The present invention relates to an element provided with portions for position determination and a measuring method.
In an element provided with a prism surface, for example, a value of an angle that the prism surface forms with another surface through which a light beam passes has to be guaranteed with a high accuracy. Accordingly, the angle that the prism surface forms with another surface through which a light beam passes has to be measured with a high accuracy. When an angle that two surfaces of an element form is measured, conventionally the element is cut by an appropriate plane, and the angle that the two surfaces form is measured in the section. However, the conventional measuring method has the following problems. Firstly, cutting an element requires a lot of trouble. Secondly, a deformation of the element due to the cutting and burrs generated by the cutting prevent a high-accuracy measurement of the angle. Thirdly, measurement values vary depending on a section that is selected. Thus, it is difficult to measure the angle that the two surfaces form with a high accuracy by the conventional measuring method.
On the other hand, methods for aligning two elements by the use of a position marker that corresponds to a portion for position determination have been developed conventionally (Patent document 1 and Patent document 2). However, a method for measuring an angle that two surfaces of an element form by the use of portions for position determination and an element that is configured such that an angle that two surfaces of the element form can be measured by the use of portions for position determination have not been developed.
Patent document 1: JP2008-216905A
Patent document 2: JP2014-137410A
Accordingly, there is a need for a method for measuring an angle that two surfaces of an element form by the use of portions for position determination and an element that is configured such that an angle that two surfaces of the element form can be measured by the use of portions for position determination.
An element according to the first aspect of the present invention is an element having a first plane and a second plane that is at an angle with the first plane, wherein the second plane is provided with at least three portions for position determination thereon, the portions for position determination being arranged such that spacing between the portions for position determination is great enough to locate the second plane, and each of the portions for position determination has a convex shape on the second plane and is configured such that a tangential plane of a surface of each portion for position determination at any point on the border line between the second plane and the surface forms a single plane, an angle formed by the tangential plane and the second plane is in a range from 20 degrees to 70 degrees, and the tangential planes on the border lines of the at least three portions for position determination are parallel to one another.
In the element according to the present aspect, the position of the second plane can be determined with respect to the position of the first plane by determining the positions of the border lines of the portions for position determination, and thereby the angle that the first plane and the second plane form can be measured with a high accuracy. In other words, when in the element according to the present aspect, the angle that the first plane and the second plane form is measured, the element need not be cut by a plane for measurement of an angle. Accordingly, a lot of trouble for cutting the element is not required, the accuracy of measurement will not deteriorate because of a deformation of the element due to the cutting and burrs generated by the cutting, and measurement values will not vary depending on a section that is selected.
In an element according to the first embodiment of the first aspect of the present invention, the portions for position determination are arranged on the periphery of the second plane.
According to the present embodiment, the position of the second plane can be determined with a high accuracy through the at least three portions for position determination that are arranged on the periphery of the second plane, and thereby the angle that the first plane and the second plane form can be measured with a high accuracy.
An element according to the second embodiment of the first aspect of the present invention is provided with four portions for position determination.
An element according to the third embodiment of the first aspect of the present invention is used for optical applications.
An element according to the fourth embodiment of the first aspect of the present invention is the element according to the third embodiment wherein at least one of the first plane and the second plane is a prism plane.
An element according to the fifth embodiment of the first aspect of the present invention is the element according to the third embodiment wherein at least one of the first plane and the second plane is provided with a lens thereon.
An element according to the sixth embodiment of the first aspect of the present invention is the element according to the third embodiment wherein at least one of the first plane and the second plane is a surface for installing an optical fiber.
An element according to the seventh embodiment of the first aspect of the present invention is provided with at least three position markers, each position marker corresponding to a single portion for position determination.
An element according to the eighth embodiment of the first aspect of the present invention is the element according to the seventh embodiment wherein the length of the border line of each position marker is from 0.1 millimeters to 3.0 millimeters.
According to the present embodiment, a sufficient number of points of measurement can be arranged along the border line, each point of measurement having a size corresponding to the size of a single pixel of an image measuring system.
An element according to the ninth embodiment of the first aspect of the present invention is provided with at least two position markers including at least one position marker corresponding to plural portions for position determination.
An element according to the tenth embodiment of the first aspect of the present invention is the element according to any of the seventh to the ninth embodiments wherein the surface of each position marker including the border line is formed as a curved surface, and the radius of curvature of the surface at the border line ranges from 0.03 millimeters to 0.2 millimeters.
According to the present embodiment, a position of the border line is clearly displayed in an image thanks to reflection on the surface including the border line of each position marker.
A method for measuring an angle according to the second aspect of the present invention is a method for measuring an angle in an element having a first plane and a second plane that is at an angle with the first plane, wherein the second plane is provided with at least three portions for position determination thereon, the portions for position determination being arranged such that spacing between the portions for position determination is great enough to locate the second plane, and each of the portions for position determination has a convex shape on the second plane and is configured such that a tangential plane of a surface of each portion for position determination at any point on the border line between the second plane and the surface forms a single plane, and the tangential planes on the border lines of the at least three portions for position determination are parallel to one another. The method includes the steps of determining positions of the border lines of the at least three portions from an image of the second plane; and determining the angle between the first plane and the second plane using the positions of the at least three portions.
In the method for measuring an angle according to the present aspect, a position of the second plane can be determined with respect to the first plane by determining positions of the border lines of the at least three portions from an image of the second plane, and thereby the angle that the first plane and the second plane form can be measured with a high accuracy. In other words, in the method for measuring an angle according to the present aspect, the element need not be cut by a plane for measurement of an angle. Accordingly, a lot of trouble for cutting the element is not required, the accuracy of measurement will not deteriorate because of a deformation of the element due to the cutting and burrs generated by the cutting, and measurement values will not vary depending on a section that is selected.
In a method for measuring an angle according to the first embodiment of the second aspect of the present invention, the positions of the border lines of the at least three portions are obtained using plural pixels in the image.
According to the present embodiment, the positions of the border lines of the at least three portions are obtained using plural pixels in the image, and therefore the accuracy of measurement can be further increased.
A measuring method according to the third aspect of the present invention is a method for measuring a position of a target surface provided with plural portions for position determination. The portions for position determination have a convex shape on the target surface and each of the portions for position determination is configured such that a tangential plane of a surface of each portion for position determination at any point on the border line with the target surface forms a single plane, and tangential planes on the border lines of the plural portions for position determination are parallel to one another. The method includes the steps of determining positions of the border lines of the plural portions for position determination from an image of the target surface; and determining the position of the target surface from the positions of the border lines of the plural portions for position determination.
With the measuring method according to the present aspect, a position of the target surface can be easily measured using the image of the target surface.
The four position markers 101A 101B, 101C and 101D are used to measure the angle that the plane 203 forms with the reference plane 201. The reference plane 201 corresponds to a first plane, and the plane 203 corresponds to a second plane. The angle that the first plane and the second plane form is greater than 0 degree and smaller than 90 degrees.
In step S1010 of
In step S1020 of
In general, a position of a plane can be determined if the number of portions for position determination is three or more.
The four position markers 101A 101B, 101C and 101D are arranged such that spacing between them is great enough to locate the position of the second plane by the four sets of x, y and z coordinates. The four position markers may be arranged on the periphery of the second plane.
In step S1030 of
Further, in general, according to steps S1010 and S1020 of
How to determine the x, y and z coordinates of the four position markers will be described below. By way of example, a method in which an image measuring system is used will be described below.
In step S2010 of
In step S2020 of
In step S2030 of
In general, provided that an angle that the tangential plane of the surface of a position marker at the border line between the position marker and the second plane and the second plane form is in a range from 20 degrees to 70 degrees and more preferably in a range from 30 degrees to 60 degrees, the tangential plane need not be parallel to the first plane 201. In this case, the angle that is opposite a light source is in a range from 110 degrees to 160 degrees and more preferably in a range from 120 degrees to 150 degrees. The tangential planes of the plural position markers should preferably be parallel to one another. Provided that the tangential planes of the plural position markers are parallel to one another and the acute angle that the tangential planes and the second plane form is in a range from 20 degrees to 70 degrees and more preferably in a range from 30 degrees and 60 degrees, an image in which the positions of the borders between the position markers and the second plane are clear can be taken when the direction from which the image is taken and the direction of illumination of light are appropriately determined.
According to the embodiment of the present invention, a position of a border line represented by plural pixels are clearly displayed in an image of an image measuring system so that x and y coordinates of the border line can be easily recognized. Further, at plural points of measurement that correspond to plural pixels, plural sets of x, y and z coordinates are determined, and the average value of the x coordinates, an average value of the y coordinates and the average value of the z coordinates are defined respectively as x, y and z coordinates of the position marker. Thus, variations in measurement values can be expected to be reduced by the use of the plural sets of x, y and z coordinates.
A shape of a position marker will be described below. The description will be given for a case that an element is made of plastic (synthetic resin), and the element provided with position markers is manufactured using a mold by injection molding.
Accordingly, when an element is manufactured by injection molding, a position marker should preferably have a convex shape on a surface where the position marker is installed.
Table 1 shows measurement values of an angle of a prism plane, which are obtained by a conventional method in which an angle is measured in a cross section of an element and the method according to the present invention. Numbers “1”, “2” and “3” represent the first, the second and the third measurement values, respectively. The unit of angle is degree. “Average value” in Table 1 represents the average value of the three measurement values. The values of “6σ” in Table 1 are obtained by estimating values of σ (standard deviation) from the three measurement values and multiplying the values by 6. CP represents a process capability index that is a ratio of variation to the tolerance range. The values of CP in Table 1 are obtained by dividing the tolerance range by 6σ.
In general, it can be determined that variations in measurement will sufficiently fall within the tolerance range if the value of CP is 1.33 or more. Accordingly, it is determined that a tolerance range of 0.6 degrees, that is, measuring accuracy of ±0.3 degrees can be obtained by the method according to the present invention.
In the embodiments described above, a single position marker forms a single portion for position determination. In general, a single position marker may have plural portions for position determination.
Further, in general, a position of a surface including a curved surface can be determined by the present invention. A surface the position of which is determined is defined as a surface A. Plural portions for position determination are provided on the surface A. Each of the portions for position determination has a convex shape on the surface A, and is configured such that each tangential plane of the surface of each portion for position determination at any point on the border line with the surface A forms a single plane. Further, the plural portions for position determination are configured such that the tangential planes of the plural portions for position determination are parallel to one another. At each point on the border line, the angle formed by the tangential plane of a portion for position determination and the tangential plane of the surface A should preferably range from 20 degrees to 70 degrees, and more preferably from 30 degrees to 60 degrees. When the plural portions for position determination are illuminated with light in a direction that is substantially perpendicular to the tangential planes of the plural portions for position determination, and an image is taken, the coordinates of the border lines of the portions for position determination can be obtained by the method shown in the flow chart of
This is a Continuation of International Patent Application No. PCT/JP2016/051696 filed Jan. 21, 2016, and which claims priority from U.S. Provisional Patent Application No. 62/131,362, dated Mar. 11, 2015. The contents of these applications are hereby incorporated by reference.
Number | Name | Date | Kind |
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4837449 | Maltby, Jr. | Jun 1989 | A |
5767960 | Orman | Jun 1998 | A |
20120026486 | Jeng | Feb 2012 | A1 |
20180045603 | Fujioka | Feb 2018 | A1 |
Number | Date | Country |
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2008-216905 | Sep 2008 | JP |
2014-137410 | Jul 2014 | JP |
2014-160111 | Sep 2014 | JP |
Entry |
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International Search Report & Written Opinion dated Apr. 19, 2016 corresponding to International Patent Application No. PCT/JP2016/051696, and English translation thereof. |
Number | Date | Country | |
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20170350695 A1 | Dec 2017 | US |
Number | Date | Country | |
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62131362 | Mar 2015 | US |
Number | Date | Country | |
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Parent | PCT/JP2016/051696 | Jan 2016 | US |
Child | 15685359 | US |