Design and fabrication of an off-axis four-mirror system for head-up displays

Holographic multiplane augmented reality head-up display with switchable display modes based on polymer dispersed liquid crystal

The multiplane augmented reality (AR) head-up display (HUD) is important in improving driving safety and comfort. In this paper, we propose an AR-HUD with switchable display modes based on polymer dispersed liquid crystal (PDLC) and lens holographic optical elements (HOEs), which can provide two display modes: the dual-virtual-image mode and the virtual-real-image mode. The dual-virtual-image mode can produce two virtual images at different depths, which can provide a better sense of reality integration for the driver to improve driving safety and comfort. The virtual-real-image mode can produce one far virtual image and one near real image at different depths, and it provides a larger eye box (EB) for both driver and passengers in the car and a higher image contrast. The two display modes can be switched by an electronically controlled scattering module consisting of a pair of PDLC films. The proposed AR-HUD system is compact and equipped with multiplane display and mode-switching functions, and is expected to be applied in the future.

Lissajous MEMS laser beam scanner with uniform and high fill-factor projection for augmented reality display

MEMS Laser beam scanning (LBS) has been identified as a key advancement for augmented reality (AR) displays due to its ability to create compact optical systems that generate bright, high-contrast images with minimal heat dissipation. This innovation can be attributed to the focus-free, efficient light-on-demand pixel projection mechanisms integral to LBS. The LBS, specifically in Lissajous-mode, outperforms the raster-mode in terms of larger scan angles and stability to external vibrations, by leveraging a MEMS mirror operating at bi-axial resonance. However, it tends to be hampered by small mirror aperture, low fill-factor, and inconsistent uniformity of image projection. In this research, a unique gimbal-less Lissajous MEMS scanner was proposed. It employs a bi-axial high frequency of 12,255 Hz and 7,182 Hz to achieve a resolution of 640 × 360 pixels and a video refresh rate of 57 Hz, all while maintaining a high image fill factor of 85.11%. The robust structure of the mirror is proven to sustain stable scanning under broad spectrum of external vibration disturbance up to 2,000 Hz. Furthermore, the large mirror diameter of 2 mm improves refined pixel projection and increased optical etendue for exit pupil. Mathematic model of Lissajous pixel-cells and image reconstruction simulation were established to validate the LBS's ability to generate a uniform and densely pixelated visual effect that fits for typical AR head-up display (AR-HUD). In a pioneering move, performance metric of figure-of-merit was defined to evaluate AR light-engines using varied picture-generation techniques, laying a foundation for guiding future AR system development.

Cooled infrared coaxial four-mirror system design with a low F-number

A low F-number and 100% cold stop efficiency are beneficial for improving the performance of optical systems and have a wide range of applications in various thermal imaging scenarios. The cooled infrared coaxial four-mirror system can meet these two requirements, improve system integration, and reduce adjustment costs and difficulties. However, the secondary obstruction caused by the central hole of the third mirror will generate potential stray light. A structure model is proposed in which the primary mirror and the quaternary mirror are processed on the same mirror blank. In this model, a method is given to calculate system parameters using the obstruction ratio and magnification of each mirror. To evaluate the performance of the method, two design examples with different F-numbers (1.4, 1.0) were constructed. The influence of initial structural constraints on the exit pupil position and secondary obstruction was analyzed based on the design objectives of the examples. The aberrations were optimized by targeting the spot. In the optimization process, the incident coordinates and directions of the restricted edge field rays in the tertiary mirror and the quaternary mirror were limited to achieve control of the obstruction caused by the holes in the center of the mirrors. In the results, the RMS spot radius of the two design examples is smaller than the Airy disk radius, and the axial beam wavefront deviation RMS values are 0.026λ and 0.024λ, respectively. Moreover, the obstruction caused by the central holes of the mirrors is controlled within the given field of view. The results show that the proposed model and method can be used to design a low F-number cooled infrared coaxial four-mirror system and have good application prospects.

Design of compact off-axis freeform imaging systems based on optical-digital joint optimization

Using a freeform optical surface can effectively reduce the imaging system weight and volume while maintaining good performance and advanced system specifications. But it is still very difficult for traditional freeform surface design when ultra-small system volume or ultra-few elements are required. Considering the images generated by the system can be recovered by digital image processing, in this paper, we proposed a design method of compact and simplified off-axis freeform imaging systems using optical-digital joint design process, which fully integrates the design of a geometric freeform system and the image recovery neural network. This design method works for off-axis nonsymmetric system structure and multiple freeform surfaces with complicated surface expression. The overall design framework, ray tracing, image simulation and recovery, and loss function establishment are demonstrated. We use two design examples to show the feasibility and effect of the framework. One is a freeform three-mirror system with a much smaller volume than a traditional freeform three-mirror reference design. The other is a freeform two-mirror system whose element number is reduced compared with the three-mirror system. Ultra-compact and/or simplified freeform system structure as well as good output recovered images can be realized.

Automated design of freeform imaging systems for automotive heads-up display applications

The freeform imaging system is playing a significant role in developing an optical system for the automotive heads-up display (HUD), which is a typical application of augmented reality (AR) technology. There exists a strong necessity to develop automated design algorithms for automotive HUDs due to its high complexity of multi-configuration caused by movable eyeballs as well as various drivers' heights, correcting additional aberrations introduced by the windshield, variable structure constraints originated from automobile types, which, however, is lacking in current research community. In this paper, we propose an automated design method for the automotive AR-HUD optical systems with two freeform surfaces as well as an arbitrary type of windshield. With optical specifications of sagittal and tangential focal lengths, and required structure constraints, our given design method can generate initial structures with different optical structures with high image quality automatically for adjusting the mechanical constructions of different types of cars. And then the final system can be realized by our proposed iterative optimization algorithms with superior performances due to the extraordinary starting point. We first present the design of a common two-mirror HUD system with longitudinal and lateral structures with high optical performances. Moreover, several typical double mirror off-axis layouts for HUDs were analyzed from the aspects of imaging performances and volumes. The most suitable layout scheme for a future two-mirror HUD is selected. The optical performance of all the proposed AR-HUD designs for an eye-box of 130 mm × 50 mm and a field of view of 13° × 5° is superior, demonstrating the feasibility and superiority of the proposed design framework. The flexibility of the proposed work for generating different optical configurations can largely reduce the efforts for the HUD design of different automotive types.

Designing reflective imaging systems with multiple-surfaces-integrated elements using a Gaussian function freeform surface

We propose a design scheme and method of a freeform off-axis reflective imaging system with multiple mirrors integrated into one element. The use of a multiple-surfaces-integrated element, described by the Gaussian basis functions freeform surface with local and nonsymmetric properties, significantly decreases the system complexity, as well as reduces the assembly and fabrication difficulty, and achieves high imaging performance. The design theory and process including the initial system design, surface conversion, and system optimization are demonstrated in detail. Three design examples are demonstrated to validate the effect and feasibility of the proposed method, and good imaging performance is obtained.

Evaluation of eye response using a wearable display with automatic interpupillary distance adjustment

In this study, we introduce a design for a near-eye, wearable display (HMD: head mounted display) that can automatically control the user's interpupillary distance (IPD). In addition, we demonstrate a test-bed module for the wearable AR display based on proposed design. Both the adjustment accuracy and the viewing effect through distance matching between the user's eyes are evaluated by the user's experience in actual wearing of the module. We demonstrate that the distance between the left and right eye pupils can be measured and adjusted using a set of IR camera sensors and a micro-actuator module that we proposed. A half-mirror unit to be mechanically controlled for each eye is designed to combine the image displayed from the projector and an image taken by the IR camera, leading to fine adjustment of the user's IPD. A set of images taken by the IR camera sensors is image-processed in real time to determine each pupil's position with high accuracy under infrared light illumination. Based on the measured information, a micro-actuator module we fabricated for the test bed can automatically adjust the binocular distance to fit each viewer's IPD. The maximum movement distance of each micro-actuator motor is ±10 mm with precision control of at least 0.5 mm. It takes about 18 seconds to calculate the user's IPD from two IR photographs and then to accurately adjust the actual binocular distance of the module that the participant wears. Using the demonstrated test bed, a total of 50 subjects participated to confirm the accuracy in the automatic IPD adjustment with an error of 0.25% as well as the improvement of the displayed image quality and 3D immersive experience.

Design method of wide field-of-view imaging systems using Gaussian radial basis functions freeform surfaces

High optical performance systems with wide field-of-view (FOV) have important applications in remote sensing. The radial basis functions, which have a prominent local characteristic in surface description, have attracted much attention in recent years. In this paper, an effective design method for the wide FOV imaging system using Gaussian radial basis function freeform surfaces is proposed. The FOV of the optical system is extended from a relatively small value to a larger one, and the Gaussian radial basis function surfaces are extended stepwise based on certain criteria. A high image quality and small distortion off-axis freeform three-mirror system with a wide FOV (${{60}}^\circ \times {0.6}^\circ$) is designed as an example. Tolerance analysis considering both surface figure error and assembly error is performed. The design results demonstrate the effectiveness of the proposed method.

Designing freeform imaging systems based on reinforcement learning

The design of complex freeform imaging systems with advanced system specification is often a tedious task that requires extensive human effort. In addition, the lack of design experience or expertise that result from the complex and uncertain nature of freeform optics, in addition to the limited history of usage, also contributes to the design difficulty. In this paper, we propose a design framework of freeform imaging systems using reinforcement learning. A trial-and-error method employing different design routes that use a successive optimization process is applied in different episodes under an ε-greedy policy. An "exploitation-exploration, evaluation and back-up" approach is used to interact with the environment and discover optimal policies. Design results with good imaging performance and related design routes can be found automatically. The design experience can be further summarized using the obtained data directly or through other methods such as clustering-based machine learning. The experience offers valuable insight for completing other related design tasks. Human effort can be significantly reduced in both the design process and the tedious process of summarizing experience. This design framework can be integrated into optical design software and runs nonstop in the background or on servers to complete design tasks and acquire experience automatically for various types of systems.