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2018/11/9Lenstolerances:Softwareeliminatestheguesswork-LaserFocusWorld
Lenstolerances:Softwareeliminatesthe
guesswork
04/01/2007
DonaldC.Dilworth
SomeyearsagoIdesignedasmallhigh-resolutionprojectionlens.Thetoleranceswere
tight,andsomeelementshadtobecenteredtowithin10µm.Thedrawingswenttoan
offshorecompany,andwhenthelensescamebacktheydidnotwork.Thevendorhad
designedthecellintwopartsthatscrewedtogether,butthethreadswerenotconcentric
withthelenses.Youcouldfeelthedecenterwithyourfingersinsomecases.Ireportedthe
errortotheshop,buttheyrepliedangrily,insultedthatIhadcriticizedtheirwork.Another
time,lensescamebackfromashopanddidnotworkproperly.Aftertwomonthsof
strenuousdenial,theshopfinallyadmittedthatthepartswerefaroutofspec.
Whilewedonotexpectlensmanufacturerstobeskilledmathematicians,theyneedto
understandthatthereisasciencebehindthetolerancesonthedrawings.Theseexamples
showthatsomedonot.Theyarenotentirelytoblame.
Beforethedevelopmentofmodernlens-designsoftware,designersassignedtolerancesto
lensdimensionsfollowingarule-of-thumbprocedureinvolvingmoreguessworkthan
calculation.Afewstilldo.Somedesignerscalculatetolerancesbyfirstgettinginverse
sensitivities,whichgivetheamountbywhicheachvariablecanbeinerrorandstillmeet
theperformancespecifications.Thentheydividethosenumbersbythesquarerootofthe
totalnumberofvariables,andthatisthebudget.
Thisprocedureisbetterthantherule-of-thumbapproach,butstillnotrigorousbymodern
standards.Thatbudgetisproperonlyincaseswhereonewouldinvariablyfindeach
parameterinerrorbyexactlytheassignedtoler
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