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Measurement
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a r t i c l e i n f o a b s t r a c t
Article history: An overview of the current status of angle metrology at the Physikalisch-Technische
Available online 14 May 2015 Bundesanstalt (PTB), the national metrology institute of Germany, is provided. We present
our novel self-calibration method for the fast and precise in-situ calibration of angle enco-
Keywords: ders without recourse to external reference standards which relies on a suitable geometric
Angle measurement arrangement of multiple heads which read out the radial grating of the encoder. Additional
Angle standard progress has been achieved by adapting an advanced error-separating shearing technique
Angle encoder
to angle metrology. This technique, by applying defined angle offsets between two angle
Autocollimator
Traceability
measuring devices, offers a unique opportunity to cross-calibrate both devices indepen-
Key comparison dently of external standards. We also present progress in the development of a novel
device for the precise and traceable calibration of spatial angles, the Spatial Angle
Autocollimator Calibrator (SAAC). Finally, we report on the status of the first European
Association of National Metrology Institutes (EURAMET) Key Comparison on autocollima-
tor calibration.
Ó 2015 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.measurement.2015.05.010
0263-2241/Ó 2015 Elsevier Ltd. All rights reserved.
232 R.D. Geckeler et al. / Measurement 73 (2015) 231–238
Fig. 4. Lateral shifting of the encoder’s grating at the nm-level during one
Fig. 3. Results of the in situ self-calibration of the WMT 220. Graduation full rotation for the angle comparator WMT 220.
errors of the radial grating registered by a single reading head (a, upper
graph) and after averaging over the eight primary reading heads (b, lower
graph) are shown. secondary angle encoder or a polygon). As part of the fam-
ily of circle division methods, self-calibration is based on
the subdivision of the full circle and makes use of circle
heads in the self calibration analysis [2]. To this purpose, closure, expressing the fact that the sum of the angles of
after self-calibration, the measurement data by the reading a divided circle in a plane equals 2p rad. The full circle
heads are corrected for the graduation errors of the enco- therefore represents the fundamental, error-free angular
der’s grating. Modelling of the resulting residuals allows standard and thus provides independence from external
deriving the grating’s lateral shift by fitting the model to reference standards. This makes self-calibration ideally
the data, see Fig. 4. suited for primary angle standards. Furthermore, in com-
Taking this information into account, the parison to cross-calibration, it is fast and therefore ideally
self-calibration analysis can then be repeated iteratively suited for industrial applications.
to derive a more accurate estimate of the graduation errors Please note that the self-calibration algorithms devel-
of the encoder’s grating. This iterative approach is feasible oped in [2] do not depend on the special arrangement of
due to the small magnitude of the influence of the axis’ lat- reading heads presented in Section 2.1 but can be applied
eral shift on the reading head’s angle measurements when universally. An infinite number of viable reading head
compared to the influence of the grating’s dominant grad- arrangements, starting with a minimal number of three
uation errors (in case of the WMT 220, two orders of mag- heads, can be realised, albeit with differing error propaga-
nitude). Note that, during operation of the WMT 220, the tion properties. Work on the general properties of viable
measurements by the eight primary reading heads are reading head arrangements with optimal error propaga-
averaged which, due to their regular spacing, effectively tion is in progress.
eliminates the influence of the grating’s lateral shifts on
the average.
Our method proved to be capable of the fast and precise 2.3. Interpolation errors
in situ calibration of angle encoders, independent of any
external standards. It is one of those techniques which Our self-calibration method successfully evaluates the
have been developed for the self-calibration [2,4–10] and graduation errors of the encoder’s grating at regularly sam-
cross-calibration [11–14] of angle encoders. They, in turn, pled points over 2p rad. At much smaller angular scales of
are part of a wider class of reversal techniques in which the order of a few arcsec, interpolation errors become rel-
measurements are set up in such a way as to provide evant. Interpolation errors result from the subdivision of
redundant data sets which allow them to separate and the angular intervals between the grating’s graduation
eliminate errors [15]. lines by the reading heads’ electronics to obtain a larger
Self-calibration offers a number of advantages, foremost effective resolution (in the case of the WMT 220, by a fac-
that it is independent of auxiliary devices (such as, e.g., a tor of 212). Progress has been achieved in this field as we
234 R.D. Geckeler et al. / Measurement 73 (2015) 231–238
have adapted an advanced error-separating shearing tech- autocollimator type Elcomat HR, Möller–Wedel Optical.
nique [16–18] to angle metrology and tested it experimen- The measurement errors of the encoder presented in
tally [19]. It proved to be ideally suited for the calibration Fig. 6b are of the order of 1 milliarcsec rms and are domi-
of interpolation errors of angle-measuring devices at small nated by its residual interpolation errors which result from
angular scales which are difficult to characterise with other the subdivision of the angular intervals between the grat-
methods. ing’s graduation lines by the reading heads’ electronics.
This technique, by comparing the angle readings of an The measurement errors of the autocollimator presented
autocollimator and an angle encoder in different relative in Fig. 6a at the smallest angular scales are dominated by
angular orientations, offers a unique opportunity to sepa- analogous interpolation errors which result from the sub-
rate the errors of the two angle-measuring systems and, division of the angular interval which corresponds to the
therefore, to calibrate both systems without recourse to size of the pixels of the CCD detector used in this device.
any external standard. The non-linear errors of the two
devices can be recovered, up to their linear components, 3. Autocollimators
from a set of three comparisons. In the case that the linear
components of the errors are needed, too, only two angle 3.1. Autocollimator calibration – plane angle
differences, which correspond to the changes in the rela-
tive angular orientations of the devices, need to be traced In Fig. 1, the measurement set-up for the calibration of
back to an external standard. In [19], we demonstrate an electronic autocollimator against the primary angle
error-separation with a standard measurement uncer- standard of the PTB, the angle comparator WMT 220 is pre-
tainty at a level of 1 milliarcsec (5 nrad) which beats sented. The calibration can be realised against coated or
uncertainties reachable by conventional calibration meth- uncoated mirrors and by using the full autocollimator
ods for autocollimators by a factor of two to three. aperture or an aperture stop. The position and the size of
Figs. 5 and 6 present the results of such a shearing anal- the aperture stop are variable. The calibration can be car-
ysis. The angle measuring devices consisted of the ried out in a limited range of fixed distances (250–
high-precision angle comparator WMT 220 and an 550 mm) between autocollimator and mirror.
Fig. 5. Data sets used for the shearing analysis (black lines) and residuals (blue lines) after correcting them for the reconstructed measurement errors of the
autocollimator and of the WMT 220. Each panel shows the comparison of the autocollimator to the WMT 220 performed in a different relative angular
orientation of both devices. (For interpretation of the references to colour in this figure legend, the reader is referred to the web version of this article.)
R.D. Geckeler et al. / Measurement 73 (2015) 231–238 235
Fig. 6. Reconstructed measurement errors of the autocollimator (a, upper The factors influencing the angle response/calibration
graph) and of the encoder (b, lower graph) obtained by the shearing of an autocollimator can be sub-divided into two broad
analysis of the data presented in Fig. 4. categories: external vs. internal. External factors are given
by the measuring conditions under which the device is
used (and can thus be specified by the user). These include:
Typically, a calibration consists of measurements in for-
ward and backward direction (to eliminate possible linear SUT reflectivity
drifts) and repeat measurements in three different relative SUT curvature
positions between the autocollimator and the WMT 220 Distance (path length) to the SUT
(to eliminate residual angle deviations of the WMT 220), Diameter and shape of the aperture stop
all realised under automatic computer control. The air path Position of the aperture stop along the autocollimator’s
between the autocollimator and the plane mirror does not optical axis
need to be specially shielded as the constant ambient tem- Position of the aperture stop perpendicular to the opti-
perature and the laminar air flow at the clean room facility cal axis
do not exert any significant disturbing influences. For more
information on autocollimator calibration at the PTB, see Internal factors are specific to each autocollimator’s
[20]. internal design (and are therefore generally beyond user
Using highly stable autocollimators, calibrations with control):
standard measurement uncertainties of u = 0.003 arcsec
(15 nrad) have been achieved. Note that, in addition to Aberrations of the optical components (autocollimator’s
the uncertainty contribution by the WMT 220, the uncer- objective, reticle illumination, beam splitter cubes . . .)
tainty of the autocollimator calibration includes compo- Alignment of the components, including the detector
nents which depend on the type of autocollimator and Non-orthogonality of the measuring axes
the calibration parameters. The later contributions usually Internal specular reflections and stray light
dominate the final uncertainty budget and may result in an Geometrical imperfections of the reticles
uncertainty for the autocollimator calibration larger than Inter-pixel variations of the CCD (geometry, quantum
the value stated above. In contrast, the uncertainty contri- efficiency, dark current . . .)
bution of the primary angle standard WMT 220 is of subor- Intra-pixel quantum efficiency pattern (across single
dinate importance. CCD pixels, due to their internal structure)
autocollimator’s angle response are occurring. However, if adequately. Therefore, the experimental characterisation
aberrations of the optical components and errors in their of its influence on the autocollimator’s angle measurement
alignment (and that of the CCD detector) are present, angle is part of EMRP SIB 58 Angle Metrology.
measuring deviations are introduced which are a function
of the SUT’s distance/path length [22]. These deviations 3.3. Autocollimator calibration – spatial angles
become more prominent as the product of the deflection
angle and the distance from the SUT increases. (Note that In most autocollimator applications (e.g., deflectometric
when the SUT is located at a distance equal to the objec- profilometry or the measurement of machine geometries –
tive’s focal length, angle measuring errors due to aberra- straightness, flatness, and parallelism – in precision engi-
tions and alignment errors are minimised.) neering), both of the autocollimator’s measuring axes are
Influences of the path length on the autocollimator’s engaged simultaneously, i.e., the autocollimator beam is
angle response are of special importance to deflectometric deflected in two orthogonal angular directions by the
profilometers, where the length of the beam to the SUT SUT. The simultaneous engagement of both axes results
changes by the entire scanning length (up to 1.2 m) as dif- in crosstalk between them, i.e., their angle measurements
ferent points on the optical surface are accessed by a mov- are not independent of each other. Reasons for this include
able pentaprism. The same holds true for applications in optical aberrations and alignment errors of the autocolli-
precision engineering (e.g., the measurement of machine mator’s internal components, as well as imperfections of
geometries) where path length changes also occur. In the the reticles which are imaged onto the autocollimator’s
case of deflectometric profilometers, this effect causes CCD. This influence has not yet been investigated in detail
the dominant uncertainty component in the form mea- and a systematic effort to characterise it is essential for
surement of extended, highly curved optical surfaces. advancing angle metrology with autocollimators.
Several solutions to this problem have been proposed The multiple challenges of traceable autocollimator cal-
[23,24]. ibration for spatial angles resulted in the development of a
We also would like to mention the influence of environ- novel concept and the realisation of a device for the precise
mental conditions, e.g., beam refraction by gradients in the and traceable calibration of spatial angles at PTB, the
air’s refractive index, which may lead to angle errors if the Spatial Angle Autocollimator Calibrator (SAAC) [27]. It
distance to the SUT is changing. Temperature and pressure makes use of an innovative Cartesian arrangement of three
are the most important parameters influencing the refrac- autocollimators (two reference autocollimators and the
tive index of air. autocollimator to be calibrated) facing a reflector cube on
a precision tilting stage. Each of the two reference autocol-
3.2.2. SUT curvature limators, which are used for the measurement of the cube’s
Most synchrotron and Free Electron Laser (FEL) beam- angular orientation, is primarily sensitive to rotations of
line optics feature strong and locally varying curvatures the cube around one of the two relevant axes. They can
of the SUT which affect both the location and the quality thus be calibrated and traced back to PTB’s national pri-
of the image of the autocollimator’s reticle on the CCD mary standard for the plane angle in a conventional
detector. Beamline optics even exhibit different radii of manner.
curvature in longitudinal and sagittal directions. Even Fig. 7 shows the complete SAAC set-up which is
polygon calibrations, where differences in the topogra- installed in PTB’s clean-room facility and thus operates
phies of the optical faces are far smaller, are affected by under favourable environmental conditions, such as a
the faces’ flatness deviations. Therefore, a systematic effort highly stable ambient temperature (DT < 0.05 K) and a
to characterise the influence of the SUT’s curvature is constant laminar air flow (v = 20 cm/s). For vibration isola-
essential for advancing deflectometric form measurement. tion, it is mounted on the concrete basement which is sep-
It was therefore chosen to be part of the European arated from the walkable floor and, additionally, passive
Metrology Research Programme (EMRP) Joint Research vibration dampening has been added to the six support
Project (JRP) SIB 58 Angle Metrology [25]. feet. The SAAC is supported by three pairs of
vibration-isolated legs (gimbal piston isolators by TMC,
3.2.3. SUT reflectivity Peabody, MA, USA) which effectively form a three-point
Optical surfaces of different reflectivity (e.g., coated and bearing. To avoid resonances of the whole structure, the
uncoated quartz, Zerodur, silicone, etc.) are commonly in base length between the opposite legs has been extended
use. The reflectivity of the SUT and the aperture size influ- by steel beams on which the granite base is mounted.
ence the autocollimator’s angle response by causing, e.g., The base of the SAAC is a massive granite plate (dimen-
changes in the signal-to-noise ratio (SNR) of the detected sion: L B H 2950 850 400 mm3, weight: 3 tons).
image, internal reflections, and stray light [21,26]. Some The autocollimators form a Cartesian arrangement: both
autocollimators adapt their light output to compensate reference autocollimators are adjustable mounted to a
for differing reflectivity which may mitigate some prob- massive granite bridge, the autocollimator to be calibrated
lems (e.g., SNR changes) while aggravating others (e.g., is placed on an air-bearing based, movable table top
internal reflections). Generally, due to differing sensitivi- (500 500 mm2). This allows for flexibly varying the dis-
ties to changes in SUT reflectivity and aperture size, differ- tance between the reflector cube and the autocollimator
ent types of errors cannot be minimised simultaneously by to be calibrated from 200 to 1500 mm. A positioning accu-
a well chosen set of parameters. Ray tracing simulations racy of <1 mm was requested which is easily met by the
are difficult as stray light influences cannot be modelled utilised incremental length measuring system LIP 300 by
R.D. Geckeler et al. / Measurement 73 (2015) 231–238 237
Fig. 8. The precision two-axis tilting unit of the SAAC. Reflector cube (1),
counterweights (2, 3), two stacked air-bearing rotational axes (4, 5), voice
coil actuator (two per axis, four in total) (6).
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Institutes (EURAMET) and the European Union.
[25] http://www.anglemetrology.com/.
[26] R.D. Geckeler, A. Just, Optimized use and calibration of
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