Automatic Optical Alignment for Complex Module Assembly
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Solution Overview
Problem
The assembly of complex optical output modules, such as those used in infrared image statistics, is time-consuming and costly due to the need for precise alignment, which is not efficiently addressed by simple optical designs like single-lens laser pointers.
Innovation Solution
An automatic alignment apparatus comprising an alignment tool, a beam splitter, multiple cameras, and a processing circuit that splits optical paths to capture and analyze images, generating movement control signals to align radiation source and optical component modules automatically.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual alignment methods are used for complex optical output modules, then alignment precision can be achieved, but assembly time increases significantly and costs increase
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated optical measurement and control system. The system uses cameras to capture images of alignment marks, processes these images computationally to determine positional deviations, and automatically controls adjustment mechanisms to correct misalignments. This substitution of manual mechanical operations with automated optical-mechanical systems resolves the contradiction by maintaining high precision while dramatically improving assembly speed and reducing labor costs.
Solution Approach 2:
The alignment system performs self-measurement and self-correction through automated feedback control. The cameras automatically capture alignment mark positions, the processing circuit computes deviations from target positions, and the adjustment mechanisms automatically correct the misalignments without requiring continuous manual intervention. This self-service capability enables the system to maintain high precision alignment while operating at high speed, resolving the contradiction between precision and productivity.
2Ease of manufacture
If simple optical designs like single-lens laser pointers are used, then manufacturing is simple and costs are low, but they cannot meet the performance requirements of complex optical output modules
Solution Approach 1:
The patent divides the optical output module into distinct functional components that can be manufactured and aligned separately. The system uses multiple alignment marks positioned at different locations to independently measure and correct positional deviations of different optical components. This segmentation allows each component to be optimized for its specific function while maintaining overall system performance, resolving the contradiction between manufacturing simplicity and optical performance.
Solution Approach 2:
The alignment system dynamically adjusts critical parameters such as the positions of optical components, the focal lengths of lenses, and the orientations of optical elements to optimize performance. By automatically measuring actual parameter values and computing corrective adjustments, the system ensures that complex optical modules meet performance specifications while maintaining manufacturing feasibility through standardized adjustment procedures.
3Productivity
If multiple cameras and beam splitters are added to achieve automatic alignment, then assembly time is reduced and precision is improved, but device complexity increases
Solution Approach 1:
The patent designs the alignment system with multi-functional components that perform multiple tasks. The beam splitter simultaneously directs light to multiple cameras and enables observation of alignment marks from different angles. The same camera system is used for both measurement and verification functions. This multi-functionality reduces the total number of components needed while maintaining high assembly speed and precision, thereby mitigating the increase in device complexity.
Solution Approach 2:
The patent combines multiple alignment measurement functions into a single integrated system. Instead of using separate measurement systems for different optical components, the system uses a unified camera and processing circuit architecture to simultaneously measure and control the alignment of multiple components. The beam splitter merges multiple optical paths into a single measurement system, reducing component count and simplifying the overall device architecture while maintaining high productivity.
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 significantly reduces assembly time and costs by ensuring precise alignment of optical output modules, enhancing the overall performance of electronic products and preventing related art issues.
Implementation Method 1
a beam splitter, positioned on an optical path that starts from the radiation source module, to split the optical path into a first sub-path allowing first image contents being projected on a screen by the optical output module and a second sub-path allowing second image contents being projected toward a direction different from that of the screen
Implementation Method 2
an optical path that starts from the radiation source module, and may be arranged to split the optical path into a first sub-path allowing first image contents being projected on a screen by the optical output module
Data Source
AI summary
An automatic alignment apparatus applicable to assembly of an optical output module and associated methods are provided. The automatic alignment apparatus includes: an alignment tool, a beam splitter, cameras, and a processing circuit. The alignment tool is arranged to hold parts of the optical output module, and align the parts to each other according to at least one movement control signal, where the parts include a radiation source module and an optical component module. The cameras capture images to generate image signals carrying the images, and the beam splitter splits the optical path into associated sub-paths. The processing circuit generates at least one movement control signal according to at least one image signal within the image signals to perform movement control of at least one part of the parts. The alignment tool automatically aligns the parts to each other according to the at least one movement control signal.