Optical Module Lens Alignment via Light Spot Minimization
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Solution Overview
Problem
The challenge lies in accurately adjusting the lens position during optical module assembly to achieve optimal alignment, which is crucial for the optical performance of the module, as existing methods lack precision in determining the most rational position based on the size of the imaging light spot.
Innovation Solution
A method and apparatus that utilize an alignment mechanism to move in a set direction, collecting and analyzing light spots imaged by the optical module to select the light spot with the minimum size, and determining the optimal position by fitting straight lines through pre and post-minimum light spots, allowing the lens to be aligned accordingly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the lens position is adjusted based on the size of the imaging light spot during assembly, then the assembly accuracy is improved, but the complexity of the alignment process increases
Solution Approach 1:
The patent implements a feedback mechanism where the image acquisition device continuously monitors the light spot size during lens adjustment, and this information is fed back to control the alignment mechanism. The system automatically adjusts the lens position based on the detected light spot size, creating a closed-loop control system that improves assembly accuracy while managing process complexity through automation.
Solution Approach 2:
The patent replaces manual mechanical alignment operations with an automated optical-mechanical system. Instead of relying on operators to visually assess and adjust lens position, the system uses an image acquisition device to detect light spot size and an alignment mechanism to automatically position the lens, substituting human judgment and manual manipulation with automated sensing and actuation.
2Manufacturing precision
If the alignment mechanism moves the lens continuously to find the optimal position, then the assembly accuracy is improved, but the assembly time increases
Solution Approach 1:
The patent applies preliminary action by first establishing a rough lens position using basic mechanical positioning, then using the light spot size detection to make fine adjustments. This two-stage approach allows the system to quickly establish a starting position and then efficiently converge to the optimal position, reducing the total time required compared to starting from scratch with continuous fine adjustments.
Solution Approach 2:
The alignment process uses periodic action by moving the lens in discrete steps rather than continuous motion, with each step followed by a light spot size measurement. This periodic measurement and adjustment cycle allows the system to efficiently search for the optimal position while maintaining control over the adjustment process, balancing speed and accuracy.
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 improves the assembly accuracy of the optical module by transforming the search for the optimal lens position into finding the light spot with the minimum size, reducing alignment difficulties and enhancing the module's optical performance.
Implementation Method 1
when an optical module to be aligned images, controlling an alignment mechanism clamping a lens to be assembled to move in a set direction by a set movement step
Data Source
AI summary
Provided are a method and an apparatus of optical module assembly, where the method includes: when an optical module to be aligned images, controlling an alignment mechanism clamping a lens to be assembled to move in a set direction by a set movement step; when the alignment mechanism moves each time, collecting, by an image acquisition device, light spots imaged by the optical module to be aligned sequentially, and selecting a light spot with a minimum size from the collected light spots; determining an optimal position of the alignment mechanism according to at least two light spots before the light spot with the minimum size and at least two light spots thereafter; and controlling the alignment mechanism to move to the optimal position to align the lens to be assembled.