Tolerancing

in CODE V

3280 East Foothill Boulevard

Pasadena, California 91107 USA
(626) 795-9101 Fax (626) 795-0184
e-mail: service@opticalres.com
World Wide Web: http://www.opticalres.com
 About This Presentation
• This presentation consists of:

– A PowerPoint show to introduce and

describe CODE V’s tolerancing features

– A few demonstrations to show how the

features work in CODE V

Tolerancing in CODE V, Slide-2

 What is “Tolerancing”?
• Tolerancing is complex interactive process
required for any system that will be
fabricated, steps include:

– Definition of fabrication and assembly

tolerance budget
– Definition of fabrication and alignment
compensators, and an alignment plan

Success requires the ability to accurately predict individual

tolerance sensitivities & the as-built performance of the
entire system, including the effects of compensation

Tolerancing in CODE V, Slide-3

 What Does Tolerancing Tells Us?
• Which lens
parameters are Cooke Triplet f/4.5 Field 1

the most
Field 2
Tolerance Analysis Field 3

sensitive to ORA 19-Jun-02

manufacture or
100.

align
80. 80% probability of
• Which achieving ~0.88 MTF

Cumulative Probability (%)

for Field 1
compensator or -or-
compensators are
60.
80% of built systems
will have about 0.88 MTF
effective for or better at Field 1
assembly or 40.

alignment
• What is the
20.

probability of
achieving a given 0.
0.972 0.835 0.698 0.561 0.424 0.287

performance
Modulation Transfer Function

level for the Typical Cumulative Probability Curve

fabricated system

Tolerancing in CODE V, Slide-4

 Why is Tolerancing Important?
• Cost reduction! When attacked with the right
tools, tolerancing can significantly reduce:

– Non-recurring costs including designer time,

production tool development, and definition of
assembly/alignment procedures
– Recurring costs including system fabrication,
assembly, and alignment

• The design that meets spec with the loosest

tolerances and the best compensator set will
minimize manufacturing and assembly costs!

Tolerancing in CODE V, Slide-5

 CODE V’s Tolerancing Options
• Analysis > Tolerancing menu allows you to
choose among CODE V’s various methods for
computing the performance impact of
manufacturing and assembly errors
• CODE V’s primary tolerancing
option, TOR, supports the
following performance
metrics
– Diffraction MTF
– RMS wavefront error
– Fiber Coupling Efficiency
– Polarization Dependent Loss
– Zernike Wavefront Coefficients
(command line only)

Tolerancing in CODE V, Slide-6

 How TOR works
• TOR uses a fast wavefront differential
algorithm to determine the performance
impact due to tolerances
– Required information computed from a
real ray trace of the nominal system
– Includes “cross-terms”, the impact of
interacting tolerances
– TOR can be 50x to 1000x faster than
alternative tolerancing methods
• This allows TOR to be use early and
frequently during the design process

Tolerancing in CODE V, Slide-7

 TOR Modes of Operation

• Inverse mode - computes the tolerance values

so each tolerance has approximately the same
impact on performance (default mode)
– However, tolerances will never violate user-
defined minimum & maximum limits
– Individual tolerance values can be “frozen” to not
change during an Inverse mode analysis if desired

• Sensitivity mode - computes the effects of

specified tolerances on performance
– CODE V will not try to change the tolerance values

Tolerancing in CODE V, Slide-8

 2-Parameter TOR Demonstration

Tolerancing in CODE V, Slide-9

 What Does This Example Show Us?
• TOR is easy to use

• For real systems, compensation is crucial

• Realistic tolerance limits can be imposed

TOR’s inverse sensitivity analysis will help

reduce system sensitivity by attempting to
set each tolerance to contribute equally to the
performance degradation of the system

Tolerancing in CODE V, Slide-10

 Assumptions of the Wavefront Differential method

• Only applicable to a subset of performance metrics that

can be adequately described by an exit pupil function

• Fundamental assumption is that optical path differences

induced by tolerance perturbations for each ray in the
ray grid vary linearly with tolerance change
– Valid when tolerance change results in a small degradation
of the nominal performance (typically true for tolerances)

• Wavefront differential equations requires knowledge of

how each tolerance affects the system
– This means that only CODE V pre-programmed tolerance
types can be analyzed

Tolerancing in CODE V, Slide-11

 Entry of Tolerances
• Along with the Surface Properties window you can
also use Review > Tolerances
– Enter specific tolerances using drop-down menu

Tolerancing in CODE V, Slide-12

 Default Tolerances
• Default tolerances can be generated for a surface or range
of surfaces via the Autofill button on the Tolerance
Review

Tolerancing in CODE V, Slide-13

 CODE V Tolerance Types
• Tolerances on single surfaces
– Radius, thickness, index, etc.
• Tolerances on elements
– Wedge
• Tolerances on components (single
elements or cemented elements)
– Decenter, tilt, etc.
• Tolerances on polarization properties
– Retardance, Faraday rotation, etc.
CODE V tolerances are used by TOR and a large
subset are used by other tolerancing features

Tolerancing in CODE V, Slide-14

 Single Surface Tolerances: Radius
• Changes in radius DLF S2

– DLR (delta radius)

– DLC (delta curvature)
– DLS (delta sag at clear aperture)
– DLF (delta fringe - test plate fit)

– IRR (cylindrical irregularity in fringes) irregularity

• CYN (cylinder normal - oriented at 0°)

• CYD (cylinder diagonal - oriented at 45°)

Underlined tolerances indicate

Default tolerance types
Photo of actual test plate fit

Tolerancing in CODE V, Slide-15

 Single Surface Tolerances: Sag
• Change in surface sag in waves at the fringe
wavelength, defined by Standard or Fringe
Zernike coefficients (can be applied to any
surface type)
– ZRN Cm (Standard Zernike coefficient)
– ZFR Cm (Fringe Zernike coefficient)

Tolerancing in CODE V, Slide-16

 Single Surface Tolerances: Index, Thickness

• Changes in refractive index

– DLN (delta index)
– DLV (delta V value)
• Only used if there are three wavelengths or more
– HOM (homogeneity)
– AXG (axial index gradient)
– RAG (radial quadratic index gradient)

• DLT (change in thickness)

DLT S1

Tolerancing in CODE V, Slide-17

 Single Surface Tolerances: Shape
• Change in aspheric coefficients (can be applied to any
surface type)
– DAK (delta conic constant)
– DAA (delta A - 4th order coefficient)
– DAB (delta B - 6th order coefficient)
– DAC (delta C - 8th order coefficient)
– DAD (delta D -10th order coefficient)
– DAE (delta E - 12th order coefficient)
– DAF (delta F - 14th order coefficient)
– DAG (delta G - 16th order coefficient)
– DAH (delta H - 18th order coefficient)
– DAJ (delta J - 20th order coefficient)

• Cosine ripple and random surface error

– RPA, RPS (cosine ripple amplitude and slope)
– RSE (random surface error)

Tolerancing in CODE V, Slide-18

 Single Surface Decenter and
Displacement Tolerances
• Decentration tolerances
– DEC (decenter)
• DLX (delta shift in X) DLY S1
• DLY (delta shift in Y)
– DLZ (delta shift in Z)
• Tilt tolerances
– TIL (tilt)
• DLA (delta tilt in alpha in radians)
• DLB (delta tilt in beta in radians)
– DLG (delta tilt in gamma in radians) DLA S1

• Wedge tolerances A
– TIR (total indicated reading)
• TRX (TIR in X)
• TRY (TIR in Y) TIR S1 = A - B

Tolerancing in CODE V, Slide-19

 Group Decenter and Displacement
Tolerances
• Group tilt
– BTI (barrel tilt in radians)
• BTX (barrel tilt in X in radians)
BTY S1..2
• BTY (barrel tilt in Y in radians)
– BRL (barrel roll about Z in radians)
• Group displacement
– DIS (displacement)
• DSX (displacement in X)
DSY S1..2
• DSY (displacement in Y)
– DSZ (displacement in Z)
• Group roll (cemented surfaces)
– ROL (roll)
• RLX (roll in X)
• RLY (roll in Y) RLY S1..2 R

• R = “reverse”
(roll about second surface)

Tolerancing in CODE V, Slide-20

 Group Tolerances (cont.)
• DOL (delta overall length - change is
divided among each surface)
• STI (shear tolerance - each surface is
independently tilted)
– STX (shear in X)
– STY (shear in Y)
STY S1..2

Tolerancing in CODE V, Slide-21

 Polarization Tolerances
• BMA, BMB, BMG – Tolerance on tilt about X, Y, and Z
crystal axes, respectively, for birefringent material
• BMN – Tolerance on ordinary and extraordinary
refractive index difference for birefringent materials
• PPA – Amplitude transmittance tolerance for a leaky
linear polarizer
• PPF – Rotation angle tolerance for Faraday rotator
• PPR – Retardance tolerance for ideal retarder
• PPO – Rotation angle tolerance for polarizing
elements

Tolerancing in CODE V, Slide-22

 Typical Tolerancing Example
• Define tolerances and compensator(s)
– Or use the CODE V default values
• Determine the tolerance performance metric
of interest
– Enter required information (e.g., MTF spatial
frequency and azimuth values)
• Modify tolerance limits
– Or use CODE V default limits
• Run TOR in inverse sensitivity mode
• Review results, optionally modify tolerance
and compensator set, adjust performance
change value, etc. & re-run TOR

Tolerancing in CODE V, Slide-23

 Demonstration - Typical TOR Run

Tolerancing in CODE V, Slide-24

 Wavefront Differential Tolerancing Statistics
MTF MTF probability distribution

MTF = A ΔP2 + B ΔP + C

Probability

Nominal
MTF (C) Nominal MTF
MTF
50% change

Integral of 50% of cases

Nominal ΔP
parameter Integral of 84% of cases (1σ)
value
Integral of 98% of cases (2σ)

Impact of single compensated "Probable change"

tolerance on MTF at one field
Integral of 99.7% of cases (3σ)

MTF performance probability

distribution due to all tolerances
(and compensation) at one field

Tolerancing in CODE V, Slide-25

 Interactive Tolerancing
• Interactive Tolerancing
is a special spreadsheet
interface that leverages
the speed of TOR’s
wavefront differential
algorithm
• Users can interactively
change tolerance values
and immediately see the
impact on performance
and compensator
motion
• Tolerances causing the
largest performance
degradation are
automatically put at the
top of the list by default

Tolerancing in CODE V, Slide-26

Interactive Tolerancing - Demonstration

Tolerancing in CODE V, Slide-27

 Other TOR Features
• Modeling your Optomechanical System accurately
for TOR
– Coupled (Grouped) Tolerances
– Labeled Tolerances & Compensators
– Zoomed Tolerances & Compensators
– Tolerance X, Y, Z offsets
• TOR Compensation Solution using Singular Value
Decomposition
• TOR Compensation for Magnification and Line-of-
Sight Errors
• TOR Distortion Analysis

Tolerancing in CODE V, Slide-28

 Other Tolerancing Options

• Analysis > Tolerancing > Distortion

– Tolerancing for the performance metric of chief
ray distortion (TOD)
– Also uses the fast wavefront differential algorithm
– Used when distortion or image mapping is the
primary performance metric of interest

Tolerancing in CODE V, Slide-29

 Distortion Tolerancing (TOD)
• Two modes:
– Listing of change in chief ray locations with tolerances
– Difference between chief ray positions for two zoom positions
• Useful for biocular (i.e., two-eye) systems analysis

Single zoom
chief ray
positional
changes in X
and Y with
tolerances

Tolerancing in CODE V, Slide-30

 Other Tolerancing Options (cont.)
• User - Finite Differences
– Macro for finite-difference tolerancing using user-
defined performance measures with optional user-
defined tolerances (TOLFDIF)
– Useful for determining tolerance drivers, but
performance summary does not include cross-terms
• User - Monte Carlo
– Macro for Monte Carlo tolerance analysis to simulate
production yield using user-defined performance
measures with optional user-defined tolerances
(TOLMONTE)
– Useful for predicting system performance but
includes no information about performance drivers

Tolerancing in CODE V, Slide-31

 What is Finite Differences Tolerancing?
• Each parameter is individually varied at the
plus & minus limits of its tolerance range,
compensation is typically achieved using
optimization, and the system performance
degradation is predicted on a tolerance-by-
tolerance basis

• These individual results are statistically

combined to yield a total system performance
prediction

Tolerancing in CODE V, Slide-32

 Pros & Cons of Finite Differences Tolerancing
+Predicted performance sensitivity for individual
tolerances is usually accurate, especially for tolerances
that cause a large decrease in performance
+Allows determination of “performance drivers”

- Does not include cross-terms (i.e., how multiple

tolerances interact), so overall performance prediction
is generally optimistic
- Accuracy of tolerance sensitivity prediction can be
poor for tolerances that cause small performance
changes
- System must be “analyzed” (e.g., ray traced) twice for
each tolerance (Typical triplet requires 100 ray traces)

Tolerancing in CODE V, Slide-33

 What is Monte Carlo Tolerancing?
• Simultaneously vary all of the parameters that
have an associated tolerance randomly within each
tolerance range, with compensation typically
achieved using optimization

• The resulting system performance is analyzed

• This process is repeated many times with different

random perturbations and results are statistically
combined to yield a total system performance
prediction
• Each analysis is called a “trial”

Tolerancing in CODE V, Slide-34

 Pros & Cons of Monte Carlo Tolerancing
+Includes cross-terms (the impact of
interacting tolerances), so system
performance prediction can be accurate

- No information about individual tolerance

sensitivities
- Requires one “analysis” (e.g., ray trace) per
trial
- Accurate predictions generally require 100 to
1000 trials!

Tolerancing in CODE V, Slide-35

 User Tolerancing - Demonstration

Tolerancing in CODE V, Slide-36

 Review: Pros of TOR
+Provides information about individual
tolerance sensitivities
• Like Finite Differences tolerancing
+Provides accurate performance prediction
since cross-terms are included
• Like Monte Carlo tolerancing
+Method requires only a single “analysis”
(ray trace) of the nominal system
• Can be 50x to 1000x faster than Finite
Differences or Monte Carlo
The speed of the wavefront differential algorithm
allows tolerancing to become part of the design
process, not just an end-of-the-project analysis

Tolerancing in CODE V, Slide-37

 Summary
• Tolerancing is a critical step in the optical
design of systems that will be built

• CODE V’s wavefront differential tolerancing

feature, TOR, is fast and accurate
– Allows tolerancing to be done early and often
during the design process

• CODE V’s finite difference and Monte Carlo

based tolerancing are available for
performance metrics not handled by TOR

Tolerancing in CODE V, Slide-38