CN109870803B - Method for manufacturing primary optical free-form surface structure - Google Patents
Method for manufacturing primary optical free-form surface structure Download PDFInfo
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Abstract
The invention discloses a method for manufacturing a primary optical free-form surface structure, which comprises the step of obtaining an image corresponding to a target optical shape. And solving a preliminary objective function. And solving a preliminary free-form surface three-dimensional model. The lead-in beam tracking software simulates the preliminary result light shape. And solving a preliminary result function corresponding to the light shape of the preliminary result. And generating a modified objective function according to the comparison result of the preliminary result function and the preliminary objective function. And obtaining a corrected free-form surface three-dimensional model. And guiding the light beam tracking software to simulate and correct the light shape of the result. And obtaining a correction result function. And comparing the correction result function with the preliminary target function, and manufacturing the primary optical free-form surface structure according to the corrected free-form surface three-dimensional model when the difference value between the correction result function and the preliminary target function is lower than a preset threshold value. The invention can obtain the best corrected free-form surface three-dimensional model and manufacture the primary optical free-form surface structure capable of generating the expected target optical shape.
Description
Technical Field
The present invention relates to a method for fabricating an optical structure, and more particularly, to a method for fabricating a primary optical free-form surface structure.
Background
Before Light-emitting diodes (LEDs) are actually used as components of lighting devices, the optical structure design is generally performed twice. First, when an LED is manufactured into a required optoelectronic component by an Integrated Circuit (IC) packaging technology, a first optical structure design is performed to solve the problems of the light emitting angle, the light intensity, the light flux size, the light intensity distribution, the range and the distribution of the color temperature, and the like of the LED. After light emitted by a general high-power LED passes through the primary optical structure lens, the light-emitting angle is about 120 degrees, and on the basis, secondary optical structure design is carried out, so that the purpose is to further adjust the light-emitting angle of the light emitted by the primary optical structure lens and change the optical performance of the light.
Under the design structure of the conventional LED structure, if the light emitted from the LED is adjusted to form a special light shape, a free-form surface design is usually performed on the surface of the secondary optical structure. The micro-machining problem of the free-form surface lens and the manufacturing cost problem of the lens limit the application of the free-form surface optical lens in the market. The existing free-form Surface optical algorithms mainly include a clipping method (Tailored), a Partial Differential Equation method (PDE method for short), a synchronous multi-Surface design method (SMS method for short), and a geometric algorithm.
The main concept of the clipping method is to establish a nonlinear partial differential equation set about the optical surface shape according to the illumination distribution of the target surface and the light source characteristics, and solve the nonlinear partial differential equation set to obtain the optical surface shape, however, the method is not suitable for being applied to an extended light source. Likewise, the PDE method is less suitable for extended light sources. An extended light source refers to a light source in which the area of a light emitting portion is relatively large (compared to a point light source), and the light emitting direction is large because the light source size is relatively large. Compared with the package body, the conventional light source applied to LED package generally belongs to an extended light source (a light source rather than a point light source).
The SMS method is mainly characterized in that the corresponding relation between two pairs of input wavefronts and two pairs of output wavefronts is established according to the light energy distribution characteristics of a light source and a target plane, and then two free curved surfaces of an optical system are designed simultaneously, so that the incident wavefronts can be in one-to-one correspondence with the emergent wavefronts after being refracted or reflected by the two free curved surfaces. However, it is disadvantageous that when the spot is diffuse, there is no guarantee that the intermediate portion light rays will be uniformly distributed in the corresponding region on the target plane.
On the other hand, the main concept of the geometric algorithm is to establish the relationship between the incident angle and the free-form surface according to the non-imaging illumination theory and the geometric relationship between the free-form surface and the light rays, so as to obtain the free-form surface.
As mentioned above, the design architecture of the conventional LED structure mainly performs free-form surface design on the surface of the secondary optical structure, mainly due to the factors of micro-machining and manufacturing cost of the lens. However, this approach not only makes the overall structure more complex and is not conducive to miniaturization of the device, but also results in a greater loss of energy because the light must be converted through more layers of media before reaching the surface of the target illumination object. Therefore, it is an important issue to solve the above problems and to complete the required design of free-form surface structure on the primary optical structure.
Disclosure of Invention
The present invention provides a method for manufacturing a primary optical free-form surface structure, which can obtain a difference value between a preset objective function and a correction result function calculated by simulation by comparing the preset objective function and the correction result function, and repeatedly adjust the correction objective function when the difference value is not lower than a preset threshold value, thereby obtaining an optimal corrected free-form surface three-dimensional model and manufacturing the primary optical free-form surface structure capable of generating a desired target light shape.
In order to solve the above technical problem, one of the technical solutions of the present invention is to provide a method for manufacturing a primary optical free-form surface structure, including: (A) obtaining an image corresponding to a target light shape; (B) analyzing the image to obtain a preliminary objective function corresponding to the target light shape; (C) according to the preliminary objective function, executing free-form surface operation of the point light source to obtain a preliminary free-form surface three-dimensional model; (D) guiding the preliminary free-form surface three-dimensional model into a light beam tracking software to simulate a preliminary result light shape; (E) analyzing the light shape of the preliminary result to obtain a preliminary result function corresponding to the light shape of the preliminary result; (F) comparing the preliminary result function and the preliminary objective function; (G) generating a modified objective function according to the comparison result of the preliminary result function and the preliminary objective function; (H) according to the corrected target function, the free-form surface operation of the body light source is executed to obtain a corrected free-form surface three-dimensional model; (I) guiding the corrected free-form surface three-dimensional model into the light beam tracking software to simulate a corrected result light shape; (J) analyzing the light shape of the correction result to obtain a correction result function corresponding to the light shape of the correction result; (K) comparing the correction result function with the preliminary objective function to obtain a difference value between the correction result function and the preliminary objective function; (L) judging whether the difference value is lower than a preset threshold value; (M) repeating steps (G) to (L) when the difference value is not less than the preset threshold value; and (N) when the difference value is lower than the preset threshold value, manufacturing the primary optical free-form surface structure according to the corrected free-form surface three-dimensional model.
One of the benefits of the present invention is that the method for manufacturing a primary optical free-form surface structure provided by the present invention can obtain an optimal modified free-form surface three-dimensional model by "comparing a preset objective function with a simulation-calculated modification result function to obtain a difference value therebetween" and "repeatedly adjusting the modified objective function when the difference value is not lower than a preset threshold", so as to make it possible to further understand the features and technical contents of the present invention.
Drawings
Fig. 1 is a flowchart of a manufacturing method according to a first embodiment of the invention.
FIG. 2 is a diagram illustrating an image corresponding to a target light shape according to a first embodiment of the present invention.
FIG. 3 is a diagram illustrating a preliminary objective function corresponding to an objective light shape according to a first embodiment of the present invention.
Fig. 4 is a schematic diagram of a freeform surface three-dimensional model simulated according to a preliminary objective function in the first embodiment of the present invention.
FIG. 5 is a diagram illustrating a first embodiment of the present invention in which a free-form surface phantom is guided into a beam tracking software to simulate its light ray trajectory.
FIG. 6 is a diagram of a light shape simulated by the beam tracking software according to the first embodiment of the present invention.
FIG. 7 is a diagram illustrating a function of a correction result corresponding to a resulting light shape according to a first embodiment of the present invention.
FIG. 8 is a diagram illustrating a first embodiment of the present invention for further generating a modified objective function according to a comparison result between the result function and the objective function.
FIG. 9 is a flowchart illustrating steps of generating the modified objective function according to a second embodiment of the present invention.
Detailed Description
The following is a description of the embodiments of the present disclosure relating to the method for fabricating a primary optical free-form surface structure, with specific embodiments, and those skilled in the art will understand the advantages and effects of the present disclosure from the disclosure of the present disclosure. The invention is capable of other and different embodiments and its several details are capable of modification and various other changes, which can be made in various details within the specification and without departing from the spirit and scope of the invention. The drawings of the present invention are for illustrative purposes only and are not intended to be drawn to scale. The following embodiments will further explain the related art of the present invention in detail, but the disclosure is not intended to limit the scope of the present invention.
It will be understood that, although the terms first, second, third, etc. may be used herein to describe various components or signals, etc., these components or signals should not be limited by these terms. These terms are used to distinguish one element from another element or from one signal to another signal. In addition, as used herein, the term "or" may include all combinations of any one or more of the associated listed items as appropriate.
First embodiment
Referring to fig. 1 to 8, fig. 1 is a flow chart of a manufacturing method according to a first embodiment of the invention; FIG. 2 is a diagram illustrating an image corresponding to a target light shape according to a first embodiment of the present invention; FIG. 3 is a diagram illustrating a preliminary objective function corresponding to an objective light shape according to a first embodiment of the present invention; FIG. 4 is a schematic diagram of a three-dimensional model of a free-form surface modeled according to a preliminary objective function according to a first embodiment of the present invention; FIG. 5 is a diagram illustrating a free-form surface solid model introduced into a light beam tracking software to simulate its light ray trajectory according to a first embodiment of the present invention; FIG. 6 is a diagram illustrating a light shape simulated by the beam tracking software according to the first embodiment of the present invention; FIG. 7 is a diagram illustrating a modified result function corresponding to a resulting light shape according to a first embodiment of the present invention; FIG. 8 is a diagram illustrating a first embodiment of the present invention for further generating a modified objective function according to a comparison result between the result function and the objective function. As can be seen from the above drawings, a first embodiment of the present invention provides a method for fabricating a primary optical free-form surface structure, which includes analyzing a target light shape to obtain a corresponding function (as shown in fig. 2 and 3), initially building a model (as shown in fig. 4), simulating a result light shape (as shown in fig. 5) by using light beam tracking software, analyzing the result light shape to obtain a corresponding function (as shown in fig. 6 and 7), and comparing the result light shape with the target light shape to obtain a function (as shown in fig. 8). The following description will explain the operation details of each step through the drawings of fig. 2 to 8, respectively, in conjunction with the main flow shown in fig. 1.
First, referring to fig. 1, 2 and 3, in a preferred embodiment of the present invention, it is first determined that a target light shape is expected to be produced by the LED. In a specific industrial application, on one hand, the optimal illumination simulation graph can be obtained by software according to a specific application occasion (such as a bedroom, a living room, a meeting room or a stage); on the other hand, the result of illumination actually applied to a specific place (for example, illumination is generated by using another light source, and the same illumination is provided by using an LED primary optical structure instead of the original illumination), and a result pattern of the illumination of the target may be obtained by means of shooting or the like. In this embodiment, the present invention first obtains an image P1 corresponding to the target light shape (as shown in fig. 2, step S200 in fig. 1), and analyzes the image P1 by an image processing program to obtain a preliminary objective function F1 corresponding to the target light shape (as shown in fig. 3, step S202 in fig. 1). As mentioned above, the image P1 may be a picture file captured from a simulation frame or a video file stored after being actually captured.
In the present embodiment, a specific analysis method is performed to obtain a corresponding preliminary objective function F1 from the illumination values of the points in the image P1. It should be noted that, for convenience of illustration, a planar graph is used as the image P1 corresponding to the target light shape in this embodiment, but the application of the present invention is not limited thereto, and besides the aforementioned simulated graph may be in a three-dimensional (3D) format, and for an actually existing object, a Computer-aided Verification (CAV) technique may be used in combination with a 3D optical measurement technique to analyze the surface of the object to be illuminated to obtain a 3D solid structure thereof, and to obtain the target illumination of each point on the surface of the object in cooperation with multi-angle photography and other techniques. In short, the image P1 is not limited to a planar figure.
On the other hand, when the corresponding preliminary objective function F1 is obtained from the image P1, the calculation may be performed by a conventional optical simulation software (for example, but not limited to, software such as LightTools, TracePro, ASAP, OSLO, or ZEMAX). The details and principles thereof have not been set forth herein in detail.
After the preliminary objective function F1 is obtained, the present invention first assumes the light source providing illumination as a point light source and performs the most preliminary free-form surface operation. It is well known that LED light sources are not true point sources for package designs, and can often be considered as a light source capable of emitting light at 180 degrees and having Lambertian characteristics with a light intensity distribution that is the strongest at the center and weaker at the periphery. However, in order to meet the limitation of the existing optical simulation software, the present invention uses a point light source to perform a free-form surface operation and obtain a preliminary free-form surface three-dimensional model M (as shown in fig. 4, step S204 in fig. 1). The principle of this part is mainly that the required free-form surface can be reversely deduced through the relation of energy conservation and energy mapping and Snell's Law. In the process of performing the free-form surface operation to obtain the preliminary free-form surface three-dimensional model M, some default conditions (such as the diameter size or height of the lens) are set for the structure of the free-form surface three-dimensional model M, so that the produced product can meet the assembly requirements in actual use.
If the preliminary free-form surface three-dimensional model M is directly used to make an actual primary optical free-form surface structure, the light shape projected by the model M will not conform to the original expected target light shape. The reason for this is that, as described above, since an actual LED light source is not a point light source, there is a deviation from an ideal point light source, and the light intensity near the center is higher than the light intensity near the periphery. Therefore, the present invention does not directly use the primary optical free-form surface structure actually required by the primary free-form surface three-dimensional model M, but introduces the primary free-form surface three-dimensional model M into the light beam tracking software, so as to simulate the illumination track L (as shown in fig. 5) projected by the LED light source through the primary free-form surface three-dimensional model M through the light beam tracking software, and simulate the corresponding resultant light shape according to the illumination result projected by the illumination track L on the surface of the target object (as shown in step S206 in fig. 1).
When the light trajectory projected by the LED light source is simulated by the light beam tracking software, the functions of the software such as the LightTools and TracePro may be adopted (similarly, the invention is not limited thereto). Specifically, the influence of the selected material property on the light traveling track is actually considered in this step, and the parameters such as the name, interpolation (interpolation), temperature, refractive index, or absorption wavelength of the material can be further defined on the relevant optical application software through a material editor or other similar functions. More importantly, in this step, the light emission characteristics of the LED light source are also actually considered for simulation. The details of this section are discussed in more detail below.
As shown in fig. 2 and fig. 6, since the light intensity of the actual LED light source is higher near the center than near the periphery, if the resulting light shape generated by the simulation is represented by the image P2 and the image P2 in fig. 6 is compared with the image P1 in fig. 2, it can be found that the image P2 corresponding to the resulting light shape does not match the image P1 of the originally expected target light shape. At this time, in order to know the difference between the two images by a more objective comparison standard and further perform the subsequent correction steps, the present invention analyzes the image P2 by an image processing program to obtain a preliminary result function F2 corresponding to the result light shape (as shown in fig. 7, step S208 in fig. 1).
When the preliminary objective function F1 corresponding to the target light shape is compared with the preliminary result function F2 corresponding to the result light shape (step S210 of fig. 1, as shown in fig. 8), it is apparent that the intermediate peak value of the preliminary result function F2 is higher than the intermediate peak value of the preliminary objective function F1. Near the periphery, the preliminary result function F2 has a lower value than the preliminary objective function F1. Therefore, if the system is directly imported with the preliminary objective function F1, the result function F2 obtained by performing steps S204 to S208 does not coincide with the preliminary objective function F1, in other words, if the system is directly imported with the preliminary objective function F1, the free-form surface solid model M obtained by performing step S204 is used to produce the primary optical free-form surface structure, and the projected light shape is not the ideal target light shape. However, the present invention is directed to finding a primary optical free-form surface structure capable of projecting an ideal target light shape, and therefore, it is necessary to find a free-form surface stereo model M having a sufficiently high degree of consistency between the result function F2 corresponding to the projected result light shape and the preliminary target function F1 generated by analyzing the image P1 corresponding to the target light shape.
Specifically, the result function F2 is compared with the preliminary objective function F1, and a set of modified objective functions F3 is further generated according to the comparison result (step S212 in fig. 1). In this embodiment, the specific adjustment manner is to adjust the values of the coordinate positions of the preliminary objective function F1 according to the preliminary result function F2 under the premise of keeping the area under the curve of the preliminary objective function F1 constant, so as to obtain the values of the coordinate positions of the modified objective function F3. Specifically, when the value of the preliminary result function F2 at a particular coordinate position is higher than the value of the preliminary objective function F1 at the particular coordinate position, the value of the preliminary objective function F1 at the particular coordinate position is adjusted down. On the other hand, the value of the preliminary objective function F1 is raised at coordinate positions where the value of the preliminary result function F3 is lower than the value of the preliminary objective function F1. By the above-mentioned procedure, a modified objective function F3 is generated. It should be noted that the method of obtaining the modified objective function F3 is not limited thereto.
Next, the present invention performs the free-form surface operation again with the modified objective function F3 as the input function to obtain the modified free-form surface three-dimensional model M corresponding to the modified objective function F3 (step S214 in fig. 1). Similarly, the modified free-form surface solid model M corresponding to the modified objective function F3 is introduced into the light beam tracking software to simulate the illumination result of the LED light source projected on the surface of the target object through the modified free-form surface solid model M by the light beam tracking software, so as to simulate the corresponding modified light shape (step S216 in fig. 1). After simulating the corresponding light shape of the correction result, a result function F2 corresponding to the light shape of the correction result is obtained according to the light shape of the correction result (as shown in step S218 of fig. 1) so as to perform an objective comparison with the "preliminary objective function F1" (instead of the correction objective function F3), and a difference value between the two is obtained (as shown in step S220 of fig. 1).
As mentioned above, the present invention is expected to obtain the result function F2 with a high enough degree of consistency with the preliminary objective function F1, so after comparing the result function F2 corresponding to the modified light shape with the preliminary objective function F1 and obtaining the aforementioned difference value, the present invention compares the difference value with the preset threshold value (step S222 in fig. 1).
It is easy to understand that the smaller the difference between the result function F2 and the preliminary objective function F1, the higher the approximation between the two functions, and the more the objective of the present invention is achieved.
Therefore, if the difference between the result function F2 and the preliminary objective function F1 can be smaller than the preset threshold, the difference indicates that the corrected free-form surface three-dimensional model M obtained by performing the free-form surface operation on the corrected objective function F3 has the required consistency between the light shape simulated by the light beam tracking software and the target light shape, and therefore, the step S224 can be performed to manufacture the primary optical free-form surface structure according to the corrected free-form surface three-dimensional model M.
On the contrary, if the difference between the result function F2 and the preliminary objective function F1 is greater than the preset threshold, it indicates that the corrected free-form surface three-dimensional model M obtained by correcting the objective function F3 cannot produce a primary optical free-form surface structure meeting the requirement. At this time, the preliminary objective function F1 must be modified again according to the comparison result of step S220, and a new set of modified objective functions F3 is obtained again. Since the deviation between the actual LED light source and the ideal point light source has been corrected by the adjustment in the previous step, the difference between the result function F2 obtained by the correction of the objective function F3 through a series of steps and the preliminary objective function F1 becomes smaller than the result function F2 obtained directly through the preliminary objective function F1. In the process of repeatedly performing the steps S212 to S220, a smaller difference value is gradually obtained (that is, the result function F2 approaches the preliminary objective function F1), and when the difference value can be smaller than a preset threshold value, a corrected free-form surface stereo model M meeting the requirement is obtained, and a mold flow analysis is performed according to the corrected free-form surface stereo model M to establish a mold required for producing the primary optical free-form surface structure, so that the required primary optical free-form surface structure is manufactured by the mold.
In summary, the flow shown in fig. 1 and the reference numerals shown in fig. 2 to 8 are used to initially organize the main flow structure of the present invention as follows:
step S200: acquiring an image P1 corresponding to the target light shape;
step S202: analyzing the image P1 to find a preliminary objective function F1 corresponding to the target light shape;
step S204: according to the preliminary objective function F1, free-form surface operation of the point light source is executed to obtain a preliminary free-form surface three-dimensional model M;
step S206: guiding the preliminary free-form surface three-dimensional model M into light beam tracking software to simulate a preliminary result light shape;
step S208: analyzing the preliminary result light shape to find a preliminary result function F2 corresponding to the preliminary result light shape;
step S210: comparing the preliminary result function F2 with the preliminary objective function F1;
step S212: generating a modified objective function F3 according to the comparison result of the preliminary result function F2 and the preliminary objective function F1;
step S214: according to the modified objective function F3, free-form surface operation is executed to obtain a modified free-form surface three-dimensional model;
step S216: guiding the corrected free-form surface three-dimensional model into light beam tracking software to simulate the light shape of a correction result;
step S218: analyzing the light shape of the correction result to obtain a correction result function F2 corresponding to the light shape of the correction result;
step S220: comparing the correction result function F2 with the preliminary objective function F1 to obtain a difference value between the two;
step S222: judging whether the difference value is lower than a preset threshold value, repeating the step S212 to the step S222 when the difference value is not lower than the preset threshold value, otherwise, entering the step S224; and
step S224: and manufacturing a primary optical free-form surface structure according to the corrected free-form surface three-dimensional model.
Second embodiment
As mentioned above, when the difference between the result function F2 and the preliminary objective function F1 is not lower than (greater than or equal to) the predetermined threshold, a modified objective function F3 is further generated, and the method of obtaining the modified objective function F3 is not limited to the method described in the first embodiment.
Referring to fig. 1 and 9, fig. 9 is a flowchart illustrating a step of generating the modified objective function according to a second embodiment of the present invention. In the second embodiment of the present invention, a difference function is first obtained according to the comparison result between the result function F2 and the preliminary objective function F1, and a plurality of modified objective functions F3 are generated according to the difference function and random numbers (step S300), and modified result functions F2 corresponding to the respective modified objective functions F3 are respectively generated according to steps 214 to S218 shown in fig. 1 (step S302).
The main purpose of the foregoing process is to generate a large number of modified objective functions F3 at one time by random number operation within the value ranges of the result function F2 and the preliminary objective function F1, and accordingly, to establish a plurality of groups of modified objective functions F3 and modified result functions F2. The main difference between the first embodiment and the second embodiment is that the first embodiment compares the modified result function F2 with the preliminary objective function F1 again and approaches the ideal value step by step after generating a set of modified objective functions F3 and the corresponding modified result function F2 each time.
In the second embodiment, after a plurality of sets of corresponding modified objective functions F3 and modified result functions F2 are generated, the corresponding modified objective functions F3 and modified result functions F2 are provided to the deep learning system to execute the training procedure of the deep learning system (step S304). Specifically, the deep learning system used may be a framework of Caffe, Theano, TensorFlow or Lasagne, Keras or even DSTNE, and the invention is not particularly limited to which framework is used. Thereby, a prediction algorithm for predicting the correction result function F2 corresponding to the inputted correction target function F3 is established by the deep learning system (step S306).
In a specific application, a part of combinations can be provided to the deep learning system to establish the prediction algorithm, and the rest combinations are used for verifying the correctness of the prediction algorithm. For example, if there are 100 sets of the corresponding modified objective function F3 and the modified result function F2, 80 sets of the corresponding modified objective function F3 and the modified result function F2 are provided to the deep learning system to perform the training procedure, and the prediction algorithm is established accordingly. After the prediction algorithm is established, the remaining 20 sets of the modified objective function F3 and the modified result function F2 corresponding to each other are used for verification, wherein for the purpose of the present invention, the preferred verification method is to predict the modified objective function F3 corresponding to the modified result function F2 by the prediction algorithm, and to compare the predicted result with the previously known modified objective function F3 to determine whether the result predicted by the prediction algorithm is consistent with the modified objective function F3 actually corresponding to the modified result function F2.
If the obtained prediction result is not ideal, a larger number of modified objective functions F3 can be generated by random numbers, and a larger number of sets of the modified objective functions F2 and F3 are established, and the deep learning system is executed again to execute the training procedure. Furthermore, it is also contemplated to perform random number operations according to a certain modified result function F2 (compared to the initial result function F2) and the initial objective function F1, so as to generate a more diversified corresponding relationship between the modified result function F2 and the modified objective function F3, thereby enabling the training process of the deep learning system to obtain more diversified learning samples.
Finally, when the verification is performed several times and the accuracy of the result predicted by the prediction algorithm is evaluated to be satisfactory, the preliminary objective function F1 initially obtained from the image P1 corresponding to the target light shape may be set as the modified result function F2 in the prediction algorithm, and the corresponding modified objective function F3 may be reversely deduced by the prediction algorithm (step S308). After obtaining the modified objective function F3, step S214 shown in fig. 1 may be further executed to obtain a corresponding free-form surface three-dimensional model M, and a primary optical free-form surface structure required for manufacturing is produced according to the free-form surface three-dimensional model M. On the other hand, before actual production, step S216 shown in fig. 1 may be further executed to actually simulate the correction result function F2 corresponding to the correction objective function F3 and confirm whether it is indeed consistent with the preliminary objective function F1.
In summary, with the flow shown in fig. 9 and the reference numerals shown in fig. 2 to 8, the main flow architecture for obtaining the final required modified objective function F3 in the second embodiment of the present invention is as follows:
step S300: random number generation of a number of modified objective functions F3;
step S302: generating a modified result function F2 corresponding to the respective modified objective function F3 according to steps 214 to 218 shown in FIG. 1;
step S304: the modified objective function F3 and the modified result function F2, which correspond to each other, are provided to the deep learning system to execute a training procedure of the deep learning system.
Step S306: establishing a prediction algorithm through a deep learning system to predict the corresponding relation between a corrected target function F3 and a corrected result function F2; and
step S308: the preliminary objective function F1 is set to the corrected result function F2, and the corresponding corrected objective function F3 is backward-inferred by the prediction algorithm.
Pre-adjustment of parameters
In order to ensure that the steel result illumination track L simulated by the beam tracking software can be closer to the illumination track L in practical application, and further simulate the most correct result light shape, fine adjustment needs to be performed according to various set parameters in the beam tracking software according to the adopted material attributes and the like. In the present invention, before the modified free-form surface three-dimensional model M is introduced into the beam tracking software, a step of pre-adjusting parameters is further included. Specifically, a plurality of different stereo models are firstly constructed, the higher the diversity is, the better the effect in the subsequent application can be reflected by the change situation of the illumination track L under different angles. After a plurality of different three-dimensional models are established, a plurality of optical structures for samples are respectively prepared according to the three-dimensional models and materials and processes which are used for actually producing the optical free-form surface structure for one time, and set parameters of the light beam tracking software are corrected according to the optical structures for the samples.
Specifically, after a plurality of optical structures for the sample are prepared by the materials and processes to be used, the prepared optical structures for the sample are actually used for illumination to obtain the actual illumination track L and the actually formed result light shape. In other words, a plurality of optical structures for a sample are first passed to generate a corresponding plurality of illumination patterns, respectively. Then, after the actual illumination track L and the actually formed result light shape are obtained, various parameters in the light beam tracking software can be calibrated by comparing the result simulated by the light beam tracking software with the actual result. That is, the plurality of three-dimensional models are introduced into the beam tracking software, respectively, to generate a plurality of simulated sample light shapes corresponding to the plurality of three-dimensional models, respectively. After analyzing the plurality of previously obtained illumination patterns, a plurality of actual light shapes corresponding to the plurality of illumination patterns may be obtained. The actual light shapes are compared with the corresponding simulated sample light shapes respectively, so that the set parameters of the light beam tracking software can be corrected.
On the other hand, in order to make the simulated free-form surface three-dimensional model M have better simulation effect with the actually produced primary optical free-form surface structure, the invention can also correct the physical property data and the molding condition parameters required when the analog flow analysis is executed by using the optical structure through a plurality of samples before the corrected free-form surface three-dimensional model M is introduced into the light beam tracking software. In a specific application, the CAV technique may be used to perform inverse three-dimensional surface scanning to confirm the actual shapes of the optical structures for the multiple samples, and compare the actual shapes with the corresponding three-dimensional models, so as to correct the physical property data and molding condition parameters required for performing the mold flow analysis.
Advantageous effects of the embodiments
One of the benefits of the present invention is that the method for manufacturing a primary optical free-form surface structure provided by the present invention can obtain an optimal modified free-form surface three-dimensional model by "comparing a preset objective function with a modification result function calculated by simulation" to obtain a difference value therebetween and "repeatedly adjusting the modified objective function when the difference value is not lower than a preset threshold" to manufacture the primary optical free-form surface structure capable of generating an expected target light shape.
The disclosure is only a preferred embodiment of the invention, and is not intended to limit the scope of the claims, so that all technical equivalents and modifications using the contents of the specification and drawings are included in the scope of the claims.
Claims (10)
1. A manufacturing method of a primary optical free-form surface structure is characterized by comprising the following steps:
(A) obtaining an image corresponding to a target light shape;
(B) analyzing the image to obtain a preliminary objective function corresponding to the target light shape;
(C) according to the preliminary objective function, executing free-form surface operation of the point light source to obtain a preliminary free-form surface three-dimensional model;
(D) guiding the preliminary free-form surface three-dimensional model into a light beam tracking software to simulate a preliminary result light shape;
(E) analyzing the light shape of the preliminary result to obtain a preliminary result function corresponding to the light shape of the preliminary result;
(F) comparing the preliminary result function and the preliminary objective function;
(G) generating a modified objective function according to the comparison result of the preliminary result function and the preliminary objective function;
(H) according to the corrected target function, the free-form surface operation of the body light source is executed to obtain a corrected free-form surface three-dimensional model;
(I) guiding the corrected free-form surface three-dimensional model into the light beam tracking software to simulate a corrected result light shape;
(J) analyzing the light shape of the correction result to obtain a correction result function corresponding to the light shape of the correction result;
(K) comparing the correction result function with the preliminary objective function to obtain a difference value between the correction result function and the preliminary objective function;
(L) judging whether the difference value is lower than a preset threshold value;
(M) repeating steps (G) to (L) when the difference value is not less than the preset threshold value; and
and (N) when the difference value is lower than the preset threshold value, manufacturing the primary optical free-form surface structure according to the corrected free-form surface three-dimensional model.
2. The method of claim 1, wherein the step of generating the modified objective function further comprises the steps of:
and on the premise that the area under the curve of the preliminary objective function is kept constant, adjusting the preliminary objective function according to the preliminary result function.
3. A method of manufacturing as claimed in claim 2, wherein the value of the preliminary objective function is adjusted down when the value of the preliminary result function is higher than the coordinate location of the value of the preliminary objective function.
4. The method of claim 2, wherein when the value of the preliminary result function is lower than the coordinate location of the value of the preliminary objective function, the value of the preliminary objective function is raised to produce the modified objective function.
5. The method of claim 1, wherein the step of generating the modified objective function further comprises the steps of:
generating a plurality of said modified objective functions based on a difference function and random numbers, and generating said modified result functions corresponding to respective said modified objective functions based on steps (H) through (J), respectively;
providing the correction target function and the correction result function which correspond to each other to a deep learning system so as to execute a training program of the deep learning system;
establishing a prediction algorithm by the deep learning system, the prediction algorithm being configured to predict the revised result function corresponding to the inputted revised objective function; and
setting the preliminary objective function as the correction result function, and reversely pushing the correction objective function through the prediction algorithm.
6. The method of claim 1, further comprising, prior to introducing the modified free-form surface phantom into the beam tracking software, the steps of:
constructing a plurality of three-dimensional models;
preparing a plurality of optical structures for the sample according to the plurality of three-dimensional models respectively; and
the setting parameters of the beam tracking software are corrected by a plurality of the sample optical structures.
7. The manufacturing method according to claim 6, wherein the step of correcting the setting parameters of the beam tracking software by the plurality of sample optical structures further comprises the steps of:
passing a plurality of said optical structures for the sample to produce a corresponding plurality of illumination patterns, respectively;
respectively introducing the plurality of three-dimensional models into the light beam tracking software to generate a plurality of simulated sample light shapes respectively corresponding to the plurality of three-dimensional models; and
and analyzing a plurality of actual light shapes of the plurality of illumination patterns, and comparing the plurality of actual light shapes with a plurality of corresponding simulated sample light shapes respectively so as to correct the set parameters of the light beam tracking software.
8. The method of claim 1, further comprising, prior to introducing the modified free-form surface phantom into the beam tracking software, the steps of:
constructing a plurality of three-dimensional models;
preparing a plurality of optical structures for the sample according to the plurality of three-dimensional models respectively; and
the physical property data and molding condition parameters required for performing a mold flow analysis are corrected by a plurality of the sample optical structures.
9. The method according to claim 8, wherein the step of correcting physical property data and molding condition parameters required for performing the mold flow analysis by the plurality of optical structures for the sample further comprises:
and confirming an actual shape of the optical structures for the samples by using an inverse three-dimensional surface scanning technology, and comparing the actual shapes with the corresponding three-dimensional models respectively so as to correct physical property data and molding condition parameters required when the mold flow analysis is executed.
10. The method of manufacturing according to claim 8, further comprising: and performing the mold flow analysis on the corrected free-form surface three-dimensional model to establish a mold required for producing the primary optical free-form surface structure.
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