Active Alignment Equipment for Projector Module Testing
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Solution Overview
Problem
Active alignment equipment faces challenges in increasing unit per hour (UPH) while maintaining a compact footprint, as testing multiple projector modules simultaneously requires a larger chamber, disrupting factory production lines.
Innovation Solution
The equipment employs a mask and camera system to allow only a portion of projected images from multiple projector modules to be projected onto a screen, enabling simultaneous testing and analysis to control settings, thereby reducing the equipment's size and footprint.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If more projector modules are tested simultaneously to improve UPH, then productivity increases, but the chamber size must increase causing larger footprint
Solution Approach 1:
The mask divides the projection area into multiple independent testing zones, each handling one projector module. This segmentation allows multiple modules to be tested simultaneously in a compact chamber, resolving the contradiction between high productivity and small footprint by organizing testing space into discrete, non-interfering segments
Solution Approach 2:
The mask introduces a new spatial dimension for organizing multiple projector modules by creating distinct projection zones that can be arranged in ways that maximize space utilization. This dimensional organization allows more modules to fit in the same chamber volume without increasing footprint
2Area of stationary object
If multiple projector modules are positioned closer to reduce footprint, then chamber size decreases, but projected images overlap causing measurement errors
Solution Approach 1:
The mask extracts and isolates the relevant portions of projected images from each module, removing the harmful overlapping portions. By taking out only the necessary non-overlapping regions for analysis, the system maintains measurement precision while allowing modules to be positioned closer together
Solution Approach 2:
The mask acts as an intermediary element between the projector modules and the screen, controlling which portions of projected images reach the screen. This intermediary prevents direct interference between multiple projected images while still allowing all modules to operate simultaneously in a compact space
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 approach allows for high UPH with a low footprint, enabling accurate focus and tilt adjustments of projector modules without image overlapping, facilitating efficient production line operations.
Implementation Method 1
the mask is arranged to mask a plurality of projected images generated by the projector modules so that only a portion of projected images is allowed to be projected to the screen
Implementation Method 2
The camera is arranged for capturing the portion of projected images on the screen
Data Source
AI summary
An equipment for testing a plurality of projector modules is provided, wherein the equipment includes a screen, a mask, at least one camera and a controller. The mask is positioned between the screen and the projector modules when the projector modules are within the equipment, and the mask is arranged to mask a plurality of projected images generated by the projector modules so that only a portion of projected images is allowed to be projected to the screen. The camera is arranged for capturing the portion of projected images on the screen. The controller is coupled to the camera, and is arranged for analyzing the captured images to control settings of the projector modules.