Optical Module Active Alignment Assembly With Conveyor Fixtures
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Solution Overview
Problem
Existing methods for assembling optical modules lack accuracy and efficiency in aligning and assembling optical components, which is crucial for their performance.
Innovation Solution
An apparatus and method that utilize a working bench with a controller and mechanical components for active alignment, including a conveying system with fixtures, a manipulator, alignment mechanism, power supply, and dispensing mechanism, to precisely position and align optical parts, using image collection for feedback to adjust alignment and UV curing for fixation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional assembly methods are used, then device complexity is reduced, but manufacturing precision deteriorates
Solution Approach 1:
The assembly system is divided into multiple independent mechanical components (manipulator, alignment mechanism, power supply, dispensing mechanism, image collecting means) that can be independently controlled and positioned. Each component operates at specific work positions along the conveying means, allowing precise localized operations without requiring the entire system to be complex and interconnected.
Solution Approach 2:
The controller serves as an intermediary that coordinates between the conveying means and all mechanical components. It receives feedback from image collecting means, processes alignment information, and generates control signals to adjust component positions and operations, thereby achieving high precision assembly through centralized intelligent coordination rather than complex mechanical linkages.
2Productivity
If sequential assembly operations are performed, then device complexity is reduced, but productivity deteriorates
Solution Approach 1:
The conveying means enables continuous movement of optical modules through the assembly system, allowing multiple assembly operations to be performed simultaneously at different work positions. While the module is being conveyed, the manipulator places components, the alignment mechanism aligns them, the power supply activates them, and the dispensing mechanism applies adhesives—all operations occur in parallel rather than sequentially, maximizing productivity.
Solution Approach 2:
The system transitions from static sequential operations to dynamic parallel operations. The conveying means provides continuous motion, while mechanical components dynamically adjust their positions and operations based on real-time feedback from image collecting means and controller coordination, enabling simultaneous multi-position assembly operations.
3Measurement precision
If manual alignment methods are used, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The image collecting means captures real-time images of the optical module assembly, providing feedback to the controller about component positions and alignment status. The controller processes this image data and generates adjustment commands to the alignment mechanism, creating a closed-loop feedback system that continuously monitors and corrects alignment errors, achieving high measurement precision through intelligent control rather than complex mechanical alignment devices.
Solution Approach 2:
The system replaces manual or purely mechanical alignment methods with an optical-electronic feedback system. Image collecting means use optical fields to detect component positions, and the controller uses electronic processing to determine alignment accuracy and generate correction commands, substituting mechanical measurement and adjustment mechanisms with optical sensing and electronic control for superior 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 improves the accuracy and efficiency of optical module assembly by enabling simultaneous operations at multiple positions, reducing assembly tolerance, and ensuring high-quality optical performance.
Implementation Method 1
a UV lamp is provided on the alignment mechanism and electrically connected to the controller
Data Source
AI summary
Provided are an apparatus and a method for assembling optical module. The apparatus includes: a working bench, a controller and a plurality of mechanical components for active alignment of optical modules; a conveying mechanism is provided on the working bench, and a plurality of fixtures are provided on the conveying mechanism with even space therebetween and are movable with the conveying mechanism; the plurality of mechanical components are configured to perform corresponding operations on the fixtures moved to respective operating positions under control of the controller.