Optical Module Alignment Using Auto-Collimator and Reference Mirror
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Solution Overview
Problem
Existing optical modules face challenges in precise alignment of optical components, leading to inefficiencies in signal light and local light coupling, which affects the overall performance of coherent optical systems.
Innovation Solution
The method involves aligning an auto-collimator with a reference mirror, replacing the mirror with the optical module, and then aligning optical components within the module using the auto-collimator to ensure precise optical axis alignment, incorporating optical hybrids, a variable optical attenuator, and a collimating lens to optimize signal and local light coupling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If optical components are precisely aligned using conventional methods, then optical coupling efficiency is improved, but alignment time and manufacturing complexity increase
Solution Approach 1:
The patent applies preliminary action by pre-aligning the optical module housing with the auto-collimator before installing optical components. The housing is positioned and fixed in advance, creating a pre-established reference framework that eliminates the need for time-consuming alignment adjustments during component installation. This preliminary positioning of the housing relative to the auto-collimator ensures that subsequent component alignments are faster and more consistent.
Solution Approach 2:
The patent uses the auto-collimator as an intermediary tool that serves dual purposes: it acts as both the alignment reference and the measurement instrument. By introducing this intermediary device that provides real-time optical feedback, the alignment process becomes more efficient as components can be quickly positioned and verified without requiring multiple measurement iterations or complex adjustment procedures.
2Adaptability or versatility
If multiple optical components are installed and aligned, then optical system functionality is improved, but alignment precision deteriorates due to cumulative errors
Solution Approach 1:
The patent applies segmentation by dividing the optical system into modular components (housing, optical components, mounting structures) that can be independently aligned and then integrated. Each component is aligned separately using the auto-collimator as a common reference, preventing cumulative errors from propagating through the entire system. This modular approach allows each segment to be optimized independently while maintaining overall system precision.
Solution Approach 2:
The patent replaces traditional mechanical alignment methods with optical feedback from the auto-collimator. Instead of relying on mechanical fixtures, jigs, or physical reference marks that can introduce cumulative errors, the system uses optical measurement and feedback to guide alignment. This substitution of mechanical alignment systems with optical measurement systems eliminates the accumulation of mechanical tolerances and provides more consistent precision across multiple components.
3Ease of manufacture
If conventional alignment methods are used, then device simplicity is maintained, but optical coupling efficiency decreases
Solution Approach 1:
The patent introduces the auto-collimator as an intermediary alignment tool that provides real-time optical feedback during the assembly process. This intermediary device enables precise alignment of optical components with the housing without requiring complex mechanical fixtures or multiple measurement steps. The auto-collimator serves as a simple yet effective mediator that bridges the gap between the optical components and the housing, achieving high coupling efficiency while maintaining ease of manufacture through straightforward alignment procedures.
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 enhances the optical coupling efficiency and reduces power fluctuations by ensuring precise alignment and optimal positioning of optical components, improving the performance of the optical module in coherent optical systems.
Implementation Method 1
The signal light concentrated by the concentrating lens has a beam waist at a position of the VOA
Implementation Method 2
aligning an optical axis of an auto-collimator with an optical axis of a reference mirror
Implementation Method 3
The first and second optical hybrids each interferes the signal light with the local light
Data Source
AI summary
A process of installing optical components as precisely aligning optical axes thereof is disclosed. The process, which relates to an optical module having a signal port and/or a local port, and optical components optically coupling the ports with an active device having a built-in photodiode (PD), includes steps of (a) preparing a reference mirror that emulates a housing with a side to which the ports are attached, (b) aligning an optical axis of the auto-collimator with an optical axis of the reference mirror; (c) replacing the reference mirror with the housing; (d) aligning optical axes of the optical components with the optical axis of the auto-collimator; and (e) installing the optical components within the housing.