1. Field of the Invention
The present invention relates to a measurement method utilizing an interferometer and a non-transitory recording medium configured to store a program of the measurement method.
2. Description of the Related Art
In measuring a shape of a test surface or a test distance utilizing an interferometer, major problems are a periodic error contained in an optical path length and a deterioration of a measurement precision due to another polarization component leakage in which a polarization component is not normally separated into P-polarized light and S-polarized light and stray light that occurs in the interference optical system.
Accordingly, Japanese Patent No. 4,717,308 discloses a method for correcting the periodic error by separating a leading term representative of test light that does not contain stray light from an appendix term representative of the stray light in a Fourier spectrum utilizing a Doppler shift. More specifically, this method quantifies the appendix term representative of the stray light, and removes the quantified appendix term from an overlap between the leading term and the appendix in the Fourier spectrum. On the other hand, Japanese Patent Laid-Open No. 2008-177561 proposes a method for minimizing a stray light quantity by inclining an optical axis of a beam and a normal of a lens in an interferometer.
In measuring the shape of the test surface, the reflectance of the test light on the test surface reduces due to light scattering etc. when the test surface is a rough surface. In this case, the rough test surface is moved relative to a light flux in a direction perpendicular to the optical axis, and this movement corresponds to a Doppler shift of the mirror surface by a micro distance in the optical axis direction. Then, due to the Doppler shift, a signal of the test light that does not contain the stray light and a signal of the stray light can become close to each other in the Fourier spectrum. When peak values of the test light and the stray light become similar and close to each other, it becomes difficult to separate them from each other.
According to the method disclosed in Japanese Patent No. 4,717,308, the quantified appendix term contains phase and amplitude information at a peak value in the Fourier spectrum, and a sufficient correction is provided only when the leading term and the appendix term perfectly overlap each other. In addition, the method disclosed in Japanese Patent Laid-Open No. 2008-177561 causes an aberration of the lens or another measurement error, and cannot eliminate the stray light generated in the lens.
The present invention provides a measurement method for precisely measuring a shape of a test surface or a test distance using an interferometer, and a non-transitory recording medium storing its program.
A measurement method according to the present invention configured to calculate a shape of an object surface of a test object or a test object distance utilizing an interferometer includes calculating a central frequency fcen expressed by the following expression where f is a frequency and DataC(f) is data expressed in a Fourier spectrum of an interference signal between reference light and test light that does not contain stray light generated in the interferometer, which is obtained by subtracting data expressed in the Fourier spectrum of an interference signal between the reference light and stray light from data expressed in the Fourier spectrum of an interference signal between the reference light and test light that contains the stray light; and
calculating a phase of the test light that does not contain the stray light at the central frequency that has been calculated, based upon a phase and amplitude of the test light that contains the stray light at the central frequency and a phase and amplitude of the stray light at the central frequency.
Further features of the present invention will become apparent from the following description of exemplary embodiments with reference to the attached drawings.
A description will now be given of a variety of embodiments according to the present invention, with reference to the accompanying drawings.
In calculating a two-dimensional shape of the test surface 107a of the test object 107, the test object 107 is moved by a driver (not illustrated) on an XY plane that is perpendicular to the optical axis parallel to the Z direction. This driver (not illustrated) can move the test object 107 also in the Z direction in separating the stray light component etc. This movement is a relative movement between the test object 107 and the light flux irradiated onto the test object 107 (or optical axis), and it is sufficient that one of the light flux and the test object 107 may be moved relative to the other.
The interferometer system according to this embodiment is applicable to a measurement apparatus configured to measure a test distance. In this case, a condenser lens 106 is removed so as to provide a parallel beam (light flux) and to measure a long distance, the test surface 107a of the test object 107 is not a rough surface but a mirror surface, and the test object 107 is relatively moved in the optical axis direction parallel to the Z direction by the driver (not illustrated).
The light source 101 is a heterodyne light source (laser) configured to emit a beam (light flux) of S-polarized light having a frequency fref and a beam of P-polarized light having a frequency fsig. These beams enter a polarization beam splitter (“PBS”) 102, and the S-polarized light beam is reflected on a polarization splitting plane of the PBS 102, and the P-polarized beam transmits through the polarization splitting plane of the PBS 102.
The S-polarized beam reflected on the polarization splitting surface of the PBS 102 is turned into circularly polarized light after transmitting a quarter waveplate 103, is reflected by a reference mirror 104, transmits the quarter waveplate 103 as P-polarized light, and re-enters the PBS 102. The re-introduced P-polarized light transmits through the polarization splitting surface of the PBS 102. This beam will be referred to as “reference light” hereinafter.
On the other hand, the P-polarized beam that has transmitted the polarization splitting surface of the PBS 102 transmits through a quarter waveplate 105, is turned into circularly polarized light, and is reflected on the test surface 107a of the test object 107 arranged near a spot position of the beam after the beam diameter is narrowed by the condenser lens 106. The beam diameter of the reflected P-polarized light is then widened, and the light is turned into parallel light by the condenser lens 106, again transmits the quarter waveplate 105, becomes S-polarized light, and again enters the PBS 102. The re-introduced S-polarized beam is reflected on the polarization splitting surface of the PBS 102. This beam will be referred to as “test light” hereinafter.
The test light and the reference light are merged by the PBS 102, enter a condenser lens 108, and are received by a detector 109. The received interference signal is sent to an analyzer 110, which calculates a phase at a point at which the beam is irradiated on the test object 107. The analyzer 110 includes a microcomputer, and serves as a controller configured to control each component in the interferometer system.
The shape of the test surface 107a of the test object 107 is calculated by calculating the phase at each point by moving the test object 107 in the XY directions perpendicular to the optical axis. When the roughness in the spot diameter is larger than the light source wavelength, a synthetic wavelength is produced and measured using a plurality of light sources. The synthetic wavelength Λ derived from two light source wavelengths λ1 and λ2 is given as follows:
The synthetic wavelength Λ is higher than each of the light source wavelengths λ1 and λ2. Thus, the synthetic wavelength enables a measurement even when the roughness in the spot diameter is larger than the light source wavelength.
Next follows a description of a periodic error that can be generated in this interferometer system. At certain time t, electric fields Eref(t) and Esig(t) of ideal reference light and ideal test light of the detector 109 will be expressed as follows:
E
ref(t)=exp{i(2πfreft)} (2)
E
sig(t)=exp{i(2π(fsig−2fDop(t))t+φtar(x,y,t)} (3)
Herein, fDop(t) is a Doppler shift associated with a change of a test distance, and Φtar(x, y, t) is a phase at a point (x, y) at which the beam is irradiated onto the object. A proportional coefficient is omitted for a simpler description. The test distance z at the time t is given as follows where λsig is a light source wavelength on the test light:
The test surface 107a of the test object 107 is a rough surface, and when it is moved in the XY directions, a target distance changes (in the Z direction) due to the roughness, and a Doppler shifts occurs. An error component that is generally referred to as a “periodic error” is added to Eref(t) and Esig(t) on the actual detector 109 due to another polarization component and the stray light because an extinction factor of the PBS 102 is not ideal.
When the test light that does not contain the stray light and the stray light are coaxial with each other, the electric field Eref(t) of the reference light on the detector 109 is similar to the expression (2), but the electric field Esig(t) of the test light is expressed as follows:
E
sig(t)=rtar(x,y)exp(i(2π(fsig−2fDop(t))t+φtar(x,y,t)))+rerrexp (i(2πfsigt+φerr)) (5)
Herein, rtar(x, y) is a product between two amplitude transmittances of the condenser lens 106 and the amplitude reflectance of the test object 107, r, is an amplitude transmittance of the condenser lens 106, and Φerr is a phase of the stray light by the condenser lens 106. The amplitude reflectance of the test object 107 significantly varies according to a position (x, y) onto which the bam is irradiated. On the other hand, rerr and Φerr are almost constant and are expressed as constants.
The intensity on the detector 109 is expressed as follows from the expressions (2) and (5):
Herein, the following expression is established, and Δf will be generally referred to as a beat frequency:
Δf=fref−fsig (7)
The analyzer 110 provides a Fourier analysis for the expression (6).
On the other hand, an error occurs when no Doppler shift occurs.
Thus, an error occurs when there is no Doppler shift. When rtar(x, y) is constant, a periodic error is added according to a test distance, but when rtar(x, y) is unconstant and significantly changes, an error is generated aperiodically.
For the examples illustrated in
However, the actual Doppler shift can have a variety of values. It is thus necessary for the Fourier analysis of actual data to use a window function so that both ends of the data can approach to zero in the actual space rather than the rectangular window. In addition, as described above, in order to measure the shape of the rough surface, it is necessary to move the optical axis relative to the rough surface in the perpendicular direction.
Hence, the optical length continues to change in the measurement, and a small amount of the Doppler shift may always occur depending upon the relative moving speed and the shape of the rough surface. Moreover, in the rough surface measurement, the amplitude reflectance of the test object 107 becomes a very small value equivalent to or smaller than the amplitude reflectance of the condenser lens 106 which generates the stray light.
Two errors occur in the above measurement conditions. First, since the Fourier components of Δf and Δf+2fDop(t) are very close to each other and their amplitudes are equivalents, it is difficult to precisely calculate Δf+2fDop(t) as a frequency of a measurement signal and an error is consequently added to the calculated phase. Moreover, since the bottoms of Δf and Δf+2fDop(t) overlap each other, an error is added to a calculated phase. When the Doppler shift is completely zero, Δf and Δf+2fDop(t) perfectly accord with each other, and an error becomes as expressed in the expression (8). However, errors are actually added under influences of rerr and Φerr different from the expression (8).
The measurement method of this embodiment contains an advance measurement and a formal measurement.
The advance measurement separates the stray light component from the test light, calculates frequency characteristics of rerr and Φerr, and produces fitting functions rerrFit(f) and ΦerrFit(f) using the frequency f. The formal measurement subtracts the influences of rerr and Φerr from a result of a fast Fourier transform (“FFT”) of data of the interference signal between the reference light and the test light that contains the stray light, and precisely determines the central frequency fcen of the interference signal between the reference light and the test light that does not contain the stray light. Thereby, the above first error can be reduced.
Next, a discrete Fourier transform (“DFT”) is executed for the data of the interference signal between the reference light and the test light that again contains the stray light, and calculates the amplitude rmea(x, y, t) and phase Φmea(x, y, t) of the test object that contains the stray light. Finally, ΦtarFit(f) is calculated using vector operations and rerrFit(fcen), ΦerrFit(fcen) rmea(x, y, t) and Φmea(x, y, t). Since the fitting function is used for the amplitude and phase of the stray light and fcen is used for its frequency, the above second error is reduced.
Illustrative parameters used for calculations of the simulation are a sampling rate of 50 MHz, a beat frequency of 20 mHz, 10,000 data, and a light source wavelength of 1 μm, rtar(x, y)=rerr, Φtar(x, y, t)=0.1λ, and Φerr=0.3λ.
In the advance measurement, the stray light is initially separated (S1). One method for separating the stray light is to generate a Doppler shift, as described above.
As illustrated in
Instead of the Doppler shift, as illustrated in
Next, rerr and Φerr near the beat frequency are calculated using the DFT rather than the FFT (S2). Herein, “near” covers a frequency range in which the bottom of rerr spreads near the beat frequency. For example, in
In the FFT, the measurable frequency depends upon the measurement time period. The frequency resolution becomes rough depending upon the measurement time period, and the precision of the fitting function, which will be described later, may remarkably lower. However, the amplitude and phase of the arbitrary frequency can be calculated in the DFT, and the fitting function can be highly precisely calculated.
The frequency resolution is 5,000 Hz for the sampling rate of 50 MHz and 10,000 data in the FFT, whereas the frequency resolution is calculated with 25 Hz in the DFT (illustrated in
Next, rerr and Φerr are fitted as a function of f, and the fitting functions rerrFit(f) and ΦerrFit(f) are produced (S3). rerr is fitted with a Gaussian function. Another function may be utilized, such as a Lorentzian function and a void function. Φerr is fitted with a linear function.
Next, data A is produced with a fitted function (S4). The data A is provided as follows, and serves as data of an interference signal between the reference light and the stray light generated in the interferometer, and expressed in a Fourier spectrum:
DataA(f)=rerrFit(f)exp(i2πφerrFit(f)) (10)
Next, the formal measurement starts. Herein, assume that the test object speed is 1 mm/sec.
Initially, the FFT is performed for data of the interference signal between and the reference light and the test light that contains the stray light, and data B is obtained (S5). The data B is data of the interference signal between the reference light and the test light that contains the stray light expressed in the Fourier spectrum. A solid line in
Next, data C is produced (S6). The data C (Data C(f)) is data expressed by an expression (11) of the interference signal between the reference light and the test light that does not contain the stray light in Fourier spectrum:
DataC(f)=DataB(f)−DataA(f) (11)
A dotted line in
Next, the central frequency fcen between the reference light and the test light that does not contain the stray light is determined based upon the data C (S7). The central frequency fcen is provided by the expression (12):
Next, the DFT is performed for the data of the interference signal between the reference signal and the test light that again contains the stray light, and the amplitude rmea(x, y, t) and phase Φmea(x, y, t) are calculated (S8).
At the end of the formal measurement, Φtar(x, y, t) is calculated based upon rmea(x, y, t), Φmea(x, y, t), rerrFit(fcen) and ΦerrFit(fcen) (S9).
It is confirmed as a simulation result that an error amount is a very large RMS of 110 mλ with the test object speed of ±1 mm/sec or smaller when the method of this embodiment is not used whereas the RMS is reduced down to 2.8 mλ, which is about 1/40 times as low as the above RMS, according to this embodiment is used.
This embodiment can reduce the periodic error even in the rough surface measurement in which the reflectance of the test object significantly changes.
A second embodiment is different in S9 illustrated in
When the Doppler shift is sufficiently small, and the central frequency fcen of the test light that does not contain the stray light is distinct, the expression (8) can be rewritten as follows: Φtar(x, y, t) can be calculated from Expression 13.
This embodiment can reduce the periodic error even in the rough surface measurement in which the reflectance of the test object significantly changes. While this embodiment limits the cause of the stray light to the condenser lens 106, the stray light caused by another optical element surface can be equivalently corrected.
While the present invention has been described with reference to exemplary embodiments, it is to be understood that the invention is not limited to the disclosed exemplary embodiments. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications and equivalent structures and functions.
This application claims the benefit of Japanese Patent Application No. 2012-020526, filed Feb. 2, 2012 which is hereby incorporated by reference herein in its entirety.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2012-020526 | Feb 2012 | JP | national |