Camera Module Lens Assembly Pre-Adjustment and Active Alignment
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Solution Overview
Problem
Current camera module assembly processes are inefficient due to high requirements for software algorithms and long adjustment times, making it difficult to meet the rapid production demands of the electronics terminal market, particularly in producing high-quality lenses with precise alignment.
Innovation Solution
A method involving the pre-adjustment of lens parts using laser ranging to align the inclination of lens surfaces in v and w directions, followed by active alignment in x, y, and z directions, and subsequent bonding to achieve precise optical system assembly, reducing the burden on the active alignment step and improving production efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment adjusts the upper lenses part at six degrees of freedom (translation in x, y, z directions and rotation in u, v, w directions) according to imaging result, then the assembly tolerance and imaging quality are improved, but the software algorithm complexity and adjustment time increase significantly
Solution Approach 1:
The patent segments the alignment adjustment into two independent stages: pre-adjustment (adjusting inclination angles α and β) and active alignment (adjusting positions in x, y, z directions). This segmentation reduces the complexity of the software algorithm by separating rotational adjustment from translational adjustment, allowing each stage to focus on specific parameters rather than handling all six degrees of freedom simultaneously.
Solution Approach 2:
The patent implements preliminary action by performing pre-adjustment of the inclination angles α and β before the active alignment process. This preliminary adjustment of the posture of the upper lenses part relative to the lower lenses part reduces the burden on the subsequent active alignment step, as the system starts from a pre-aligned state rather than requiring full six-degree-of-freedom adjustment from scratch.
2Manufacturing precision
If active alignment adjusts the upper lenses part at six degrees of freedom according to imaging result, then the imaging quality meets requirements, but the production efficiency decreases due to long adjustment time
Solution Approach 1:
The patent implements preliminary action by performing pre-adjustment of the inclination angles α and β before the active alignment process. This preliminary adjustment reduces the adjustment time required in the subsequent active alignment step, as the system starts from a pre-aligned state. The pre-adjustment phase handles the inclination alignment separately, allowing the active alignment to focus only on positional adjustments, thereby reducing total adjustment time and improving production efficiency.
Solution Approach 2:
The patent segments the alignment process into two phases: pre-adjustment (handling inclination angles) and active alignment (handling positional parameters). This segmentation allows parallel processing or optimized sequencing of adjustment operations, reducing the total time required to achieve the required imaging quality while maintaining manufacturing precision.
3Ease of manufacture
If the complete lenses is assembled as a single unit, then the assembly process is simple, but the assembly tolerance between components affects the resolution of the lenses
Solution Approach 1:
The patent divides the complete lenses into two separate parts (upper lenses part and lower lenses part) that can be adjusted independently. This segmentation allows for precise control of each part's position and orientation through the pre-adjustment and active alignment process, compensating for component tolerances and achieving high-resolution imaging quality that would be difficult to obtain through simple assembly of a complete lenses as a single unit.
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
This approach reduces the complexity of the active alignment algorithm, enhances the consistency of product positioning, maintains imaging quality, and increases production efficiency by transferring some adjustments from the active alignment step to a pre-adjustment phase, thus addressing the inefficiencies in existing assembly methods.
Implementation Method 1
measuring at least 30 second distance-measuring points on the second end surface with a distance-measuring device so as to identify a current inclination posture of the second end surface
Data Source
AI summary
A method for assembling an optical lens includes preparing a first lenses part including a first lens and a second lenses part including a second lens, capturing the first lenses part, and adjusting a posture of the first lenses part according to a distance measurement result, so that an included angle between a first end surface of the first lenses part and a second end surface of the second lenses part is less than a threshold of inclination angle. The method also includes adjusting the first lenses part at degree of freedom of linear movement to complete pre-positioning, performing an active alignment of a position of the first lenses part at the degree of freedom of linear movement according to an actual imaging result, and fixing the first and second lenses parts together, so that their relative positions are maintained at the relative positions determined by the active alignment.