Method and system for designing and manufacturing lens modules

Abstract

A method for designing and manufacturing lens modules includes selecting design parameters from a design database stored with the design parameters suitable for a lens module desired to be manufactured to design the lens module according to characteristics of the lens module and storing the design parameters of the lens module in an analysis database, analyzing the lens module based on a predetermined analysis process to generate analysis parameters corresponding to the lens module and storing the generated analysis parameters in the analysis database, and re-designing the lens module based on the analysis parameters stored in the analysis database.

Description

BRIEF DESCRIPTION OF DRAWINGS

The invention can be more fully understood by reading the following detailed description of the preferred embodiments, with reference made to the accompanying drawings, wherein:

FIG. 1 is a functional block diagram of an integrated lens module designing and manufacturing system of the preferred embodiment according to the present invention; and

FIG. 2 is a flow chart of an integrated lens module designing and manufacturing method corresponding to the system shown in FIG. 1.

Claims

1. A method for designing and manufacturing a lens module, the method comprising: selecting design parameters from a design database having a plurality of design parameters in accordance with characteristics of a lens module desired to be designed, designing the lens module according to the selected design parameters, and storing the selected design parameters of the lens module in an analysis database;analyzing the lens module according to a predetermined analysis process to generate analysis parameters corresponding to the lens module, so as to show quality problems of the lens module due to manufacturing, light engine interface and assembly, and storing the quality problems and the analysis parameters corresponding to the lens module into the analysis database; andre-designing the lens module in accordance with the analysis parameters stored in the analysis database with information obtained after the lens module has been manufactured, so as to adjust precision of the method.

2. The method of claim 1, wherein the design parameters comprise an optic type, an optic primary specifications and claims of the lens module.

3. The method of claim 1, wherein the lens module is designed by the use of an auxiliary optic design selection and patent design-around of an expert system.

4. The method of claim 1, wherein the design parameters are classified into an optic part and a mechanism part.

5. The method of claim 4 taking the design parameters in both the optic part and the mechanism part into consideration when designing the lens module.

6. The method of claim 4, wherein the lens module is designed by the use of individual software, or integrated optic and mechanism design software.

7. The method of claim 1 further storing the lens module-related information and the design parameters corresponding to the lens module in a case database when design the lens module and storing the design parameters of the lens module into the analysis database.

8. The method of claim 1 further generating manufacturing parameters corresponding to the lens module when analyzing the lens module according to the predetermined analysis process.

9. The method of claim 8, wherein the predetermined analysis process adopts a tolerance analysis to distribute the design parameters and the manufacture parameters of the lens module.

10. The method of claim 9 further grading assembly capability of the lens module when adopting the tolerance analysis to analyze the lens module.

11. The method of claim 9 further grading basic optic and mechanism manufacture capability parameters of the lens module when adopting the tolerance analysis to analyze the lens module.

12. The method of claim 9 further classifying optic errors of the lens module into a symmetric part and an asymmetric part when adopting the tolerance analysis to analyze the lens module.

13. The method of claim 12 further comprising adjusting degrees of freedom of axial direction and lateral direction compensation components of the lens module, so as to decrease the symmetric and asymmetric errors, and optimize the yield rate and reduce the cost of the lens module.

14. The method of claim 12 further comprising classifying the symmetric and asymmetric optic errors systematically through the use of a bargain-basement model, to classify the bargain-basement model which are serious or which usually happens.

15. The method of claim 14 further comprising performing a failure symptom test in accordance with analysis results analyzed by the bargain-basement model with an automatic or semi-automatic test instrument to discover any flaws of the lens module, and adopting a quality engineering method to evaluate and infer reasons why the flaws exist in the lens module according to the flaws of the lens module.

16. The method of claim 15, wherein the quality engineering method is Taguchi method.

17. The method of claim 15 further combining a shop floor control system to collect manufacture and quality data when performing the failure symptom test in accordance with analysis results analyzed by the bargain-basement model with the automatic or semi-automatic test instrument to discover the flaws of the lens module.

18. The method of claim 8, wherein the manufacture parameters comprise injection molding, glass molding, grinding and polishing, and mold fabricating-related parameters.

19. A system for designing and manufacturing a lens module, the system comprising: a design database comprising a plurality of design parameters;a design module coupled to the design database for selecting from the design database design parameters suitable for the lens module according to characteristics of the lens module, to design the lens module;an analysis module for analyzing the lens module designed by the design module in accordance with a predetermined analysis process, and generating analysis parameters corresponding to the lens module, so as to shown quality problems of the lens module due to manufacturing, light engine interface and assembly; andan analysis database for storing the design parameters, the analysis parameters and the quality problems analyzed by the analysis module;wherein the design module further re-design the lens module in accordance with the analysis parameters stored in the analysis database with information obtained after the lens module has been manufactured, so as to adjust precision of the system.

20. The system of claim 19, wherein the design parameters comprise an optic type, an optic primary specifications and claims of the lens module.

21. The system of claim 19, wherein the design module designs the lens module through the use of an auxiliary optic design selection and patent design-around of an expert system.

22. The system of claim 19, wherein the design parameters are classified into an optic part and a mechanism part, and the design module comprises an optic design unit and a mechanism design unit for selecting, in accordance with the characteristics of the lens module, the design parameters in the optic part and the mechanism part suitable for the lens module, to design an optic part and a mechanism part of the lens module respectively.

23. The system of claim 22, wherein the design module takes the design parameters in both the optic part and the mechanism part into consideration when designing the lens module.

24. The system of claim 22, wherein the lens module adopts individual software, or integrated optic and mechanism design software to design the lens module.

25. The system of claim 19 further comprising a case database for storing the lens module-related information and the design parameters corresponding to the lens module after the design module has designed the lens module.

26. The system of claim 19, wherein the analysis module further generates manufacturing parameters corresponding to the lens module when analyzing the lens module according to the predetermined analysis process.

27. The system of claim 26, wherein the analysis module comprises a manufacturability unit for analyzing the lens module in accordance with the predetermined analysis process, and generates the analysis parameters of the lens module.

28. The system of claim 27, wherein the manufacturability unit further grades assembly capability of the lens module when analyzing the lens module.

29. The system of claim 27, wherein the analysis module further comprises an error mode effect analysis unit for grading basic optic and mechanism manufacture capability parameters of the lens module.

30. The system of claim 29, wherein the error mode effect analysis unit further classifies optic errors of the lens module into a symmetric part and an asymmetric part.

31. The system of claim 30, wherein the error mode effect analysis unit further adjusts degrees of freedom of axial direction and lateral direction compensation components of the lens module, so as to decrease the symmetric and asymmetric errors, and optimize the yield rate and reduce the cost of the lens module.

32. The system of claim 30 further comprising a manufacture module for classifying the symmetric and asymmetric optic errors systematically through the use of a bargain-basement model, to classify the bargain-basement model which are serious or which usually happens.

33. The system of claim 32 further comprising a test instrument for performing a failure symptom test in accordance with analysis results analyzed by the bargain-basement model to discover any flaws of the lens module, and evaluating and inferring reasons why the flaws exist in the lens module according to the flaws of the lens module with a quality engineering method.

34. The system of claim 33, wherein the quality engineering method is Taguchi method.

35. The system of claim 33 further comprising a shop floor control system for collecting manufacture and quality data.