Receiver Unit Shim Layout for 3D Optical Axis Alignment
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Solution Overview
Problem
Existing optical sensors face limitations in optical axis adjustment accuracy due to manufacturing tolerances, particularly in three-dimensional adjustments, which affect the precision of detecting external environments.
Innovation Solution
The optical sensor employs a three-dimensional coordinate system with a sensor base and receiver unit, utilizing primary and secondary shims positioned at specific locations to adjust the orientation of the received light optical axis, ensuring accurate alignment through three-point and two-point support states, respectively.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional optical sensor assembly methods are used, then device complexity is low, but manufacturing precision of optical axis alignment deteriorates
Solution Approach 1:
The patent divides the alignment adjustment into multiple independent dimensional adjustments using separate shim components. Primary shims handle Y and Z axis alignment, while secondary shims handle X axis alignment. This segmentation allows each component to focus on a specific alignment dimension, improving overall manufacturing precision without requiring a single complex adjustment mechanism.
Solution Approach 2:
The patent introduces shim components as intermediary elements between the receiver unit and sensor base. These shims act as mediators that compensate for misalignment by providing controlled thickness variations. The shims are positioned at specific locations and have precisely controlled thicknesses that enable three-dimensional optical axis alignment while maintaining a relatively simple overall structure.
2Measurement precision
If three-dimensional optical axis adjustment is implemented, then measurement precision of external environment improves, but device complexity increases
Solution Approach 1:
The patent segments the three-dimensional alignment adjustment into independent X, Y, and Z axis adjustments using separate shim components. Primary shims are positioned at three distinct locations for Y and Z axis adjustment, while secondary shims are positioned at two distinct locations for X axis adjustment. This segmentation enables precise three-dimensional control of the optical axis orientation without requiring a single complex adjustment mechanism.
Solution Approach 2:
The patent achieves three-dimensional optical axis adjustment by changing the thickness parameter of the shim components. Each shim has a specifically controlled thickness that corresponds to the required adjustment in its respective dimension. By varying the thickness parameter of these simple planar components, the system achieves complex three-dimensional alignment without adding mechanical complexity.
3Manufacturing precision
If multiple shim components are added for precise alignment, then manufacturing precision improves, but ease of manufacture deteriorates
Solution Approach 1:
The patent segments the alignment function into multiple simple shim components with specific positioning locations. Each shim is a simple planar element with controlled thickness, and they are positioned at predetermined locations (three for primary shims, two for secondary shims). This segmentation makes each component easy to manufacture individually while collectively achieving precise alignment, and the modular nature simplifies the assembly process.
Data Source
AI summary
An optical sensor includes: a sensor base that forms a first base surface, which is parallel to a Y-Z plane, and a second base surface, which is parallel to an X-Z plane; a receiver unit that is configured to receive a reflection beam along a received light optical axis; a plurality of primary shims that are respectively positioned at three distinct locations to position the receiver unit relative to the sensor base around a Y-axis and also around a Z-axis; and a plurality of secondary shims that are respectively positioned at two distinct locations to position the receiver unit relative to the sensor base around an X-axis. Each primary shim has a thickness set based on an orientation angle of the received light optical axis. Each secondary shim has a thickness set based on the orientation angle.