Ultra-low-distortion optical system design based on tolerance sensitivity optimization

This study theoretically analyzed the relationship between the primary aberrations and tolerances to meet the distortion requirements of an ultra-low-distortion optical system. Theoretical analysis shows that the distortion sensitivities of the optical system are related to the primary aberrations of the optical surfaces. Consequently, a method of optimizing the primary aberrations on the surface of the optical system to reduce the distortion sensitivities of sensitive tolerances is proposed. A distortion sensitivity analysis of manufacturing and assembly tolerance was carried out for the designed ultra-low-distortion and telecentric optical system. The distortion sensitivities of the sensitive tolerances were reduced by optimizing the primary aberrations on the surface of the optical system. A Monte Carlo analysis of the optimized ultra-low-distortion optical system showed that the proposed method has a remarkable effect on the distortion sensitivity optimization of the tolerances.