Wedge Mechanism for Light Modulator Alignment
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Solution Overview
Problem
The alignment of red, green, and blue sub-images in projectors with digital micromirror devices (DMDs) is challenging due to the small pixel sizes, as conventional mechanical image adjusting methods are not suitable for such small pixel resolution adjustments.
Innovation Solution
A device with a wedge mechanism that allows for rotational and linear adjustments of a light modulator plate, using biasing mechanisms and wedge devices to precisely align the sub-images, enabling finer positional adjustments than conventional convergence techniques.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional mechanical image adjusting methods are used, then the structure is simple, but the alignment precision is insufficient for small pixel sizes
Solution Approach 1:
The patent replaces conventional mechanical screw-based adjustment mechanisms with a wedge-based mechanical system. The wedge device converts rotational motion into precise linear displacement of the light modulator plate, achieving sub-pixel alignment precision (better than 5-6 microns) while maintaining a relatively simple mechanical structure. The wedge mechanism provides mechanical advantage for fine positioning without requiring complex multi-axial adjustment assemblies.
Solution Approach 2:
The invention changes the adjustment parameter from coarse threaded screw movement to fine wedge-based displacement. By using the wedge geometry, a small rotational input produces a controlled linear output displacement that is proportional to the wedge angle, enabling precise positioning of the light modulator plate relative to the pixel array dimensions.
2Manufacturing precision
If the pixel size is reduced to 5-6 microns, then the image resolution is improved, but the alignment difficulty increases
Solution Approach 1:
The wedge-based adjustment mechanism provides fine-grained control over the light modulator plate position, enabling alignment precision that matches the reduced 5-6 micron pixel dimensions. The mechanical wedge system translates small rotational adjustments into sub-pixel linear displacements, making it possible to detect and correct misalignment at the scale of modern high-resolution DMD devices.
3Ease of operation
If conventional convergence techniques are used, then the device complexity is low, but the adjustment fineness is insufficient
Solution Approach 1:
The patent replaces conventional convergence adjustment techniques with a wedge-based mechanical system that provides superior adjustment fineness. The wedge mechanism allows for precise, repeatable positioning of the light modulator plate with fine resolution, enabling operators to achieve accurate image alignment while maintaining a mechanically simple and robust adjustment system.
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
The wedge mechanism provides precise alignment of pixels in sub-images, improving the quality of projected images by allowing for finer adjustments than conventional methods, particularly for DMDs with small pixel sizes.
Implementation Method 1
a first wedge device (121) configured to interact with a first edge (131) of the second plate (102) to move the second plate (102), relative to the first plate (101), against the one or more biasing mechanisms (107)
Implementation Method 2
one or more biasing mechanisms (107, 108) configured to bias the second plate (102) in a biased position relative to the first plate (101), the one or more biasing mechanisms (107, 108) configured to allow the second plate (102) to move with respect to the first plate (101)
Data Source
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AI summary
A wedge mechanism comprising: a first plate (101); a second plate (102) for receiving a light modulator; one or more biasing mechanisms(107-1, 107-2; 108-1, 108-2) to bias the second plate in a biased position relative to the first plate, to allow the second plate to move with respect to the first plate; first and second wedge devices (121, 122) configured respectively to interact with a first and second edges of the second plate to move the second plate, relative to the first plate, against the one or more biasing mechanisms, the second edge of the second plate being about perpendicular to the first edge of the second plate; and first and second wedge device adjustment mechanisms (141-1, 141-2; 142), configured to respectively adjust positions of the first and second wedges device relative to the first and second edges, to move the second plate.