Active Alignment Fixture for Floating Lens Assembly
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Solution Overview
Problem
Current methods for aligning optical components, such as lenses, with digital camera sensors lack precision due to variations in dimensions and symmetries, limiting the ability to compensate for piece-to-piece variations and requiring complex adjustments to achieve optimal image quality.
Innovation Solution
A robotic alignment system that temporarily electrically connects test probes to electrical contact points on a lens, allowing motor control signals to move a floating optical element to a predetermined position, enabling precise alignment along multiple axes and orientations, and using image data to estimate and maintain the optimal alignment position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If passive alignment methods are used, then manufacturing cost is reduced, but manufacturing precision deteriorates due to inability to compensate for piece-to-piece variations
Solution Approach 1:
The patent implements active alignment using feedback from image sensors to measure actual optical performance and automatically adjust lens position and orientation. The system captures test images, analyzes focus quality metrics, and iteratively adjusts lens parameters until optimal alignment is achieved, thereby compensating for component variations while maintaining automation.
Solution Approach 2:
The patent replaces traditional mechanical passive alignment fixtures with an automated robotic system that uses image processing feedback. Instead of relying on precision mechanical positioning, the system uses software-controlled robotic actuators to adjust lens position based on real-time optical performance measurements, achieving higher precision without complex mechanical tooling.
2Manufacturing precision
If active alignment with 6 degrees of freedom is used, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent employs a multi-functional robotic system that integrates positioning, orientation, imaging, and actuation capabilities into a single platform. The robotic arm performs both coarse positioning and fine adjustment, while the same system captures test images and controls lens actuators, reducing the need for separate specialized devices for each function.
Solution Approach 2:
The system performs self-calibration and self-optimization by automatically capturing test images, analyzing focus quality, and adjusting lens parameters without manual intervention. The automated feedback loop enables the system to compensate for its own positioning errors and achieve optimal alignment independently, reducing the complexity of external calibration equipment.
3Ease of manufacture
If threaded barrel alignment method is used, then ease of manufacture is improved, but manufacturing precision deteriorates due to limited adjustment degrees of freedom
Solution Approach 1:
The patent replaces static threaded barrel adjustment with dynamic robotic positioning that can move the lens assembly in six degrees of freedom. The system uses motorized actuators to continuously adjust position and orientation parameters during alignment, enabling precise compensation for component variations that cannot be achieved with fixed-threaded mechanisms.
Solution Approach 2:
The system systematically varies multiple alignment parameters simultaneously (x, y, z positions and tip, tilt, rotation angles) to find the optimal configuration. By controlling six independent parameters through robotic actuators, the system can navigate the alignment parameter space efficiently and achieve superior precision compared to single-parameter threaded adjustment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This method achieves precise alignment of optical components, compensating for variations and ensuring optimal image quality by allowing for adjustments in multiple degrees of freedom, thereby improving the consistency and accuracy of lens alignment with digital camera sensors.
Implementation Method 1
A motor is disposed within the housing and is configured to move the floating optical element to a predetermined position
Data Source
AI summary
Methods and apparatus actively align a lens to a digital camera sensor. The lens includes a “floating” optical element. One or more test probes are temporarily electrically connected to electrical contacts, such as traces on a flexible printed circuit, of the lens. Motor control signals are injected via the test probes and the electrical contacts, so as to move the floating optical element to a predetermined position and maintain that position during the active alignment process.