Optical Module Alignment via Iterative Pressure Sensing
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Solution Overview
Problem
Existing methods for assembling optical modules often result in misalignment between the cap and stem, leading to an inclined angle, which complicates precise alignment of the optical sleeve with the semiconductor optical element, affecting the optical coupling with external fibers.
Innovation Solution
A method involving a positioner with a goniometer and pressure sensor to iteratively adjust the rotating, rolling, and pitching angles of the optical device relative to the receptacle, ensuring minimal pressure and precise alignment, using stages for X and Y-axis adjustments to align the optical device's axis with the receptacle's axis.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the cap is fixed to the stem with conventional assembly methods, then the assembly process is simple, but the alignment precision between cap and stem deteriorates, causing inclined angles
Solution Approach 1:
The patent applies preliminary action by pre-positioning the cap and stem in their correct aligned states before final assembly. The alignment is established in advance using precision fixtures and measurement tools, ensuring that when the components are fixed together, they maintain the predetermined precise alignment without developing inclined angles during the assembly process.
Solution Approach 2:
The patent replaces conventional mechanical alignment methods with optical measurement systems. By using optical instruments to detect and measure the alignment between cap and stem, the system achieves higher precision than traditional mechanical fixtures alone, eliminating inclined angles through optical feedback and adjustment.
2Ease of operation
If conventional alignment methods are used for the optical sleeve and semiconductor optical element, then the assembly process is straightforward, but the optical coupling precision deteriorates
Solution Approach 1:
The patent replaces mechanical alignment methods with optical measurement and adjustment systems. Optical instruments are used to directly measure the alignment between the optical sleeve and semiconductor optical element, providing real-time feedback that enables precise adjustment and achieves high optical coupling precision that mechanical methods alone cannot attain.
Solution Approach 2:
The patent implements feedback by using optical measurement systems to continuously monitor the alignment status between components during assembly. The measurement results are fed back to adjust the positioning, creating a closed-loop control system that ensures optimal optical coupling precision by eliminating misalignment through iterative measurement and adjustment.
3Manufacturing precision
If iterative angle adjustment with pressure sensing is implemented, then the alignment precision improves, but the assembly time increases
Solution Approach 1:
The patent uses pressure sensing as a feedback mechanism to detect alignment status in real-time during the assembly process. The pressure sensor provides immediate information about the relative positioning of components, enabling rapid adjustment decisions that reduce the number of iterative steps needed compared to traditional measurement methods, thereby minimizing time loss while achieving high precision.
Solution Approach 2:
The patent applies self-service by designing the assembly system to automatically detect and indicate alignment status through pressure sensing. The system itself provides the measurement and feedback without requiring external intervention or complex measurement procedures, enabling operators to quickly identify and correct alignment issues, thus reducing assembly time while maintaining high precision.
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 approach ensures accurate alignment of the optical device with the receptacle, minimizing pressure and optimizing optical coupling, thereby enhancing the assembly precision and efficiency of optical modules.
Implementation Method 1
The pressure sensor, which is put between the base and the goniometer, may senses a pressure applied to the base from the receptacle
Data Source
AI summary
An alignment apparatus and an alignment method that enables to align an optical device with a receptacle, where the optical device and the receptacle have respective axes tilted to each other. The method includes steps of: (1) obtaining a minimum pressure caused to the optical device from the receptacle as varying a rolling angle around the X-axis of the optical device but fixing the pitching angle around the Y-axis at a rotating angle around the Z-axis; (2) determining a rotating angle where thus obtained minimum pressure becomes the minimum; and (3) iterating those procedures until the rotating angle obtained as varying the rolling angle and another rotating angle obtained as varying the pitching angle substantially coincides to each other.