Multi-Channel Optical Projection Quality Assessment
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Solution Overview
Problem
Micro- and subwavelength-optical projection units face challenges in quality assessment due to variations in production process parameters, such as optical element size, curvature, and positioning, as well as defects like pinholes, which affect their performance and require efficient evaluation methods to ensure quality criteria are met.
Innovation Solution
A method and system for assessing the quality of multi-channel micro- and subwavelength-optical projection units by illuminating a predefined portion, capturing and analyzing the generated image to determine characteristic quantities associated with defects, using image processing techniques, statistical methods, and machine learning modules to categorize the projection units into quality classes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional production techniques are used for micro-optical and subwavelength-optical projection units, then manufacturing complexity is reduced, but manufacturing precision deteriorates due to high package density requirements and process variations
Solution Approach 1:
The patent replaces mechanical measurement and inspection methods with optical imaging and image processing techniques. A camera captures images of the projection unit, and software algorithms automatically analyze the images to measure optical element positions, sizes, and detect defects, eliminating the need for complex mechanical measurement systems while achieving high precision
Solution Approach 2:
The patent creates optical copies (images) of the projection unit using a camera system. These digital images serve as replicas that can be analyzed without physically touching or disturbing the actual device, enabling non-contact measurement and inspection while preserving the original structure
2Manufacturing precision
If comprehensive quality inspection methods are implemented, then manufacturing precision is improved, but productivity deteriorates due to time-consuming inspection processes
Solution Approach 1:
The patent implements continuous automated image capture and processing that can inspect multiple projection units in sequence without interruption. The system continuously acquires images, processes them through algorithms, and generates quality reports, maintaining a steady workflow that improves both accuracy and speed compared to intermittent manual inspection
Solution Approach 2:
The inspection system is self-automating, where the camera automatically captures images, the software automatically analyzes the images to measure parameters and detect defects, and the system automatically generates quality assessments without requiring constant human intervention, thereby significantly improving inspection speed
3Measurement precision
If manual inspection methods are used, then device complexity is reduced, but measurement precision deteriorates due to inability to detect subtle defects
Solution Approach 1:
The patent replaces manual visual inspection with an automated optical imaging system coupled with computer vision algorithms. The camera captures high-resolution images, and software algorithms automatically detect and measure defects, providing superior measurement precision while the computational complexity is managed through automated processing
Solution Approach 2:
The patent introduces an intermediary image processing system that acts as a bridge between the optical elements and the human inspector. The software algorithms serve as intermediaries that automatically analyze the captured images, extract measurement data, and present results in a comprehensible format, reducing the complexity burden on the overall system
4Productivity
If high package density is achieved in projection units, then productivity is improved, but manufacturing precision deteriorates due to tolerances and process variations
Solution Approach 1:
The patent uses optical imaging and automated image processing to measure the positions and distances of optical elements with high precision, enabling quality control that can keep pace with high package density manufacturing while maintaining accurate measurement of inter-element spacing
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 fast and accurate quality assessment of projection units by linking image defects to production defects, allowing for timely identification of issues and adaptation of manufacturing parameters to enhance unit quality, thereby saving resources and ensuring compliance with quality criteria.
Implementation Method 1
At least a predefined portion of the micro- and/or subwavelength-optical projection unit is illuminated so that an image is generated by at least two channels
Implementation Method 2
The image is captured and analyzed
Data Source
AI summary
A method for assessing the quality of a multi-channel micro- and/or subwavelength-optical projection unit is disclosed. The method comprises the following steps: At least a predefined portion of the optical projection unit is illuminated so that an image is generated by at least two channels of the predefined portion of the multi-channel optical projection unit. At least one characteristic quantity is determined based on the analysis of the image, wherein a value of the characteristic quantity is associated with a characteristic feature of the projection unit, a defect of the projection unit and/or a defect class of the projection unit. The quality of the projection unit is assessed based on the at least one characteristic quantity. Moreover, a test system for assessing the quality of a multi-channel micro- and/or subwavelength-optical projection unit and a computer program are disclosed.