Complex Optical Alignment in Tiny Space

Features:Two different nanosystec gluing stations align and assemble up to 30 individual optical components in a butterfly housing using automated sub processes. This customized combination demonstrates the perfect fit of the assembly configuration regarding the process requirements.

The VersaGlue station uses high-performance machine vision algorithms to precisely pick and place half of the components in the micron regime. The heat conductive resin needs to be applied evenly to maintain the optical path parallel to the bottom of the housing. In addition, the uniform resin line guarantees a good heat transfer.

Optical power, beam parameters and the optical spectrum serve as feedback signals for the active alignment and positioning of the demanding optics. Machine vision combined with sensor measurements allow for a well-defined starting position followed by the assembly with submicron precision.

These actively aligned optics use epoxy glue which is cured by UV LED sources. Especially in these process steps, the position during assembly must not change.

Optical power is measured via a single mode fiber which transmits the signal into an integrating sphere with a photodetector. The NanoProfiler – developed by nanosystec on basis of a CCD camera – provides fast measurement capability. An optical spectrum analyzer measures the spectral properties.

The versatile software package TestMaster allows for the fast and efficient realization of the automated process flow.

The concept of manual interchange with trays fulfills the requirements for small and medium production volumes. Feeders, belts and robots serve higher production volumes and the linking of various manufacturing systems.