Light Redirecting Optical Module Rotary Joint Alignment
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Solution Overview
Problem
The alignment of passive optical elements in safety light curtains is cumbersome, time-consuming, and not entirely reliable, especially when multiple elements with six degrees of freedom need to be manually adjusted, leading to potential misalignment and increased complexity with multiple beams.
Innovation Solution
A light redirecting optical module with a passive optical element, such as a mirror or prism, is fixed to a carrier unit with a curved surface that forms a rotary joint with a complementary curved surface on a support unit, allowing guided rotary movement and simplifying alignment through a handle for precise adjustment, using a UV curing adhesive for secure fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual alignment of passive optical elements is performed, then the light beam can be directed to the receiver, but the alignment process becomes cumbersome and time-consuming
Solution Approach 1:
The alignment system is segmented into two independent parts: coarse alignment handled by the support unit with translational degrees of freedom, and fine alignment handled by the carrier unit with rotational degrees of freedom. This segmentation allows each unit to be optimized for its specific function, making the overall alignment process more efficient and less cumbersome.
Solution Approach 2:
The support unit performs preliminary coarse alignment by providing translational movement to position the carrier unit in the correct location. This preliminary action eliminates the need for the operator to manipulate multiple elements simultaneously, as the support unit prepares the system for the subsequent fine alignment operation.
2Reliability
If multiple passive optical elements with six degrees of freedom are adjusted manually, then the light beam path can be established, but the complexity of the alignment process increases significantly
Solution Approach 1:
The six degrees of freedom are segmented and distributed between two units: the support unit handles three translational degrees of freedom for coarse positioning, while the carrier unit handles three rotational degrees of freedom for fine alignment. This segmentation reduces the complexity by allowing each unit to be manipulated independently rather than requiring simultaneous control of all six parameters.
Solution Approach 2:
The carrier unit acts as an intermediary between the support unit and the passive optical element. It provides a specialized rotational adjustment mechanism that simplifies the control of angular parameters, mediating between the coarse translational positioning and the final optical alignment requirements.
3Adaptability or versatility
If tilt movement of mirrors is not around the center, then orientation adjustment is possible, but correction by translation is required following the tilt movement
Solution Approach 1:
The system provides dynamic adaptability by allowing tilt movements around any chosen point on the mirror surface. The support unit can then dynamically compensate for the resulting positional shift through translational adjustment, enabling operators to perform tilt adjustments from any convenient location without being constrained to the mirror center.
Solution Approach 2:
The system changes the parameters of the optical element's position and orientation in a coordinated manner. After a tilt movement changes the angular parameter, the support unit adjusts the positional parameters to maintain the correct beam path, allowing flexible orientation adjustment without compromising alignment ease.
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 enables faster and more reliable alignment of passive optical elements, reducing the need for complex manual adjustments and minimizing misalignment, with the ability to correct rotational errors through single-element tilting, and allows for quicker testing and assembly of safety light curtains.
Implementation Method 1
the carrier unit has a curved surface, preferably a spherical surface, at a side facing away from the passive optical element and the support unit has a complementary curved surface facing the curved surface of the carrier unit, wherein the curved surfaces together form a rotary joint
Implementation Method 2
support unit to a support structure of an optical device, such as a housing or a rail, wherein the carrier unit has a curved surface, preferably a spherical surface
Data Source
AI summary
A light redirecting optical module for a light curtain includes a passive optical element to change a direction of an incident light beam, a carrier unit to which the passive optical element is rigidly fixed, a support unit, wherein the carrier unit has a curved surface at a side facing away from the passive optical element and has a complementary curved surface facing the curved surface, the curved surfaces together forming a rotary joint, engagement means to keep the two curved surfaces engaged to each other to allow for a guided rotary movement of the two surfaces. A passive component of a light curtain includes one or more passive elements to redirect a light beam received from an emitter such that the light beam leaving the passive component impinges on a receiver of the light curtain and a method for aligning passive optical elements.