Polygon Mirror Tilt Adjustment Mechanism for LiDAR
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Solution Overview
Problem
LiDAR systems require precise control of polygon mirror facet tilt angles to less than 0.01° for accurate scan patterns, which is costly and beyond typical manufacturing capabilities.
Innovation Solution
An economical active alignment mechanism using flexures and adjustment mechanisms, such as tapered jack/drive screws, to adjust the tilt angles of mirror bonding plates post-fabrication, allowing for precise control without stringent manufacturing tolerances.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If tight angle tolerances (less than 0.01°) are applied to polygon mirror facets during manufacturing, then scan pattern accuracy is improved, but manufacturing cost increases and manufacturing complexity increases
Solution Approach 1:
The patent applies preliminary action by pre-adjusting the tilt angles of polygon mirror facets during the manufacturing process using alignment mechanisms, rather than relying solely on post-manufacturing precision. This allows the facets to be brought to the required angular precision before final assembly, reducing the stringency of manufacturing tolerances and lowering overall manufacturing cost while achieving the necessary scan pattern accuracy.
Solution Approach 2:
The patent utilizes parameter changes by introducing adjustable alignment mechanisms that can modify the tilt angle parameters of individual facets after manufacturing. This allows the angular parameters to be fine-tuned independently of the base manufacturing process, decoupling the manufacturing precision requirements from the final performance requirements and reducing manufacturing cost.
2Manufacturing precision
If tight angle tolerances (less than 0.01°) are applied to polygon mirror facets during manufacturing, then scan pattern accuracy is improved, but device complexity increases
Solution Approach 1:
The patent applies preliminary action by incorporating alignment mechanisms during the manufacturing process that can pre-adjust facet angles. This approach consolidates the complexity into a controlled manufacturing step rather than requiring complex post-manufacturing adjustment procedures, thereby managing device complexity while achieving scan pattern accuracy.
Solution Approach 2:
The patent introduces intermediary alignment mechanisms and adjustment devices that mediate between the manufactured facets and the required angular precision. These intermediaries absorb the complexity of achieving tight tolerances by providing a controlled adjustment process, separating the manufacturing function from the precision requirement and managing overall device complexity.
3Ease of manufacture
If standard manufacturing tolerances are used for polygon mirror facets, then manufacturing cost is reduced, but scan pattern accuracy deteriorates
Solution Approach 1:
The patent applies preliminary action by using alignment mechanisms during manufacturing to pre-establish the correct facet angles. This allows standard manufacturing tolerances to be used while still achieving accurate scan patterns, as the alignment process compensates for any variations introduced during standard manufacturing.
Solution Approach 2:
The patent utilizes parameter changes by introducing adjustable alignment mechanisms that can modify the angular parameters of facets after standard manufacturing. This allows the system to accept standard manufacturing tolerances (lowering cost) while achieving the required precision through controlled parameter adjustment during assembly or commissioning.
4Ease of manufacture
If standard manufacturing tolerances are used for polygon mirror facets, then manufacturing cost is reduced, but vertical gap control in scan pattern deteriorates
Solution Approach 1:
The patent applies preliminary action by incorporating angle adjustment mechanisms during the manufacturing process that can pre-align each facet to the correct tilt angle. This ensures that even with standard manufacturing tolerances, the vertical gaps between scan bands are well-controlled, as the alignment process compensates for manufacturing variations.
Solution Approach 2:
The patent utilizes parameter changes by introducing adjustable mechanisms that can fine-tune the angular parameters of individual facets. This allows the system to use standard manufacturing tolerances (reducing cost) while achieving precise vertical gap control through controlled parameter adjustment during assembly or commissioning.
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 control of tilt angles within the required tolerance, reducing manufacturing costs and achieving well-controlled scan patterns in LiDAR systems.
Implementation Method 1
at least some mirror bonding plates of the plurality of mirror bonding plates are adjustably attached to the frame based on corresponding flexures of the one or more flexures
Implementation Method 2
A plurality of adjustment mechanisms is inserted between the frame and corresponding mirror bonding plates of the plurality of mirror bonding plates, where the plurality of adjustment mechanisms is configured to adjust tilt angles of the corresponding mirror bonding plates
Implementation Method 3
a plurality of mirror bonding plates configured to reflect light
Data Source
AI summary
A light scanning device comprises a rotatable polygon-shaped structure comprising a frame, a plurality of mirror bonding plates configured to reflect light, and one or more flexures. At least some mirror bonding plates of the plurality of mirror bonding plates are adjustably attached to the frame based on corresponding flexures of the one or more flexures. A plurality of adjustment mechanisms is inserted between the frame and corresponding mirror bonding plates of the plurality of mirror bonding plates, where the plurality of adjustment mechanisms is configured to adjust tilt angles of the corresponding mirror bonding plates.