Optical Module Adjustment Using Wavefront Sensor Parallelism
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Solution Overview
Problem
Existing methods for adjusting optical modules that project light or video are time-consuming and lack accuracy due to the need to form a test pattern on a transmissive screen and detect slight changes with a camera.
Innovation Solution
An examination and adjustment method that uses a wavefront sensor to analyze a test pattern with dot-shaped light-on portions, calculating phase distribution, cutting out regions of light flux, calculating parallelism, and determining the inclination of the display panel relative to the projection lens.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a test pattern is formed on a transmissive screen and detected by a camera, then the optical module can be adjusted, but the adjustment process becomes time-consuming and lacks accuracy
Solution Approach 1:
The patent replaces the mechanical/optical detection system (camera capturing test pattern on transmissive screen) with a wavefront sensor that directly measures the wavefront characteristics of light passing through the optical module. This substitution enables direct measurement of panel inclination through wavefront analysis, eliminating the need for screen formation and camera detection, thereby achieving both high-speed and high-accuracy adjustment
Solution Approach 2:
The patent introduces a wavefront sensor as an intermediary measurement device between the light source and the detection system. The wavefront sensor serves as a mediator that converts the physical state of light (wavefront characteristics) into measurable data that directly reflects panel inclination, providing a more efficient and accurate measurement pathway compared to the traditional camera-based approach
2Ease of operation
If the position and orientation of the display panel are adjusted using a robot, then the optical module can be positioned, but the process requires complex equipment and multiple steps
Solution Approach 1:
The patent enables the optical module adjustment system to perform self-diagnosis and self-adjustment. The wavefront sensor provides real-time feedback on panel inclination, and the control device automatically processes this information to determine adjustment requirements, reducing the need for complex robotic positioning systems and manual intervention
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 enables high-speed and high-accuracy adjustment of optical modules by eliminating the need to form a test pattern on a transmissive screen and allowing precise determination of panel inclination.
Implementation Method 1
a test pattern receiving step of receiving, by a light receiving unit of a wavefront sensor, the test pattern including each light flux of the dot-shaped light-on portions projected from the projection lens; a phase distribution calculation step of calculating, by a controller, a phase distribution of a wavefront of the test pattern received by the wavefront sensor
Data Source
AI summary
At least three light fluxes of the test pattern projected from optical module 1 are acquired by wavefront sensor 9, the parallelism of the respective light fluxes is calculated, and the orientation of display panel 5 of the optical module is adjusted so that the parallelism of each light flux coincides.