Collimator Holder for Electro-Optical Sensor Alignment
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Solution Overview
Problem
Existing optical sensors face alignment and bonding challenges due to thermal expansion issues, leading to inaccurate measurements of current and voltage in current-carrying cables, particularly when multiple collimator assemblies are involved, which complicates precise alignment and bonding processes.
Innovation Solution
A collimator holder with precision-machined channels that accommodate collimator assemblies, allowing for precise alignment and bonding, and featuring channels with thermal expansion coefficients matching those of the components to minimize thermal effects, along with a magnetic concentrator to stabilize the optical sensor assembly and reduce environmental interference.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If collimator assemblies are bonded directly to the PBS with tight tolerances, then measurement precision is improved, but manufacturing precision becomes more difficult to achieve due to thermal expansion effects
Solution Approach 1:
The patent introduces a collimator holder as an intermediary component between the collimator assemblies and the PBS. This holder provides a stable mounting structure with precision-machined channels that accommodate the collimator assemblies, eliminating the need for direct bonding to the PBS while maintaining precise alignment. The holder acts as a mediator that isolates the optical components from thermal expansion effects of the PBS.
Solution Approach 2:
The patent changes the mounting parameter from direct bonding (requiring tight angular tolerances) to precision-machined channel accommodation. The channels are designed with specific dimensional parameters that allow the collimator assemblies to be positioned and held at the correct orientation without bonding, thereby relaxing the manufacturing tolerance requirements while maintaining measurement precision.
2Measurement precision
If multiple collimator assemblies are aligned precisely relative to each other, then measurement precision is improved, but device complexity increases due to the need for precise parallel alignment
Solution Approach 1:
The patent merges multiple collimator assemblies into a single integrated structure by mounting them simultaneously in precision-machined channels within one collimator holder. This approach ensures that all collimator assemblies are automatically aligned parallel to each other relative to the PBS, eliminating the need for separate alignment procedures for each assembly while maintaining high measurement precision.
3Strength
If bonding surface area between GRIN lens and PBS is increased, then bonding strength is improved, but the cross-sectional area constraint limits the available surface area
Solution Approach 1:
The collimator holder serves as an intermediary that provides a larger bonding surface area between the optical components and the PBS. Instead of bonding the GRIN lens directly to the PBS with limited surface area, the holder acts as a mediator with sufficient surface area for strong bonding, thereby improving bonding strength without being constrained by the small cross-sectional area of the GRIN lens.
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 collimator holder ensures precise alignment and stability of collimator assemblies over temperature changes, enhancing the accuracy and reliability of current and voltage sensing in optical sensors, while the magnetic concentrator maintains sensor stability and reduces measurement errors caused by environmental factors.
Implementation Method 1
channels with thermal expansion coefficients matching those of the components to minimize thermal effects
Implementation Method 2
magnetic concentrator to stabilize the optical sensor assembly and reduce environmental interference
Data Source
AI summary
A collimator holder in the form of a glass or ceramic block that has precisely machined holes formed in the block to receive respective collimator assemblies. Each collimator assembly includes an optical fiber attached to a GRIN lens by a ferrule. Optionally, each collimator assembly can include a glass tube that surrounds at least the lens and optionally part or all of the ferrule. The lens or the tube is inserted into the hole and bonded therein by an epoxy. The block, together with the collimator assemblies installed, is bonded to the bottom surface of a crystal assembly thereby forming an electro-optic sensor. The crystal assembly can include one or more polarizing beam splitters, an electro-optic crystal, and a prism, configured to sense a current through a current-carrying cable or a voltage between the cable and another potential.