Optical Alignment via Continuous Motion Sweeps
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Solution Overview
Problem
Current methods for aligning optical components, such as lenses and image sensors, often require multiple degrees of freedom to compensate for variations in dimensions and orientation, but are inefficient due to the need for discrete position adjustments and lengthy alignment processes, which increase manufacturing time and costs.
Innovation Solution
A continuous scan method that uses a robotic system to actively align optical elements by collecting timed position information, estimating relationships between position and time, and determining optimum alignment positions based on image data, allowing for simultaneous adjustments along multiple axes and orientations, thereby reducing alignment time and improving precision.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If discrete position adjustments are used for alignment, then alignment precision can be achieved, but alignment time increases significantly
Solution Approach 1:
The patent applies continuous motion sweeps where the optical component is moved continuously through a range of positions and orientations while image data is captured at multiple time points. This continuous action eliminates the need for discrete stopping and positioning steps, thereby reducing alignment time while maintaining precision through temporal interpolation of the continuous motion data.
Solution Approach 2:
The patent performs preliminary continuous motion sweeps to collect extensive position-time-image data before final alignment is determined. By gathering data during continuous motion rather than requiring precise discrete positioning first, the system can later interpolate to find optimal alignment positions, reducing the time needed for the alignment process itself.
2Manufacturing precision
If multiple degrees of freedom are adjusted to compensate for variations, then alignment accuracy improves, but manufacturing complexity increases
Solution Approach 1:
The patent uses a single continuous motion sweep mechanism that simultaneously adjusts multiple degrees of freedom (position and orientation parameters). This multi-functional approach allows one motion system to compensate for various asymmetries and variations in optical components without requiring separate adjustment mechanisms for each degree of freedom, thereby reducing manufacturing complexity while maintaining high alignment accuracy.
3Ease of manufacture
If traditional stepped scan methods are used, then alignment can be performed with simple equipment, but productivity decreases due to lengthy alignment processes
Solution Approach 1:
The patent transitions from stepped scan methods with discrete positioning to continuous motion sweeps where the optical component moves continuously through the alignment range. This continuous action captures image data at multiple time points during motion, eliminating waiting time between steps and significantly increasing alignment speed while maintaining the simplicity of the motion control system.
Solution Approach 2:
The system performs preliminary continuous motion and data collection before final alignment determination. By gathering extensive position-time-image data during continuous motion rather than requiring slow discrete positioning, the system can rapidly determine optimal alignment parameters, thereby increasing productivity without requiring complex equipment.
Data Source
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AI summary
Methods and apparatus for actively aligning a first optical element, such as a lens, to a second optical element, such as an image sensor, use continuous scans, even absent a synchronization signal from one of the optical elements. During a scan, timed position information about the scanned optical element is collected, and then a relationship between position of the scanned optical element and time is estimated, such as by fitting a curve to a set of position-time pairs. This relationship can then be used to estimate locations of the scanned optical element at times when image data or other alignment quality-indicating data samples are acquired. From this alignment quality versus location data, an optimum alignment position can be determined, and the scanned optical element can then be positioned at the determined alignment position.