As an important technology for realizing national strategies such as intelligent manufacturing and industrial 4.0, digital twin (DT) has received great attention from scholars and enterprises. At present, it has been applied to vehicles, ships, spacecraft, satellite, machining process and other fields, but there is no research report in the field of optical manufacturing. Aiming at this problem, and taking the reflective optical systems as the object, the applications of DT were discussed from the lifecycle dimension, including design and development, manufacturing and assembly, operation, and maintenance, et al. On this basis, taking the construction of the optical DT model as an example, the modelling methods of machining error and assembly error were mainly studied, the applications of the DT in computer-aided alignment and active optics were discussed, which demonstrate the importance of DT technology in the manufacturing process of reflective optical systems.
Computer-aided alignment (CAA) is a key technology for improving the assembly efficiency and performance of optical systems. However, because of the coma-free pivot point in two-mirror optical systems (TMOSs), the wavefront aberrations from multiple fields of view (FoVs) are required to compute misalignments, and this is not practical. Therefore, misalignment-caused wavefront aberrations were investigated based on the nodal aberration theory, and an analytical aberration computation model for TMOSs was derived. Based on this, an efficient misalignment calculation method based on single-FoV aberrations that introduces known misalignments was proposed and tested by conducting Monte Carlo simulations using the Hilbert telescope. The results showed that micron-level precision can be achieved for the aberration and misalignment calculation without any measurement noise and that a greater number of introduced misalignments can decrease the effect of measurement noise, thereby verifying the effectiveness of the proposed model and method. The findings of this research will open a new direction in CAA by introducing the misalignment rather than the FoV.
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