Optical Sensor Axis Alignment Using 3D Positioning Shims
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Solution Overview
Problem
Conventional optical sensors face limitations in adjusting the optical axis with precision due to manufacturing tolerances such as tilt within and between modules, leading to reduced accuracy in beam projection and reception.
Innovation Solution
A manufacturing method using a three-dimensional coordinate system adjusts the projection and receiving optical axes by displacing optical centers relative to the principal points of the lens modules, incorporating positioning shims, and aligning axes in the XZ-plane to absorb manufacturing tolerances, ensuring high precision alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optical sensors use standard module assembly without positioning shims, then the device complexity is low, but the manufacturing precision of optical axis alignment deteriorates due to manufacturing tolerances
Solution Approach 1:
Positioning shims are introduced as intermediary components between the light source module and light receiving module. These shims with precisely controlled thicknesses (e.g., 0.01mm to 0.1mm) act as mediators to compensate for manufacturing tolerances and achieve accurate optical axis alignment without requiring complex adjustment mechanisms.
Solution Approach 2:
The invention changes the physical parameter of the assembly by introducing positioning shims with specific thickness values. By selecting shims with controlled thickness parameters, the system compensates for dimensional tolerances in the optical modules and achieves precise alignment of the optical axes with the sensor chip.
2Manufacturing precision
If positioning shims are introduced to align optical axes, then the manufacturing precision improves, but the ease of manufacture deteriorates due to additional alignment steps
Solution Approach 1:
The positioning shims are pre-formed with predetermined thicknesses during the manufacturing process, before assembly. This preliminary preparation of positioning components with accurate dimensions allows for simpler final assembly, as the shims are ready to be inserted and provide immediate alignment without requiring complex on-site adjustment procedures.
3Manufacturing precision
If the optical center is displaced relative to the principal point to adjust the optical axis, then the alignment precision improves, but the device complexity increases due to additional positioning requirements
Solution Approach 1:
The positioning shims serve as intermediary elements that embody the displacement requirement. Instead of directly adjusting the optical center position through complex mechanisms, the shims provide a simple thickness-based solution that achieves the required optical path difference and alignment precision.
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 precise alignment of optical axes, enhancing the accuracy of beam projection and reception, thereby improving the sensor's ability to detect external environments with high precision.
Implementation Method 1
A projection lens module, bonded to the light source module, guides the projected beam to the external environment along a projection optical axis
Implementation Method 2
A light-receiving lens module, bonded to the light-receiving detection module, guides the reflected beam to the light-receiving detection module along a light-receiving axis
Implementation Method 3
Conventional optical sensors detect an external environment by projecting a light beam toward the external environment and receiving a reflected beam from the field in response to the projected beam
Data Source
AI summary
A method for manufacturing an optical sensor detects an external environment by projecting a beam and receiving a reflected beam. The sensor uses a three-dimensional coordinate system defined by X, Y, and Z axes. The optical sensor includes a light source module with a projection-positioning surface projecting the beam, and a projection lens module bonded to the light source module. A sensor base positions the projection-positioning surface, while a light-receiving detection module with a receiving-positioning surface detects the reflected beam. A light-receiving lens module guides the reflected beam to the light-receiving detection module. The method involves measuring projection and receiving angles, bonding the modules, measuring error angles, adjusting positioning shims, and fixing the modules to the sensor base.