Optical Module Lens Alignment Using Prism-Based Color Spot Detection
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Solution Overview
Problem
Existing methods for actively aligning lenses in optical modules are inefficient, requiring low accuracy and high manual adjustment time.
Innovation Solution
An apparatus and method utilizing a spectroscopic prism, color image collecting means, and an alignment mechanism to determine and adjust lens positions based on imaging light spots, with a controller generating aligning instructions for the alignment mechanism to improve efficiency and accuracy in aligning multiple optical modules simultaneously.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If active alignment method using image collecting means is used, then lens alignment accuracy is improved, but assembly efficiency deteriorates due to low throughput and high manual adjustment time
Solution Approach 1:
The patent segments the assembly process into two distinct phases: a rough positioning phase using automated placement, and a fine-tuning phase using active alignment with image collecting means. This segmentation allows the majority of assemblies to be completed efficiently through automation, while only requiring precise manual adjustment for cases that need it, thereby resolving the contradiction between alignment accuracy and assembly efficiency
Solution Approach 2:
The patent applies partial action by implementing active alignment only when necessary, rather than for every assembly. The system first attempts automated positioning, and only invokes manual active alignment when the initial positioning does not meet the required tolerance, thus avoiding the time consumption of full active alignment for all components while maintaining the necessary alignment accuracy
2Manufacturing precision
If manual active alignment adjustment is performed for each lens, then alignment precision is improved, but time consumption increases significantly
Solution Approach 1:
The patent implements self-service by enabling the system to automatically determine whether active alignment is needed through image collecting means, and to perform the alignment adjustments autonomously when required. This eliminates the need for continuous manual inspection and adjustment of every lens, reducing time consumption while maintaining alignment precision through automated feedback control
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 solution significantly enhances the efficiency and accuracy of lens alignment in optical modules by using color image collecting means to identify misaligned lenses and adjust their positions, allowing for simultaneous alignment of multiple modules with improved optical performance.
Implementation Method 1
a spectroscopic prism with a light incident surface close to the plurality of optical modules to be aligned
Data Source
AI summary
An apparatus and a method for assembling optical module. The apparatus includes: a plurality of fixtures, an alignment mechanism, a power supply, a spectroscopic prism with a light incident surface close to the plurality of optical modules to be aligned, a first color image collecting means close to a first light emitting surface of the spectroscopic prism and a second color image collecting means with a second light emitting surface of the spectroscopic prism; the controller is configured to determine a light spot that does not meet a quality requirement according to the positions and/or sizes of the plurality of imaging light spots, and generate a corresponding aligning instruction, and determine a to-be-assembled lens necessary to be adjusted according to a color of the light spot that does not meet quality requirements, and output the aligning instruction to an alignment mechanism to adjust a position of the lens necessary to be adjusted.