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3D-Messverfahren für Freiformgeometrien

Komplexe Freiformgeometrien werden heute vor allem in Autoscheinwerfern oder Optiken für Kameras und Beamer eingesetzt. Diese optischen Komponenten sind teuer in der Herstellung und Prüfung. Wissenschaftler vom Fraunhofer-Institut für Angewandte Optik und Feinmechanik IOF in Jena stellten in April auf der Hannover-Messe das 3D-Messverfahren LensShape vor, mit dem die Produktion schneller und kostengünstiger wird.

Rubrik: Visualisierung      Tag: 3D,Bildgebung,Scanner
LensShape 3D-Messverfahren

LensShape 3D-Messverfahren

Mit einem digitalen Projektor werden Streifen auf eine Freiform projiziert und mit einer CCD-Kamera aus unterschiedlichen Richtungen aufgenommen. Anschließend werden die Verformungen mit einem mathematischen Verfahren am PC ausgewertet.

© Fraunhofer IOF   Lupe

Bei vielen optischen Komponenten, etwa in Autoscheinwerfern, Optiken für Beamer oder Fotoapparaten, handelt es sich heute nicht mehr um sphärische Linsen, sondern um Freiformgeometrien. Freiformgeometrien sind nicht mehr rotationssymmetrisch, sondern beliebig geformte Flächen. Das macht sie teuer in der Herstellung, außerdem können die Linsen und Spiegel mit herkömmlichen Verfahren bisher nur unzureichend geprüft werden. Bisher dauerte das Vermessen der ashpärischen Linsen mit hochpräzisen Koordinatenmessmaschinen über eine Stunde. Für die Carl Zeiss Jena GmbH war dies ein Grund, zusammen mit den Fraunhofer-Forschern und dem mittelständischen Unternehmen IVB GmbH ein neues Messverfahren für die teuren Linsen zu entwickeln.

LensShape

LensShape ist das Ergebnis aus der erfolgreichen Zusammenarbeit von Forschung und Wirtschaft in den Optischen Technologien. Unter dem Motto "Erfolg durch Kooperation - schneller von der Idee zum Produkt" hat die Fraunhofer Gesellschaft bisher deutschlandweit elf Innovationscluster ins Leben gerufen. Eines davon ist das Cluster Optische Technologien JOIN in Jena.

Optisches 3D-Scan-System

Mit dem optischen 3D-Scan-System konnten die Wissenschaftler die Geschwindigkeit deutlich erhöhen. Eine Messung dauert nur noch 15 Minuten und hat noch weitere Vorteile. Da kein Taster die Oberfläche berührt, werden Kratzer vermieden und der Bearbeitungsprozess lässt sich sofort mit Hilfe der gewonnenen Daten korrigieren.Die Wissenschaftler projizieren dazu mit einem digitalen Projektor Streifen auf die Freiform, die mit einer CCD-Kamera aus unterschiedlichen Richtungen aufgenommen werden, und werten die Verformungen mit einem speziellen mathematischen Verfahren am PC aus. Dabei lassen sich die Abweichungen im Bereich eines Mikrometers gegenüber den Sollwerten schnell und einfach feststellen, was die Vorzüge des Verfahrens sind . Das besondere am neuen Verfahren ist, dass die gewonnen Daten außerdem für den anschließenden Schleifvorgang genutzt werden können. Damit ist der Korrekturkreis geschlossen.

Anwendungen des Systems

Doch nicht nur die Hersteller von Autoscheinwerfern und Beamer-Linsen werden schon bald von dem neuen Prüfverfahren profitieren. Während die Carl Zeiss GmbH die Messvariante bis 300 Millimeter benötigt, können die Wissentschaftler von IOF Jena auch kleinere Optiken bis sogar unter 10 Millimeter vermessen. Derzeit testet ein weiterer namhafter Optikhersteller die Technologie für die Vermessung von besonders kleinen Optiken für die Lichtauskopplung von LEDs. Das neue Verfahren wird seit einigen Monaten von der IVB GmbH vertrieben.

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