Laser Centering Optical Elements Endoscope Image Quality
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Solution Overview
Problem
Current methods for centering optical elements in endoscopes, such as grinding and encasing in brass sleeves, fail to achieve precise alignment necessary for high-resolution image sensors, leading to decreased image quality, increased costs, and potential damage during the centering and rotating process.
Innovation Solution
The method involves using an ultra-short pulse laser for precise removal of the outer peripheral surface of optical elements, allowing them to be aligned and centered without a sleeve, enabling precise alignment of optical axes and preventing chipping, thus improving image quality and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If grinding process is used to center optical elements, then manufacturing simplicity is improved, but manufacturing precision deteriorates (cannot achieve required tolerances for high-resolution image sensors)
Solution Approach 1:
The patent replaces the mechanical grinding process with a laser-based centering and rotating device. The laser device uses optical fields to precisely measure and adjust the optical axis alignment, eliminating the need for mechanical grinding while achieving the required manufacturing precision for high-resolution image sensors.
Solution Approach 2:
The patent changes the physical parameters of the centering process by using laser beams to measure and adjust alignment. The laser device can precisely control and measure angular and positional parameters, enabling achievement of tight tolerances without the mechanical constraints of grinding processes.
2Manufacturing precision
If brass sleeve encasing and turning process is used, then manufacturing precision is improved (smaller diameter tolerances), but device complexity increases and process time increases
Solution Approach 1:
The patent extracts and eliminates the brass sleeve component from the system. Instead of encasing the optical element in a brass sleeve and then performing turning operations, the laser device directly centers and rotates the optical element itself, simplifying the device complexity while maintaining manufacturing precision.
Solution Approach 2:
The patent replaces the mechanical turning process with a laser-based system. The laser device uses optical measurement and control to achieve precise centering and rotating, eliminating the need for mechanical cutting tools and complex turning operations, thereby reducing process complexity while maintaining precision.
3Manufacturing precision
If brass sleeve encasing is used, then manufacturing precision is improved, but loss of substance increases and costs increase
Solution Approach 1:
The patent removes the brass sleeve from the process entirely. By using the laser device to directly center and rotate the optical element, the need for additional brass sleeve material is eliminated, reducing material waste and associated costs while maintaining the required manufacturing precision.
Solution Approach 2:
The patent eliminates the need for expensive brass sleeves and complex turning processes. The laser-based method uses minimal additional materials (primarily optical components) and reduces overall manufacturing costs while achieving the same precision outcomes.
4Manufacturing precision
If centering and rotating process is used, then manufacturing precision is improved, but loss of time increases
Solution Approach 1:
The patent replaces time-consuming mechanical centering and rotating processes with a laser-based system. The laser device can rapidly measure, detect, and adjust optical axis alignment through optical fields, significantly reducing the time required to achieve precise alignment while maintaining manufacturing precision.
Solution Approach 2:
The patent changes the measurement and control parameters from mechanical to optical domains. The laser device can rapidly acquire and process alignment data, enabling faster adjustment and centering operations compared to traditional mechanical methods, thereby reducing overall process time.
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 allows for the production of optical elements with larger diameters or reduced size without brass sleeves, enhancing image quality and eliminating the need for costly sleeve embedding, while ensuring precise alignment and preventing chipping during the centering process.
Implementation Method 1
the removal of the outer peripheral surface region takes place by laser ablation, such as by means of an ultra-short pulse laser
Data Source
AI summary
A method for preparing an optical element for insertion into an optical system of an endoscope, wherein the optical element has an optical axis and a peripheral surface that is basically parallel to the optical axis, the method including: arranging the optical element in a mounting of a spindle which rotates the optical element about an axis of rotation of the spindle, aligning the optical element on the spindle such that the optical axis of the optical element coincides with the axis of rotation of the spindle, and subsequent to the aligning, removing an outer peripheral surface region of the optical element until the peripheral surface has a constant spacing from the optical axis of the optical element, wherein the removing of the outer peripheral surface region takes place by laser ablation.