Beam Coupler Asymmetric Binding Mechanism
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Solution Overview
Problem
Conventional beam couplers in laser systems face inefficiencies in alignment processes due to the need for repetitive adjustments across multiple axes, leading to continuous misalignment and refocusing issues, which are time-consuming and mechanically challenging.
Innovation Solution
A beam coupler assembly with an asymmetric load mechanism that secures the inner lens housing, allowing for predictable and repeatable Z-axis adjustment while minimizing X and Y-axis movement, using a focus adjust lever and compression springs to maintain alignment and allow sliding Z-axis movement with minimal effort.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If conventional three-screw adjustment mechanism is used for X, Y, and Z axis alignment, then all three axes can be adjusted, but continuous X and Y axis misalignment occurs during Z axis adjustment requiring repetitive refocusing
Solution Approach 1:
The adjustment mechanism is segmented into two independent functional parts: a bind mechanism (using bind screws and bind surfaces) that constrains X and Y axis movement, and a focus adjustment mechanism (using focus adjustment screw) that enables Z axis movement. This segmentation allows Z axis adjustment without affecting X and Y alignment, eliminating the need for repetitive refocusing.
Solution Approach 2:
The bind condition is created through asymmetric positioning of bind screws relative to the lens housing, where the bind screws contact off-center surfaces of the lens housing. This asymmetric arrangement creates a mechanical constraint that prevents rotational and lateral movement while allowing axial movement, thereby maintaining X and Y alignment during Z axis focus adjustment.
2Manufacturing precision
If fine pitch adjust screws are used for precise alignment, then alignment precision can be achieved, but the adjustment process becomes mechanically complex and difficult
Solution Approach 1:
The complex three-screw adjustment system is simplified by extracting and separating the alignment function from the focus adjustment function. The bind mechanism extracts the X and Y axis constraint function, while the focus adjustment screw handles only Z axis movement. This extraction reduces device complexity while maintaining alignment precision through the bind condition that prevents misalignment during focus adjustment.
3Reliability
If repetitive X, Y, refocus Z cycles are performed to achieve alignment, then both alignment and focus can be achieved, but the process is time-consuming and mechanically challenging
Solution Approach 1:
The bind mechanism is configured to maintain the bind condition before and during focus adjustment, preliminarily constraining X and Y axis movement. This preliminary action ensures that when focus adjustment is performed, the lens housing cannot shift in X or Y directions, thereby maintaining alignment stability without requiring repetitive realignment cycles and significantly improving alignment speed.
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
Enables efficient and time-saving alignment of fiber laser components by preventing X and Y-axis misalignment during Z-axis adjustments, facilitating a more economical and precise optical alignment process.
Implementation Method 1
compression springs to maintain alignment and allow sliding Z-axis movement with minimal effort
Implementation Method 2
at least one adjustment screw and a focus lever having a pivot; the adjustment screw is threadably extendable and retractable relative to the lens assembly
Implementation Method 3
focus lever having a pivot; the adjustment screw is threadably extendable and retractable relative to the lens assembly
Data Source
Figure 1~2
Figure 3
Figure 4~5
AI summary
A beam coupler alignment system for a fiber laser system is disclosed. The system includes a focus adjust collimator assembly having an inner and outer housing assembly portion. The inner assembly includes a coupler housing assembly and a modified lens housing received within and adjustable relative to via a mechanism configured and arranged to apply an asymmetric binding force in a predictable and repeatable manner. A lever assembly contacts the lens housing and exerts an off-center (asymmetric) force relative to coupler housing assembly creating a friction bind eliminating X and Y axis movement yet allowing Z axis movement with minimal effort. The assembly may further include an alignment mechanism configured and arranged to optically align an input collimator unit and an output collimator unit of a complex fiber laser system about a common optical axis using the proposed assembly.