Indicia Reader Imaging Engines With Interchangeable Aiming Optics
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Solution Overview
Problem
Existing imaging engines for indicia readers face challenges in being easily implemented across multiple device platforms due to costly and complex manufacturing processes for interchangeable aiming patterns, particularly when using one-piece molded collimator/pattern generator lenses.
Innovation Solution
The imaging engine design incorporates a polycarbonate optic element holder with active alignment features and interchangeable optical elements, such as a ZEONEX Cyclo Olefin Polymer collimator lens, allowing for efficient and cost-effective manufacturing by enabling active alignment and good adhesion to a Zink or Zink-alloy chassis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If one-piece molded collimator/pattern generator lenses are used, then manufacturing simplicity is improved, but manufacturing precision and adaptability deteriorate due to inability to easily customize aiming patterns
Solution Approach 1:
The optical element holder is divided into separate components: a holder body and interchangeable optical elements. This segmentation allows the holder to be manufactured once and reused with different optical elements, enabling customization of aiming patterns without remanufacturing the entire assembly.
Solution Approach 2:
The optical element holder is designed with universal mounting features that can accommodate different types of optical elements (collimators, pattern generators, diffractive elements). This multi-functionality allows a single holder design to support multiple aiming pattern configurations, improving adaptability while maintaining manufacturing simplicity.
2Manufacturing precision
If active alignment features are added to the optic element holder, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The active alignment features are merged directly into the optical element holder structure itself rather than being separate components. The holder includes integrated alignment features such as alignment pins, recesses, or indexing mechanisms that are part of the holder body, reducing overall structural complexity while maintaining precision.
Solution Approach 2:
The optical element holder is designed with self-aligning features that automatically position optical elements correctly during assembly. Features such as precision-machined recesses, alignment pins, or interference-fit mounting structures enable the optical elements to self-align without requiring complex external alignment apparatus, reducing device complexity.
3Adaptability or versatility
If interchangeable optical elements are implemented, then adaptability is improved, but manufacturing complexity increases
Solution Approach 1:
The optical element holder is pre-manufactured with all necessary mounting features, alignment structures, and retention mechanisms in place. This preliminary preparation allows optical elements to be quickly interchanged without requiring complex assembly procedures, as the holder is already configured to receive and secure the optical elements properly.
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 design facilitates easier customization and manufacturing of imaging engines with desired aiming patterns, reducing costs and complexity while maintaining optical performance.
Implementation Method 1
the aiming illumination source is coupled to the aiming-assembly chassis such that the aiming-assembly chassis is a heatsink for the aiming illumination source
Implementation Method 2
the first optical lens arrangement includes an optical polymer collimator lens
Data Source
AI summary
Concepts described in the present disclosure relate to imaging engines used in indicia readers, such as barcode readers. The imaging engine includes a printed circuit board, an imaging sensor, and imaging optics. Also, it includes an aiming assembly with an aiming illumination source and an aiming optics assembly. The assembly has an optic element holder and a first optical lens arrangement, where the optical holder includes at least one feature for active alignment in the XYZ direction. These arrangements produce different aim light patterns when projected on a surface.