PGI Dimension A versatile automated system for precision optics measurement
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PGI DimensionA versatile automated system for precision optics measurement
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Talysurf PGI DimensionFully automated one-touch aspheric optics measurement
Based on two of Taylor Hobson’s core technologies...
Aspheric profilometry and high accuracy roundness...
Delivering rapid optics cresting and precise measurement.
The most versatile metrology in the industry
Steep spheres and aspheres Highly aspheric gullwings Roundness and runout Large diameter asphero-diffractive
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Versatile 2D and 3D analysis for spheres, aspherics and diffractives Form repeatability of <100 nm and slope angles of up to 85 degrees mean that the Talysurf PGI Dimension instrument is a versatile instrument for spherical, aspheric, diffractive lenses and molds, which allows a wide range of accurate 2D and 3D measurements and analysis. The fully automatic centre and levelling feature includes new routines to ensure the accurate alignment of virtually any part: steep, shallow, large and small.
Designed for ease of use in the production environment The new production interface gives fully automated operation, ideal for use on the shop-floor. The easy-to-use ‘single-click’ operation is quick to learn and will provide an automatic 2D or 3D analysis and output display. The instrument can be initially set up by quality specialists for the use of a wide range of manufacturing staff. After commencing the measurement PGI Dimension can then be left unmanned to complete the cycle.
Unique software saves production time and increases output Advanced Aspheric analysis software guarantees the quality of aspheres and saves time with instant analysis of form error, zone depth and spacing. Unique patented technology delivers nm level residual form error analysis, and advanced algorithms can extract a sub-micron lens form error from much larger diffractive zone depths. Derived co-efficient functions enable reverse engineering of aspheric and diffractive components, giving feedback to designers of the as-is manufactured lens (with error) to enable adjustment of critical design systems to improve performance.
Technology advancements The patented ball calibration routine gives dimensional measurement capability and gauge linearity in a single automated operation, to exacting standards calibrated from our own UKAS approved laboratory. New levels of measurement capability are achieved through the unique calibration unit and software which help to achieve centering and levelling of the lens for accurate rotational lens measurement.
The benefits of Talysurf PGI Dimension
PGI Dimension’s enhanced capabilities support IR Optics, projector lenses, digital camera lenses, high power LEDs, Blu-ray and standard DVD optics and cellphone camera lenses.
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Automatic configuration of results into templates or custom-made outputs
To measure new components, this interface is able to automatically self-configure the most optimum programme routine that can be later saved under a new unique customer code. Operation of such programmes results in fully automated measurement, analysis and results output. Results are displayed in either a pre-defined, or custom configured, template and are instantly displayed post measurement without any user-intervention.
A sag calculator and theoretical image is also provided based on the user’s equation. This allows quick verification of designed optics parameters against those entered to the user interface
Typical output results include:
• Profileformforeach2Dtrace
• Profileerrormapforeach2Dtrace
• Average2Derrormap
• Multi-traceerrormapandastigmatismanalysis
• 3Dastigmaticanalysis
• 2Dand3Derrormapscanbelinkedbacktothemanufacturing process for process improvement with MRF,3-axisDiamondTurningandCNCpolishing.
Easy-to-use interface increases productivityWith automation further reducing operator dependency
A dedicated user-friendly interface is supplied for the specific measurement of optical molds and lenses. This interface provides an easy method of instrument operation, presenting clear control options to the operator – ideal for production use.
Instrument calibration can be conducted using pre-programmed calibration routines. After specifying the correct stylus type and calibration standard, the sequence runs to completion concluding with the presentation of the resultant calibration profile.
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Automated measurement and analysis can reduce labour and training costs.
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Research units, factories and universities worldwidehavemadeTalyMaptheirpreferredsurface analysis software, using it for product development, process improvement, predictive behaviour analysis and routine inspection.
Powerful new software features TalyMap analysis software
TalyMapiscontinuouslyevolvedbyamulti-disciplinaryteam of specialists in metrology, software engineering and automation in order to meet present and future surface metrology needs.
Key features:
Full metrological traceability
A new analysis workflow makes it easy to trace every step in an analysis document. New steps can be added and existing steps can be fine-tuned or deleted at any time.
Statistics for quality control
The new statistics option makes it possible to track and generate statistics on parameters across multiple measurement data sets.
Multi-language support
It is possible to change the software to work in one of six European languages, Japanese,Chinese,KoreanorBrazilianPortuguese.
Quick results UsingtheMinidocfunction,anysequenceofanalysis steps can be defined and saved into aMinidoclibrary,significantlyspeedingupthe preparation of a new report.
Customisation Add company logos, measurement identity cards, screen notes and illustrations including bitmaps, text blocks and arrows.
Advanced modules TalyMapadvancedmodulesenhancethefunctionalityofTalyMapbyprovidingadditional analysis or presentation capabilities.
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Aspherics Analysis Utility (AAU)
Expressly designed for aspheric optical components the software fits measurement data to the component design formula, and aligns the resultant error profile with respect to the aspheric axis.
Base radius optimization to highlight base radius variation in production, allowing users to quickly determine the best-fit radius for the component, which can then be checked against allowable production tolerances.
Sag table modules for reporting and exporting to spreadsheet software give user-authored analysis or feedback to the machining system. Slope analysis gives further insight into a component’s mid-spatial frequency errors.
Derived coefficients module for calculation of best fit asphere through a particular measurement. Resulting values can be used in conjunction with optical design software to assess the impact of form deviations on the optical performance of critical systems.
Software functionality to save time and improve error detection
Diffractive analysis
Software for the analysis of diffractive componentsAn increasing number of applications, particularly in infra-red applications, are making use of asphero-diffractive designs. Diffractive analysis software is written specifically to enable the assessment of these complex surfaces, providing the user with form error and zone dimension parameters.
Diffractive analysis when used in conjunction with the aspheric analysis software, allows the user to examine the underlying form of an asphero-diffractive component. Individual zone results are tabulated and canbeoutputtoaCSVfileforfurtheranalysis.Diffractive polynomial settings can be saved and restored, enabling the user to quickly change between different designs.
‘‘ ’’Only Taylor Hobson can extract the true form.
9.0282 um PV
0.4502 um PV
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Patented ball calibration routine from UKAS approved laboratoryDimensional measurement capability and gauge linearity
The Talysurf PGI systems use a patented ball calibration routine to ensure that both of these requirements are dealt with in a single, automated operation. High-precision spherical calibration artefacts that have been produced to exacting standards and then calibrated for radius, form and surface finish in our own UKAS approved laboratory.
In operation the user simply completes a dialog confirming parameters such as the percentage of gauge range to be used and the traverse speed. Working from knowledge of the stylus geometry and the dimensions of the calibration standard, the software automatically calculates the measurement properties and drives the traverse unit and column appropriately, completing the calibration with the minimum of operator intervention.
In addition to the ball calibration routine the Talysurf PGI Optics also includes a unique calibration unit and software to determine the position of the stylus to achieve the centering of the stylus for accurate rotational measurement of the lens.
Phase Grating Interferometer (PGI) gauge
This gauging technology, developed and patented by Taylor Hobson, delivers new levels of measurement capability. The heart of the PGI gauge is a cylindrical grating. It is this grating that is primarily responsible for the measuring capability of the gauge. The grating rotates about a precision pivot, and is illuminated using a collimated laser beam derived from a low power laser diode. Specially designed optics analyse the diffraction patterns from the grating to provide the movement information.
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The PGI Dimension is a high accuracy measurement platform based on two of Taylor Hobson’s core technologies: Aspheric profilometry and high accuracy roundness.
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Gauging technology developed and patented by Taylor Hobson.
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Measurable benefits of reduced costs and improved manufacturingIndustry leading accuracy for the competitive edge
Reduced costs and improved manufacturing yields
The PGI Dimension’s high measurement precision (Pt < 0.1 um) means that pass/fail tolerances can be widened. The 3D measurement of new and emerging designs, like steep slope, gull-wing aspheres, etc, enable widened pass/fail tolerances on more complex designs. Automated measurement and analysis means there is no need for instrument supervision, which reduces labour and training costs.
Improved utilisation
Built from industrially proven parts, your production level up-times and reliability are increased.
Future metrology savings
With high instrument accuracy and versatility you are able to measure new and emerging designs, future-proofing investment. You also have the option to upgrade packages by adding on new functionality, and therefore protect your metrology investment.
Improve your competitiveness
With the PGI Dimension’s accuracy and flexibility your products could improve in quality and more repeatable performance. With the added benefit of reverse engineering of aspheres and diffractives, the true form derivation you can receive will add valuable feedback to your design team.
CASE STUDY
A manufacturer of steep sided molded lenses had serious yield and capacity problems with lenses and molds, which were difficult to manufacture with steep slopes and tight dimensional tolerances.
The data from PGI Dimension improved their process control and mold manufacture, increasing yields from under 60% to over 70%. This increased their production by 20,000 more lenses each day.
Cost saving:
$3,000 per day
$850,000 per year
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The PGI Dimension offers premium optics metrology packages designed to optimize performance and enhance your manufacturing capability. Its highly versatile modular system gives you future-proofed design that grows with, and adapts to, your changing business needs, as upgrade packages are available to convert PGI Dimension 1 products to PGI Dimension 3 or 5 at a later date.
Our versatile modular system future-proofs your investmentAdapt with upgrade packages as your company grows
Advanced analysis tools for comprehensive parameter reports
Slope angles up to 85 degrees
Up to 300 mm diameter
Sags of up to 50 mm
Spatial frequencies from sub-micron to centimetres
Form repeatability typically <50 nm, better than λ/10
Extremelylowtotalsystemnoise<4nmRMS,includingGaugenoise<1nmRMS
Fully automatic alignment of aspheric axis to spindle axis, up to 0.8 um of de-centre and up to 0.008 degrees of tilt
Fast measurement speed with minimal loss of accuracy
All form, finish and waviness spectra
ISO compliant output
Measure and analyze a wide range of shapes, sags, slopes and frequencies
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Five flexible instrument packagesHelping you adapt to changing business needs
Automatic operation ü ü ü ü üAutomaticC&L ü ü ü ü ü300 mm dia optics û ü û ü üRoundness û û l l üHigh slope <70 deg l l l l üSteep slope <85 deg l l l l üHigh speed (10mm/s) û ü û ü üActiveAV l l l l l
TalyMap3D l l ü ü üAsphere (AAU 1) ü ü ü ü üDerived aspheres (AAU 3) l l ü ü üDiffractives (AAU 2) l l l l üDerived Diffractives (AAU 4) l l l l ü
ü Standard l Option û Not available
PGI Dimension
1
PGI Dimension
5XL
PGI Dimension
3XL
PGI Dimension
3
PGI Dimension
1XL
Future-proof your investment by adding technology as your markets and needs evolve. These packages will optimize performance and enhance manufacturing capability.
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The PGI Dimension is a modular system, adaptable to differing budgets and technical needs.
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PGI Dimension 1With automated 2D lens measurement and optimization for <200mm lenses, the PGI Dimension1isdesignedforthermalimaging,DVDandmobilephonecameraoptics.
PGI Dimension 1 XLExtending the capability to for lenses up to 300mm, the PGI Dimension 1 XL is designed for remote surveillance LWIR, domes, free-space communications and custom null optics.
Standard featuresAutomated measurement
Automatedcentre&level
Classleadingaccuracy&repeatabilityofup to 0.8 nm resolution
Asphere form analysis
Quick 90 degree astigmatism check
Key optionsHigh slope surfaces up to 70 degrees
Rapid automated 2D analysis of aspheres and diffractives using AAU (including reverse engineering capability)
ActiveAVforfactoryenvironments
Additional standard features300mm diameter capability
Enhanced roughness measurement of up to 0.2 nm resolution
Faster stylus trace speed of up to 10 mm/s
Key optionsHigh slope surfaces up to 70 degrees
Rapid automated 2D analysis of aspheres and diffractives using AAU (including reverse engineering capability)
ActiveAVforfactoryenvironments
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PGI Dimension 3Automated lens measurement in 3D as well as 2D, with optimization for lenses of up to 200 mm. Applications include Blu Ray, hi-res mobile phone cameras, machine vision, medical and precision cameras.
PGI Dimension 3 XLExtendsPGIDimension3capabilityto<300mmlenses.DesignedforMWIR,astronomy, collimators and HD broadcast camera
Standard featuresAutomated 3D measurement
Automatedcentre&level
Classleadingaccuracy&repeatability
Enhanced roughness measurement, up to 0.2 nm resolution
Rapid automated asphere form analysis
Asphere reverse engineering capability
High slope surfaces, up to 70 degrees
TalyMapadvancedanalysis
Superb report building tools
Key optionsSteep slope surfaces, up to 85 degrees
Rapid automated 3D diffractive analysis
Diffractive reverse engineering capability
Roundness measurement
Molddiameterrunout
ActiveAVforfactoryenvironments
Additional standard features300 mm diameter capability
Faster stylus trace speed, up to 10 mm/s
Key optionsSteep slope surfaces of up to 85 degrees
Rapid automated 3D diffractive analysis
Diffractive reverse engineering capability
Roundness measurement, including mold diameter runout
ActiveAVforfactoryenvironments
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PGI Dimension 5 XLWith fully specified asphere measurement and analysis, this is the one system to measure all your optics.Theperfecttoolforopticsresearch&developmentand‘onestopshops’.
Standard features300mm diameter capability
Fast stylus trace speed, 10mm/s
Automated 3D measurement
Automatedcentre&level
Classleadingaccuracy&repeatability
Enhanced roughness measurement of up to 0.2 nm resolution
Rapid automated asphere and diffractive form analysis
Asphere and diffractive reverse engineering capability
Steep slope surfaces of up to 85 degrees
TalyMapadvancedanalysiswithsuperbreport building tools
Key optionsActiveAVforfactoryenvironments
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Specifications
Horizontal performance
Traverselength-XMax/Min 200 mm / 0.1 mm (7.9 in / 0.004 in)
Measuringspeeds10.1 mm/s to 10 mm/s (0.004 in/s to 0.4 in/s)
Traverse speeds up to 15 mm/s max (0.59 in/s max)
Data sampling interval in X 0.125 µm over 200 mm length (5 µin over 7.9 in length)
Vertical performance
Nominal measuring range (Z) (traverse set to 0º)
12.5 mm [60 mm stylus arm] (0.49 in [2.36 in] ) 25.0 mm [120 mm stylus arm] (0.98 in [4.72 in] )
Resolution 0.2 nm @ 12.5 mm range (0.008 µin @ 0.5 in) range
Stylus arm length, tip size, force 60 mm arm, 2 µm radius conisphere diamond stylus, 1 mN force
Spindle axis
Spindle construction Ultra precision air bearing
Radial limit of error (height above table) +/- ( 0.02 µm + 0.0003 µm/mm) +/-(0.8 µin + 0.3 µin/in)
Axial limit of error (radius from centre) +/- (0.02 µm + 0.0003 µm/mm) +/-(0.8 µin + 0.3 µin/in)
Positional control +/- 0.2º
Positional resolution 0.02º
Minimummovement 0.1º
Centre & levelling axis
Construction Patented 3 point kinematic support
Centreandlevellingtablecontrol Automatic
Centeringrange 10 mm (0.4 in)
Levelling range +/- 0.5°
Achievable accuracy of auto-centering < 0.8 µm (31.5 µin)
Achievable accuracy of auto-levelling <0.008˚
System performance 2
Form error - Pt 3 (ball calibration radius)
Max0.2µm@80mm(8µ[email protected]) Typically less than 0.1 µm @ 80 mm (4 µin @ 3.15 in)
Radius measurement uncertainty 4
0.1 - 80 mm (0.004 - 3.15 in) = 1 - 0.005% of nominal 80 - 1000 mm (3.15 - 39.4 in) = 0.005 - 0.1% of nominal
1000 - 2000 mm (39.4 - 78.7 in) = 0.1% of nominal
Inclination measurement uncertainty 0.5 arc minute uncertainty (+ / - 35º maximum range)
Physical dimensions
Dimensions L x D x H 2100 mm x 900 mm x 1750 mm (82.7 in x 35.4 in x 68.9 in)
Weight (main instrument) 282 Kg (620 lb)
1 For surface texture measurements, speeds of 0.5 mm/s (0.02 in/s) and less are recommended.
2 Using a 60 mm arm with a diamond stylus.
3 From a repeat measurement on the calibration artifact over 75% of the gauge range (LS Arc analysis, primary filter λs = 0.25 mm).
4 Assumes a calibration artifact of perfect radius.
NOTE: Taylor Hobson pursues a policy of continual improvement due to technical developments. We therefore reserve the right to deviate from catalogue specifications.
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Floor plans
EnvironmentStorage temperature 5ºCto40ºC(41ºFto104ºF)
Storage humidity 10% to 80% relative, non condensing
Operating temperature 18ºCto22ºC(64ºFto72ºF)
Temperature gradient <2ºC(<3.6ºF)perhour
Operating humidity45% to 75% relative, non condensing
MaximumRMSfloorvibration2.5 µm/s (100 µin/s) at < 50 Hz 5.0 µm/s (200 µin/s) at > 50 Hz
Air supply
Air pressure550 to 1030 kPa (5.5 to 10.3 bar) (80 to 150 psi)
Regulator (pre-set) 350 kPa (3.5 bar) (50 psi)
Max.particlesize 5 micron (0.0002 in)
Moisturecontent–dewpoint -20°C(-4ºF)
Flow rate at operating pressure150 litres/minute (minimum) 5.3 ft3/minute
Maxoilcontent 25 mg/m3 (0.01 grains/ft3)
Solid particle content 5 mg/m3 (0.002 grains/ft3)
Electrical supply
Supply typeAlternating supply, single phase with earth (3-wire system)
Instrument and computer voltage
90V-130Vor200V-260V(switch selectable)
Frequency 47 Hz to 63 Hz
Supply voltage transients – width EN 61000 - 4 - 4 : 1995
Power consumption 500VA
Safety EN 61010 - 1 : 2001
EMCEN 61000 - 6 - 4 : 2001 EN 61000 - 6 - 1 : 2001
Laser classification
Class1producttoEN60825-1(2001) ContinuousWave(CW)output <1mWMaxpowerforthelaser <50µWMaxpowerfortheproduct
The above technical data is for measurements taken in a metrology laboratorycontrolledenvironment:20ºC±1ºC(68ºF±1.8ºF),draftfree,and isolated from low frequency floor borne vibration. Uncertainties and maximumpermissibleerrors(MPEs)areat95%confidenceinaccordancewith recommendations in the ISO Guide to the expression of uncertainty in measurement(GUM:1993).AllerrorsareexpressedasMPEs.
1120
mm
900
mm
1750
mm
900 mm
1750
mm
Ove
rall h
eight
with
cab
inet
880
mm
1200 mm553 mm
Front elevationIllustrating typical layout of main system components. (Traverse set to 0º)
Side elevation
200 mm 850 mm
850 mm
470
mm
940
mm
1200 mm
900
mm
Plan viewIllustrating floor space needed to accommodate the swivel arm and monitor.
System Dimensions(standard system)
Height: 1750mm (69 in)Width: 2100 mm (82.7 in)Depth: 900 mm (35.4 in)
Electrical enclosure (can be positioned either side of main instrument)
Copyright© 2012 • Taylor Hobson • PGI Dimension_V10
Taylor Hobson UK (Global Headquarters)
PO Box 36, 2 New Star RoadLeicester, LE4 9JQ, England
Tel: +44 116 276 3771 Fax: +44 116 246 0579 email: [email protected]
Taylor Hobson FranceRond Point de l’Epine Champs
Batiment D, 78990 Elancourt, FranceTel: +33 130 68 89 30 Fax: +33 130 68 89 39
Taylor Hobson GermanyPostfach 4827, Kreuzberger Ring 6
65205 Wiesbaden, GermanyTel: +49 611 973040 Fax: +49 611 97304600
Taylor Hobson India1st Floor, Prestige Featherlite Tech Park
148, EPIP II Phase, Whitefield, Bangalore – 560 006Tel: +91 1860 2662 468 Fax: +91 80 6782 3232
Taylor Hobson ItalyVia De Barzi
20087 Robecco sul Naviglio, Milan, ItalyTel: +39 02 946 93401 Fax: +39 02 946 93450
Taylor Hobson Japan3F Shiba NBF Tower, 1-1-30, Shiba Daimon Minato-ku
Tokyo 105-0012, JapanTel: +81 (0) 3 6809-2406 Fax: +81 (0) 3 6809-2410
Taylor Hobson Korea#310, Gyeonggi R&DB Center, 906-5, lui-dong
Yeongtong-gu, Suwon, Gyeonggi, 443-766, KoreaTel: +82 31 888 5255 Fax: +82 31 888 5256
Taylor Hobson China Beijing OfficeWestern Section, 2nd Floor, Jing Dong Fang Building (B10)
No.10, Jiu Xian Qiao Road, Chaoyang District, Beijing, 100015, ChinaTel: +86 10 8526 2111 Fax: +86 10 8526 2141
Taylor Hobson China Shanghai OfficePart A, 1st Floor, No. 460 North Fute Road
Waigaoqiao Free Trade Zone, Shanghai, 200131, ChinaTel: +86 21 5868 5111-110 Fax: +86 21 5866 0969-110
Taylor Hobson SingaporeAMETEK Singapore, 10 Ang Mo Kio Street 65
No. 05-12 Techpoint, Singapore 569059Tel: +65 6484 2388 Ext 120 Fax: +65 6484 2388 Ext 120
Taylor Hobson USA1725 Western Drive
West Chicago, Illinois 60185, USATel: +1 630 621 3099 Fax: +1 630 231 1739
www.taylor-hobson.com
© DiskArt™ 1988
TAYLOR HOBSONA8248 ISO9001
OPTIMA�UKAS
Serving a global marketTaylor Hobson is world renowned as a manufacturer of precision measuring instruments used for inspection in research and production facilities. Our equipment performs at nanometric levels of resolution and accuracy.
To complement our precision manufacturing capability we also offer a host of metrology support services to provide our customers with complete solutions to their measuring needs and total confidence in their results.
Contracted Services from Taylor Hobson
• Inspection services measurement of your production parts by skilled technicians using industry leading instruments in accord with ISO standards
• Metrology training practical, hands-on training courses for roundness and surface finish conducted by experienced metrologists • Operator training on-site instruction will lead to greater proficiency and higher productivity • UKAS Calibration and Testing certification for artifacts or instruments in our laboratory or at customer’s site
For the above services, contact our Center of Excellence:email: [email protected] or call: +44 116 276 3779
• Design engineering special purpose, dedicated metrology systems for demanding applications
• Precision manufacturing contract machining services for high precision applications and industries
• Preventative maintenance protect your metrology investment with a Talycare service cover plan
For the above services, contact our Sales Department:email: [email protected] or call: +44 116 246 2034
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