Automated and model-based assembly of an anamorphic telescope
Since the first usage of optical glasses there has been an increasing demand for optical systems which are highly customized for a wide field of applications. To meet the challenge of the production of so many unique systems, the development of new techniques and approaches has risen in importance. However, the assembly of precision optical systems with lot sizes of one up to a few tens of systems is still dominated by manual labor. In contrast, highly adaptive and model-based approaches may offer a solution for manufacturing with a high degree of automation and high throughput while maintaining high precision. In this work a model-based automated assembly approach based on ray-tracing is presented. This process runs autonomously, and accounts for a wide range of functionality. It firstly identifies the sequence for an optimized assembly and secondly, generates and matches intermediate figures of merit to predict the overall optical functionality of the optical system. This process also takes into account the generation of a digital twin of the optical system, by mapping key-performance-indicators like the first and the second momentum of intensity into the optical model. This approach is verified by the automatic assembly of an anamorphic telescope within an assembly cell. By continuous measuring and mapping the key-performance-indicators into the optical model, the quality of the digital twin is determined. Moreover, by measuring the optical quality and geometrical parameters of the telescope, the precision of this approach is determined. Finally, the productivity of the process is evaluated by monitoring the speed of the different steps of the process.