A Novel Dwell Time Modification Framework for Low Spatial Frequency Errors Suppression Under Complex Task Interactions in Optical Fabrication

Abstract

The manufacturing extremity and surface convergence efficiency of high-precision, large optical free-form surfaces produced through computer-controlled optical surfacing and industrial robotics face significant challenges. These challenges arise from task-related stiffness deficiencies of industrial robots and dynamic uncertainties in the tool influence function, which severely impact low spatial frequency (LSF) errors and the clarity of imaging in high-resolution optical systems. To address these issues and achieve consistent optical polishing outcomes, we propose a novel polishing dwell time modification framework. This framework is based on the spatial compliance field linked to the specific machining task and the Frenet frame, dynamically adjusting the polishing dwell time to mitigate LSF errors and enhance surface convergence efficiency. The efficacy of this modification framework was evaluated through a series of multilevel gradient experiments in Sim2Real machining environments. The experimental results show a significant reduction in low-frequency spatial errors, underscoring the potential of our approach to improve precision in high-resolution optical systems.