Optical Module Alignment via Image-Captured Center Line Overlap
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Solution Overview
Problem
Conventional optical modules face challenges in achieving precise optical alignment due to large tolerances, leading to misalignment and degraded resolution, primarily because the lens unit is assembled manually without considering the optical length tolerance, resulting in over or under focus issues.
Innovation Solution
An optical alignment method that uses image-capturing techniques to determine the actual optical path length, correct it, and align the lens unit such that imaginary center lines coincide, ensuring precise assembly and focusing, thereby enhancing the optical resolution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual assembly of the lens unit is used to reduce cost, then manufacturing cost is reduced, but optical alignment precision deteriorates due to large tolerances
Solution Approach 1:
The patent replaces manual mechanical assembly with an automated optical alignment system that uses image capturing and processing to automatically determine lens unit position and guide precise assembly, eliminating the trade-off between manual assembly cost and alignment precision
Solution Approach 2:
The system uses the lens unit itself and the housing unit as objects to be aligned, with the alignment system automatically detecting their relative positions and guiding the assembly process without requiring external measurement tools or manual adjustment
2Device complexity
If the groove depth is predefined according to theoretical value, then assembly process is simplified, but optical alignment precision deteriorates due to tolerance accumulation
Solution Approach 1:
The patent implements a feedback mechanism where the image capturing system detects the actual positions of the lens unit and housing unit, processes the images to determine relative positioning, and uses this information to guide the assembly process, ensuring high precision without increasing groove definition complexity
Solution Approach 2:
The system performs preliminary image capturing and position determination before the actual assembly operation, allowing the assembly process to proceed directly based on pre-calculated positioning information without requiring complex real-time adjustments
3Productivity
If tolerance of optical length is neglected to reduce assembly time, then assembly efficiency is improved, but optical resolution deteriorates due to misalignment
Solution Approach 1:
The patent replaces time-consuming manual measurement and adjustment with an automated image-based alignment system that rapidly determines precise positions and guides assembly, achieving both high efficiency and high precision simultaneously
Solution Approach 2:
The patent introduces image capturing and processing as an intermediary step between the lens unit and housing unit, using visual information to mediate the alignment process and achieve precise positioning without direct physical measurement or adjustment
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 method significantly reduces the number of assembly steps and time, ensuring high-resolution imaging by maintaining the modulation transfer function (MTF) close to ideal even with small variations in optical path length, thus improving the overall imaging quality and reducing manufacturing costs.
Implementation Method 1
the source light is refracted, and the refracted light travels through the lens unit 13 along a Z-axis direction toward the light-sensing components 121 so as to be focused into an image
Implementation Method 2
the light-sensing components 121 sense the light impinged thereon and captures an image of the object
Data Source
AI summary
An optical alignment method is for an optical module including a housing unit, a light-sensing unit, and a lens unit. The method includes: (a) through image-capturing techniques, finding a light-sensing component of the light-sensing unit and a predetermined reference point, and determining an actual total optical path length between the light-sensing component and an object position; (b) subtracting a correction distance from the actual total optical path length to obtain a corrected total optical path length; (c) finding a first center line that divides the corrected total optical path length in half; (d) through image-capturing techniques, finding opposite first and second edges of the lens unit, and determining a lens length between the first and second edges; (e) finding a second center line that divides the lens length in half; and (f) assembling the lens unit to the housing unit such that the first and second center lines overlap.