Lens Flat Surface Center Marker for Optical Module Alignment
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Solution Overview
Problem
The continuous convex-curved shape of the lens surface causes non-uniform reflected light intensity, leading to inaccurate recognition of the lens center position, resulting in beam spreading and direction deviation, which affects system performance.
Innovation Solution
A flat surface perpendicular to the laser light's optical axis is integrated into the lens's upper surface, ensuring even reflection and clear distinction between the bright spot and its surroundings, allowing precise recognition of the lens center.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a continuously convex-curved lens surface is used, then the lens can collect or collimate laser light, but the reflected light intensity distribution becomes continuous and non-uniform, making it difficult to accurately recognize the lens center position
Solution Approach 1:
The lens surface is segmented into two distinct regions: a continuously convex-curved region for light collection/collimation and a flat surface region for accurate center recognition. This segmentation allows each region to fulfill its specific function without interfering with the other, solving the contradiction between maintaining continuous curvature for optical performance and creating a distinguishable center marker for positioning accuracy.
Solution Approach 2:
A flat surface is created at the center portion of the lens, while the peripheral regions maintain the continuously convex-curved shape. This local quality change creates a distinct reflected light pattern (uniform brightness from the flat center vs. gradient brightness from the curved periphery), enabling accurate center recognition while preserving the optical collimation function in the curved regions.
2Manufacturing precision
If active alignment method is used to install the lens, then the lens center can be aligned with the light emission point, but the manufacturing apparatus becomes complex and the manufacturing time increases
Solution Approach 1:
The lens structure itself provides the alignment function through its flat surface center marker. When recognition light is radiated onto the lens, the flat surface creates a distinct reflected light pattern that automatically indicates the center position, eliminating the need for complex active alignment apparatus that would otherwise be required to observe and adjust the emission pattern.
Solution Approach 2:
The complex mechanical active alignment system (requiring light emission, pattern observation, and iterative lens position adjustment) is replaced by a simpler optical reflection-based center recognition method. The flat surface on the lens creates a clear reflected light signature that directly indicates the center position, substituting a simple optical detection method for the complex mechanical alignment system.
3Productivity
If the lens center position is incorrectly recognized, then assembly can be performed quickly, but the beam spreading angle increases and the emission direction deviates, deteriorating system characteristics
Solution Approach 1:
The flat surface is pre-formed on the lens during lens manufacturing, creating a permanent center marker that simplifies subsequent assembly operations. This preliminary action eliminates the need for time-consuming alignment procedures during assembly, as the center position can be quickly and accurately identified by observing the reflected light pattern from the flat surface, thereby improving both assembly speed and alignment accuracy.
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 solution reduces the displacement between the light emission point and the lens center, minimizing beam spreading and direction deviation, thereby enhancing system characteristics.
Implementation Method 1
When recognition light is radiated toward the upper surface of the lens, the reflected light from the flat surface enters the camera at the center position thereof evenly with an identical strength
Data Source
AI summary
A laser device (3) emits laser light. A lens cap (4) covers the laser device (3). A lens (5) is built in the lens cap (4) and collects or collimates the laser light. A flat surface (7) perpendicular to an optical axis (6) of the laser light is provided in an upper surface of the lens (5).