Optical Module Assembly Using Beam Shaping and Self-Alignment
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Solution Overview
Problem
Existing optical inspection systems face limitations in precisely assembling optical modules and achieving desired beam shapes for accurate part inspection, with challenges in beam divergence and profile uniformity.
Innovation Solution
A method involving beam shaping components and an optical mount to adjust and secure lenses for achieving a desired laser beam shape, such as converting a circular beam to a rectangular shape with controlled divergence and power distribution, using cylindrical lenses and precise alignment techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional manual assembly methods are used for optical modules, then ease of operation is maintained, but manufacturing precision deteriorates
Solution Approach 1:
The patent implements preliminary alignment actions during the assembly process. The optical components are pre-positioned and aligned using alignment features and adjustment mechanisms before final securing. This allows manual assembly to achieve precision comparable to automated methods by performing alignment operations in advance of final assembly steps.
Solution Approach 2:
The patent introduces alignment features, adjustment mechanisms, and fixture elements as intermediary tools during assembly. These intermediaries facilitate precise positioning of optical components without requiring complex automated equipment. The intermediaries include alignment pins, adjustment screws, and fixture elements that guide component placement and enable fine-tuning of positions.
2Measurement precision
If beam shaping components are not precisely aligned, then device complexity is reduced, but measurement precision deteriorates
Solution Approach 1:
The patent implements self-aligning features where the optical components and beam shaping elements are designed with built-in alignment mechanisms. The components automatically guide their own positioning through geometric constraints, tolerance stacking, and self-correcting alignment features. This reduces the need for complex external alignment procedures while maintaining beam shape accuracy.
Solution Approach 2:
The patent replaces complex mechanical alignment procedures with optical alignment methods. Using the laser beam itself as an alignment reference, the system achieves precise beam shaping through optical feedback and adjustment rather than relying solely on mechanical positioning accuracy. This substitution simplifies the alignment process while improving measurement 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
The method ensures a laser beam with a desired rectangular shape and low divergence, enhancing the accuracy and precision of optical inspections by maintaining a flat profile and balanced power distribution, thereby improving the overall performance of optical inspection systems.
Implementation Method 1
providing a set of optical components including a plurality of beam shaping components for converting at least one initial shape in cross section of a laser beam to at least one desired shape in cross section
Implementation Method 2
converting a circular beam to a rectangular shape with controlled divergence and power distribution, using cylindrical lenses
Data Source
AI summary
Optical modules and a method of precisely assembling the modules are provided. The method includes the step of providing a set of optical components including a plurality of beam shaping components for converting at least one initial shape in cross section of a laser beam to at least one desired shape in cross section and an optical mount for supporting the set of optical components. The method further includes holding and locating the optical mount relative to a reference axis. The method still further includes holding the optical components in position relative to the optical mount during the step of holding and locating wherein the positions of the beam shaping components are initial positions. The method includes directing a laser beam having the at least one initial shape at the set of optical components during the step of holding the optical components. The method further includes adjusting the initial positions of the beam shaping components to obtain final positions of the beam shaping components relative to the optical mount during the step of directing until the laser beam has the at least one desired shape.