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This study proposes a modified optical design to improve the issue of autofocus accuracy in existing optical systems. The proposed system uses lens offset to convert incident light into non-parallel light, achieving a focus shift and avoiding severe deformation of the light spot near the focal point of the objective lens. Based on triangulation theory and optical focusing theories such as the centroid method, the proposed optical design improves the shortcomings of existing technology. Experimental results demonstrate that the proposed optical autofocusing system has better autofocus accuracy than traditional systems while also reducing the difficulty of image processing. In summary, the proposed optical system is not only an effective autofocusing technology but also a highly valuable optical inspection and industrial application technology. This system has broader application and development opportunities for future research and practice.

For automated optical inspection, autofocusing microscopes play an important role in capturing clear images of the measured object. At present, the image processing part of optics-based autofocusing microscopes often has various factors, which makes it impossible to describe the image information of the semicircular (or elliptical) spot with a simple circle-finding method. Accordingly, this study has developed a novel algorithm that can quickly calculate the ideal center of the elliptical spot and effectively compensate the linearity of the focusing characteristic curve. A prototype model was used to characterize and verify the proposed algorithm. The experimental results show that by using the proposed algorithm, the autofocusing accuracy can be effectively improved to less than 1.5 μm.

In order to improve the quality of the laser and shorten the optical path of the fast steering mirror (FSM) laser compensation system, this paper proposes a four-degrees-of-freedom (4-DOF) voice coil motor (VCM) with the function of reducing laser geometrical fluctuations. The feature of this paper is the combination of a DC brushed spindle motor and the proposed 4-DOF VCM. A diffuser is installed on the shaft of the DC brushed motor for suppressing the laser speckle. The proposed 4-DOF VCM is combined with a laboratory-designed mirror set, controlling the laser direction to compensate for laser fluctuations. The proposed actuator was designed and verified by using the commercial CAD software SolidWorks and finite element analysis (FEA) software ANSYS. A mathematical model was built to simulate the dynamic response of the proposed 4-DOF VCM in MATLAB Simulink.

Laser beams can fluctuate in four directions, which requires active compensation by a fast steering mirror (FSM) motion system. This paper deals with the design of four-degrees-of-freedom (DoF) compliant parallel manipulators, for responding to the requirements of the FSM. In order to simplify high-precision control in parallel manipulators, maximum kinematic decoupling is always desired. A constraint map method is used to propose the four required DoF with the consideration of maximum kinematic decoupling. A specific compliant mechanism is presented based on the constraint map, and its kinematics is estimated analytically. Finite element analysis demonstrates the desired qualitative motion and provides some initial quantitative analysis. A normalization-based compliance matrix is finally derived to verify and demonstrate the mobility of the system clearly. In a case study, the results of normalization-based compliance matrix modelling show that the diagonal entries corresponding to the four DoF directions are about 10 times larger than those corresponding to the two-constraint directions, validating the desired mobility.

Multi-DOF motion is realized in the eyes and joints of robots mostly through the combination of multiple one-degree-of-freedom (1-DOF) motors. However, this results in reduced efficiency, a large volume, reduced response speed, and inaccurate positioning. To solve these problems, this study proposes a novel 3-DOF spherical voice coil motor (VCM). In this VCM, 16 coils and a radially oriented ring magnet are used to generate a Lorentz force to achieve motion. In particular, coils for Z-axis rotation are sandwiched between the coils for X- and Y-axis rotation. Furthermore, the proposed VCM can achieve 360° rotation about the Z-axis. The commercial software ANSYS was used to design and verify the performance of the proposed VCM. Simulation results indicate that this VCM affords improved power efficiency because only a suitable combination of coils, rather than all coils, needs to be powered on. The results demonstrate the feasibility of the proposed 3-DOF spherical VCM.

In keeping with consumers’ preferences for electromagnetic motors of ever smaller power consumption, it is necessary to improve the power efficiency of the electromagnetic motors used in unmanned aerial vehicles and robots without sacrificing their performance. Three-degree-of-freedom (3-DOF) spherical motors have been developed for these applications. Accordingly, this study modifies the 3-DOF spherical motor proposed by Hirata’s group in a previous study (Heya, A.; Hirata, K.; Niguchi, N., Dynamic modeling and control of three-degree-of-freedom electromagnetic actuator for image stabilization, IEEE Transactions on Magnetics 2018, 54, 8207905.) to accomplish a 3-DOF spherical motor for camera module with higher torque output in the large rotation angle. The main contribution of this study is to improve the static torque in the X- and Y-axes with an improved electromagnetic structure and a particular controlling strategy. In the structural design, eight symmetrical coils with specific coil combination are used instead of conventional four symmetrical coils. In this study, the development of the proposed 3-DOF spherical motor was constructed and verified by using a 3D finite-element method (3D FEM). The simulation results show that the proposed 3-DOF spherical motor has higher torque output in the large rotation angle when compared to the original 3-DOF spherical motor.

In the manufacturing industry, grinding is used as a major process for machining difficult-to-cut materials. Grinding is the most complicated and precise machining process. For grinding machines, continuous generating gear grinding machines are widely used to machine gears which are essential machine elements. However, due to its complicated process, it is very difficult to design a reliable measurement method to identify the grinding wheel loading phenomena during the grinding process. Therefore, this paper proposes a measurement method to identify the grinding wheel loading phenomenon in the grinding process for continuous generating gear grinding machines. In the proposed approach, an acoustic emission (AE) sensor was embedded to monitor the grinding wheel conditions; an offline digital image processing technique was used to determine the loading areas over the surface of Al2O3 grinding wheels; and surface roughness of the ground workpiece was measured to quantify its machining quality. Then these three data were analyzed to find their correlation. The experimental results have shown that there are two stages of grinding in the grinding process and the proposed measurement method can provide a quantitative grinding wheel loading evaluation from the AE signals online.

This paper describes the implementation and optimization of a dual-confocal autofocusing system that can easily describe a real-time position by measuring the response signal (i.e., intensity) of the front and the rear focal points of the system. This is a new and systematic design strategy that would make it possible to use this system for other applications while retrieving their characteristic curves experimentally; there is even a good chance of this technique becoming the gold standard for optimizing these dual-confocal configurations. We adopt two indexes to predict our system performance and discover that the rear focal position and its physical design are major factors. A laboratory-built prototype was constructed and demonstrated to ensure that its optimization was valid. The experimental results showed that a total optical difference from 150 to 400 mm significantly affected the effective volume of our designed autofocusing system. The results also showed that the sensitivity of the dual-confocal autofocusing system is affected more by the position of the rear focal point than the position of the front focal point. The final optimizing setup indicated that the rear focal length and the front focal length should be set at 200 and 100 mm, respectively. In addition, the characteristic curve between the focus error signal and its position could successfully define the exact position by a polynomial equation of the sixth order, meaning that the system can be straightforwardly applied to an accurate micro-optical auto-focusing system.

This paper proposes a system utilizing a Renishaw XL80 positioning error measuring interferometer and sensitivity analysis design to measure six-degree-of-freedom (6 DOF) geometric errors of a machine tool’s linear guide. Each error is characterized by high independence with significantly reduced crosstalk, and error calculations are extremely fast and accurate. Initially, the real light path was simulated using Zemax. Then, Matlab’s skew ray tracing method was used to perform mathematical modeling and ray matching. Each error’s sensitivity to the sensor was then analyzed, and curve fitting was used to simplify and speed up the mathematical model computations. Finally, Solidworks was used to design the set of system modules, bringing the proposed system closer to a product. This system measured actual 6 DOF geometric errors of a machine tool’s linear guide, and a comparison is made with the Renishaw XL-80 interferometer measurements. The resulting pitch, yaw, horizontal straightness, and vertical straightness error deviation ranges are ±0.5 arcsec, ±3.6 arcsec, ±2.1 μm, and ±2.3 μm, respectively. The maximum repeatability deviations for the measured guide’s pitch, yaw, roll, horizontal straightness, vertical straightness, and positioning errors are 0.4 arcsec, 0.2 arcsec, 4.2 arcsec, 1.5 μm, 0.3 μm, and 3 μm, respectively.

This study proposes a novel FSM compensation system for four degrees of freedom (DOF) laser errors compensation, which has the advantage of shorter optical path length, fewer elements and an easier set-up process, meaning that it can be used at different locations. A commercial software, Zemax, is used to evaluate the function of the proposed FSM compensation system and the mathematical modelling of the proposed FSM compensation system is established by using a skew-ray tracing method. Finally, the proposed FSM compensation system is then verified experimentally using a laboratory-built prototype and the result shows that the proposed FSM compensation system achieves the ability to compensate the 4 DOF of the laser source.

This study designs and characterizes a novel precise measurement system for simultaneously measuring six-degree-of-freedom geometric motion errors of a long linear stage of a machine tool. The proposed measurement system is based on a method combined with the geometrical optics method and laser interferometer method. In contrast to conventional laser interferometers using only the interferometer method, the proposed measurement system can simultaneously measure six-degree-of-freedom geometric motion errors of a long linear stage with lower cost and faster operational time. The proposed measurement system is characterized numerically using commercial software ZEMAX and mathematical modeling established by using a skew-ray tracing method, a homogeneous transformation matrix, and a first-order Taylor series expansion. The proposed measurement system is then verified experimentally using a laboratory-built prototype. The experimental results show that, compared to conventional laser interferometers, the proposed measurement system better achieves the ability to simultaneously measure six-degree-of-freedom geometric errors of a long linear stage (a traveling range of 250 mm).

Automated optical inspection is a very important technique. For this reason, this study proposes an optical non-contact slanting surface measuring system. The essential features of the measurement system are obtained through simulations using the optical design software Zemax. The actual propagation of laser beams within the measurement system is traced by using a homogeneous transformation matrix (HTM), the skew-ray tracing method, and a first-order Taylor series expansion. Additionally, a complete mathematical model that describes the variations in light spots on photoelectric sensors and the corresponding changes in the sample orientation and distance was established. Finally, a laboratory prototype system was constructed on an optical bench to verify experimentally the proposed system. This measurement system can simultaneously detect the slanting angles (x, z) in the x and z directions of the sample and the distance (y) between the biconvex lens and the flat sample surface.