Optical Engine Bracket Tilt Adjustment for Image Alignment
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Solution Overview
Problem
Projector optical engines often suffer from image tilt due to accumulated assembly and manufacturing tolerances, leading to non-compliance and increased production costs when the tilt angle exceeds product specifications.
Innovation Solution
An adjustable optical engine bracket with a threaded hole and adjustment rod mechanism allows for fine-tuning the projection angle by tilting the optical engine bracket relative to the base, compensating for manufacturing and assembly tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional fixed optical engine mounting is used, then assembly is simple, but manufacturing tolerances cause image tilt exceeding product specifications
Solution Approach 1:
The optical engine bracket is transformed from a fixed rigid structure to an adjustable dynamic structure. The bracket can be tilted to different angles and locked in position, allowing compensation for manufacturing tolerances while maintaining structural integrity during operation.
Solution Approach 2:
The mounting structure is divided into separate functional components: a base, an adjustable bracket, and a locking mechanism. This segmentation allows independent optimization of each component and simplifies the adjustment process while achieving precise projection angle control.
2Manufacturing precision
If adjustable optical engine bracket is implemented, then projection angle can be fine-tuned, but device complexity increases
Solution Approach 1:
An adjustable bracket serves as an intermediary component between the fixed base and the optical engine. This mediator absorbs the complexity of adjustment mechanisms while presenting a simple interface to both the base structure and the optical engine, isolating the complexity to a specific module.
Solution Approach 2:
The bracket's tilt angle is used as an adjustable parameter to compensate for manufacturing variations. By changing this geometric parameter, the system can fine-tune the projection angle without requiring complex active control systems or multiple components.
3Manufacturing precision
If manufacturing tolerances are strictly controlled, then image tilt is minimized, but production costs increase
Solution Approach 1:
The adjustable bracket enables self-adjustment of the optical engine's projection angle, allowing the system to compensate for its own manufacturing tolerances without requiring expensive precision machining or complex external alignment equipment during assembly.
Solution Approach 2:
The bracket is pre-configured with adjustment capability before final assembly. This preliminary design feature allows for easy field adjustment and quality control verification without requiring complex tools or procedures, reducing both manufacturing and quality assurance costs.
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
Enables compliance with product specifications by adjusting the projection angle before and after shipment, extending the projector's service life and reducing production costs.
Implementation Method 1
The adjustment portion includes a threaded hole. The adjustment rod includes a connecting portion, a threaded portion, and a rotating portion. The threaded portion is engaged with the threaded hole. By rotating the rotating portion to turn the threaded portion, the optical engine bracket tilts away from or toward the base.
Data Source
AI summary
An optical engine adjustment mechanism includes a base, an optical engine bracket, and an adjustment rod. The optical engine bracket has a fixing portion, an installation portion, and an adjustment portion. The optical engine bracket is fixed to the base through the fixing portion. The installation portion is used for mounting an optical engine thereon. The adjustment portion includes a threaded hole. The adjustment rod includes a connecting portion, a threaded portion, and a rotating portion. The adjustment rod is pivotally connected to the base through the connecting portion. The threaded portion is engaged with the threaded hole. By rotating the rotating portion to turn the threaded portion, the optical engine bracket tilts away from or toward the base.