Lens Selection for Camera Focus via MTF Testing
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Solution Overview
Problem
Existing camera assembly processes face challenges in achieving consistent Modulation Transfer Function (MTF) performance due to variations in lens focus ability caused by subtle assembly conditions, leading to high failure rates in end-of-line testing and significant waste of camera assemblies.
Innovation Solution
The implementation of a method using CMAT equipment to actively select lenses by performing initial and subsequent five-axis lens alignment checks with and without adhesive, ensuring that only lenses meeting MTF thresholds are used in final camera assemblies, thereby reducing waste and improving production output.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If lenses are selected without active MTF testing during assembly, then production speed is improved, but MTF performance consistency deteriorates
Solution Approach 1:
The system performs preliminary MTF testing and lens selection during the assembly process itself, rather than relying on pre-sorted lenses. The CMAT equipment tests lenses in situ and identifies suitable lenses before adhesive curing, ensuring MTF performance requirements are met while maintaining production flow.
Solution Approach 2:
The assembly process itself performs the selection function through integrated MTF measurement and lens identification capabilities. The system uses the final assembly's own optical path and measurement equipment to evaluate and select lenses, eliminating the need for separate pre-sorting operations.
2Manufacturing precision
If pre-sorting of lenses is performed, then MTF performance is improved, but loss of time increases
Solution Approach 1:
The patent combines the lens selection function with the final assembly process by integrating MTF measurement and lens identification into the CMAT equipment. This merges what were previously separate operations (pre-sorting and assembly) into a single unified process, eliminating redundant time.
Solution Approach 2:
The system extracts the lens selection decision-making process from the pre-assembly stage and relocates it to the final assembly stage. By taking out the selection function and performing it in situ, the process eliminates the time loss associated with transporting and pre-sorting lenses separately.
3Productivity
If adhesive is applied before lens selection, then productivity is improved, but MTF performance deteriorates
Solution Approach 1:
The system performs preliminary lens evaluation and selection before the adhesive curing process completes. By measuring MTF performance during the assembly process and identifying suitable lenses before final bonding, the system ensures performance requirements are met while maintaining continuous production flow.
Data Source
AI summary
The techniques of this disclosure relate to actively selecting lenses for camera focus processes. Lenses to be used during camera assembly are chosen based on whether their pairing with a specific set of production components can satisfy focus performance criteria of end of line test. Test equipment may check the lenses by dry-fit aligning them to a particular set of production components. If minimum focus performance cannot be achieved, then a different set of lenses are used to with that set of production components to produce a final camera assembly. This way, because the lenses are actively selected during production to achieve satisfactory focus performance of the EOLT, each final camera assembly is more likely to pass the EOLT, thereby improving camera production output.