Optical Surface Alignment Using Spheres for Off-Axis Components
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Solution Overview
Problem
Existing optical systems with off-axis components are challenging to accurately align, as traditional methods rely on tight mechanical tolerances that may not be precise enough for certain applications.
Innovation Solution
A method involving the use of spheres positioned at the center of curvature of optical components, with reference signals from interferometers or point source microscopes, to align optical components along the optical axis of symmetry, allowing for precise alignment without relying solely on mechanical tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight mechanical tolerances are placed on the mounting mechanism to align off-axis optical components, then alignment precision is improved, but manufacturing cost increases and the precision is limited to mechanical tolerance levels (e.g., 0.025 mm)
Solution Approach 1:
The patent replaces mechanical alignment methods with optical measurement methods. Instead of relying on mechanical tolerances of mounting mechanisms, the invention uses interferometers and spheres to create optical reference signals that define the optical axis. This substitution allows alignment precision to exceed mechanical tolerance limits while reducing dependence on expensive tight-tolerance mechanical components
Solution Approach 2:
The patent introduces spheres as intermediary objects that facilitate alignment. The spheres are positioned at centers of curvature of optical components and serve as reference points for interferometric measurement. These intermediary spheres enable precise determination of optical axes without requiring direct mechanical contact or tight mechanical tolerances between components
2Manufacturing precision
If tight mechanical tolerances are placed on the mounting mechanism to align off-axis optical components, then alignment precision is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical alignment mechanisms with simpler optical measurement systems. Instead of using complicated mounting mechanisms with tight tolerances, the invention employs interferometers and spheres to optically define and measure alignment, thereby reducing mechanical complexity while achieving superior precision
Solution Approach 2:
The optical components themselves participate in defining the alignment reference. The centers of curvature of the optical components serve as the reference points for alignment, eliminating the need for separate complex mechanical reference systems. The system uses its own geometric properties to establish the alignment criteria
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 method enables precise alignment of off-axis optical components with improved accuracy, achieving alignment within very tight tolerances, such as less than a micrometer variance, thereby enhancing the performance of optical systems.
Implementation Method 1
aligning a focus of a first reference signal with the sphere at the first position
Implementation Method 2
aligning a focus of a first reference signal with the sphere at the first position
Data Source
AI summary
A method for aligning multiple optical components in an optical system including placing a sphere at a first position that is at a center of curvature of a first optical component, and aligning a focus of a first reference signal with the sphere at the first position. Then, moving the sphere along an axis of optical symmetry to a second position that is at a center of curvature of a second optical component, and aligning a focus of a second reference signal with the sphere at the second position. The first optical component is aligned with the first reference signal and fixing the first optical component, and the second optical component is aligned with the second reference signal and fixing the second optical component.