The present application is directed to interferometers, and, more particularly, to mechanisms for suppressing measurement errors due to reflections other than from surfaces of interest.
Fabrication of an optical component depends upon the ability to measure the optical properties of the component. An essential characteristic of an optical component is the quality of a wavefront after transmission through or reflection from the component. If the optical component is a mirror, then it is the reflected wavefront or surface figure of the component that is of interest. If the optical component is a transmissive element, then it is the transmitted wavefront that is of primary interest. An optical dome is a transmissive optical element whose angular extent is large and whose surfaces have historically been concentric, or nearly so, in the ideal case. Deterministic fabrication techniques for domes make it necessary to measure with greater accuracy and density than has been historically possible. Additionally, the use of domes having a more aerodynamic shape than a hemisphere is limited because of the difficulty in measuring the transmitted wavefront of such domes. The present invention is directed towards the measurement of the transmitted wavefront of optical domes and windows or similar optical components.
Historically, the concentricity of the two surfaces of a dome have been tested by using a point source of monochromatic light placed at the center-of-curvatures of the two surfaces and then looking at an interference pattern produced by the light reflected from each of the two surfaces of the dome as illustrated in
Deterministic fabrication techniques are limited by the quality of the measured data. High-quality interferometric measurements are often performed using phase-shifting methods where the phase of one wavefront is modulated relative to the other wavefront and the wavefront phase is calculated from a series of phase-shifted images in any of a variety of known methods. However, if both surfaces are rigidly attached to each other, then it is not possible to move one surface relative to the other in order to modulate the relative phase of the two wavefronts. If a monochromatic source whose wavelength can be varied is used, then varying the wavelength of the source will modulate the relative phase of the two wavefronts.
In order to obtain an interference pattern using the configuration of
Zygo Corporation has developed a general purpose device and method for using a Fizeau interferometer to measure multiple interference cavities which is embodied in their Verifire model interferometer. One of the applications of the Verifire technology is the measurement of the front surface, back surface and optical thickness variation of a parallel window in a single setup. The Zygo instrument provides the means to measure an optical surface or transmitted wavefront in the presence of multiple reflections that are coherent (i.e. the multiple reflections interfere). However, the Zygo instrument incorporates a reference surface and when used to measure a dome it is still necessary to align the instrument (i.e. reference surface) to the dome with high precision to obtain the desired interference pattern produced by a combination of reflections from multiple surfaces.
What is required therefore is a device and method for measurement of the transmitted wavefront of a dome or dome like optic whose alignment tolerances are modest and measurement errors due to multiple reflections are suppressed.
An interferometer is provided that comprises a time-delayed source, light emitted from the time-delayed source, a unit under test where the unit under test has a first surface and a second surface, and a detector. Light emitted from the time-delayed source has a delay length. A first portion of the light is reflected off the first surface of the unit under test and a second portion of the light is reflected off of the second surface of the unit under test. A portion of the two reflected portions of light are incident on the detector where the light coherently adds which forms an interference pattern that is detected by the detector.
The above and other features of the invention including various novel details of construction and combination of parts will now be more particularly described with reference to the accompanying drawings and pointed out in the claims. It will be understood that the particular interferometer apparatus embodying the invention is shown by way of illustration only and not as a limitation of the invention. The principles and features of this invention may be employed in varied and numerous embodiments without departing from the scope of the invention,
An interferometer is described that is capable of measuring the transmitted wavefront of a substantial portion of a dome like optic without the use of a reference surface separate from the unit under test (UUT) while also suppressing measurement errors due to reflections other than the first reflection from each of the two surfaces of interest (i.e., the primary reflections of interest). Suppression of measurement error is accomplished through the use of a short coherence length source, such as a superluminescent diode, in conjunction with a time-delayed source generator. The combination of a short coherence length source and time-delayed source generator is referred to as a time-delayed source (TDS).
The TDS includes a source with a coherence length shorter than the optical path length between the primary reflections of interest from the UUT. The output of the short coherence length source is split into two parts of similar power each following a different path. The two paths have a difference in length that substantially matches the path length difference between the primary reflections of interest. The light from the two paths in the TDS is combined and then used as the source for an interferometric test of the transmitted wavefront of a dome-like optic. The maximum fringe visibility possible is one if there is no stray light and the two interfering beams have equal power. For the invention described herein, the maximum fringe visibility possible is one-half, since both surfaces of the UUT reflect light from both paths in the TDS. A fringe visibility of close to one-half is more than adequate to obtain good data using phase-shifting algorithms that are known. An additional benefit of the TDS is that modifying the time-delay between the two paths within the TDS modulates the phase of the interference pattern making it possible to use phase shifting algorithms known in the art while suppressing errors due to undesired reflections.
The present invention has significant benefits for the measurement of a UUT with a large numerical aperture. One approach to measuring a UUT with a large numerical aperture is to use a wavefront matching optic such as the reflective optic described in the concurrently-filed patent application referenced above. The reduced alignment sensitivity reduces the difficulty and measurement errors resulting from the use of a wavefront matching optic with a large numerical aperture. A second approach is to measure only a small portion or sub-aperture of the UUT at a time. A scanning mechanism is used that moves either the instrument, UUT or both to change the relative position of the UUT and instrument so that a second, possibly overlapping sub-aperture is measured. The process is repeated until measurements over the desired portion of the UUT are obtained. The multiple measurements are then assembled (“stitched”) into a single measurement of UUT. The performance requirements of the scanning mechanism are reduced due to the reduced alignment sensitivity of the present invention.
There are additional benefits to the present invention in regards to sub-aperture measurements and stitching of the data. When stitching data that is measured against a reference surface it is necessary to account very accurately for the reference surface, either by calibrating it directly via measurement or indirectly by incorporating the reference surface into the equations solved for stitching of the data. Even if the reference surface is well calibrated, stitching of such data requires the use of compensators for all six translations and rotations of the individual data sets relative to each other. Since the present invention does not have a reference surface, stitching is simpler than if the data is acquired with an instrument having a reference surface. Mapping and retrace errors may limit the size of a sub-aperture that can be measured for any given UUT.
The prior art configuration 100 in
Zygo Corporation has developed algorithms to process a large number of interferograms taken using prior art configuration 120 so as to determine the errors on first surface 130, second surface 132 and optical thickness variation (i.e. transmitted wavefront) of a plane parallel plate. The Zygo instrument is capable of measuring the transmitted wavefront of plane parallel windows as well as dome like optics with the use of appropriate wavefront matching optics (i.e. reference optics). However, the reference surface of the Fizeau interferometer 120 must be well aligned to the unit under test. In addition, measurements made using Fizeau interferometer 120 are sensitive to the environment.
In the same manner as described for ray 322, ray 322a and ray 322b, a second ray 324 from interferometer 300 is directed towards UUT 360 and a portion of the light represented by ray 324 will be reflected by first surface 362 and is represented by ray 324a and a second portion will be reflected by second surface 364 and is represented by ray 324b. The ray 324 is incident on the UUT 360 in a region where the UUT 360 is thinner than in the region around ray 322. Because the physical thickness of the UUT 360 has changed, the phase between the reflected portion 324a and 324b will be different than the phase between 322a and 322b. The dependence of phase or optical path length, as a function of position on the UUT 360 results in an interference pattern 342 (see
One of the advantages of the invention is that the two portions of light that interfere are common path on the way to the UUT 360 and they are substantially common path on the way from the UUT 360 to the detector 344. The only region in which the two reflected wavefronts are not substantially common path is between surface 362 and surface 364 of UUT 360, where the difference between the two paths is the means by which the transmitted wavefront is measured. Since the first portion of light 322a is reflected light from ray 322 and the second portion of light 322b is also reflected light from ray 322, any wavefront errors introduced by imperfect optics or alignment errors will be identical in both portions of light. The second portion of light 322b passes through the UUT 360 twice and records the transmitted wavefront. If the UUT 360 is not perfect, the path that the second portion of light 322b takes to the detector will be slightly different than the path that the first portion of light 322a takes. This slightly different path results in what is commonly called retrace error. If the intersection location of a ray with detector 344 differs from the expected location, then a mapping error between the UUT 360 and detector 344 exists and will result in a measurement error. Mapping error is a generalization of the concept of distortion and is the difference between the expected and actual coordinates. Distortion if present, but known and corrected for would result in no mapping error. Mapping and retrace errors are a common problem in interferometers. It is known that the retrace error tends to zero as the part being tested approaches perfection. Methods for dealing with mapping and retrace errors are known in the art. If the UUT 360 is misaligned, the errors introduced in the first portion of reflected light will be substantially identical to the errors introduced in the second portion of reflected light. This is because the first surface 362 and the second surface 364 always move together. This makes the transmitted wavefront measurement substantially insensitive to misalignment.
For any UUT 360 that is of modest quality, the first portion of light 322a and the second portion of light 322b will have a substantially common path from the UUT 360 to the detector 344. Since so much of the path is common, the interferometer is substantially insensitive to misalignment and environmental changes. If one of the components is misaligned, then the errors introduced into the first and second portions of light 322a and 322b will be substantially identical and cancel in the interference pattern. This is also true if one of the optical components does not have its ideal shape. A lens with astigmatism is one example. The interferometer is also insensitive to many environmental factors. For example, normal room air turbulence will not have a significant impact on the system because the turbulence will be substantially common path.
The output light 290 from TDS 400 includes light from short coherence length source 210 that has traversed two different paths with lengths that are not necessarily equal. If the coherence length properties of output light 290 from TDS 400 are measured by using it as a source for a Michelson interferometer, then the dotted curve 550 is produced with a maximum fringe visibility for a distance L equal zero about one-half the maximum of the short coherence length source 210 by itself. Similarly, for a distance L2, the fringe visibility is zero. However, for a distance L3 that is equal to the optical path length difference between the first path 250 and second path 252, the fringe visibility reaches a second maximum. In other words, this source has two localized regions of coherence that are at substantially different optical paths differences. As long as optical path difference L is varied a small amount about the value L3, substantial fringe visibility will result. Since this distance, L3, determines the optical path difference at which the fringe contrast is maximum, it is referred to as the delay length of TDS 400. L3 is set, in practice, to substantially match the optical path difference between the reflections from the first surface 362 and second surface 364 of UUT 360. This configuration is desirable because there will be coherence between light reflected from two different surfaces if the optical path length between them is approximately one half of L3. The coherence length of the source will determine how the coherence changes as the distance is varied, but it is possible to isolate the surfaces being tested by selecting an appropriate source and matching the path in the TDS 400. This is valuable when testing multi-layer systems.
In one embodiment of TDS 400, source 210 is fiber coupled and a two-by-two fiber optic coupler is used for path splitting and combining device 240. First path 250 and second path 252 would be made of fiber optic cable. One or both reflector assemblies 260 and 262 can incorporate a means to stretch a coil of fiber optic for paths 250 and 252, respectively. Stretching the fiber optic stretches the optical paths and can be used for path matching or phase modulation or both. One embodiment is to optimize the implementation of one path, (either first path 250 or second path 252) for optical path matching of UUT 360 and the other path for phase modulation since the range of motions are substantially different.
If output path 270 of the TDS 400 is implemented in single mode fiber than the two, time-delayed sources will both be certain to be at the same location. A fiber optic cable and connector can be thought of as a low-pass spatial filter. If the TDS 400 is implemented using free space components, then it is advantageous to incorporate a low-pass spatial filter in out-put coupling device 280 to ensure that both time-delayed sources are coincident so that an accurate measurement of tilt between the first surface 362 and second surface 364 of UUT 360 can be obtained.
Also included in
If an optional scanning mechanism 370, 380 is present, it is preferably designed so as to take advantage of symmetry present in UUT 360. For instance,
Sub-aperture measurements of a spherical or a tangent ogive dome can be effectively acquired by using a rotary stage for optional scanning mechanism 370. The axis of revolution of UUT 360 is aligned to the axis of rotation of optional scanning mechanism 370. A wavefront matching optic 350 may be used to produce a converging spherical wavefront 730. If UUT 360 is a spherical dome, then the center of curvature 720 of the spherical wavefront 730 should be aligned to the center of curvature of the dome. If the UUT 360 is an ogive, then the center of curvature 720 of the spherical wavefront 730 should be aligned to the center of curvature of the circular arc 702 that is used to create the ogive.
If UUT 360 is a spherical dome, then the sub-aperture that can be measured would be a circular patch, while if UUT 360 is a tangent ogive, then the sub-aperture that can be measured would be a vertical strip that is wider at the base than the tip. A cylindrical window lends itself to being scanned with a linear motion. A window with different radii of curvature in different directions lends itself to being scanned with an angular motion. A free-form optic might require more generalized scanning. In all cases though, the reduced alignment sensitivity reduces the demands on the scanning system to obtain useful measurements of the transmitted wavefront. Additionally, since there is no reference surface in interferometer 300, it is not necessary to calibrate the reference surface or account for it in when stitching sub-aperture data.
A TDS 400 can be implemented for any wavelength with available suitable components. If a wavelength is used that is not visible, it is often possible to mix a visible wave-length with the source to simplify test setup.
The reflector assembly 260, 262 can be used to scan through the volume of UUT 360 and to acquire data from other interfaces within the UUT, not just the outer surfaces of the UUT. All that is required is to incorporate sufficient precision in the mechanism to make the data useful.
Although the description of the present invention has referred to dome-like optics, the present invention is directly applicable to the testing of a variety of other optics including conformal windows and domes. The benefits described for both measurement of an aperture as well as scanning combined with measurements of sub-apertures all apply. The only restriction on the shape of a UUT is that the patch of a UUT measured in any particular setup produces an interference pattern that can be acquired. If the UUT is substantially constant thickness then the transmitted wavefront error from a portion of the UUT may be obtained from the interference pattern over the UUT patch with sufficient accuracy without considering mapping or retrace errors. Alternatively, a non-constant thickness patch of a UUT may be measured if algorithms that account for mapping and retrace errors are incorporated into the software for processing of the acquired data. The present invention can be used to measure the transmitted wavefront of optics including concentric spherical shells or plane parallel windows, conformal domes or conformal windows and even free-form optics in combination with appropriate wavefront matching optics, scanning mechanisms and software, or both.
Thus, there has been disclosed a time-delayed source and interferometric measurement of windows and domes. It will be readily apparent to those skilled in this art that various changes and modifications of an obvious nature may be made, and all such changes and modifications are considered to fall within the scope of the present invention, as defined by the appended claims.
The present application claims priority from provisional application Ser. No. 60/700,987, filed Jul. 19, 2005. The present application is also related to application Ser. No. ______, filed con-currently herewith, entitled “Interferometer for Measurement of Dome Like Objects”, by the present inventors.
Number | Date | Country | |
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60700987 | Jul 2005 | US |