Lens Testing Station Self-Calibration for Faster Setup Correction
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Solution Overview
Problem
Conventional lens testing stations suffer from prolonged calibration times due to manual adjustments of servo motors and lack of automatic correction for setup variations, leading to inefficiencies in factory operations.
Innovation Solution
A calibration method for lens testing stations that automatically calculates and corrects setup variations by aligning a calibrating lens with a testing pattern, capturing images, calculating central coordinates, and adjusting original center coordinates using a control unit to determine lens quality.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual calibration of servo motors is performed in conventional lens testing stations, then measurement precision can be maintained, but calibration time increases significantly and operation efficiency decreases
Solution Approach 1:
The lens testing station performs self-calibration by automatically capturing images of the test pattern, calculating coordinate offsets, and correcting servo motor parameters without requiring manual intervention. The system uses its own imaging and processing capabilities to identify and correct calibration deviations, transforming from a manual calibration process to an autonomous self-correction process that maintains precision while dramatically reducing calibration time
Solution Approach 2:
The patent replaces manual mechanical adjustment of servo motors with an automated digital correction system. Instead of physically adjusting motor parameters manually, the system uses image coordinate analysis and digital offset calculation to automatically determine and apply correction values, substituting mechanical manual operations with automated computational and electronic adjustment processes
2Reliability
If conventional lens testing stations are calibrated manually once a week, then setup variations can be corrected, but operation efficiency of the factory is reduced due to significant calibration time
Solution Approach 1:
The system performs automated self-calibration by capturing test pattern images, calculating coordinate offsets, and automatically correcting servo motor parameters. This self-service calibration process eliminates the need for manual weekly calibration interventions, maintaining testing reliability through automatic correction of setup variations while minimizing disruption to factory operation efficiency
Solution Approach 2:
The patent implements preliminary calibration actions by automatically detecting and correcting setup variations before they significantly impact testing accuracy. The system continuously monitors and corrects calibration drift through automated image analysis and parameter adjustment, preventing accumulation of errors that would require extensive manual recalibration and thereby maintaining both reliability and productivity
3Manufacturing precision
If manual measurement and adjustment of servo motor rotation errors is performed, then component errors can be corrected, but the calibration process becomes complex and time-consuming
Solution Approach 1:
The patent extracts the essential calibration information by capturing images of the test pattern and calculating coordinate offsets, separating the critical measurement data from the complex servo motor adjustment process. This extraction approach simplifies the calibration process by focusing only on the essential coordinate correction data needed to maintain component accuracy, eliminating unnecessary manual measurement and adjustment steps
Solution Approach 2:
The system replaces complex manual measurement and adjustment procedures with automated image capture and digital coordinate analysis. Instead of manually measuring servo motor rotation errors and performing complex adjustments, the system uses automated imaging, coordinate calculation, and digital parameter correction to achieve the same component accuracy with significantly reduced process complexity
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
The method reduces calibration time, improves accuracy and reliability, and enhances factory efficiency by quickly correcting setup variations without manual adjustments.
Implementation Method 1
a calibrating lens being mounted to an image capture unit of a lens holder
Implementation Method 2
capturing the testing pattern by the calibrating lens and the image capture unit, the image capture unit capturing the calibration image
Data Source
AI summary
A calibration method for a lens testing station is described. Install a calibrating lens on a lens holder. The calibrating lens is aligned with a testing pattern. Capture the testing pattern. An image capture unit captures a calibration image. Calculate a central coordinate of the calibration image, and calculate an offset of the central coordinate relative to an original center coordinate. Check whether shot times of the calibration image are less than preset capturing times. Execute the third step when the shot times of the calibration image are less than the preset capturing times, execute the next step when the shot times of the calibration image are equal to the preset capturing times. Calculate an average offset of all stored offsets by a control unit. Add the average offset to the original center coordinate to obtain a corrected original center coordinate.