Optical Mounting Apparatus for Backlash-Free Independent Alignment
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Solution Overview
Problem
Existing mounts and housings for optical components in precision systems suffer from cross-coupling between adjustment inputs, leading to undesired displacements and requiring multiple iterations for alignment, and are often bulky and costly.
Innovation Solution
A compact adjustable apparatus with a virtual center pivot, utilizing spheres and cylindrical pins for rotary and linear displacement, allowing independent adjustments without backlash, and incorporating preloaded springs for zero backlash movement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mounts and housings are used for optical components, then manufacturing is simpler and cost is lower, but cross-coupling between adjustments occurs leading to undesired displacements and requiring multiple iterations for alignment
Solution Approach 1:
The adjustment mechanism is divided into independent modules, each responsible for a specific degree of freedom. The mounting apparatus includes separate adjustment mechanisms for lateral, longitudinal, and angular adjustments, allowing each to operate independently without affecting others. This segmentation eliminates cross-coupling while maintaining manufacturing feasibility.
Solution Approach 2:
Spherical interfaces and cylindrical pins serve as intermediary elements between the optical component and the mounting structure. These intermediaries enable precise movement and positioning while decoupling the adjustment mechanisms, allowing independent control of each degree of freedom without direct mechanical coupling.
2Measurement precision
If dedicated adjustment stages and mounts are used to achieve precise alignment, then alignment precision improves, but the device size increases and becomes bulkier
Solution Approach 1:
The adjustment mechanisms are nested within a compact mounting structure. The spherical interfaces and cylindrical pins are integrated into the housing in a space-efficient manner, with adjustment components arranged concentrically and in overlapping configurations. This nesting allows precise multi-degree-of-freedom adjustment without increasing overall device volume.
Solution Approach 2:
The design transitions from traditional multi-stage mechanical adjustments to a spherical coordinate system-based adjustment mechanism. By using spherical interfaces and defining adjustment axes through the sphere center, the mechanism achieves compact 3D positioning and orientation control in a single integrated structure rather than requiring multiple sequential adjustment stages.
3Ease of operation
If tilt adjustments are made via a pivot offset from the center aperture, then angular adjustment is achieved, but lateral and axial displacements occur perpendicular to the aperture axis
Solution Approach 1:
The spherical interface is positioned asymmetrically relative to the aperture, with the sphere center deliberately offset from the aperture center. This asymmetric arrangement allows the tilt adjustment axis to pass through the sphere center rather than the aperture center, enabling angular adjustment without inducing lateral or axial displacements at the aperture plane.
Solution Approach 2:
The spherical interface acts as an intermediary element that decouples angular adjustment from positional displacement. By introducing this spherical intermediary between the adjustment mechanism and the optical component, the system achieves independent control of orientation and position, eliminating the cross-coupling that occurs with conventional offset pivot designs.
4Device complexity
If adjustment screws serve a dual role in gimbal-style mounts, then device complexity is reduced, but unpredictable misalignments occur and backlash is introduced
Solution Approach 1:
The adjustment mechanism is segmented into dedicated components for each function: adjustment screws for positional control and separate spherical-cylindrical interfaces for angular control. This functional segmentation eliminates the dual-role ambiguity that causes misalignments, with each component optimized for its specific purpose and unable to introduce cross-axis errors.
Solution Approach 2:
The design replaces traditional dual-function mechanical adjustment screws with a hybrid mechanism combining spherical interfaces and cylindrical pins. This substitution eliminates backlash by using spherical contact surfaces that maintain continuous contact during adjustment, while the cylindrical pins provide precise rotational positioning without the play inherent in screw-based dual-role mechanisms.
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
Enables precise, independent adjustments in 4, 5, or 6 degrees-of-freedom without cross-coupling, providing a compact and economical solution for optical alignment.
Implementation Method 1
a spherical interface between the optical component and the mounting structure, the axis of rotation passing through a center of the sphere
Implementation Method 2
two spheres each in tangential contact with a pair of cylindrical pins thereby allowing rotary displacement about a first axis defined between the centers of the two spheres and linear displacement along the same first axis
Implementation Method 3
Linear and tilt adjustments of the first moving member with respect to the stationary base are performed by actuating first axis linear and tilt adjustment screws
Implementation Method 4
actuating first axis linear and tilt adjustment screws against two preloaded springs
Data Source
AI summary
The presently claimed and described technology provides an apparatus configured to adjustably position a focal location of a first instrument of a first body with respect to a target location of a second instrument of a second body. The apparatus further includes a third body, a first joint, and a second joint. The first joint is configured to adjustably linearly position the first body with respect to the third body along a first axis and thereby perform a first adjustment and is further configured to adjustably rotatably position the first body with respect to the third body about the first axis and thereby perform a second adjustment. The second joint is configured to adjustably linearly position the second body with respect to the third body along a second axis and thereby perform a third adjustment and further configured to adjustably rotatably position the second body with respect to the third body about the second axis and thereby perform a fourth adjustment. Each of the first, second, third, and/or fourth adjustments are performed independently of each other and may have zero backlash. Additional third axis linear and/or rotational adjustment mechanism(s) may be added. In certain embodiments, the first, second, and/or third axes intersect each other at a point.