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<p>In the Roll-to-Roll (R2R) manufacturing of high-quality Fresnel lens films, the precision of the roller mold is crucial for accurate replication of the Fresnel lens from the mold surface to a flexible substrate. However, the substantial mass and length of the roller mold present significant challenges for conventional offline measurement instruments in accurately assessing the three-dimensional profile of the radial Fresnel lens on the mold surface. This study proposes an innovative on-machine measurement system employing a chromatic confocal sensor to overcome these limitations. The system integrates position-synchronized output (PSO) technology with a spiral scanning trajectory, markedly enhancing data acquisition and processing efficiency. This approach aims to enable real-time quality control during the machining process of Fresnel structures on roller molds, thereby improving production efficiency and machining precision. To assess the system's performance, profile sections measured in situ were compared against reference measurements obtained using a Taylor Hobson PGI1240 profilometer. The high correlation between the two sets of results validates the accuracy and reliability of the proposed on-machine measurement system.</p>

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Development of an On-Machine Measurement System for the 3D Profile of Radial Fresnel Lens of Roller Mold

  • 期刊论文

  • 发表日期：

    2025年1月3日

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  • Songtao Meng,
  • Feiyu Fang,
  • Ning Chai,
  • Senbin Xia,
  • Chao Li

摘要

In the Roll-to-Roll (R2R) manufacturing of high-quality Fresnel lens films, the precision of the roller mold is crucial for accurate replication of the Fresnel lens from the mold surface to a flexible substrate. However, the substantial mass and length of the roller mold present significant challenges for conventional offline measurement instruments in accurately assessing the three-dimensional profile of the radial Fresnel lens on the mold surface. This study proposes an innovative on-machine measurement system employing a chromatic confocal sensor to overcome these limitations. The system integrates position-synchronized output (PSO) technology with a spiral scanning trajectory, markedly enhancing data acquisition and processing efficiency. This approach aims to enable real-time quality control during the machining process of Fresnel structures on roller molds, thereby improving production efficiency and machining precision. To assess the system's performance, profile sections measured in situ were compared against reference measurements obtained using a Taylor Hobson PGI1240 profilometer. The high correlation between the two sets of results validates the accuracy and reliability of the proposed on-machine measurement system.