An astronaut helmet display device and process method

Abstract

An astronaut helmet display device adjusting device, a gantry support is used for supporting and positioning the remaining four function modules, a picture source adjusting mechanism is detachably mounted on the gantry support, used for carrying and adjusting the spatial posture and position of the picture source assembly in the astronaut helmet display device, a surface tool is detachably mounted on the gantry support, used for positioning and fixing a plurality of optical elements in the astronaut helmet display device, and ensuring the relative position relationship among them, a process goggles is detachably mounted on the gantry support, used for simulating the observation path of the human eye, forming a closed light path to evaluate the imaging quality. The application simulates the light path by constructing the picture source, the optical element and the process goggles under the unified reference, so that the internal imaging performance which cannot be detected after packaging can be intuitively evaluated before assembly, realizing the leap from "blind assembly" to "visible assembly and adjustment", and greatly reducing the risk of rework and scrap caused by assembly deviation.

Description

Technical Field

[0001] This invention belongs to the field of optomechanical assembly and adjustment technology, specifically an assembly and adjustment device and process method for an astronaut helmet display. Background Technology

[0002] As a crucial optomechanical device, the astronaut helmet-mounted display (HUD) receives external input signals, including display and control signals, and displays various types of information, such as images and videos, enhancing the astronaut's awareness of the flight situation. As an off-axis binocular imaging optical system, the HUD's optical display components are designed to be lightweight due to space and weight constraints within the spacesuit. The optical engine housing cannot provide a high-precision assembly reference, making it a significant challenge in the manufacturing process to ensure precise positional relationships between optical components and between optical components and structural components.

[0003] Therefore, an astronaut helmet display assembly and adjustment device and process method are provided to solve the above problems. Summary of the Invention

[0004] In view of the above situation and to overcome the defects of the prior art, the present invention provides an astronaut helmet display assembly and adjustment device and process method to at least partially solve the above technical problems.

[0005] The technical solution adopted in this invention is as follows:

[0006] This invention proposes an astronaut helmet display assembly and adjustment device, comprising:

[0007] Gantry bracket, image source adjustment mechanism, backing fixture, process goggles and eye positioning fixture;

[0008] The gantry support is used to support and position the other four functional modules. The image source adjustment mechanism is detachably mounted on the gantry support and is used to carry and adjust the spatial attitude and position of the image source components in the astronaut helmet display. The surface fixture is detachably mounted on the gantry support and is used to position and fix multiple optical elements in the astronaut helmet display and ensure their relative positional relationship. The process goggles are detachably mounted on the gantry support and are used to simulate the human eye observation path to form a closed optical path for evaluating image quality. The eye positioning fixture is set in front of the process goggles and is used to guide the operator to interpret the image quality in a standard observation position.

[0009] As a further embodiment of the present invention: the gantry support is composed of a support block 1(a), a column 1(b) and a reference plate 1(c). The support block 1(a) and the column 1(b) are fastened together by screws, and the column 1(b) and the reference plate 1(c) are fastened together by screws to form a stable portal frame structure.

[0010] The reference plate 1(c) is provided with multiple pre-machined pin holes, which serve as a unified reference for the installation of the image source adjustment mechanism, the surface tooling, and the process goggles, ensuring the consistency of the relative positions of each module in space.

[0011] As a further embodiment of the present invention: the image source adjustment mechanism mainly consists of an adjustment screw 2(a), a support frame 2(b), an elastic rope 2(c), and a mounting frame 2(d). The support frame 2(b) is rigidly connected to the reference plate 1(c) of the gantry bracket by screws and pins. The mounting frame 2(d) is used to install the image source assembly, and it is flexibly connected to the support frame 2(b) by at least two pre-tightened elastic ropes 2(c) to provide restoring force. Multiple adjustment screws 2(a) are distributed on the support frame 2(b) and contact the mounting frame 2(d). By adjusting the screwing depth of each adjustment screw 2(a), the tilt angle of the mounting frame 2(d) around the horizontal axis and the vertical axis, as well as the translation distance along the optical axis, can be independently controlled.

[0012] As a further embodiment of the present invention: the surface fixture has a left-right mirror symmetrical structure, corresponding to the left and right optical channels of the helmet display respectively;

[0013] Taking the left eye section as an example, the backing fixture consists of a left bracket 3(a), a mirror 1 bracket 3(b), a mirror 2 bracket 3(c), a mirror 3 bracket 3(d), and an upper housing fixture 3(e). The left bracket 3(a) is connected to the reference plate 1(c) of the gantry bracket by screws and pins, serving as the installation reference for the internal sub-components. The mirror bracket 3(b), mirror 2 bracket 3(c), mirror 3 bracket 3(d), and upper housing fixture 3(e) are all positioned and installed with the left bracket 3(a) as the reference, using screws and pins.

[0014] As a further aspect of the present invention: the support 3(b) for the mirror 1 is used to install the aspherical mirror 1, and its mating surface with the mirror 1 is conformal, and it is provided with two mating surfaces with different radii of curvature, so that the mirror 1 can achieve surface contact in at least two discrete regions.

[0015] As a further embodiment of the present invention: the process goggles consist of a lens mount 4(a) and a goggle 4(b). The goggle 4(b) is installed in the lens mount 4(a) by a centering clamp to ensure that the optical axis of the goggle 4(b) coincides with the mechanical axis of the lens mount 4(a). The lens mount 4(a) is fixedly connected to the reference plate 1(c) of the gantry bracket by screws and pins, so that the optical axis of the process goggles has a definite spatial position in the assembly and adjustment system, thereby forming an evaluable simulated optical path together with the surface tooling and the image source adjustment mechanism.

[0016] As a further aspect of the present invention: a process method for assembling and adjusting an astronaut helmet display, specifically including the following steps:

[0017] Step 1, Optical component positioning: Install and lock the surface fixture onto the reference plate 1 (c) of the gantry bracket using screws and pins. Install the optical components of mirror 1, mirror 2, and mirror 3 from the astronaut helmet display onto the corresponding mirror 1 bracket 3 (b), mirror 2 bracket 3 (c), and mirror 3 bracket 3 (d) of the surface fixture in sequence. Ensure the initial position of each optical component by relying on the machining of the surface fixture and the positioning of the pins, and temporarily fix them with screws.

[0018] Step 2, Image quality judgment and image source adjustment: Install the image source adjustment mechanism and the process goggles to the designated positions on the gantry bracket using screws and pins, install the image source assembly on the mounting bracket 2(d) of the image source adjustment mechanism, and power on the image source to make it emit light;

[0019] By operating the adjusting screw 2(a) on the image source adjustment mechanism, the attitude and position of the image source are adjusted so that the image emitted by it is formed at the process goggles after passing through the optical system, resulting in a clear, distortion-free image with parallax that meets the requirements.

[0020] The operator observes the image quality through the eye-positioning fixture. If the image quality meets the preset acceptance standard, the positional accuracy of the optical component is deemed qualified. Otherwise, the optical component must be disassembled and its installation status on the surface fixture must be readjusted, and this step must be repeated until the standard is met.

[0021] Step 3, Housing Encapsulation and Curing: After the positional accuracy of the optical components is verified to be qualified, the upper housing of the astronaut helmet display is installed on the upper housing fixture 3(e) of the surface fixture 3. The upper housing fixture 3(e) and the left bracket 3(a) are positioned by screws and pins, thereby ensuring that the upper housing and the positioned optical components have the correct relative position.

[0022] Apply a special adhesive evenly to the mating surface between the upper housing and the optical components, then press them together to fix them. After the adhesive has completely cured, bond the lower housing to the upper housing to complete the final encapsulation of the entire optical system.

[0023] As a further aspect of the present invention: In step two, the image source adjustment process follows the principle of coarse adjustment followed by fine adjustment. The Z-axis position of the image source is changed first by adjusting screw 2(a) so that it is approximately located near the theoretical focal plane of the optical system. Then, its pitch and yaw angles are finely adjusted to eliminate astigmatism and binocular parallax, and finally achieve the best focusing and alignment of the image in the entire field of view.

[0024] As a further aspect of the present invention: In step three, the type of adhesive, the amount applied, the application path, the pressing pressure, and the curing process parameters (temperature and time) are all preset and strictly controlled according to the characteristics of the adhesive material and structural requirements, to ensure that the bonded joint has sufficient mechanical strength, environmental stability, and long-term reliability, while preventing the adhesive from overflowing and contaminating the optical surface.

[0025] Implementing the embodiments of the present invention will have the following beneficial effects:

[0026] This embodiment enables open verification of a closed optical system. By constructing a simulated optical path under a unified standard for the image source, optical components, and process goggles, the internal imaging performance, which was originally impossible to detect after packaging, can be intuitively evaluated before assembly. Operators can directly interpret key indicators such as field of view, sharpness, distortion, and binocular parallax at a standard observation position using eye-positioning fixtures. This achieves a leap from "blind assembly" to "visual assembly and adjustment," significantly reducing the risk of rework and scrap due to assembly deviations.

[0027] This embodiment uses a combination of flexible suspension and multi-directional screw adjustment in the image source adjustment mechanism, which can perform micron-level precision adjustment of the image source's attitude and position without disassembling the optical components. As an "adjustable probe," it reverse-optimizes the optical path, effectively compensates for minor deviations in the manufacturing and assembly process, improves the system's tolerance to processing tolerances, and ensures that the final imaging quality reaches its limit.

[0028] This embodiment uses a hierarchical reference transfer and conformal multi-point contact through a surface tooling, which not only ensures the relative positional accuracy between multiple optical elements, but also achieves stable positioning with low stress and high constraint, especially for complex surface-shaped aspherical mirrors. This avoids the redundancy of degrees of freedom and surface distortion caused by traditional point contact, and improves the structural stability and environmental adaptability of the optical system.

[0029] The above overview is for illustrative purposes only and is not intended to be limiting in any way. In addition to the illustrative aspects, embodiments, and features described above, further aspects, embodiments, and features of the invention will become readily apparent from the accompanying drawings and the following detailed description. Attached Figure Description

[0030] To more clearly illustrate the technical solutions in the embodiments of this application or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of this application. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0031] Figure 1 This is a schematic diagram of the astronaut helmet display assembly and adjustment device proposed in an embodiment of the present invention;

[0032] Figure 2 This is a schematic diagram of the gantry bracket of the astronaut helmet display assembly and adjustment device proposed in an embodiment of the present invention;

[0033] Figure 3This is a schematic diagram of the image source adjustment mechanism of the astronaut helmet display assembly and adjustment device proposed in an embodiment of the present invention;

[0034] Figure 4 This is a schematic diagram of the components of the mounting and adjusting device for an astronaut helmet display proposed in an embodiment of the present invention.

[0035] Figure 5 This is a schematic diagram of the positioning of the first optical component of the astronaut helmet display assembly and adjustment device proposed in an embodiment of the present invention;

[0036] Figure 6 This is a schematic diagram of the positioning of the second optical component of the astronaut helmet display assembly and adjustment device proposed in an embodiment of the present invention;

[0037] Figure 7 This is a schematic diagram of the process goggles of the astronaut helmet display assembly and adjustment device proposed in an embodiment of the present invention.

[0038] In the diagram: 1. Gantry support; 2. Image source adjustment mechanism; 3. Backrest fixture; 4. Process goggles; 5. Eye positioning fixture; 6. Helmet display;

[0039] 1(a) Support block; 1(b) Column; 1(c) Base plate;

[0040] 2(a) Screws; 2(b) Support frame; 2(c) Elastic rope; 2(d) Mounting bracket;

[0041] 3(a) Left support; 3(b) Mirror 1 support; 3(c) Mirror 2 support; 3(d) Mirror 3 support; 3(e) Upper housing fixture;

[0042] 4(a) Mirror base; (b) 4(b) Goggles.

[0043] The accompanying drawings are provided to further illustrate the invention and form part of the specification. They are used together with the embodiments of the invention to explain the invention and do not constitute a limitation thereof. Detailed Implementation

[0044] In the following description, only certain exemplary embodiments are briefly described. As those skilled in the art will recognize, the described embodiments can be modified in various ways without departing from the spirit or scope of the invention. Therefore, the drawings and description are considered to be exemplary in nature and not restrictive.

[0045] It is important to note that the terms "first," "second," etc., are used only to distinguish between descriptive and positional descriptions, and should not be construed as indicating or implying relative importance or implicitly specifying the number of technical features indicated. Therefore, features specified with "first," etc., may explicitly or implicitly include one or more of that feature; similarly, when the quantity of certain features is not limited by words such as "two" or "three," it should be noted that such features also explicitly or implicitly include one or more features.

[0046] In the embodiments of this invention, unless otherwise explicitly specified and limited, terms such as "installation," "connection," and "fixation" should be interpreted broadly; for example, they can refer to a fixed connection, a detachable connection, or an integral molding; they can refer to a mechanical connection, a direct connection, a welding connection, or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components. Those skilled in the art can understand the specific meaning of the above terms in this invention based on the accompanying drawings and specific circumstances.

[0047] In the description of the embodiments of the present invention, it should be understood that the terms "upper", "lower", "front", "rear", "left", "right", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on the embodiments of the present invention.

[0048] like Figures 1 to 7 As shown, an astronaut helmet display assembly and adjustment device includes:

[0049] 1. Gantry bracket; 2. Image source adjustment mechanism; 3. Backing fixture; 4. Process goggles; 5. Eye position fixture;

[0050] The gantry bracket 1 is used to support and position the other four functional modules. The image source adjustment mechanism 2 is detachably mounted on the gantry bracket 1 and is used to carry and adjust the spatial attitude and position of the image source components in the astronaut helmet display 6. The surface fixture 3 is detachably mounted on the gantry bracket 1 and is used to position and fix multiple optical elements in the astronaut helmet display 6 and ensure their relative positional relationship. The process goggles 4 are detachably mounted on the gantry bracket 1 and are used to simulate the human eye observation path to form a closed optical path to evaluate the image quality. The eye position fixture 5 is set in front of the process goggles 4 and is used to guide the operator to interpret the image quality in a standard observation position.

[0051] In a specific application of this invention, the entire process unfolds on a gantry frame, which consists of support blocks, columns, and a reference plate, forming a highly rigid portal frame. The reference plate serves as the "geocentric coordinate system" of the entire system, with pre-set pin holes to ensure that all subsequent functional modules are positioned using the same physical reference. This avoids the cumulative errors caused by traditional multi-tool conversion and ensures that the relative positional relationship between the image source, optical components, and simulated human eye is highly deterministic and repeatable.

[0052] Based on this benchmark, the pre-positioning of optical components is first performed. The surface fixture serves as a platform supporting the optical components, rigidly connected to the reference plate of the gantry bracket via pins and screws, achieving precise spatial positioning. The fixture employs a hierarchical benchmark system: the main bracket serves as the primary benchmark, and each lens bracket and housing fixture serves as the secondary benchmark, all connected to the main bracket via pins, forming a stable hierarchical positioning chain. Specifically for key components of aspherical lenses, their brackets are conformal and feature multi-curvature contact surfaces, ensuring the lens contacts at multiple discrete points, effectively suppressing redundancy and positioning drift caused by single-point contact. After all optical components are installed on the fixture, their relative positions are guaranteed by the fixture's machining accuracy and positioning method, forming a preliminary optical link.

[0053] The core imaging quality verification phase then begins. At this stage, the image source adjustment mechanism is installed at a designated position on the reference plate. Its support frame is positioned using pins to ensure the initial spatial coordinates of the image source are known. The image source assembly is mounted on the mechanism's adjustable platform, which is flexibly constrained by elastic ropes and finely adjusted for orientation using multiple adjustment screws. The process goggle is then installed at the end of the optical path, its mount connected to the reference plate by pins to ensure the optical axis direction of the goggle is fixed. Thus, a complete simulated optical path is constructed, starting from the image source, passing through optical elements on the mounting surface for reflection / transmission, and finally reaching the process goggle.

[0054] The operator uses an eye-positioning fixture to assess image quality from a standard observation position. If the image is blurry, exhibits parallax, or is distorted, it indicates that the optical link is misaligned. Instead of adjusting the fixed optical components, the operator fine-tunes the screws on the image source adjustment mechanism to change the image source's orientation and position, ensuring that the emitted beam matches the theoretical focal plane and field of view requirements of the optical system. Essentially, the image source is used as an "adjustable probe" to verify the assembly accuracy of the optical system. When a clear, error-free image is observed through the eye-positioning fixture, it indicates that the optical components on the mounting fixture are in the correct position, and the alignment of the entire optical link meets the requirements.

[0055] After passing the verification, the final packaging stage begins. The upper housing is precisely positioned on the mating fixture using the housing fixture, forming the correct spatial relationship with the aligned optical components. Adhesive is applied to the mating surfaces and pressed together. After curing, the lower housing is bonded together.

[0056] In one embodiment, the gantry bracket 1 consists of a support block 1(a), a column 1(b), and a reference plate 1(c). The support block 1(a) and the column 1(b) are fastened together by screws, and the column 1(b) and the reference plate 1(c) are fastened together by screws to form a stable portal frame structure. The reference plate 1(c) is provided with multiple pre-machined pin holes, which serve as a unified reference for the installation of the image source adjustment mechanism 2, the backing fixture 3, and the process goggles 4, ensuring the consistency of the relative positions of each module in space.

[0057] The image source adjustment mechanism 2 mainly consists of adjusting screws 2(a), support frame 2(b), elastic ropes 2(c), and mounting frame 2(d). The support frame 2(b) is rigidly connected to the reference plate 1(c) of the gantry bracket 1 by screws and pins. The mounting frame 2(d) is used to install the image source assembly. It is flexibly connected to the support frame 2(b) by at least two pre-tightened elastic ropes 2(c) to provide restoring force. Multiple adjusting screws 2(a) are distributed on the support frame 2(b) and contact the mounting frame 2(d). By adjusting the screwing depth of each adjusting screw 2(a), the tilt angle of the mounting frame 2(d) around the horizontal axis and the vertical axis, as well as the translation distance along the optical axis, can be independently controlled.

[0058] In the specific application of this invention, the support block serves as the base of the structure, rigidly connected to the column via high-strength screws to form a vertical support. The top of the column is then fastened to the reference plate with screws, forming a "door"-shaped frame with extremely high overall rigidity. The structure not only possesses excellent bending and torsional resistance, effectively resisting external disturbances, but also, as a highly flat horizontal platform, the reference plate has multiple sets of high-precision pin holes pre-machined on it. These holes are machined using the same coordinate system during manufacturing, becoming the "geocentric point" of the entire assembly and adjustment system. When the image source adjustment mechanism, the surface tooling, and the process goggle module are installed onto the reference plate via pins and screws, their spatial position and orientation are uniquely determined by these holes, completely eliminating the cumulative errors caused by multiple clamping or positioning reference conversions, ensuring consistency and repeatability when assembling and adjusting different batches at different times.

[0059] Based on this absolute benchmark, the precision adjustment process of the image source is initiated. The support frame of the image source adjustment mechanism is rigidly connected to the designated holes on the benchmark plate through double positioning with pins and screws, completely locking its position in space and becoming the local benchmark for subsequent adjustments. The mounting frame is used to support the image source components (such as miniature OLED or LCD displays). It is not rigidly connected to the support frame, but is flexibly suspended by at least two pre-tensioned elastic ropes. First, the elastic ropes provide continuous restoring force, ensuring that the mounting frame is always in the preset neutral position without external force, avoiding loosening or drifting. Second, it allows the mounting frame to float freely within a small range, creating conditions for subsequent fine adjustments. At the same time, the flexible connection eliminates the friction dead zone and backlash error introduced by mechanical hinges or guide rails, making the adjustment process smoother and more continuous.

[0060] The core actuator for adjustment consists of multiple adjusting screws distributed on the support frame. These screws are asymmetrically arranged, typically along different directions (such as the X, Y, and Z axes), with their ends contacting the surface of the mounting frame. By manually or through a fine-tuning device, the screw depth of each screw can be controlled, allowing independent changes to the attitude and position of the mounting frame. For example, simultaneously screwing in two symmetrical Z-axis screws can push the mounting frame to translate along the optical axis, precisely compensating for distance deviations between the image source and the focal plane of the optical system. Differential adjustment of a pair of horizontal screws can cause a slight deflection of the mounting frame around the vertical axis, correcting field tilt or binocular parallax. Similarly, adjusting the vertical screws allows for pitch angle adjustment. Because the support frame is fixed to an absolute reference, and the movement of the mounting frame is entirely driven by the mechanical displacement of the screws, each adjustment has a clear physical meaning and a predictable trajectory.

[0061] In one embodiment, the surface fixture 3 has a left-right mirror symmetrical structure, corresponding to the left and right optical channels of the helmet display respectively. Taking the left eye part as an example, the surface fixture 3 is composed of a left bracket 3(a), a mirror 1 bracket 3(b), a mirror 2 bracket 3(c), a mirror 3 bracket 3(d), and an upper shell fixture 3(e). The left bracket 3(a) is connected to the reference plate 1(c) of the gantry bracket 1 by screws and pins, serving as the installation reference for the internal sub-components. The mirror 1 bracket 3(b), mirror 2 bracket 3(c), mirror 3 bracket 3(d), and upper shell fixture 3(e) are all installed with the left bracket 3(a) as the reference, using screws and pins for positioning. The mirror 1 bracket 3(b) is used to install the aspherical reflector 1. Its mating surface with the mirror 1 is conformal and has two mating surfaces with different radii of curvature, so that the mirror 1 can achieve surface contact in at least two discrete regions.

[0062] In the specific application of this invention, the backrest fixture adopts left and right mirror symmetry, corresponding to the left and right optical channels of the helmet display, respectively, to ensure the symmetry and consistency of the binocular system. Taking the left eye part as an example, its main structure is the left bracket 3(a). The bracket is rigidly connected to the reference plate 1(c) of the gantry bracket through high-precision pins and screws. Since the reference plate is the unified coordinate origin of the entire assembly and adjustment system, the spatial position and attitude of the left bracket 3(a) are uniquely determined, becoming the "first-level reference" inside the backrest fixture.

[0063] Based on this primary reference, the mirror 1 bracket 3(b), mirror 2 bracket 3(c), mirror 3 bracket 3(d), and upper housing fixture 3(e) all use the left bracket 3(a) as the mounting reference, achieving precise connection with the left bracket 3(a) through their respective pin holes and screw holes. The "master-slave" structure forms a stable hierarchical positioning chain: the spatial relationship of all sub-components is determined by the common reference of the left bracket 3(a), avoiding reference divergence and cumulative errors caused by multiple independent installations. At the same time, the introduction of the upper housing fixture 3(e) allows the relative position of the housing and optical components to be precisely controlled during the assembly and adjustment stage, providing a reliable geometric basis for subsequent adhesive encapsulation.

[0064] Specifically, traditional point contact or single-sided bonding methods are insufficient to constrain all degrees of freedom of the lens, and the lens is prone to tilting or warping due to gravity or assembly stress. This working method adopts conformal bonding and sets two bonding surfaces with different radii of curvature on the support 3(b) of the lens 1, forming at least two discrete surface contacts with the back of the aspherical lens 1. Multi-curvature bonding has profound mechanical and geometric significance: First, it breaks through the limitations of single curvature matching and can adapt to the complex local curvature changes of the aspherical lens, achieving a more uniform stress distribution; second, the two discrete contact areas form a "double-point support" in space, effectively restricting the rotational degrees of freedom (pitch and yaw) of the lens around two horizontal axes. At the same time, combined with the limiting structure at the edge of the lens, it can completely constrain its six degrees of freedom of motion.

[0065] In one embodiment, the process goggles 4 consist of a lens mount 4(a) and goggles 4(b). The goggles 4(b) are installed in the lens mount 4(a) by a centering clamp to ensure that the optical axis of the goggles 4(b) coincides with the mechanical axis of the lens mount 4(a). The lens mount 4(a) is fixedly connected to the reference plate 1(c) of the gantry bracket 1 by screws and pins, so that the optical axis of the process goggles 4 has a definite spatial position in the assembly and adjustment system, thereby forming an evaluable simulated optical path together with the surface tooling 3 and the image source adjustment mechanism 2.

[0066] In the specific application of this invention, the goggles 4(b) serve as the terminal element of the simulated human eye optical system, and their optical axis must be strictly aligned with the mechanical reference of the entire assembly system. Therefore, a high-precision centering clamping process is used to install the goggles 4(b) into the lens mount 4(a): on a dedicated centering instrument, the concentricity of the goggles' edge and center is monitored in real time using interference or autocollimation methods. Adjustments are made while fixing the goggles to ensure that the optical center of the goggles 4(b) is completely coincident with the mechanical rotation axis of the lens mount 4(a). This process eliminates additional aberrations introduced by lens eccentricity or tilt, making the process goggles themselves a low-distortion, high-fidelity imaging window.

[0067] Specifically, the lens mount 4(a) is rigidly connected to the reference plate 1(c) of the gantry bracket by pins and screws. Since the reference plate is the unified spatial origin of the entire assembly and adjustment device, and the surface fixture 3 and the image source adjustment mechanism 2 are also installed on the same reference plate, the spatial position and attitude of the process goggles 4 are precisely locked. The light emitted from the image source is reflected and imaged by the aspherical mirror and relay mirror optical elements on the surface fixture 3. The theoretical direction and convergence point of the emitted light beam have a definite geometric relationship in three-dimensional space. When this theoretical light path is precisely aligned with the optical axis of the process goggles 4, the operator can see a clear, unobstructed, and complete image at the standard observation distance and angle through the eye position fixture.

[0068] In actual use, the astronaut's eyes are positioned in a specific eye position, receiving a virtual image projected from the helmet-mounted display. During assembly and adjustment, the process goggles 4 and the eye positioning fixture in front of them jointly simulate this physiological observation condition. The image quality observed through the goggles—including resolution, contrast, field of view uniformity, binocular fusion, and the presence of ghosting or stray light—directly reflects the visual performance of the future product in actual use. If the image is blurry, it indicates that the image source is not aligned with the focal plane; if parallax occurs, it indicates that the left and right eye paths are asymmetrical; if the distortion at the edge of the field of view is severe, it suggests that the angle or position of the reflector is incorrect.

[0069] In one embodiment, a process method for assembling and adjusting an astronaut helmet display specifically includes the following steps:

[0070] Step 1, Optical component positioning: Install and lock the surface fixture 3 onto the reference plate 1(c) of the gantry bracket 1 using screws and pins. Install the optical components of mirror 1, mirror 2, and mirror 3 in the astronaut helmet display 6 onto the corresponding mirror 1 bracket 3(b), mirror 2 bracket 3(c), and mirror 3 bracket 3(d) of the surface fixture 3 in sequence. Ensure the initial position of each optical component by processing the surface fixture 3 and positioning it with pins, and temporarily fix it with screws.

[0071] Step 2, Image Quality Judgment and Image Source Adjustment: Install the image source adjustment mechanism 2 and the process goggle 4 to the designated positions on the gantry bracket 1 using screws and pins. Install the image source assembly onto the mounting bracket 2(d) of the image source adjustment mechanism 2 and power on the image source to make it emit light. Adjust the posture and position of the image source by operating the adjustment screw 2(a) on the image source adjustment mechanism 2 so that the image emitted by it forms a clear, distortion-free image with parallax meeting the requirements at the process goggle 4 after passing through the optical system. The operator observes through the eye position fixture 5. If the image quality meets the preset acceptance standard, the position accuracy of the optical component is deemed qualified; otherwise, the optical component needs to be disassembled and readjusted on the surface fixture 3, and this step is repeated until the standard is met.

[0072] Step 3, Housing Encapsulation and Curing: After the positional accuracy of the optical components is verified to be qualified, the upper housing of the astronaut helmet display 6 is installed on the upper housing fixture 3(e) of the surface fixture 3. The upper housing fixture 3(e) and the left bracket 3(a) are positioned by screws and pins to ensure that the upper housing and the positioned optical components have the correct relative position. Special adhesive is evenly applied to the mating surface of the upper housing and the optical components, and then pressed and fixed. After the adhesive is completely cured, the lower housing is bonded to the upper housing to complete the final encapsulation of the entire optical system.

[0073] In the specific application of this invention, firstly, the surface fixture is rigidly mounted on the reference plate of the gantry bracket using pins and screws, establishing a definite relationship with the system's global coordinate system. Subsequently, key optical components such as mirrors 1, 2, and 3 are installed one by one according to the bracket structure preset on the fixture. The bracket uses the main bracket as a primary reference, and through precision machining and pin positioning, ensures that the relative positions of each lens in three-dimensional space meet optical requirements. Especially for aspherical mirrors, the bracket adopts multi-curvature conformal fitting to achieve surface contact constraint, effectively suppressing surface distortion caused by gravitational deformation and assembly stress. At this point, the geometric configuration of the entire optical path has been preliminarily determined by the machining accuracy of the fixture, but it has not yet been functionally verified and is still in a "potentially correct" state.

[0074] Next comes the core closed-loop verification phase. The image source adjustment mechanism and the process goggles are installed at designated positions on the reference plate. All three (optical components, image source, and goggles) use the same reference plate as a reference, forming a physically continuous and geometrically closed simulated optical path. After the image source is powered on, the test image it emits is reflected and imaged step by step by the installed optical components, and finally projected onto the process goggles. The operator uses an eye-positioning fixture to interpret the image from a standard observation position, directly perceiving the image's clarity, field of view integrity, binocular parallax, and distortion. If the image quality is substandard, the root cause is inevitably a deviation in the optical component's position or misalignment of the image source. In this case, instead of adjusting the fixed optical components, the multi-degree-of-freedom fine-tuning capability of the image source adjustment mechanism—changing the image source's attitude and Z-axis position by rotating the adjustment screw—is used as an "adjustable probe" for reverse optimization. Only when the image observed through the eye-positioning fixture fully meets the acceptance criteria is the assembly accuracy of the optical link deemed qualified.

[0075] After functional verification is successful, the final structural curing process is initiated. At this point, the "correct state" of the optical system is locked, and subsequent operations only require converting it into a permanent structure. The upper housing is precisely positioned on the mating fixture using a housing tooling, with its spatial relationship guaranteed by the same reference chain as the optical components. A special optical adhesive is applied to the mating surfaces of the housing and the optical components, and after pressing and curing, a rigid connection is formed. Since all optical alignment is completed in a stress-free, open state, the adhesive process only serves to fix the components and will not introduce new deformations. After the upper housing has cured, the lower housing is then bonded to achieve a fully enclosed package.

[0076] In one embodiment, in step two, the image source adjustment process follows the principle of coarse adjustment followed by fine adjustment. First, the Z-axis position of the image source is changed by adjusting screw 2(a) so that it is approximately located near the theoretical focal plane of the optical system. Then, its pitch and yaw angles are finely adjusted to eliminate astigmatism and binocular parallax, and finally achieve the best focusing and alignment of the image across the entire field of view.

[0077] In step three, the type of adhesive, the amount applied, the application path, the pressing pressure, and the curing process parameters (temperature and time) are all preset and strictly controlled according to the characteristics of the adhesive material and structural requirements to ensure that the bonded joint has sufficient mechanical strength, environmental stability, and long-term reliability, while preventing adhesive overflow and contamination of the optical surface.

[0078] In the specific application of this invention, during the image quality assessment stage, facing complex multi-degree-of-freedom coupling problems (such as Z-axis defocus, astigmatism caused by angular tilt, and parallax caused by binocular asymmetry), blindly adjusting various parameters can easily cause mutual interference, prolonging the debugging cycle and even preventing convergence. Therefore, an iterative optimization strategy of "coarse to fine, from primary to secondary" is adopted: First, focus is placed on the most significant factor affecting image sharpness—axial defocus. By synchronously adjusting the Z-axis adjustment screws on both sides of the mounting bracket, the image source is pushed to move along the optical axis, making it quickly approach the theoretical focal plane. This stage allows for a large adjustment step size, with the goal of making the image change from completely blurred to roughly visible, completing the initial focusing. Once a basically discernible image is obtained, the fine adjustment stage begins. At this point, the focus shifts to eliminating aberrations caused by lens attitude deviations. By differentially adjusting the pitch adjustment screws, the focusing difference at the upper and lower edges of the image is corrected, eliminating longitudinal astigmatism; similarly, adjusting the yaw screws eliminates the focusing inconsistency at the left and right edges and binocular parallax.

[0079] This step-by-step strategy effectively decouples the strong correlations between multiple degrees of freedom, making the impact of each adjustment more explicit and predictable, and significantly improving calibration efficiency and accuracy. Ultimately, it achieves pixel-level clear focusing across the entire field of view and ensures that the field-of-view overlap of the two optical channels meets the requirements for comfortable human observation.

[0080] Once the optical link reaches its optimal state, any minute disturbance will disrupt the achieved precise balance. Therefore, adhesive encapsulation is no longer a simple mechanical connection, but a controlled physicochemical transformation process. The entire process is strictly executed based on pre-defined process specifications: First, according to the material properties of the optical components and the housing (such as the coefficient of thermal expansion and surface energy), the structural gap dimensions, and the service environment (vacuum, high and low temperature cycling, vibration), a special optical adhesive with matching elastic modulus, low shrinkage, high light transmittance, and excellent weather resistance is selected.

[0081] Secondly, precise control of the adhesive application amount and path is crucial. Typically, dispensing equipment is used to apply a precise amount to non-optical areas, preventing excessive application that could lead to capillary runoff and contamination of the mirror surface. The application path is either a continuous closed loop or a radial pattern to ensure even spread of the adhesive during the lamination process and to eliminate air bubbles. The lamination process is performed under a specialized fixture, applying precise and controllable pressure to ensure sufficient contact between the adhesive layers to form a complete bonding interface, while preventing excessive pressure that could cause elastic deformation of the optical components or buckling of the support structure.

[0082] Finally, the curing process strictly follows the adhesive's TTT (time-temperature-conversion) curve, with staged heating and holding in a constant temperature and humidity environment to ensure a sufficient and uniform cross-linking reaction, avoiding internal stress gradients caused by localized overheating or uneven curing rates. The entire curing process lasts for tens of hours, during which the structure remains under the reference constraints of the assembly and adjustment system to prevent overall warping caused by its own weight or shrinkage forces.

[0083] It should be noted that, in this document, relational terms such as "first" and "second" are used only to distinguish one entity or operation from another, and do not necessarily require or imply any such actual relationship or order between these entities or operations. Furthermore, the terms "comprising," "including," or any other variations thereof are intended to cover non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements includes not only those elements but also other elements not expressly listed, or elements inherent to such process, method, article, or apparatus.

[0084] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

[0085] The present invention and its embodiments have been described above. This description is not restrictive, and the accompanying drawings are only one embodiment of the present invention; the actual structure is not limited thereto. In conclusion, if those skilled in the art are inspired by this description and design similar structures and embodiments without departing from the spirit of the invention, such designs should fall within the protection scope of the present invention.

Claims

1. An astronaut helmet display assembly and adjustment device, characterized in that, include: Gantry bracket (1), image source adjustment mechanism (2), surface fixture (3), process goggles (4) and eye position fixture (5); The gantry bracket (1) is used to support and position the other four functional modules. The image source adjustment mechanism (2) is detachably installed on the gantry bracket (1) and is used to carry and adjust the spatial attitude and position of the image source components in the astronaut helmet display (6). The surface fixture (3) is detachably installed on the gantry bracket (1) and is used to position and fix multiple optical elements in the astronaut helmet display (6) and ensure their relative positional relationship. The process goggles (4) are detachably installed on the gantry bracket (1) and are used to simulate the human eye observation path to form a closed optical path to evaluate the imaging quality. The eye position fixture (5) is set in front of the process goggles (4) and is used to guide the operator to judge the imaging quality in the standard observation position. The gantry support (1) consists of a support block 1 (a), a column 1 (b) and a reference plate 1 (c). The support block 1 (a) and the column 1 (b) are fastened together by screws, and the column 1 (b) and the reference plate 1 (c) are fastened together by screws to form a stable portal frame structure. The reference plate 1 (c) is provided with multiple pre-machined pin holes, which serve as a unified reference for the installation of the image source adjustment mechanism (2), the surface tooling (3) and the process goggles (4), ensuring the consistency of the relative positions of each module in space. The image source adjustment mechanism (2) mainly consists of an adjustment screw 2 (a), a support frame 2 (b), an elastic rope 2 (c), and a mounting frame 2 (d). The support frame 2 (b) is rigidly connected to the reference plate 1 (c) of the gantry bracket (1) by screws and pins. The mounting frame 2 (d) is used to install the image source assembly. It is flexibly connected to the support frame 2 (b) by at least two pre-tightened elastic ropes 2 (c) to provide restoring force. Multiple adjustment screws 2 (a) are distributed on the support frame 2 (b) and contact the mounting frame 2 (d). By adjusting the screwing depth of each adjustment screw 2 (a), the tilt angle of the mounting frame 2 (d) around the horizontal axis and the vertical axis, as well as the translation distance along the optical axis, can be independently controlled.

2. The astronaut helmet display assembly and adjustment device according to claim 1, characterized in that, The surface fixture (3) has a left-right mirror symmetrical structure, which corresponds to the left and right eye optical channels of the helmet display respectively; Taking the left eye section as an example, the backing fixture (3) consists of a left bracket 3 (a), a mirror 1 bracket 3 (b), a mirror 2 bracket 3 (c), a mirror 3 bracket 3 (d), and an upper housing fixture 3 (e). The left bracket 3 (a) is connected to the reference plate 1 (c) of the gantry bracket (1) by screws and pins, serving as the installation reference for the internal sub-components. The mirror 1 bracket 3 (b), mirror 2 bracket 3 (c), mirror 3 bracket 3 (d), and upper housing fixture 3 (e) are all installed with the left bracket 3 (a) as the reference and are positioned by screws and pins.

3. The astronaut helmet display assembly and adjustment device according to claim 2, characterized in that, The support 3(b) for the mirror 1 is used to install the aspherical mirror 1. Its mating surface with the mirror 1 is conformal and has two mating surfaces with different radii of curvature, so that the mirror 1 can achieve surface contact in at least two discrete regions.

4. The astronaut helmet display assembly and adjustment device according to claim 1, characterized in that, The process goggles (4) consist of a lens mount 4 (a) and a goggle 4 (b). The goggle 4 (b) is installed in the lens mount 4 (a) by a centering clamp to ensure that the optical axis of the goggle 4 (b) coincides with the mechanical axis of the lens mount 4 (a). The lens mount 4 (a) is fixedly connected to the reference plate 1 (c) of the gantry bracket (1) by screws and pins, so that the optical axis of the process goggles (4) has a definite spatial position in the assembly and adjustment system, thereby forming an evaluable simulated optical path together with the surface tooling (3) and the image source adjustment mechanism (2).

5. A process method for assembling and adjusting an astronaut helmet display, characterized in that, The assembly and adjustment device according to any one of claims 1 to 4 specifically includes the following steps: Step 1, Optical component positioning: Install and lock the surface fixture (3) onto the reference plate 1 (c) of the gantry bracket (1) using screws and pins. Install the optical components of mirror 1, mirror 2 and mirror 3 in the astronaut helmet display (6) onto the corresponding mirror 1 bracket 3 (b), mirror 2 bracket 3 (c) and mirror 3 bracket 3 (d) of the surface fixture (3) in sequence. Ensure the initial position of each optical component by relying on the processing of the surface fixture (3) and the positioning of the pins, and temporarily fix it with screws. Step 2, Imaging quality judgment and image source adjustment: Install the image source adjustment mechanism (2) and the process goggles (4) into the designated positions of the gantry bracket (1) by screws and pins respectively, install the image source assembly onto the mounting bracket 2 (d) of the image source adjustment mechanism (2), and power on the image source to make it emit light; By operating the adjusting screw 2(a) on the image source adjustment mechanism (2), the posture and position of the image source are adjusted so that the image emitted by it is formed at the process goggles (4) after passing through the optical system, resulting in a clear, distortion-free image with parallax that meets the requirements. The operator observes through the eye position fixture (5). If the imaging quality meets the preset acceptance standard, the position accuracy of the optical component is deemed qualified; otherwise, the optical component needs to be disassembled and the installation status on the surface fixture (3) needs to be readjusted, and this step is repeated until the standard is met. Step 3, Housing Encapsulation and Curing: After the positional accuracy of the optical components is verified to be qualified, the upper housing of the astronaut helmet display (6) is installed on the upper housing fixture 3(e) of the surface fixture (3). The upper housing fixture 3(e) and the left bracket 3(a) are positioned by screws and pins, thereby ensuring that the upper housing and the positioned optical components have the correct relative position. Apply a special adhesive evenly to the mating surface between the upper housing and the optical components, then press them together to fix them. After the adhesive has completely cured, bond the lower housing to the upper housing to complete the final encapsulation of the entire optical system.

6. The process method for the astronaut helmet display assembly and adjustment device according to claim 5, characterized in that, In step two, the image source adjustment process follows the principle of coarse adjustment followed by fine adjustment. First, the Z-axis position of the image source is changed by adjusting screw 2(a) so that it is roughly located near the theoretical focal plane of the optical system. Then, its pitch and yaw angles are finely adjusted to eliminate astigmatism and binocular parallax, and finally achieve the best focusing and alignment of the image in the entire field of view.

7. The process method for the astronaut helmet display assembly and adjustment device according to claim 5, characterized in that, In step three, the type of adhesive, the amount applied, the application path, the pressing pressure, and the curing process parameters (temperature and time) are all preset and strictly controlled according to the characteristics of the adhesive material and structural requirements to ensure that the bonded joint has sufficient mechanical strength, environmental stability, and long-term reliability, while preventing adhesive overflow and contamination of the optical surface.

Images