precision four DOF alignment
    ( 2020)
    Berger, Marvin
    ;
    Alippi, Andrea
    ;
    Haag, Sebastian
    ;
    Hoeren, Maximilian
    ;
    Müller, Tobias
    ;
    Zontar, Daniel
    ;
    Brecher, Christian
    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 mm) 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.
  • Patent
    Vorrichtung und Verfahren zur Ausrichtung von polarisationserhaltenden Lichtleitfasern
    ( 2019)
    Haag, Sebastian
    ;
    Alippi, Andrea
    ;
    Dekker, Ronald
    ;
    Müller, Tobias
    ;
    Zontar, Daniel
    Bei einem Verfahren zur Ausrichtung einer polarisationserhaltenden Lichtleitfaser, bei dem die Lichtleitfaser (7a, 7b, 7c) mit einer Klemmeinrichtung (12, 19, 23) klemmend gehalten wird, eine um die Faserlängsachse gegebene Rotationslage der Lichtleitfaser (7a, 7b, 7c) detektiert wird, und die Lichtleitfaser (7a, 7b, 7c) mittels der Klemmeinrichtung (12, 19, 23) um die Faserlängsachse rotiert wird, wird vorgeschlagen, dass für die Rotation der Lichtleitfaser (7a, 7b, 7c) mindestens ein an der Lichtleitfaser (7a, 7b, 7c) anliegendes Klemmelement (13, 14, 20-22, 24-27) der Klemmeinrichtung (12, 19, 23) relativ zu mindestens einem weiteren, ebenfalls an der Lichtleitfaser (7a, 7b, 7c) anliegenden Klemmelement (13, 14, 20-22, 24-27) der Klemmeinrichtung (12, 19, 23) bewegt wird. Des Weiteren wird eine entsprechend eingerichtete Vorrichtung vorgestellt.
  • Publication
    Automated sprue removal from injection moulded micro-optics with ultrasonic cutting
    ( 2019)
    Berger, Marvin
    ;
    Hoeren, Maximilian
    ;
    Sauer, Sebastian
    ;
    Müller, Tobias
    ;
    Zontar, Daniel
    ;
    Brecher, Christian
    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 l/2 to l/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.
  • Publication
    Offline development of active-alignment-algorithms by efficient interpolation of discrete databases
    ( 2019)
    Hoeren, Maximilian
    ;
    Zontar, Daniel
    ;
    Sauer, Sebastian
    ;
    Schmetz, Arno
    ;
    Berger, Marvin
    ;
    Müller, Tobias
    ;
    Brecher, Christian
    Automated active alignment of optical components during the assembly process of optical systems is state of the art in todays 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-alignment algorithms. 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.
  • Publication
    Individualized FAC on bottom tab subassemblies to minimize adhesive gap between emitter and optics
    ( 2017)
    Sauer, Sebastian
    ;
    Müller, Tobias
    ;
    Haag, Sebastian
    ;
    Beleke, Andreas
    ;
    Zontar, Daniel
    ;
    Baum, Christoph
    ;
    Brecher, Christian
    High Power Diode Laser (HPDL) systems with short focal length fast-axis collimators (FAC) require submicron assembly precision. Conventional FAC-Lens assembly processes require adhesive gaps of 50 microns or more in order to compensate for component tolerances (e.g. deviation of back focal length) and previous assembly steps. In order to control volumetric shrinkage of fast-curing UV-adhesives shrinkage compensation is mandatory. The novel approach described in this paper aims to minimize the impact of volumetric shrinkage due to the adhesive gap between HPDL edge emitters and FAC-Lens. Firstly, the FAC is actively aligned to the edge emitter without adhesives or bottom tab. The relative position and orientation of FAC to emitter are measured and stored. Consecutively, an individual subassembly of FAC and bottom tab is assembled on Fraunhofer IPT's mounting station with a precision of +/- 1 micron. Translational and lateral offsets can be compensated, so that a narrow and uniform glue gap for the consecutive bonding process of bottom tab to heatsink applies (Figure 4). Accordingly, FAC and bottom tab are mounted to the heatsink without major shrinkage compensation. Fraunhofer IPT's department assembly of optical systems and automation has made several publications regarding active alignment of FAC lenses [SPIE LASE 8241-12], volumetric shrinkage compensation [SPIE LASE 9730-28] and FAC on bottom tab assembly [SPIE LASE 9727-31] in automated production environments. The approach described in this paper combines these and is the logical continuation of that work towards higher quality of HPDLs.
  • Publication
    Chain of refined perception in self-optimizing assembly of micro-optical systems
    ( 2014)
    Haag, Sebastian
    ;
    Zontar, Daniel
    ;
    Schleupen, Josef
    ;
    Müller, Tobias
    ;
    Brecher, Christian
    Today, the assembly of laser systems requires a large share of manual operations due to its complexity regarding the optimal alignment of optics. Although the feasibility of automated alignment of laser optics has been shown in research labs, the development effort for the automation of assembly does not meet economic requirements - especially for low-volume laser production. This paper presents a model-based and sensor-integrated assembly execution approach for flexible assembly cells consisting of a macro-positioner covering a large workspace and a compact micromanipulator with camera attached to the positioner. In order to make full use of available models from computer-aided design (CAD) and optical simulation, sensor systems at different levels of accuracy are used for matching perceived information with model data. This approach is named "chain of refined perception", and it allows for automated planning of complex assembly tasks along all major phases of assembly such as collision-free path planning, part feeding, and active and passive alignment. The focus of the paper is put on the in-process image-based metrology and information extraction used for identifying and calibrating local coordinate systems as well as the exploitation of that information for a part feeding process for micro-optics. Results will be presented regarding the processes of automated calibration of the robot camera as well as the local coordinate systems of part feeding area and robot base.