Camera Assembly Using Precision Lens Holder Posts
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Solution Overview
Problem
The current method of active alignment for positioning the lens relative to the image sensor in cameras is time-consuming and expensive, and the accuracy cannot be verified until the outer housing is assembled, making it inefficient and costly.
Innovation Solution
A camera assembly method that fixes the image sensor relative to the lens using a lens holder with posts and seats, eliminating all degrees of freedom by precision machining and non-adjustable alignment, allowing for a cost-effective and time-saving alternative to active alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If active alignment with software and mechanisms is used to align the lens relative to the image sensor, then alignment accuracy is improved, but assembly time and cost increase
Solution Approach 1:
The lens holder is pre-aligned to the circuit board using precision posts and seats with predetermined spacing relationships before final assembly. The posts extend from the lens holder at precise positions and the circuit board is aligned to these posts, establishing accurate relative positioning in advance of final assembly operations
Solution Approach 2:
Posts and seats serve as intermediary alignment features between the lens holder and circuit board. The posts extend from the lens holder and engage with corresponding features on the circuit board, mediating the alignment relationship and transferring precise positional information without requiring direct measurement or active adjustment
2Measurement precision
If active alignment with software and mechanisms is used to align the lens relative to the image sensor, then alignment accuracy is improved, but assembly cost increases
Solution Approach 1:
The alignment function is extracted from complex active alignment software and mechanisms and embedded directly into the mechanical structure of the lens holder and circuit board through precision-machined posts and seats. This eliminates the need for separate alignment systems while maintaining accuracy
Solution Approach 2:
Simple mechanical posts and seats replace expensive alignment software and mechanisms. These basic mechanical features provide sufficient alignment accuracy without requiring costly computational tools or complex adjustment mechanisms
3Adaptability or versatility
If the lens holder is aligned to the circuit board before mounting the outer housing, then alignment accuracy cannot be verified, but assembly flexibility is reduced
Solution Approach 1:
Alignment features (posts and seats) are established in advance during lens holder and circuit board preparation, before outer housing assembly. This preliminary establishment of precise mechanical relationships enables subsequent assembly steps to proceed without requiring disassembly for verification
Data Source
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AI summary
A method for assembling a camera includes providing a circuit board with a first surface defining a plane and an aperture extending entirely through the circuit board. An image sensor is fixed on the first surface. A lens holder is provided with a lens barrel defining a central axis and supporting a lens in a fixed position relative to the lens barrel. A post extends outward from the lens barrel in a first direction. The circuit board and the lens holder are oriented such that the plane defined by a first surface of the circuit board is perpendicular to the central axis. The circuit board and the lens holder are axially joined so that the post is received by the aperture. A final alignment of the image sensor relative to the central axis and the lens is non-adjustably fixed upon sliding the post through the aperture.