Automated Optical Lens Alignment System for Pancake Assemblies
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Solution Overview
Problem
Conventional systems for assembling pancake lens assemblies in optical devices face high manufacturing costs, high output quality control costs, and long cycle times due to the need for precise alignment of polarization-sensitive optical elements, leading to a high failure rate and wasted products.
Innovation Solution
A fully automated assembling and testing system that includes a first assembly and validation line for initial lens assembly and a second line for adjusting centering, tilting, and polarization alignment, allowing for the reassembly of failed lenses to meet specifications, reducing waste and cycle time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional manual alignment methods are used for polarization-sensitive optical elements, then alignment precision can be achieved, but manufacturing cost increases and cycle time extends
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated system that uses image capture devices, processors, and robotic positioning mechanisms. The system captures images of optical elements, processes them to determine alignment status, and automatically adjusts positions, eliminating the need for expensive manual alignment equipment and operations while maintaining precision.
Solution Approach 2:
The system enables the optical assembly process to self-correct alignment issues through automated feedback loops. When misalignment is detected via image processing, the system automatically repositions elements without external intervention, and can even disassemble and reassemble components to achieve proper alignment, reducing dependency on external alignment equipment.
2Manufacturing precision
If conventional manual alignment methods are used for polarization-sensitive optical elements, then alignment precision can be achieved, but cycle time increases
Solution Approach 1:
The patent replaces time-consuming manual alignment operations with automated image capture and processing systems that can rapidly assess alignment status and execute corrections. The automated system eliminates the sequential steps of manual inspection and adjustment, enabling parallel processing and significantly reducing the time required to achieve precise alignment.
Solution Approach 2:
The system performs preliminary alignment assessments using image capture before final assembly is completed. By detecting potential alignment issues early in the process and making preliminary corrections, the system prevents the need for time-consuming rework and ensures proper alignment is achieved during the initial assembly phase.
3Ease of manufacture
If conventional assembly methods are used, then manufacturing process is simple, but failure rate increases and quality control cost increases
Solution Approach 1:
The patent implements a feedback mechanism where image capture devices continuously monitor the alignment status of optical elements during assembly. The processor analyzes these images and provides real-time feedback on alignment quality, enabling the system to detect and correct deviations before they result in assembly failures. This automated inspection and correction loop significantly reduces the failure rate while maintaining process simplicity.
Solution Approach 2:
The system introduces an intermediary automated inspection and correction layer between the manual assembly process and the final quality control stage. This intermediary system uses image processing to detect alignment issues that might be missed by simple visual inspection, providing an additional safeguard against assembly failures without significantly complicating the manufacturing process.
4Ease of manufacture
If conventional assembly methods are used, then manufacturing process is simple, but quality control cost increases
Solution Approach 1:
The patent integrates quality control feedback directly into the manufacturing process through automated image capture and analysis. Rather than requiring separate, expensive quality control equipment and manual inspection procedures, the system uses the same imaging infrastructure to provide continuous quality monitoring, eliminating the need for duplicate quality control investments.
Solution Approach 2:
The patent merges the quality control function with the manufacturing process itself. The same image capture devices and processing systems used for alignment monitoring during assembly are also used for final quality verification, combining multiple functions into a single integrated system and reducing the need for separate quality control equipment and personnel.
Data Source
AI summary
A housing assembly for mounting a first lens and a second lens includes a first lens holder. The first lens holder includes a ring-shaped structure configured to mount the first lens. The housing assembly also includes a second lens holder including a cup-shaped structure. The cup-shaped structure includes an upper portion configured to mount the first lens holder, and a lower portion configured to mount the second lens.