1. Introduction
Heterodyne laser interferometers are widely applied in precision metrology, nanotechnology, and lithography due to their high accuracy and robustness [
1,
2,
3]. With the development of science and technology, it is badly in need of laser interferometers with picometer accuracy [
4] such as the next-generation laser interferometers. However, the improvement of the measurement accuracy of heterodyne laser interferometers is seriously restricted by the nonlinearity [
5,
6,
7], i.e., the periodic nonlinear error. The measurement method of nonlinearity as an indispensable auxiliary tool plays an essential role in developing the next-generation laser interferometers.
Several methods for measuring the nonlinearity of heterodyne laser interferometers have been developed [
8,
9,
10]. The most widely used method is the frequency domain method [
8]. This method is simple and convenient to operate, but it is only applicable to the cases with constant velocity. Moreover, limited by the background noise of the spectrometer, picometer accuracy is not available for this method. Another method is the displacement comparison method [
9] when compared to an identical displacement. By subtracting the result of an X-ray interferometer from that of a laser interferometer, the nonlinearity can be obtained. Picometer accuracy is easily achieved by this method while the X-ray interferometer is difficult to be replicated due to technique and cost issues and the measurement process is complex because of the special property of X-rays. Benefited from lock-in amplification, the phase quadrature measurement method [
10] is promising in a nonlinearity measurement up to picometer accuracy. In this method, the reference signal of the interferometer serves as the external reference signal of a lock-in amplifier in which there is a phase-locked loop that tracks the frequency of the external reference signal. Then a pair of quadrature signals with the same frequency are generated internally for the phase demodulation. The frequency of the external reference signal is expected to keep constant or to vary slowly. Otherwise, the phase-locked loop might work in the tracing state rather than the locked state [
11], which will cause an error for phase demodulation. For the traditional heterodyne laser interferometers, the frequency of the reference signal is of constant frequency, i.e., the split frequency of the laser source, so there is no such problem. For the next generation heterodyne laser interferometers [
12,
13], most of them adopt an optical configuration with bidirectional Doppler frequency shift (DFS), i.e., the measurement and reference signals have equal DFS but come with an opposite sign. When the target is in fast and non-uniform motion, the frequency of the reference signal will change rapidly. In this case, the existing phase quadrature measurement method is not applicable.
This paper presents a novel measurement method for nonlinearity in heterodyne laser interferometers, which adopts the architecture of double-channel quadrature demodulation with internal references and, thereby, is able to break through the limits in type of heterodyne laser interferometers and in motion state of the target. In addition, the phase differential algorithm is utilized to improve the computing efficiency. Experiments are carried out to verify the performance of the proposed method.
2. Measurement Method for Nonlinearity Based on Double-Channel Quadrature Demodulation
The nonlinearity in heterodyne laser interferometers originates from the frequency mixing in the reference and measurement arms [
14,
15,
16]. In recent years, to avoid the nonlinearity, heterodyne interferometers with spatially separated optical paths have been developed [
12,
13]. In this kind of interferometers, the reference and measurement beams with slightly different frequencies are separated spatially before interference. In theory, there is no frequency mixing and, thereby, the nonlinearity can be completely avoided. However, an experimental study reveals that there is still nonlinearity in this kind of interferometer and its source is ascribed to the multi-order DFS induced by ghost reflection [
17,
18], i.e., the laser beams are repeatedly reflected between the beam splitter and the target. To improve the resolution by a factor of two, this kind of heterodyne laser interferometer usually adopts an optical layout with bidirectional DFS.
Figure 1 shows the schematic of the formation mechanism of the reference and measurement signals in this type of interferometer. Considering the multi-order DFS, the reference and measurement signals can be expressed by the equation below.
where
A and
B are the amplitudes of the intended reference and measurement signals, respectively.
and
are the amplitudes of the
mth and
nth order nonlinear harmonics in the reference and measurement signals, respectively, generally
and
.
is the beat frequency,
and
are the optical frequencies of the dual-frequency laser source.
= −(
m + 1)
and
= (
n + 1)
.
is the measured phase and can be calculated by using Equation (2).
where
is the DFS.
As indicated by Equation (1), the reference and measurement signals for the new type interferometer have equal DFS but come with an opposite sign. Therefore, the frequency of the reference signal is also determined by the motion state of the target. When the target is in non-uniform motion, the frequency of the reference signal is not constant. As mentioned above, in this case, the existing phase quadrature measurement method is not applicable. To solve this problem, a novel measurement method of nonlinearity based on a double-channel quadrature demodulation is presented, which is illustrated in
Figure 2. This is realized in the field programmable gate array (FPGA). Compared with the traditional phase quadrature measurement method, there are two key distinctions. The first distinction is that the traditional method is based on a single lock-in amplifier while the new method adopted two lock-in amplifiers (a lock-in amplifier mainly consists of two mixers and two low pass filters). The second distinction is that, in the traditional method, the reference signal of the interferometer serves as the external reference of the lock-in amplifier while, in the new method, the external reference signal is abandoned. Instead, a pair of quadrature signals generated inside the FPGA are used as the reference signals of the lock-in amplifiers and both the reference and measurement signals of the interferometer serve as the measurement signals of the two amplifiers.
The two quadrature signals generated inside the FPGA can be expressed as
and
where
is the angular frequency. As shown in
Figure 2, in the first step, the internally generated quadrature signals are mixed with reference and measurement signals of the heterodyne interferometer, respectively. This operation is performed by four mixers. After low pass filtering, the output of the mixers can be expressed by the equation below.
Based on Equation (3), the cosine component
C(
t) and sine component
S(
t) can be calculated using the formula below.
then the amplitude and phase can be calculated using Equations (5) and (6).
and
As the reference and measurement signals,
Im and
Ir have equal but opposite DFS. The theoretical phase difference between them is
. Therefore, the measurement error of phase is shown below.
By using the first order approximation of the Taylor expansion for Equation (6), Equation (7) is expressed by the formula below.
Similarly,
R(
t)/
R(
t) can be expressed by the equation below.
where
is the amplitude when
. Equations (8) and (9) are similar in mathematical expressions except for a 90° phase delay. Thus, in real applications, to evaluate the nonlinearity, we can calculate
R(
t)
/R(
t) rather than
since the calculation of
R(
t)/
R(
t) are much easier to realize in practical applications. As shown by Equation (7), to calculate the phase error
, it is necessary to know the real phase
. However, this is not easy to realize in practical applications because it is extremely difficult to provide a controlled displacement at nanometer or sub-nanometer level. Actually, in most of the practical applications, the real phase is an unknown value. However, for calculating
, it is not necessary to know the real phase. To evaluate the system nonlinearity, the phase delay is a negligible factor. Therefore, the nonlinearity can be calculated by the equation below.
where
M is the optical fold factor and
is the laser wavelength for the heterodyne laser interferometers with bidirectional DFS,
M = 4. For digital signals,
R(
t)/
R(
t) can be calculated by the formula below.
where
The above analysis shows the overall procedure of the proposed method for measuring the nonlinearity in heterodyne laser interferometers. By adopting internal references for the lock-in amplifiers, this method avoids the problems induced by frequency variation of external references, which means it is no longer limited by the motion state of the target. By utilizing double-channel quadrature demodulation, the method can be applied extensively to the new type heterodyne laser interferometers with bidirectional DFS. In addition, for phase demodulation, it is not a simple subtraction of the measured phases of the two lock-in amplifiers. Instead, the phase differential algorithm is employed to improve computing efficiency.