Optical Mount Rotational Interface Curvature Optimization
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Solution Overview
Problem
Optical assemblies face significant performance degradation due to misalignment errors, particularly decenter and tilt misalignments, which are difficult to control and occur at interfaces between components and their mounts, leading to aberrations and reduced image quality.
Innovation Solution
The optimization of rotational interfaces between optical components and their mounts by identifying the center of curvature at which the optical performance is least sensitive to misalignment, allowing for improved alignment without tightening manufacturing tolerances, and using a mathematically defined model to assess and minimize the impact of angular misalignments through a merit function.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If clearance space is provided between components and mounts to facilitate assembly and accommodate dimensional changes, then ease of manufacture and assembly are improved, but misalignment errors increase leading to degraded optical performance
Solution Approach 1:
The patent employs spherical mounting interfaces instead of planar interfaces. The rotational interface between the optical component and mount is defined by spherical surfaces with a specific radius of curvature, allowing the component to pivot about a center of curvature. This curved interface geometry converts lateral clearance into controlled angular rotation, reducing the impact of clearance-induced misalignment on optical performance.
2Manufacturing precision
If manufacturing tolerances are tightened to reduce misalignment errors, then optical performance is improved, but manufacturing cost and complexity increase
Solution Approach 1:
The patent changes the geometric parameters of the mounting interface, specifically the radius of curvature of the spherical surfaces. By optimizing this parameter, the system achieves reduced sensitivity to misalignment without requiring tighter manufacturing tolerances on the component or mount dimensions themselves.
3Ease of manufacture
If planar mounting interfaces are used, then manufacturing is simplified, but decenter misalignments occur throughout the clearance space
Solution Approach 1:
The patent replaces planar mounting interfaces with spherical interfaces. The rotational interface is formed by spherical surfaces that pivot about a center of curvature, which prevents decenter misalignment by constraining the optical component to rotate about a fixed point on the alignment axis rather than allowing lateral translation throughout the clearance space.
4Manufacturing precision
If spherical optical surfaces are engaged by mounts, then some alignment coincidences are achieved, but tilt and decenter misalignments still occur on the opposite side
Solution Approach 1:
The patent uses spherical mounting interfaces that pivot about a center of curvature located on the alignment axis. This configuration ensures that when the optical component rotates within the clearance space, both optical surfaces remain properly aligned because the rotation occurs about a point that maintains the optical axis alignment, preventing tilt and decenter misalignments on both sides of the component.
Data Source
AI summary
Different rotational interfaces between individual optical components and their mounts are compared based on a sensitivity of optical system performance to misalignment of the optical component to an alignment axis of the optical mount within a clearance space. The rotational interfaces at which the sensitivity of the optical system performance to the misalignment of the optical component approaches a minimum are incorporated into the optical design.