Imaging Module Compensation Algorithm for Manufacturing Variations
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Solution Overview
Problem
Imaging modules face imperfections due to design and manufacturing-related issues, as well as environmental factors like temperature and humidity, leading to inconsistent image performance across different units.
Innovation Solution
A compensation algorithm is applied to correct image distortions by using lens design parameters, actual module performance data, and environmental conditions, stored in an electronic memory, to produce consistent imaging performance across units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manufacturing tolerances are relaxed to reduce cost and complexity, then manufacturing precision deteriorates, but statistical variations cause actual lens performance to deviate from design values
Solution Approach 1:
The patent applies preliminary action by pre-characterizing each lens's actual optical performance through measurement against a reference imager, storing these measurements as lookup tables in memory before the lens is used. This allows the system to compensate for manufacturing variations without requiring tighter manufacturing tolerances, effectively decoupling manufacturing precision from final performance consistency.
Solution Approach 2:
The patent changes parameters by using software-based optical parameter adjustments to compensate for manufacturing deviations. Instead of physically adjusting lens dimensions or materials, the system modifies imaging parameters through processing algorithms that reference pre-stored performance data, allowing cost-effective production while maintaining consistent optical performance.
2Manufacturing precision
If mechanical alignment devices are used to align focal plane with image sensor, then manufacturing precision improves, but device complexity increases and thermal expansion causes focus drift
Solution Approach 1:
The patent replaces mechanical alignment and adjustment devices with a software-based system. Instead of using complex mechanical mechanisms to physically align the focal plane with the image sensor, the system uses pre-stored performance measurements and processing algorithms to compensate for misalignment, eliminating the need for mechanical adjustment components and reducing thermal expansion issues.
Solution Approach 2:
The patent introduces an intermediary element in the form of a lookup table stored in memory, which acts as a mediator between the physical lens-imager assembly and the final image output. This intermediary contains pre-measured performance data that allows the system to compensate for alignment errors without requiring real-time mechanical adjustment, simplifying the overall device architecture.
3Manufacturing precision
If lens design is optimized for high resolution, then imaging performance improves, but manufacturing complexity and cost increase due to special processes and equipment
Solution Approach 1:
The patent applies preliminary action by pre-measuring and storing the actual optical performance characteristics of each lens during or after manufacturing. This allows the lens to be produced using standard, cost-effective manufacturing processes, while the pre-stored performance data enables subsequent software compensation to achieve high-resolution imaging quality without requiring complex or expensive manufacturing techniques.
Data Source
AI summary
An imaging module is described that acquires images of objects and outputs a digital image of the objects that is corrected for aberrations and flaws due to design, manufacturing constraints and variability, and, the local environment (temperature and humidity). The imaging module includes memory to store adjustment parameters, environmental sensors, and, a computing device that processes the raw acquired image into a corrected processed image. The imaging module is used with a test apparatus to calibrate the imaging module and calculate empirically determined correction factors that are stored in memory within the imaging module.