Modular Optical Analytic System Alignment
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Solution Overview
Problem
The increasing complexity of biological optical analysis instruments, such as genetic sequencers, leads to higher manufacturing and operation costs due to the need for precise alignment of numerous internal optical components, which can be affected by temperature changes and mechanical vibrations.
Innovation Solution
A modular optical analytic system is introduced, where components are grouped into pre-fabricated sub-assemblies with reduced degrees of freedom, allowing for simplified alignment and configuration using a precision mounting plate and stage motion assembly, with sensors and actuators for real-time adjustment and monitoring.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If all components are installed on a precision plate with multiple degrees of freedom for precise alignment, then alignment precision is improved, but device complexity and manufacturing cost increase
Solution Approach 1:
The optical system is divided into multiple modular subassemblies (objective lens subassembly, tube lens subassembly, detector subassembly, laser subassembly) that can be independently manufactured, aligned, and tested. Each subassembly is pre-aligned to internal tolerances and then mounted as a unit on the precision plate, reducing the overall system complexity while maintaining alignment precision.
2Manufacturing precision
If multiple components are configured and aligned individually on a precision plate, then alignment precision is improved, but operation time and skill requirement increase
Solution Approach 1:
Each modular subassembly is pre-configured and pre-aligned to predetermined internal tolerances during manufacturing before being installed on the precision plate. This preliminary alignment action eliminates the need for time-consuming individual component alignment during system setup or maintenance, reducing operation time and skill requirements.
3Measurement precision
If precise alignment of numerous optical components is maintained, then measurement precision is improved, but manufacturing and operation expense increase
Solution Approach 1:
The system is segmented into independent modular subassemblies that can be manufactured using standard tolerances and then precisely aligned as complete modules. This approach reduces manufacturing expense by avoiding the need for expensive custom precision machining of the entire system while maintaining optical analysis precision through modular pre-alignment.
Solution Approach 2:
The precision alignment is captured in the modular subassembly design and manufacturing process, creating a reproducible alignment template. Once a subassembly is precisely aligned, that configuration can be copied and replicated across multiple units, reducing the expense of achieving and maintaining precision alignment in each individual system.
4Adaptability or versatility
If components are allowed to move freely for configuration flexibility, then adaptability is improved, but alignment stability deteriorates
Solution Approach 1:
The system employs a hybrid approach where modular subassemblies are rigidly mounted to the precision plate to maintain alignment stability, while the precision plate itself and stage motion assemblies provide controlled dynamic adjustment capabilities. This allows the system to be stable during operation but adaptable when reconfiguration is needed.
Data Source
AI summary
A system includes a plurality of modular subassemblies and a plate; wherein each modular subassembly comprises an enclosure and a plurality of optical components aligned to the enclosure, and each enclosure comprises a plurality of mounting structures; and wherein each modular subassembly is mechanically coupled to the plate by attachment of a mounting structure of the modular subassembly directly to a corresponding mounting structure located on the plate, such that by mechanically coupling each modular subassembly to the plate using the mounting structure of the modular subassembly and the corresponding mounting structure on the plate, adjacent modular subassemblies are aligned to each other upon such attachment, and wherein two of the modular subassemblies mechanically coupled to the plate are also attached to each other by mechanically coupling an alignment structure on one of the two modular subassemblies to a respective alignment structure on the other of the two modular subassemblies.