Integration von Gestaltungsprinzipien der Industrie 4.0 bei der Montage optischer Systeme

  • Integration of industry 4.0 design principles for the assembly of optical systems

Prochnau, Marcel Sebastian; Loosen, Peter (Thesis advisor); Schmitt, Robert H. (Thesis advisor)

Aachen : RWTH Aachen University (2020, 2021)
Dissertation / PhD Thesis

Dissertation, Rheinisch-Westfälische Technische Hochschule Aachen, 2020


The interlinking of production processes and operational procedures based on intelligent information and communication technology is revolutionizing the industry decisively. Developments in the context of the fourth industrial revolution also open up significant potentials for photonics - especially with regard to the improvement of precise assembly processes of optical components and the compensation of manufacturing tolerances. The present work focuses on the central research question of how the design principles of Industry 4.0 can be successfully transferred to the field of assembly of optical systems. The aim of determining a digital twin accompanies the demand for an exact representation of physical system states, which, through the information transparency thus created, lays the foundation for decentralized decision-making. Against the background of the goal of networking on the one hand and the realization of a digital technical assistance of an optical assembly cell on the other hand, the work initially shows the current state of the art. On the basis of the deficits derived from the state of the art, the research questions regarding a concept for the technical realisation of networking and digital technical assistance of an optical assembly cell are answered, taking into account the necessary measurement variables and the possibility of exchanging sensor data across devices. Furthermore, the implementation and validation of the developed sensor system concept as well as the technically assisted presentation of the collected measurement data are realized. The representation of collected measurement data over time is done in diagrams, whereby quality-relevant threshold values can be specified and monitored. The digital technical assistance also enables the user to make statements regarding the quality of the assembly process, possible sources of disturbances or errors and any necessary maintenance measures. The work creates a definition of the concept of the Digital Optical Twin (DOT). Based on the scope of the DOT defined in this definition, investigations on suitable optical characterization parameters and measuring methods for the identification of the DOT are determined. By means of an approach developed in the scope of this thesis, the tracing back of measured data calculated by Zemax OpticStudio to the optical system state (determination of the component and/or positional deviations) is investigated and a solution of the inverse problem is created if validation is successful. After the identification of a suitable measurement method for the acquisition of the characterization parameters, the experimental investigation of the measurement method allows the formulation of a suitable measurement strategy. Using 22 Zernike coefficients and two measuring wavelengths, the highest accuracy for identifying the DOT can be achieved. Practical experiments demonstrate the metrological implementation for the identification of the DOT using a bichromatic measurement for the exact determination of the radius of curvature of a lens.