Lens Alignment Using Laser Displacement Measurement
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for aligning and positioning lenses in manufacturing are time-consuming and limited in their ability to accurately align a wide range of optical radii, including cylinder shapes and toroids, which hinders the achievement of high concentricity and consistent lens thickness.
Innovation Solution
A method and apparatus utilizing a laser displacement measurement device in conjunction with an X-Y-Z micron stage and a processor to calculate the apex of a curved lens surface by measuring displacement at multiple points, allowing for precise alignment and positioning of lenses beyond the limitations of conventional optical systems.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment and positioning methods are used, then flexibility and ease of operation are maintained, but time consumption increases and manufacturing precision deteriorates
Solution Approach 1:
The patent replaces manual mechanical alignment methods with an automated optical measurement system. A camera captures images of the lens surface, and a computer processes these images to automatically determine the apex position and calculate alignment parameters, eliminating the need for manual measurement tools and procedures while significantly improving both precision and speed.
Solution Approach 2:
The patent creates a digital copy (image) of the lens surface instead of relying on physical manual measurement. By capturing the lens surface geometry through photography and then analyzing the digital image data, the system achieves repeatable, high-precision measurements without the variability inherent in manual operations.
2Measurement precision
If conventional optical systems with reticle images are used, then measurement accuracy is maintained, but the range of measurable optical radii is limited and processing speed decreases
Solution Approach 1:
The patent changes the fundamental measurement parameter from optical image focusing (which has fixed focal length constraints) to direct laser displacement measurement. By using a laser to measure the actual physical distance to the lens surface at multiple points, the system can accurately measure any optical radius regardless of the lens curvature or shape, thereby expanding the measurable range while maintaining precision.
Solution Approach 2:
The patent transitions from two-dimensional optical image analysis to three-dimensional spatial measurement. By using a laser displacement sensor that can measure distances in multiple spatial dimensions (x, y, z coordinates), the system gains the ability to characterize complex three-dimensional lens geometries including cylinders, toroids, and other non-spherical forms that were difficult or impossible to measure with conventional optical methods.
3Manufacturing precision
If conventional optical alignment methods are used, then focus on spherical surfaces is maintained, but capability to align cylinder shapes, toroids, and other geometric figures is limited
Solution Approach 1:
The patent creates a universal measurement and alignment system that can handle multiple geometric shapes (spheres, cylinders, toroids, and other forms) with a single laser displacement measurement device. By measuring the apex position and surface geometry at multiple points in three-dimensional space, the same system can accurately align any lens shape, making the equipment multi-functional and adaptable to various lens manufacturing requirements.
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 enables faster and more accurate alignment and positioning of lenses across a broader range of radii, reducing cycle time and manufacturing costs, and facilitating fully automated processes without manual intervention.
Implementation Method 1
a laser displacement measurement device... Displacement between the laser displacement measurement device and the curved surface is then measured
Implementation Method 2
measuring displacement at multiple points... displacement between the laser and the surface
Data Source
Figure 1a~1d
Figure 2
Figure 3
AI summary
A method and apparatus for aligning and positioning a surface such that the optical and/or cylinder axis of the surface is precisely aligned with a fixture for the purpose of assembly or further mechanical operations such as machining and polishing. According to another aspect of the invention, a lens apex is located and precisely positioned a constant distance from a reference point. In order to implement the above, a method and apparatus is disclosed for optically aligning and positioning surfaces using a precision laser displacement measurement device, an X-Y-Z micron stage, and a microprocessor (or computer) capable of performing curvature analysis.