Patent Application
20240160032
The present application generally relates to an actuator assembly and a method of operation thereof, and in particular to a shape memory alloy (SMA) actuator assembly.
Shape memory alloy (SMA) actuators are used in camera assemblies for effecting a range of motions of a lens carriage or an image sensor. For example, WO 2013/175197 A1 describes a camera with an SMA actuator assembly SMA wires are configured to, on contraction, move a lens carriage in directions perpendicular to an optical axis to provide optical image stabilization (OIS). In these known embodiments, the lens carriage is permanently attached to, and sometimes suspended by, the SMA wires. When the actuator assembly is subjected to sudden accelerations, e.g. during a drop, the inertia of the lens may subject the SMA wires to excessive tension and in some cases causes irreversible damage. This problem is particularly prominent in SMA actuators carrying heavier lenses.
WO2017/072525A1 discloses a similar actuator arrangement configured to shift an image sensor perpendicular to the optical axis. During the assembly process, the SMA actuators typically have some degree of component integration with an Image sensor assembly (including a sensor, a bracket, and circuitry). Since the integration with the image sensor involves processes that can affect actuator performance, it is improbable to test the actuator performance before assembly. Therefore, any performance issue in the SMA actuator discovered after assembly would mean the entire module being rejected.
The present invention provides ways to allow components such as a lens carriage or an image sensor to be removably attached to a moveable platform, and wherein the components may be repositioned to or realigned at the desired position in a completed assembly by actuating only the moveable platform.
According to a first aspect of the present invention, there is provided an actuator assembly comprising:
The actuator assembly may be a micro-actuator for a camera or a mobile phone. The first part may correspond to a support structure and the second part may correspond to a movable platform. The third part may correspond to any one of a lens carriage, an AF module, a support for an image sensor or light emitter, e.g. VCSEL used in time-of-flight 3D sensing. The actuator assembly may comprise one or more (e.g. elongate) SMA wires, which may directly connect with the second part, or may connect to the second part by a force-modifying mechanism. That is, in relation to the latter, one end of the SMA wire may be attached to the force-modifying mechanism, whereby the actuating force from the SMA wire may be applied as an output force to the second part through the force-modifying mechanism. Specifically, the force-modifying mechanism is not an SMA wire, and the output force may be the same, or different from, the actuating force.
The term ‘shape memory alloy (SMA) wire’ may refer to any element comprising SMA. The SMA wire may have any shape that is suitable for the purposes described herein. The SMA wire may be elongate and may have a round cross section or any other shape cross section. The cross section may vary along the length of the SMA wire. It is also possible that the length of the SMA wire (however defined) may be similar to one or more of its other dimensions. The SMA wire may be pliant or, in other words, flexible. In some examples, when connected in a straight line between two elements, the SMA wire can apply only a tensile force which urges the two elements together. In other examples, the SMA wire may be bent around an element and can apply a force to the element as the SMA wire tends to straighten under tension. The SMA wire may be beam-like or rigid and may be able to apply different (e.g. non-tensile) forces to elements. The SMA wire may or may not include material(s) and/or component(s) that are not SMA. For example, the SMA wire may comprise a core of SMA and a coating of non-SMA material. Unless the context requires otherwise, the term ‘SMA wire’ may refer to any configuration of SMA wire acting as a single actuating element which, for example, can be individually controlled to produce a force on an element. For example, the SMA wire may comprise two or more portions of SMA wire that are arranged mechanically in parallel and/or in series. In some arrangements, the SMA wire may be part of a larger piece of SMA wire. Such a larger piece of SMA wire might comprise two or more parts that are individually controllable, thereby forming two or more SMA wires.
The SMA wires may be formed of any suitable shape memory alloy material, typically a nickel-titanium alloy (e.g. Nitinol), possibly also containing tertiary components such as copper. The SMA wires may have any cross-sectional profile and diameter suitable for the application. For example, the SMA wires may have a cross section diameter of 25 μm, or 30 μm, or 35 μm, capable of generating a maximum force of between 120 mN to 400 mN whilst maintaining the strain in the SMA wire within safe limits (e.g. 2-3% reduction in length over original length). Increasing the diameter of each SMA wire from 25 μm to 35 μm approximately doubles the cross-sectional area of the SMA wire and thus approximately doubles the force provided by each SMA wire.
Broadly speaking, during normal operation the second part may move in the movement direction wherein the third part, in absence of any resistance, moves with the second part. Therefore, the relative positions and orientations of the second part and the third part may remain unchanged. (For brevity, the term “position” will be generally used herein to refer to position and/or orientation.) The movement of the lens carriage, the image sensor, or the light emitter (e.g. the third part), may precisely follow the movement of the moving platform (e.g. the second part).
The third part may be arranged to, when positioned away from a default position, return to the default position when it is being driven against the endstop. When the third part is required to be moved into a predetermined position, e.g. a centred or default position relative to the second part, the second part moves into a position (within or outside a movement range suitable for normal operation) where a side of the third part engages, or abuts, a corresponding endstop on the first part. When the second part continues to move towards the endstop, the latter pushes against the third part and therefore causing the third part (whilst remaining engaged with the endstop) to move or slide relative to the second part. The second part may continue to move until the endstop has pushed the third part to a desired position, e.g. the centred or default position, on the second part. The third part may be maintained at the desired moved position on the second part when the second part moves in an opposite direction to the movement direction, e.g. when the second part retracts from the endstop.
Advantageously, such an arrangement may allow the third part to slide along the surface of the second part. Therefore, in the event of sudden acceleration, the inertia of the third part would not cause excessive tension in the SMA wires. Moreover, such an arrangement may allow the second part to be realigned or repositioned into a default position. This may take place after the third part has been dislodged from the second part, or as a part of a calibration sequence, e.g. after assembly during a factory calibration, or when the device is switched on, or upon receiving a user input. In addition, such a technique may allow rework of an image sensor assembly from a camera module that has failed its final camera test, e.g. arising from shift actuator performance reasons or for other reasons such as particle ingress, excessive tilt or failure in another actuator such as autofocus (AF) actuator in the assembly.
Optionally, at a default position the third part is separated from the endstop by a predetermined clearance, and this predetermined clearance is arranged to accommodate the movement of the second part during normal operation during which the third part is maintained at the default position on the second part. Advantageously, such predetermined clearance may prevent the second part from accidentally coming into contact with the endstop. The predetermined clearance may be selected totr54 e adequate tolerance, yet not too large such that the third part has to move excessively before engaging the endstop.
Optionally, at the default position, the third part is centred on the second part in the movement direction. Alternatively, or in addition, at the default position, the third part is centred at an optical axis such that it is aligned with other components in the assembly.
Optionally, the second part is moveable within a movement range during normal operation, wherein the second part is configured to move beyond the movement range to return the third part to the default position. For example, the second part may have to a stroke longer than its normal displacement range (e.g. 100 μm) in order to allow the endstop to push the third part further along the surface of the second part. In some cases, such a longer stroke may allow the third part to be pushed to, and beyond, the default position.
Optionally, the endstops are provided on opposite sides of the third part along the movement direction. The two opposite endstops may push on the corresponding side of the third part, in opposite directions, to the default position.
Optionally, the actuator arrangement comprises a plurality of the SMA wires capable of being selectively driven to move the second part in two orthogonal directions in a movement plane, and wherein an endstop is provided at each of four sides of the second part. Optionally, the actuator arrangement comprises four non-collinear SMA wires each connected at a respective quadrilateral side of the second part, wherein the SMA actuator wires are capable of being selectively driven to move the second part in two orthogonal directions in a movement plane without applying any net torque to the second part, and wherein an endstop is provided at each quadrilateral side. For example, endstops may be provided for each of the four sides of the support structure, such that the third part may be recalibrated to a default position on the second part.
Optionally, the actuator arrangement is configured to sequentially move the second part toward the four quadrilateral sides so as to drive the third part against the respective endstops to move the third part to its default position. The sequence may comprise moving the third part in two opposite directions (e.g. forward and rearward) before moving it perpendicularly (e.g. leftward and rightward). The sequence may be moving the third part in different directions sequentially clockwise (e.g. forward, rightward, rearward, and leftward) or anticlockwise.
Optionally, the actuator arrangement is configured to move the second part diagonally towards a corner between two sides so as to drive the third part against two adjacent endstops to move the third part to its default position. For example, the second part may move diagonally towards a corner between endstops at the front and right sides, before moving in the reverse direction towards an opposite corner between endstops at the rear and left sides.
Optionally, the second part comprises a planar surface, wherein the third part is supported, and movable, on the planar surface. Advantageously, such an arrangement prevents jitter during the movement of the third part. The surface may comprise a bearing element or frictional material depending on the frictional forces required to retain the third part on the second part during normal operation.
Optionally, the actuator arrangement comprises means (i.e. “retaining means”) arranged to apply a retaining force on the third part in order to maintain the relative positions of the third part and the second part during normal operation, wherein the retaining force is insufficient to maintain said relative position when the third part is driven against the endstop. The means may comprise one or more of a biasing element, a magnet, and a viscous fluid, or any other suitable means.
The actuator assembly may comprise one or more further endstops configured to limit movement of the third part relative to the second part in a direction other than a movement direction. The direction other than a movement direction may be a direction perpendicular to the movement plane. The third part may engage with the further endstops if, for example, the third part becomes at least partly disconnected from the second part due to a mechanical shock. The further endstop may limit the movement of the third part such that the retaining means is subsequently able to re-connect the second and third parts.
According to a second aspect of the present invention, there is provided a method of operating an actuator assembly having a first part and a second part movable relative to the first part, comprising:
Optionally, the method comprises moving the third part to a default position. At the default position, the third part may be separated from the endstop by a predetermined clearance.
The method may comprise, after moving the second part so as to move the third part to the default position, affixing the third part to the second part. This fixing may be achieved with an adhesive, for example. Such a method may, for example, be applied as part of the factory calibration process once the third part is assembled in the actuator assembly in the factory. There may be provided an actuator assembly obtainable by this method.
Alternatively, the method may be applied as a regular calibration procedure that runs upon start-up of the device or upon receiving a user command. The method may also be applied to realign the third part with other components once misalignment is detected or upon receiving user input.
Certain embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which:
A camera apparatus 1 that incorporates an OIS sensor shift camera assembly 2 in accordance with the present invention is shown in
The camera assembly 2 is shown in detail in
The camera assembly 2 comprises a support structure 4 on which is supported an image sensor 6 having a light-sensitive region 7. The optical axis O is orthogonal to the light-sensitive region 7. The image sensor 6 captures an image and may be of any suitable type, for example a CCD (charge-coupled device) or a CMOS (complementary metal-oxide-semiconductor) device. As is conventional, the image sensor 6 has a rectangular light-sensitive region 7. Without limitation to the invention, in this example the camera apparatus 1 is a miniature camera in which the light-sensitive region 7 of the image sensor 6 has a diagonal length of at most 12 mm.
The image sensor 6 is mounted on a carrier 8 (e.g. the third part) which is supported on a moving plate 9. The moving plate 9 may formed from sheet material, which may be a metal for example steel such as stainless steel. The moving plate 9 is shown in isolation in
The image sensor 6 as illustrated here is merely used as an example. Other components, such as a lens carriage carrying one or more lenses, as well as light emitters such as VCSEL may be mounted on the carrier 8.
The carrier 8 may comprise a single layer of material, or other layers of material which may be attached to each other or laminated.
The support structure 4 comprises a support plate 5 which may be formed from sheet material, which may be a metal for example steel such as stainless steel.
Although the support structure 4 comprises a single support plate 5 in this example, optionally the support structure 4 may comprise other layers which may be attached to or laminated with the support plate 5.
The support structure 4 further comprises a rim portion 10 fixed to the front side of the support plate 5 and extending around the support plate 5. The rim portion 10 has a central aperture 11.
The support structure 4 further comprises an IC (integrated circuit) chip 30 and a gyroscope sensor 31 fixed on the rear side of the support plate 5. A control circuit described further below is implemented in the IC chip 30.
The moving plate 9, together with the carrier 8 supported thereon, is suspended on the support structure 4 in a manner allowing movement of the image sensor 6 in any direction laterally to the light-sensitive region 7 of the image sensor 6 (i.e. laterally of the optical axis O and parallel to the plane in which the light-sensitive region 7 extends) and further allowing rotation of the image sensor about the optical axis O. In the illustrated example, the moving plate 9 is suspended on the support structure 4 by a suspension system in the form of a plain bearing 100 provided between the support plate 5 and the moving plate 9 as will now be described.
In this example, the plain bearing 100 comprises a first bearing surface 101 on the moving plate 9, in particular being the lower surface of the moving plate 9, and a second bearing surface 102 on the support structure 4, in particular being the upper surface of the support plate 5. In this example, bearing surfaces 101 and 102 are each planar. The bearing surfaces 101 and 102 bear on each other and thereby suspend the moving plate 9 on the support structure 4. Since the bearing surfaces 101 and 102 may slide relative to each other, they allow movement of the image sensor 6 in any direction laterally to the light-sensitive region 7 of the image sensor 6 and further allow rotation of the image sensor about the optical axis O.
The plain bearing 100 not only suspends the image sensor 6, but also facilitates heat transfer from the image sensor 6 to the support structure 4. This is because the bearing surface surfaces 101 and 102 provide a continuous region of thermally conductive material without an air gap. This provides a path having good thermal conductivity for dissipating heat from the image sensor 6, as well as providing the requisite suspension. This allows the support structure 4 to act as a heat sink for the image sensor 6.
Heat transfer from the image sensor 6 is further facilitated by forming the carrier 8, the moving plate 9 and support plate 5 from materials having a high thermal conductivity, for example metal.
Movement of the image sensor 6 relative to the support structure 4 is driven by an actuator arrangement that is arranged as follows, and seen most easily in
Although in this example the crimp portions 41 and 42 are separate elements fixed to the moving plate 9 and the rim portion 10, as an alternative the crimp portions 41 could be formed integrally with the moving plate 9 and/or the crimp portions 42 could be formed integrally with the support plate 5.
The SMA actuator wires 40 are arranged as follows so that they are capable, on selective driving, of moving the image sensor 6 relative to the support structure 4 in any direction laterally to the light-sensitive region 7 of the image sensor 6 and also of rotating the image sensor 6 about the optical axis O.
Each of the SMA actuator wires 40 is held in tension, thereby applying a force between the support structure 4 and the carrier 8.
The SMA actuator wires 40 may be perpendicular to the optical axis O so that the force applied to the moving plate 9 is lateral to the light-sensitive region 7 of the image sensor 6. Alternatively, the SMA actuator wires 40 may be inclined at a small angle to the light-sensitive region 7 of the image sensor 6 so that the force applied to the carrier 8 includes a component lateral to the light-sensitive region 7 of the image sensor 6 and a component along the optical axis O that acts as a biasing force that biases the bearing surfaces 101 and 102 of the plain bearing 100 together.
The overall arrangement of the SMA actuator wires 40 is similar to that described in WO2017/072525A1, incorporated herein by reference.
Typically this force would be minimised to be just sufficient normal operation for all tolerance conditions. Minimising the force ensures that the resulting frictional force is low so that it does not hinder the movement of the carrier 8 relative to the moving plate 9. That is, a low frictional force reduces the likelihood of jitter.
During normal operation, e.g., no resistance is exerted on carrier 8 during the movement of moving plate 9, the force is sufficient to retain the position of the carrier 8 on the moving plate 9. However, when the resistance to the movement of carrier 8 exceeds the force, the carrier 8 may slide across the planar surface of the moving plate 9. Moreover, the carrier 8 may be detached from the moving plate 9 if the device is subjected to sudden acceleration, or if the carrier 8 is being lifted from the moving plate 9. The force applied by the magnet is sufficient to reattach the carrier 8 onto the moving plate 9 after it has been detached.
The carrier 8 has precision side surfaces and is surrounded by precision manufactured endstops 504 (item 5 in
Notably, the stroke of movement of the moving plate 9 is greater than that of the carrier 8, e.g. the movement of carrier 8 would stop once it engages the endstops 54. Therefore, when the moving plate 9 is displaced beyond a movement range as adapted by a normal operation, it causes the carrier 8 to engage (or abut) the endstops 504, and in the process eliminates any clearance therebetween. In order to move the carrier 8 relative to the moving plate 9, the actuator is configured to continue moving the moving plate 9 towards the endstop 504. Since the carrier 8 is already engaging the endstops 504, it can no longer move with the moving plate 9 and therefore the endstops 504 causes it to slide across the planar surface of the moving plate, thereby changing its relative position on the moving plate 9.
In the particular configuration as shown in
Such an arrangement is particularly useful if the carrier 8 is not positioned at the default position as shown in
Therefore, the use of a suitable realignment technique, the actuator arrangement is capable of restoring the carrier 8 to its default position. As shown in
To return the carrier to its default position, the moving plate 9 moves in a diagonally opposite direction towards the other two endstops 504, as shown in
| Number | Date | Country | Kind |
|---|---|---|---|
| 2104687.5 | Mar 2021 | GB | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/058738 | 3/31/2022 | WO |
