Adjustable Sensor Mount Systems for Sealed Optical Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Optical performance in imaging systems is compromised by sensor misalignment and contamination, particularly in high-resolution systems with large apertures, where tilt-adjustable sensors fail to maintain alignment and are prone to debris-related issues.
Innovation Solution
The development of adjustable sensor mount systems that include a platform and a sensor assembly forming a sealed cavity, allowing for precise tilt adjustment via movement of the sensor assembly relative to the platform, with options for fixation using fasteners or bonding glue, and incorporating UV-transmitting materials for enhanced bonding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tilt-adjustable imaging sensors are used, then sensor alignment can be adjusted, but the sensor fails to maintain alignment for extended periods and over repeated use
Solution Approach 1:
The sensor is pre-aligned using adjustment mechanisms (screws, stages, or flexure assemblies) before being permanently fixed in place using adhesive or bonding. This preliminary alignment action ensures precise positioning is achieved before fixation, resolving the contradiction between adjustability and long-term alignment maintenance.
2Measurement precision
If tilt-adjustable imaging sensors are used, then fine adjustment of sensor tilt alignment is possible, but the sensor assembly becomes too large and bulky for compact imaging systems
Solution Approach 1:
The adjustment function is segmented from the sensor assembly proper. Adjustment mechanisms (screws, stages, or flexure assemblies) are positioned around the sensor rather than integrated within it, allowing fine tilt alignment capability while maintaining a compact sensor assembly volume.
Solution Approach 2:
The adjustment mechanisms operate in spatial dimensions external to the sensor assembly volume. For example, adjustment screws are positioned laterally around the sensor, and flexure assemblies are mounted on the housing, allowing tilt adjustment without increasing the sensor assembly's footprint in the optical path dimensions.
3Object-affected harmful factors
If sensors are located within sealed, closed compartments, then protection against dust and debris is improved, but adjustment mechanisms may release debris particles due to wear
Solution Approach 1:
The adjustment mechanisms are extracted from the sealed sensor compartment and positioned in the external environment. Adjustment screws, stages, or flexure assemblies are located outside the sealed housing, allowing the sensor itself to remain protected within the sealed compartment while adjustment operations occur externally, eliminating wear debris generation inside the sealed space.
Solution Approach 2:
A sealed housing or protective barrier acts as an intermediary between the sensor and the external environment. The sensor remains enclosed in the sealed compartment, while adjustment mechanisms operate externally on the housing or mounting structure, preventing direct contact between wear mechanisms and the sealed sensor environment.
4Measurement precision
If adjustable moving parts are used in sensor mounts, then sensor alignment adjustment is enabled, but optical performance decreases due to debris release from wear
Solution Approach 1:
Adjustment mechanisms are extracted from the sealed optical environment and positioned externally. This allows the sensor alignment to be adjusted while preventing wear debris from contaminating the optical path, thereby maintaining optical performance while enabling alignment adjustment.
Solution Approach 2:
The patent replaces traditional mechanical adjustment mechanisms that generate wear debris with alternative mechanisms such as adhesive bonding systems or flexure assemblies that minimize wear. These substitutions maintain alignment adjustability while preserving optical performance by eliminating debris generation in the optical environment.
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
These systems maintain optical performance by ensuring precise sensor alignment and protection against dust and debris, allowing for both fine adjustment and secure fixation, thereby improving image quality and extending the lifespan of imaging components.
Implementation Method 1
the sensor may be fixed by bonding the sensor assembly to the platform
Implementation Method 2
At least a portion of the sensor assembly may optionally comprise a UV-transmitting material, such as but not limited to glass, in order to allow for UV-activation of a bonding glue
Data Source
AI summary
Closed cavity adjustable sensor mount systems and methods are disclosed. The sensor mount systems include a sealed, closed cavity enclosing a sensor and forming a closed cavity sensor assembly. The closed cavity sensor assembly may be tilted and/or translated relative to a platform in order to adjust the orientation of the sensor to align it with an imaging optical axis. Following alignment, the closed cavity sensor assembly may be permanently or reversibly fixed in place. The closed cavity adjustable sensor mount systems may be part of medical imaging systems such as endoscopic imaging systems and/or open field imaging systems.