Bidirectional Lens Pressing System with Counterbalanced Motor Stages
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Solution Overview
Problem
Existing lens pressing technologies for optical devices are imprecise, slow, and prone to damaging lenses or holders due to unbalanced forces, leading to low productivity and poor part throughput.
Innovation Solution
A bidirectional lens pressing system with a frame supporting top and bottom motor stages and an indexing stage, using opposing pressing tools to precisely insert lenses into holders while minimizing stress on the indexer stage, and incorporating a separator housing to prevent sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual lens pressing is used, then operation simplicity is maintained, but manufacturing precision and productivity are poor
Solution Approach 1:
The pressing system is divided into two independent motor stages (top and bottom) that can be controlled separately. Each motor stage independently controls one pressing tool, allowing precise bidirectional force application without requiring a complex single-stage mechanism.
Solution Approach 2:
The system changes the pressing parameter from unidirectional force application to bidirectional force application. By controlling both top and bottom motor stages, the system can apply forces from opposite directions simultaneously, achieving precise lens placement while balancing forces on the indexer stage.
2Productivity
If automatic lens pressing is used, then productivity is improved, but lens position control accuracy deteriorates
Solution Approach 1:
The system incorporates feedback control through motor stages that can precisely control the position and force of pressing tools. The bidirectional control allows real-time adjustment of pressing forces from both top and bottom, maintaining accurate lens positioning while achieving high throughput through automated operation.
3Reliability
If unidirectional pressing force is applied, then device simplicity is maintained, but component damage risk increases due to unbalanced forces
Solution Approach 1:
The bottom motor stage acts as a counterbalance to the top motor stage. By applying opposing forces from both directions, the system balances the net force on the indexer stage, preventing damage to the lens, holder, or stage while maintaining a relatively simple mechanical structure.
4Productivity
If manual pressing operation is used, then ease of operation is maintained, but productivity and production speed are slow
Solution Approach 1:
The automated pressing system performs the pressing operation autonomously without requiring manual intervention. The motor stages automatically control the pressing tools, and the system manages its own operation sequence, achieving high productivity while reducing the need for complex manual operations.
Data Source
AI summary
A bidirectional lens pressing system for use in pressing a lens into a port housing is disclosed. The lens pressing system includes a frame that supports a top motor stage, a bottom motor stage, and an indexing stage. The indexing stage is interposed between the top and bottom motor stages and includes a hole that retains a port housing or other component. The top pressing tool is selectively movable in a first direction by the top motor stage and includes a first engagement surface for engaging the lens. Correspondingly, the bottom pressing tool is selectively movable in a an opposing second direction by the bottom motor stage and includes a second engagement surface for engaging the port housing. The first and second engagement surfaces of the top and bottom pressing tools cooperate to press the lens into the port housing while imposing no net force on the indexing stage.