Optical Sensor Shim Alignment for Precise 3D Optical Axis Adjustment
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Solution Overview
Problem
Existing optical sensors face limitations in optical axis adjustment accuracy due to manufacturing tolerances, which are substantially limited to three axial directions, leading to inadequate adjustment precision.
Innovation Solution
The optical sensor employs a three-dimensional coordinate system with primary and secondary shims positioned at specific locations to adjust the orientation of the receiver and projector units, allowing for precise alignment along the X, Y, and Z axes through a combination of three-point and two-point support states, using shims with individually set thicknesses based on adjusted orientation angles.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If adjustment is limited to three axial directions, then the adjustment method is simple, but the adjustment accuracy is insufficient due to manufacturing tolerances
Solution Approach 1:
The patent introduces adjustment capabilities in rotational directions (around optical axes) in addition to the conventional three translational directions. This dimensional expansion allows compensation for manufacturing tolerances by rotating the receiver unit to achieve precise optical axis alignment, thereby resolving the contradiction between adjustment accuracy and mechanism complexity.
Solution Approach 2:
The patent employs movable adjustment mechanisms that allow dynamic repositioning of the receiver unit both translationally and rotationally. This dynamic adjustment capability enables real-time compensation for manufacturing tolerances, achieving high precision optical axis alignment while maintaining a manageable adjustment mechanism through sequential adjustment steps.
2Adaptability or versatility
If primary shims are positioned at three distinct locations, then the receiver unit can be positioned around Y-axis and Z-axis, but the structure becomes more complex
Solution Approach 1:
The patent divides the positioning function into separate modular components: primary shims for Y-axis and Z-axis positioning, and secondary shims for X-axis positioning. This segmentation allows each shim type to be optimized for its specific function while maintaining overall system versatility. The modular design achieves comprehensive positioning capability without excessive complexity by assigning dedicated components to specific adjustment tasks.
3Manufacturing precision
If shims with individually set thicknesses are used, then optical axis alignment precision is improved, but the manufacturing process becomes more complex
Solution Approach 1:
The patent utilizes shims with precisely controlled thickness parameters that are individually set based on measured orientation angles. By varying the thickness parameter of each shim according to specific orientation requirements, the system achieves high optical axis alignment precision. The manufacturing complexity is managed by calculating and specifying thickness values based on measured angular deviations, allowing standardized manufacturing processes to produce customized precision components.
Data Source
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AI summary
An optical sensor (10) includes: a sensor base (14) that forms a surface (141), which is parallel to a Y-Z plane, and a surface (142), which is parallel to an X-Z plane; a receiver unit (41) that is configured to receive a reflection beam (Br) along a received light optical axis (Or), an orientation of which is adjusted in a three-dimensional coordinate system; a plurality of primary shims (15) that are respectively positioned at three distinct locations to position the receiver unit (41) relative to the sensor base (14) around a Y-axis and also around a Z-axis; and a plurality of secondary shims (16) that are respectively positioned at two distinct locations to position the receiver unit (41) relative to the sensor base (14) around an X-axis. Each primary shim (15) has a thickness set based on an orientation angle (θ) of the received light optical axis (Or) and is screw-fastened between a contact surface of the receiver unit (41) and the surface (141) in a state where a corner portion of the primary shim is in contact. Each secondary shim (16) has a thickness set based on the orientation angle (θ) and is screw-fastened between a surface (452) perpendicular to a surface (451) of the receiver unit (41) and the surface (142) in a state where a corner portion (160) of the secondary shims (16) is in contact with the surface (142).