Lens Array Alignment with PD Arrays via Image Processing
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Solution Overview
Problem
Existing methods for aligning and bonding lens arrays with photodiode (PD) or laser arrays in optical communication systems suffer from high artificial error, poor repeatability, and high maintenance costs due to manual alignment and the use of expensive high-precision die bonders.
Innovation Solution
An automatic aligning bonding device and method utilizing image processing to precisely align and bond lens arrays with PD or laser arrays, featuring a cassette holding fixture, image acquisition CCD, high-resolution adjustment stage, pressure sensor, and stepping actuator, which calculates and adjusts the position of the lens array to coincide with the PD array's centers, ensuring high precision and repeatability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment method is used to align lens array and PD array, then operation simplicity is maintained, but alignment precision deteriorates due to large artificial error
Solution Approach 1:
The patent replaces the manual mechanical alignment system with an automated optical measurement and control system. The image acquisition device captures images of the lens array and PD array, and the control system automatically processes these images to determine center positions and calculate alignment deviations, substituting human visual judgment and manual adjustment with automated optical-mechanical systems.
Solution Approach 2:
The patent uses image acquisition to create optical copies (images) of the lens array and PD array positions. By capturing and processing these image copies, the system can analyze center positions and alignment relationships without direct physical contact or manual visual inspection, thereby improving measurement precision while maintaining operational simplicity.
2Manufacturing precision
If high-precision die bonder is used to achieve accurate alignment, then alignment precision is improved, but device cost and maintenance cost deteriorate
Solution Approach 1:
The patent replaces expensive high-precision mechanical die bonders with an automated optical measurement and control system. The system uses image acquisition devices and computational algorithms to achieve precise alignment without requiring costly mechanical bonding equipment, thereby reducing device investment and maintenance costs while maintaining high alignment precision.
Solution Approach 2:
The system enables self-alignment through automated image processing and control. The control system automatically processes images, calculates center positions, determines alignment deviations, and guides adjustment without requiring expensive external equipment or manual intervention, making the alignment process self-sufficient and cost-effective.
3Device complexity
If manual alignment method is used, then device complexity is reduced, but repeatability deteriorates due to poor repeatability
Solution Approach 1:
The patent implements a feedback control mechanism where the image acquisition device continuously monitors the positions of the lens array and PD array, the control system processes this information to calculate alignment deviations, and the system adjusts positions based on this feedback until alignment requirements are met. This closed-loop feedback ensures high repeatability while maintaining relatively simple device structure.
Solution Approach 2:
The patent replaces manual alignment operations with an automated control system that uses optical measurement and computational processing. This substitution eliminates human variability and ensures consistent, repeatable alignment results through standardized automated procedures, while keeping the overall device structure relatively simple.
4Manufacturing precision
If image processing alignment method is implemented, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent designs the control system to perform multiple functions: acquiring images, processing images, calculating center positions, determining alignment deviations, and controlling adjustment operations. By making the control system universal and multi-functional, the patent achieves high alignment precision without adding separate dedicated devices for each function, thereby limiting the increase in device complexity.
Solution Approach 2:
The patent combines the image acquisition, image processing, calculation, and control functions into an integrated control system. By merging these functions into a single coordinated system rather than separate independent devices, the patent achieves high alignment precision while minimizing the increase in overall device complexity.
Data Source
AI summary
Device and method are provided to align and bond a lens array to a PD array with high precision, which can implement aligning and bonding of the lens array automatically. A telescopic rod of the stepping actuator is adjusted until photosensitive areas of the PD array form a clear image on the image acquisition CCD through the lens array, an adjusted distance h1 of the telescopic rod is recorded, and a position coordinate (xn, yn) of center of each circular photosensitive area in the image may be obtained, and a slope k1 of a line connecting the centers of the photosensitive areas is calculated. The telescopic rod is adjusted again, and a slope k2 of a line connecting the centers of the apertures of the lens array is calculated. Based on calculated values Δxn, Δyn, arctan(k1)−arctan(k2), the high-resolution adjustment stage is adjusted to adjust position of the lens array.