Camera Module Optical Alignment System
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Solution Overview
Problem
The alignment of camera modules during assembly and inspection is often disrupted, leading to defects and damage due to loose mechanical couplings in inspection and assembly devices, which results in a high defect rate and inefficient inspection processes.
Innovation Solution
A camera module inspection system comprising a control unit, alignment camera, alignment stage, and support socket, which uses image processing to determine the alignment of camera modules by comparing patterns and adjusting the alignment stage to align the camera module accurately with reference positions, minimizing mechanical stress and improving inspection efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a mechanical frame is used to align the camera module, then the alignment can be maintained during inspection and assembly, but the mechanical coupling becomes loose over time resulting in a high defect rate
Solution Approach 1:
The patent replaces the mechanical frame alignment system with an optical alignment system. The inspection device includes an alignment camera that captures images of the camera module, and a control unit that processes these images to determine alignment status. This optical system eliminates the mechanical coupling issues while maintaining alignment precision throughout the inspection and assembly processes.
Solution Approach 2:
The patent uses image capture to create a visual copy of the camera module's alignment state. The alignment camera photographs the camera module, and the control unit compares the captured image with reference patterns to determine alignment. This copying approach allows non-contact alignment verification, avoiding mechanical interference while ensuring precision.
2Adaptability or versatility
If the camera module is transported to multiple assembly and inspection devices, then comprehensive inspection and assembly can be performed, but the alignment of the camera module may be disturbed during transport
Solution Approach 1:
The patent replaces mechanical alignment maintenance with optical field-based alignment detection. The alignment camera and control unit continuously monitor the camera module's alignment status through image processing, allowing the module to be transported between devices without mechanical constraint. This enables comprehensive inspection while maintaining alignment reliability through non-contact optical verification.
3Productivity
If inspection is attempted while alignment is disturbed, then inspection can proceed without stopping the process, but strain is applied to the camera module and it may be damaged
Solution Approach 1:
The patent replaces mechanical alignment enforcement with optical alignment detection. The alignment camera captures images and the control unit analyzes them to determine if the camera module is properly aligned. This non-contact optical system allows inspection to proceed at high speed without applying mechanical stress, as the system can identify misalignment conditions and alert operators without forcing the module into position.
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
The system ensures precise alignment of camera modules, reduces defects, and enhances inspection speed and accuracy by using image processing to adjust the alignment stage, thereby minimizing mechanical stress and improving inspection efficiency.
Implementation Method 1
obtaining an image of the camera module by photographing a predetermined region of the camera module above the support socket by the alignment camera
Implementation Method 2
comparing the image of the camera module with the first pattern image to obtain a position of a first point included in the image of the camera module
Data Source
AI summary
A camera module inspection system and a method for operating the inspection system. More specifically, the inspection system can quickly check and correct the alignment of the camera module.