Optical device assembly auxiliary method and system construction

Abstract

The invention discloses an optical device assembling auxiliary element and method, and belongs to the technical field of precision optical manufacturing. And the auxiliary element is a magnetic high-sensitivity pressure sensing array and is arranged between the optical device and the mounting base. The method comprises the steps of collecting pressure distribution data of an assembly contact interface in real time, judging eccentric and inclined states of an optical device, and performing position correction based on a result. The pressure center and the inclination amount are identified by processing the pressure distribution data, so that the state of the device is judged; and driving a fine adjustment mechanism or guiding manual correction through a prompt unit according to the judgment until the pressure distribution meets the requirements of preset uniformity and coaxiality. Eccentricity and inclination are easily caused due to uneven distribution of contact stress in assembly, optical performance is affected, the method monitors pressure distribution in real time through a sensing array, and adjustment difficulty and period can be remarkably reduced. The method has a good application prospect in the fields of precision optical instrument manufacturing, space optical load assembly and the like.

Description

Technical Field

[0001] This invention relates to the field of precision assembly technology for optical devices, specifically to an auxiliary component and method for assembling optical devices based on high-sensitivity magnetic pressure sensing and real-time posture feedback, applicable to the automated precision assembly of optical components such as lenses and prisms. Background Technology

[0002] The assembly quality of precision optical components directly determines the imaging performance and reliability of optical systems, playing a crucial role in high-tech fields such as aerospace, medical imaging, and mobile communications. However, in traditional assembly processes, the positioning of optical components mainly relies on rigid structures such as mechanical slots and locating pins, and is corrected and fixed by manual experience. This method is not only inefficient and inconsistent, but also makes it difficult to avoid component eccentricity, tilting, or stress concentration caused by uneven assembly forces, affecting the wavefront accuracy and image quality of the optical system.

[0003] With the development of automation and sensing technologies, assembly technologies based on machine vision and robot manipulation are gradually being applied to the field of optical manufacturing, significantly improving the level of automation in assembly. However, existing technologies still lack the ability to monitor the mechanical state in situ during assembly, especially in the perception and control of micro-Newton level contact forces. The contact stress distribution between the lens and the lens barrel cannot be obtained in real time during assembly, making it difficult to identify and correct micron-level pose errors online, which has become a technical bottleneck restricting further improvement in the assembly quality of high-precision optical devices. Summary of the Invention

[0004] To address the technical problems of uncontrollable assembly force and difficulty in timely detection and correction of pose errors in the assembly process of existing optical devices, this invention proposes an auxiliary component and method for optical device assembly based on a high-sensitivity magnetic pressure sensor, which can realize real-time mechanical sensing, pose determination, and active calibration during the assembly process.

[0005] S1. Construction of an optical component-assisted assembly system (see [link]). Figure 1 (a) includes a pressure sensing system, a data processing unit, an assembly and calibration unit, an optical device clamping device, a three-dimensional motion platform, and a human-machine interface.

[0006] S1-1, wherein the pressure sensing system includes a magnetically sensitive pressure sensing array and a fixed support structure;

[0007] S1-2, wherein the data processing unit includes an impedance analysis module connected to the soft magnetic amorphous wire sensing unit and Python software for acquiring and processing data;

[0008] S1-3, wherein the assembly calibration unit includes a multi-axis robotic arm, a servo motor drive system and a vacuum nozzle, and calibration can be performed manually or automatically;

[0009] S1-4, wherein the optical device clamping device includes a robotic arm connection mechanism and a flexible clamping assembly;

[0010] S1-5, where the human-computer interaction system is developed based on the LabVIEW software platform.

[0011] S2. Pressure distribution acquisition and processing based on magnetic high-sensitivity pressure sensing array: The array is based on the GMI effect, and its core sensing unit consists of a neodymium iron boron flexible magnetic film, a soft magnetic amorphous wire sensing unit, and a micro assembly unit.

[0012] S2-1 The NdFeB flexible magnetic film is made by mixing, curing and magnetizing NdFeB magnetic powder with Ecoflex flexible substrate.

[0013] S2-2, The soft magnetic amorphous wire sensing unit is made of Fe 77.5 Si 7.5 B 15 The composition consists of glass-coated amorphous fibers; see [link / reference]. Figure 4 (a) Preferably, a combination of 10 amorphous wires with a length of 24 mm.

[0014] S2-3, see also Figure 4 (b)(c) The array operates at a frequency of 200 kHz and provides a bias magnetic field of 1 to 2 Oe through six permanent magnets with a diameter of 3 mm.

[0015] S2-4, see also Figure 4 (d) The height of the neodymium iron boron flexible magnetic film and the soft magnetic amorphous wire sensing unit in the micro-combination unit is selected to be about 16cm.

[0016] S2-5, see also Figure 4 (e)(f) The pressure sensing system performed well in both the backlash difference test and the response time test.

[0017] S3. Optical device pose determination based on COP-plane tilt solution algorithm: The impedance change of each unit in the magnetic sensing array is collected using the impedance analysis module.

[0018] S3-1, The impedance analysis module includes the Sciospec ISX-3 series impedance analysis module and adapter capacitors and wires;

[0019] S3-2. The pressure distribution data processing algorithm based on Python first converts the impedance signal into a mechanical signal, and then converts it into pose parameters.

[0020] S3-3, The posture parameters include the coordinates of the pressure center, the tilt angle, and the tilt amplitude.

[0021] S4. Feedback display and calibration control based on LabVIEW CNC software: See Figure 7 LabVIEW is used to monitor pressure changes in real time, and threshold judgments for eccentricity and tilt are made. Then, the assembly correction unit is controlled via serial port for correction.

[0022] S4-1. Optical devices are translated along the X and Y axes using a multi-axis robotic arm, and precisely pressed down along the Z axis using a vacuum nozzle.

[0023] S4-2. Complete the initial pose calibration and display the calibration process in real time.

[0024] S5, see below Figure 2 Repeat steps S2 to S4 to form a real-time closed loop until all pose parameters meet the preset assembly conditions.

[0025] S6. After the position and orientation calibration is completed, perform processes such as dispensing and curing to permanently fix the lens inside the lens barrel, thus completing the assembly.

[0026] Compared with existing technologies, the beneficial effects of this invention are: (1) Real-time, in-situ mechanical sensing of the optical device assembly process is realized, and the pressure distribution is quantified into precise pose parameters; (2) High-sensitivity detection of micro-Newton pressure is realized through optimized magnetic sensing elements and algorithms; (3) A software and hardware collaborative intelligent assembly system is constructed to support precise pose calibration; (4) The system has a fast response speed and high precision, which can meet the requirements of industrial production for efficiency and stability. Attached Figure Description

[0027] Figure 1 The diagram shows the overall structure of the optical component-assisted assembly system (a) and the assembly diagram of some components (b).

[0028] Figure 2 A flowchart for assembling auxiliary optical components;

[0029] Figure 3 This is a schematic diagram illustrating the working principle of a magnetically sensitive pressure sensor array.

[0030] Figure 4 Optimization of parametric diagrams and test diagrams for magnetic high-sensitivity pressure sensor arrays: (a) Selection of amorphous wire number and length; (b) Selection of bias magnetic field structure; (c) Selection of amorphous wire operating frequency; (d) Selection of magnetic film and amorphous wire internal structure height; (e) Backlash test; (f) Response time test.

[0031] Figure 5 This is a schematic diagram of the impedance gradient mapping method;

[0032] Figure 6 This is a schematic diagram of the COP-plane tilt solution algorithm;

[0033] Figure 7 This is a real-time pressure distribution monitoring interface.

[0034] In the figure, 1-pressure sensing system, 2-data processing unit, 3-assembly and correction unit, 4-optical device clamping device, 5-three-dimensional motion platform, 6-human-computer interaction system, 7-neodymium iron boron flexible magnetic film, 8-soft magnetic amorphous wire sensing unit, 9-micro assembly unit, 10-impedance analysis module, 11-rigid ring clamp, 12-permanent magnet, 301-vacuum nozzle, 302-clamping device, 303-multi-axis robotic arm, 401-flexible clamping assembly, 402-dual-axis robotic arm, 403-lens to be assembled, 404-lens to be assembled. Detailed Implementation

[0035] The specific embodiments of this invention adopt the following technical solution: its optical device assembly auxiliary components and methods are as follows:

[0036] First, start each unit of the system, such as... Figure 1 As shown in (a), the pressure sensing system is started in sequence to bring the array into the working frequency band and complete the impedance baseline acquisition; data processing unit; assembly and calibration unit; three-dimensional motion platform and human-machine interface.

[0037] Secondly, a flexible clamping assembly is used to stabilize the target assembly lens barrel, and the vacuum nozzle is controlled to initially lower the target assembly lens into the lens barrel for manual fine-tuning until the lens is observed to be roughly horizontal.

[0038] Furthermore, the robotic arm is manually observed and controlled to move the microscope tube directly above the center of the neodymium iron boron flexible magnetic film;

[0039] Further, see Figure 1 (b) Control the robotic arm to move the lens barrel vertically and slowly until the convex surface of the lens makes initial contact with the neodymium iron boron flexible magnetic film;

[0040] Furthermore, preliminary impedance change data at various points were acquired using a magnetically sensitive pressure sensing array, see [link / reference]. Figure 5 and Figure 6 After processing with Python software, the pose parameters are obtained. If the eccentricity or tilt exceeds a set deviation threshold, manual visual adjustment is performed until it falls below the set threshold; see [link / reference]. Figure 7 If the set threshold is not reached, LabVIEW will monitor and precisely control the servo motor to drive the robotic arm and vacuum nozzle for fine-tuning in real time.

[0041] Furthermore, after fine-tuning, the site data is collected again and the processing steps are repeated. If the pose parameters meet the preset assembly conditions, the calibration is completed; if they do not meet the conditions, the above "collection-processing-coarse-fine-tuning" steps are repeated.

[0042] Furthermore, a colloidal material is dripped into the lens barrel to fix the lens in the barrel. After curing, the assembly is removed from the flexible clamping assembly to complete the assembly.

Claims

1. An auxiliary method and system for assembling optical devices, characterized in that, Includes the following steps: Construction based on optical device assembly auxiliary system; Pressure distribution acquisition based on a magnetically sensitive pressure sensor array; Optical device pose determination based on COP-plane tilt solution algorithm; Feedback display and calibration control based on LabVIEW CNC software.

2. The construction of the optical device assembly auxiliary system according to claim 1. Its characteristics are... It includes a pressure sensing system (1), a data processing unit (2), an assembly and calibration unit (3), an optical device clamping device (4), a three-dimensional motion platform (5), and a human-computer interaction system (6).

3. The contact interface pressure distribution acquisition based on a magnetically sensitive pressure sensing array according to claim 1, characterized in that... The array is based on the GMI effect, and its core sensing unit consists of a neodymium iron boron flexible magnetic film (7), a rigid ring clamp (11), a soft magnetic amorphous wire sensing unit (8), and a micro assembly unit (9). Referring to Figure 3, the array is used to collect the pressure distribution at the contact interface between the optical device and the neodymium iron boron flexible magnetic film in real time, and convert the mechanical signal into an impedance change for output.

4. The optical device pose determination based on the COP-plane tilt solution algorithm according to claim 1, characterized in that... The impedance analysis module (10) is used to collect the impedance changes of each unit in the magnetic sensing array. See Figures 5 and 6. The pressure distribution data processing algorithm based on Python first converts the impedance signal into a mechanical signal and then into pose parameters. The pose parameters include the pressure center coordinates, tilt angle and tilt amplitude.

5. The feedback display and calibration control based on LabVIEW CNC software according to claim 1, characterized in that... Using LabVIEW to process the pose parameters in real time, the assembly correction unit (3) is controlled via serial port to realize the translation of the optical device on the X and Y axes and the precise pressing on the Z axis, thus completing the pose calibration.

6. The pressure sensing system (1) according to claim 2 includes a magnetically sensitive pressure sensing array and a fixed support structure; the data processing unit (2) includes an impedance analysis module (10) connected to the soft magnetic amorphous wire sensing unit (8) and Python software for acquiring and processing its data; the assembly and correction unit (3) includes a vacuum nozzle (301), a clamping device (302), a multi-axis robotic arm (303) and a servo motor drive system; the optical device clamping device (4) includes a flexible clamping assembly (401), a dual-axis robotic arm (402), a lens barrel to be assembled (403) and a lens to be assembled (404); referring to Figure 7, the human-computer interaction system (6) is developed based on the LabVIEW software platform and monitors the pressure distribution in real time.

7. The NdFeB flexible magnetic film (7) according to claim 3 is made by mixing, curing and magnetizing NdFeB magnetic powder with Ecoflex flexible substrate; six permanent magnets (12) with a diameter of 3 mm are disposed below the magnetic film to provide a preferred working bias magnetic field of 1 to 2 Oe; the soft magnetic amorphous wire sensing unit (8) is made of Fe 77.5 Si 7.5 B 15 The component is composed of glass-coated amorphous filaments, with a preferred operating frequency of 200 kHz; preferably, the sensing unit is composed of 10 amorphous filaments with a length of 24 mm, and the GMI effect is greater than 700% in this configuration; the micro assembly unit (9) includes 3D printed assembly parts and permanent magnets (12).

8. The impedance analysis module (10) according to claim 4 includes an ISX-3 series impedance analysis module manufactured by Sciospec and an adapter capacitor and wires connecting the soft magnetic amorphous wire sensing unit (8); the pressure distribution data processing algorithm includes an impedance gradient mapping method that converts the impedance signal into a mechanical signal and a COP-plane tilt solution algorithm that converts the mechanical signal into pose parameters. The impedance gradient mapping method first obtains the initial impedance value Z of each sensing unit when the system is unloaded. 基 Using this as a zero-point reference, a known standard pressure F0 is then applied and the corresponding impedance value Z0 is recorded to determine the calibration point and calculate the response slope K0 = (Z0 - Z0). 基 ) / F0; Calculate the change ΔZ = Z1 - Z based on the real-time acquired impedance value Z1. 基 Finally, the pressure value is calculated using the linear relationship F = ΔZ / K0. The COP-plane tilt solution method first calculates the total contact force F using the previously calculated real-time pressure data. total =∑F i and the coordinates of the pressure center X cop =∑(F i ·x i ) / F total With Y cop =∑(F i ·y i ) / F total Based on the equivalent displacement δ of each sensing point i =F i / k, calculate the east-west θ EW ≈(δ E -δ w ) / 2r, North-South θ NS ≈(δ N -δ S The tilt amplitude θ is obtained by combining the tilt angle θ / 2r and the tilt angle along the diagonal direction. magnitude With direction θ direction .

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