CN114302044B - AA assembling method for medical lens module - Google Patents
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Abstract
The application relates to the technical field of cameras, and discloses an AA assembling method for a medical lens module, which comprises the following steps: s1: acquiring depth of field data of a lens according to the actual shooting distance of the lens module to obtain a plurality of AA object distances; s2: designing a plurality of chart artwork according to the AA object distance and the size of the sensor; s3: obtaining distortion data of a lens; s4: performing anti-distortion processing on the chart original image according to the distortion data of the lens to obtain a plurality of anti-distortion chart images; s5: superposing a plurality of anti-distortion chart images; s6: and carrying out multi-distance AA calibration on the lens module according to the superimposed anti-distortion chart. The limitation of the AA machine can be solved from the optical angle, so that the application field is wider, the problems of large picture distortion and difficult AA in a plurality of distances in the AA assembling process of the medical lens module are effectively solved, and the assembling precision of the medical lens module is improved.
Description
Technical Field
The application relates to the technical field of cameras, in particular to an AA assembling method for a medical lens module.
Background
The medical lens module (mainly comprising a gastroscope module) has the characteristics of wide angle, miniaturization and micro-distance. Wide angle means that the shot range of the lens is wider; miniaturization means that the lens can safely enter the human body; macro means that the lens in the body needs to be imaged clearly within 1-100 mm. It is the particularity of the above three points that makes the assembly of the medical module more difficult than the assembly of the traditional mobile phone module.
An AA (Active Alignment) process is a technology for determining a relative position in an assembly process of a part, and includes detecting an assembled semi-finished product, and performing Active Alignment according to an actual situation of the assembled semi-finished product; and then assembling the next spare and accessory parts in place, thereby achieving the purpose of reducing the assembly tolerance of the whole module. When the module is assembled, the camera chip and the focus of the lens are overlapped by aligning 6 degrees of freedom (the moving degrees of freedom along the directions of three right-angle coordinate axes of x, y and z and the rotating degrees of freedom around the three coordinate axes) of the lens so as to obtain a clear image, so that the assembly tolerance of the whole module is effectively reduced, the consistency of camera products is effectively improved, and the possibility is created for higher-order packaging of the camera products.
Currently, the AA process of conventional cell phones requires that the imaged picture be planar (neither barrel nor pillow). In addition, the AA distance is mostly a single specific value (2 cm/10cm/50cm/Inf, etc.). The application field of the mobile phone module is limited by factors such as an AA machine table, and the like, and the AA distance and the test distance of the millimeter level are not related. Therefore, AA process has problems of large frame distortion, insufficient assembly accuracy due to difficulty in multiple AA distances, etc. due to the characteristics of wide angle, miniaturization and micro-distance during assembly (active calibration) of the medical module.
Disclosure of Invention
The application aims to provide an AA assembling method for a medical lens module, which can solve the limitation of an AA machine from the optical angle, so that the application field is wider, the problems of large picture distortion and difficult AA in a plurality of distances in the AA assembling process of the medical lens module are effectively solved, and the assembling precision of the medical lens module is improved.
The technical scheme provided by the application is as follows: an AA assembling method for a medical lens module, comprising the steps of:
s1: acquiring depth of field data of a lens according to the actual shooting distance of the lens module to obtain a plurality of AA object distances;
s2: designing a plurality of chart artwork according to the AA object distance and the size of the sensor;
s3: obtaining distortion data of a lens;
s4: performing anti-distortion processing on the chart original image according to the distortion data of the lens to obtain a plurality of anti-distortion chart images;
s5: superposing a plurality of anti-distortion chart images;
s6: and carrying out multi-distance AA calibration on the lens module according to the superimposed anti-distortion chart.
The working principle and the advantages of the application are as follows: the lens angle of vision that medical module relates to can be greater than 120 in order to satisfy its wide demand of shooting scope far away. As the angle of view of the lens increases, the distortion of the lens increases gradually, and the maximum optical distortion value of the lens with the angle of view of more than 120 degrees generally reaches more than 10%, and then increases more severely, and the maximum optical distortion is 80% currently. When the optical distortion reaches more than 8%, the lens is assembled on an AA machine table, and errors are reported, because an imaging picture is deformed, mark points of a grabbing frame of different view fields (0.3F/0.5F/0.7F/0.8F) are obviously not on the same plane, the grabbing frame fails, and the numerical value of an MTF (modulation transfer function for analyzing an analysis item of the lens) cannot be further read. The AA chart must be de-distorted to achieve the imaged picture in the same plane. According to the method, corresponding anti-distortion treatment is carried out on the chart original pictures with different AA object distances, then superposition is carried out, and multi-distance AA calibration is carried out by using the superposed chart, so that the problems of large picture distortion and difficult multi-distance AA in the AA assembling process of the medical lens module are effectively solved, and the assembling precision of the medical lens module is improved. The method solves the limitation of the current AA machine, and has wide application field for the AA assembly process of some unconventional lens modules.
Further, the step S3 includes:
s3-1: using an instrument to test the optical distortion value of the lens at each view field position;
s3-2: and simulating and outputting a distortion value by adopting software for the position of which the test distance is lower than the limit of the instrument.
The optical distortion values of the professional instrument test lens at the positions of each view field are closer to reality, but are limited by an instrument machine table, and the mode of simulating an actual optical system by software is adopted for the position with the too low test distance so as to obtain more comprehensive data.
Further, the S4 includes:
s4-1: inputting distortion data, and automatically fitting by software to generate a distortion model;
s4-2: on the basis of a distortion model, ideal image height of a lens is subjected to homogeneous transformation of coordinates to obtain ideal coordinates which are paved on pixel points of the whole sensor, and an inverse distortion model matched with the lens is obtained by combining a negative value of the actual image height of the lens;
s4-3: processing the coordinates of Mark points in the chart through an anti-distortion model to obtain anti-distortion coordinates;
s4-4: and importing the anti-distortion coordinates into the chart original drawing to obtain the anti-distortion chart.
The original coordinates of distortion points in distortion data are input in a program, the coordinates after distortion correction are output after distortion correction, the optical distortion of a lens is a two-dimensional vector, and the transformation of the optical distortion is carried out in all directions, so that an additional coordinate Z is required to be added to the two-dimensional coordinates to realize that the coordinates can be scaled, rotated and translated, and the coordinates are converted to obtain infinite coordinates (the number of pixel points of a chip can be met) to be paved on the whole chip plane. Therefore, the ideal image height of the lens is input, the ideal coordinates of the pixel points of the whole chip are obtained through homogeneous transformation of the coordinates, then the negative value of the actual image height (distortion occurrence) of the lens is input to obtain an anti-distortion model matched with the lens, and further the anti-distortion coordinates are obtained.
Further, in the distortion model in S4-1, the distortion model of the conventional lens is described by using the first two terms of taylor series expansion, and the distortion model of the fish-eye lens is described by using the first three terms of taylor series expansion.
According to the obtained lens distortion data, the software automatically fits and generates a distortion parameter model, different lenses generate different distortion parameters corresponding to different distortion curves so as to match different formula models, the conventional mathematical distortion model is described by using the first two terms K1 and K2 of Taylor series expansion around a principal point, and a third term K3 can be added to a fisheye lens with more complex curves and larger distortion.
Further, the S5 includes:
s5-1: manufacturing a hollow cone instrument according to the size of the field angle of the lens;
s5-2: and respectively placing the anti-distortion chart in the appliance according to the corresponding AA object distance, and placing the appliance in a corresponding position of the machine.
The medical module has the micro-distance requirement that the medical module can clearly image within 1-100mm, so that the AA object distance is very close when the lens and the sensor chip are assembled, the lens is limited by the design of the lens, the depth of field of the lens under the micro-distance cannot meet a larger range, and most of the depth of field is only within 10-20 mm. Therefore, due to the depth of field limitation of the lens, the lens module cannot meet 1-100mm under the condition of one AA object distance, and the lens module is clear. The conventional AA machine has the advantages that only one light source plate is placed in the conventional AA machine, the descending space of the light source plate is limited, and the light source plate cannot be lowered to the mm-level object distance. To solve this problem, an instrument with a shape like a "barrel" is designed according to the construction of the AA machine, which can hold a plurality of macro charts.
Further, the material of the anti-distortion chart is transparent glass, and Mark points of the anti-distortion chart are filled with black.
The transparent glass has good light transmittance, mark points are filled in black, imaging is clear under the irradiation of a light source, and identification is accurate.
Further, the device is designed to be of a size according to a field angle corresponding to the furthest field of view where the Mark point of the anti-distortion chart is located, and an edge area is arranged at the position where the anti-distortion chart is placed.
When the angle of view of the lens is large, along with the increase of the AA object distance, the size of the device is exponentially increased, at the moment, the design can be performed by referring to the angle of view corresponding to the furthest view field where the Mark point is located, and a certain edge area of the device needs to be reserved at the position where the anti-distortion chart is placed, so that the Mark point can be conveniently identified by the machine.
Further, the S6 includes:
s6-1: turning on a light source, wherein the illuminance position of the light source enables Mark points of a plurality of anti-distortion chart to be imaged in a plane without interference and can be grasped by an AA machine;
s6-2: any AA object distance is selected to draw a '0' visual field Mark point, and active calibration OC is carried out;
s6-3: selecting a central view field and a peripheral view field of the middle distance between the near focus and the far focus to actively calibrate tilt;
s6-4: setting an analysis threshold value corresponding to the distance between the near focus and the far focus to actively calibrate the FFL;
s6-5: and respectively carrying out the steps of photoresist painting, UV irradiation and MTF value check.
The traditional mobile phone module only needs AA to calibrate a distance and check a distance, but the medical module cannot be subjected to the joint influence of the depth of field and the defocus curve of the lens by the AA a distance and the check a distance to ensure that the module assembled by the lens and the chip can clearly image in both near focus and far focus (1-100 mm). At this time, active calibration is required for a plurality of distances to obtain an AA (check) curve of each distance, threshold values are set for each distance respectively, and the active calibration is finished after the MTF value of each distance reaches the set threshold value.
Further, it is characterized in that: and the AA object distance selected in the step S6-2 is the AA object distance of the middle distance.
And (3) selecting a chart with a middle distance to draw a Mark point of a 0 field of view, and calibrating an optical center of a lens and an imaging center of a chip by the AA machine station according to the Mark point, so that better active calibration OC is facilitated.
Further, S7: and checking the actively calibrated lens module.
And the quality inspection is carried out on the lens after the active calibration is finished, so that the yield is further improved.
Drawings
FIG. 1 is a side view of a method for assembling an AA medical lens module according to an embodiment of the present application;
FIG. 2 is a front view of an AA assembly method for a medical lens module according to an embodiment of the present application;
fig. 3 is a logic block diagram of an AA assembling method for a medical lens module according to an embodiment of the application.
Detailed Description
The following is a further detailed description of the embodiments:
the labels in the drawings of this specification include: 4mm chart 1, 9mm chart 2, 100mm chart 3, lens module 4 and hollow cone appliance 5.
Examples:
as shown in fig. 3, the embodiment discloses an AA assembling method for a medical lens module, which specifically includes the following steps (in this scheme, the numbers of the steps only perform step distinguishing function, the specific execution sequence of the steps is not limited, and the steps can also be performed simultaneously):
s1: and obtaining depth of field data of the lens according to the actual shooting distance of the lens module 4 to obtain a plurality of AA object distances. Optical parameters of the lens in this embodiment: lens structure 1G3P; efl=0.982 mm; DFOV = 140 °; f# =8.02; image height=1.045 mm; optical distortion = -62.56%.
Test distance (AA object distance) of the present lens module 4: near focal length 4mm; far focus 100mm; the intermediate distance is 9mm.
Chip parameters: resolution 1920 x 1080; pixel dot size: 1.4 x 1.4 μm.
S2: and designing a plurality of chart artwork according to the AA object distance and the size of the sensor. Taking the actual size (unit mm) of a module chip as a rectangle, then taking the diagonal length as a diameter to make a circle, reducing the diameter proportionally to obtain a frame grabbing position, putting on a drawn Mark, and designing three chart artwork according to the chip size of 2.688 x 1.512mm and the field of view of the module to be controlled, wherein the field of view is 4mm for controlling 0.2F,100mm for controlling 0.25F and 9mm for controlling 0F and 0.5F.
S3-1: the optical distortion values of the lens at the respective field positions are measured with an instrument. Dividing 0-1.0F into 100 parts to obtain 101 test points from center to periphery, thereby outputting ideal image height, real image height and distortion value of each point, and the three parts satisfy(y=true image height, Y'=ideal image height);
s3-2: and simulating and outputting a distortion value by adopting software for the position of which the test distance is lower than the limit of the instrument. The method has the advantages that the distortion value and the true image height are obtained more nearly to reality, but are limited by a machine, and when the test distance is smaller than or equal to 4cm, the zemax software is adopted to simulate and output the distortion value of an actual optical system (considering tolerance analysis).
S4-1: and inputting distortion data, and automatically fitting by software to generate a distortion model. According to the obtained lens distortion data, the software automatically fits and generates a distortion parameter model, different lenses generate different distortion parameters corresponding to different distortion curves so as to match different formula models, the conventional mathematical distortion model is described by using the first two terms K1 and K2 of Taylor series expansion around a principal point, and a third term K3 can be added to a fisheye lens with more complex curves and larger distortion. Such as:
X 0 ＝X*(1+K 1 R 2 +K 2 R 4 +K 3 R 6 )
Y 0 ＝Y*(1+K 1 R 2 +K 2 R 4 +K 3 R 6 ) Radial distortion
X 0 ＝2P 1 XY+P 2 *(R 2 +2X 2 )
Y 0 ＝2P 2 XY+P 1 *(R 2 +2Y 2 ) Tangential distortion
Tangential distortion is due to tilt and offset tolerances when the chip and lens are assembled. The mathematical distortion model can be described as above with two additional parameters P1 and P2.
S4-2: on the basis of the distortion model, ideal image height of the lens is transformed through the uniformity of coordinates to obtain ideal coordinates which are paved on the pixel points of the whole sensor, and an inverse distortion model matched with the lens is obtained by combining the negative value of the actual image height of the lens. The (X0, Y0) in the two groups of distortion parameter models is the original position of a distortion point, and the (X, Y) is the position after distortion correction; the optical distortion of the lens is a two-dimensional vector, and the transformation of the lens occurs in all directions, so that an additional coordinate Z needs to be added to the two-dimensional coordinate to realize that the coordinate (X, Y) can be scaled, rotated and translated, and then 101 coordinates can be converted to obtain infinite coordinates (the number of pixels of a chip can be met) to be paved on the whole chip plane, and the above can be integrated:
coordinate homogeneous transformation
X 0 ＝X(1+K 1 R 2 +K 2 R 4 +K 3 R 6 )+2P 1 XY+P 2 *(R 2 +2X 2 )
Y 0 ＝Y(1+K 1 R 2 +K 2 R 4 +K 3 R 6 )+2P 2 XY+P 1 *(R 2 +2Y 2 ) -distortion model
On the basis of the distortion model, the ideal image height of the lens is transformed to obtain ideal coordinates which are paved with the pixel points of the whole sensor through homogeneous transformation of the coordinates, and the negative value of the actual image height (distortion) of the lens is combined to obtain an anti-distortion model (the determined values of K1, K2, K3, P1 and P2) which is matched with the lens
S4-3: and processing the coordinates of Mark points in the chart original image through an anti-distortion model to obtain anti-distortion coordinates.
S4-4: and (3) importing the anti-distortion coordinates into a chart original designed according to the sensor size to obtain three anti-distortion chart.
S5-1: manufacturing a hollow cone appliance 5 according to the size of the lens angle of view;
s5-2: and respectively placing the anti-distortion chart in the appliance according to the corresponding AA object distance, and placing the appliance in a corresponding position of the machine.
After the Mark point in the Chart Chart is distorted, the size of the glass outer frame is designed, so that the size of an appliance is matched, three Chart charts are ensured to be free from shielding, and the frame can be normally grasped by an AA machine. Therefore, the diagonal distance of the design 4mm chart of FIG. 1 is more than or equal to 13.2mm; the diagonal distance of 9mm chart of FIG. 2 is equal to or greater than 29.7mm; the diagonal distance of 100mm chart of FIG. 3 is equal to or greater than 164.98mm. The final dimensions of the three glasses were determined by matching the dimensions of the tool on this basis as follows: 4mm:18 x 12mm (diagonal distance 21.6 mm); 9mm 29 x 29mm (diagonal distance 41 mm); 100mm 170 x 170mm (diagonal distance 240.4 mm).
Manufacturing a hollow cone appliance 5 according to the size of the lens angle (if the size of the appliance increases exponentially with the increase of the AA object distance when the lens angle is large, at this time, designing can be performed by referring to the angle corresponding to the furthest view field where the Mark point is located, a certain edge area needs to be reserved to facilitate the machine to identify the Mark point), and designing steps or peripheral hollowed-out parts at the corresponding object distance of the appliance to place glass chart of the corresponding object distance respectively, wherein the size of the glass chart is to be matched with the size of the appliance according to the actual size (the transparent area of the glass chart edge can be enlarged). Therefore, a plurality of glass chart images with AA object distance are overlapped into the device to form a whole, and the whole is arranged at the corresponding position of the AA machine. The hollow cone apparatus 5 is shown in fig. 1 and 2 (the broken line part of fig. 2 is the angle of view).
Wherein the chart is made of transparent glass, and the transmittance is more than or equal to 95%; the Mark points are filled in black, and other positions are transparent; no burr and dirt spot; the thickness of the glass chart is reasonably changed along with the size of the chart.
S6-1: the light source is turned on, and the light source illumination positions enable Mark points of a plurality of anti-distortion chart to be imaged in a plane without interference and can be gripped by the AA machine.
S6-2: and selecting any AA object distance to draw a '0' field Mark point, and performing active calibration OC. The AA object distance selected in this example is the AA object distance of the intermediate distance, i.e., the AA object distance of 9mm. When the Chart diagram is designed, the middle distance is selected to draw a '0' field Mark point, and the size of the Mark point can be slightly larger than that of other Mark points. Mark points of other view fields of the AA chart with the distance need to be supplemented according to other requirements. As for the "0" field of view of the chart of the other two distances, mark points cannot be drawn so as to avoid frame grabbing interference when the active calibration center of the AA machine is shifted. Therefore, the AA machine station relies on the Mark point to calibrate the optical center of the lens and the imaging center of the chip.
S6-3: and selecting a central view field and a peripheral view field of the intermediate distance between the near focus and the far focus for active calibration tilt. Calibration tilt is a major issue in module assembly. And selecting a central view field and a peripheral view field of the intermediate distance (namely, an AA distance corresponding to the average value position of an imaging focal plane) of the far focus and the near focus to actively calibrate tilt (X and Y directions), and not calibrating FFL (Z axis direction). When the MTF curve of the lens is in an inverted U shape under the proper frequency (most 1/2 frequency and 1/4 frequency), the X, Y value when the optimal MTF value is found is the end of the active calibration tilt; when the MTF curve of the lens is approximately 'one' at a proper frequency (most 1/2 frequency and 1/4 frequency), a tilt value is manually set so that the lens plane is parallel to the chip plane (X, Y value can be calculated by four-point height of the chip).
S6-4: and setting an analysis threshold corresponding to the distance between the near focus and the far focus to actively calibrate the FFL. Calibration FFL is another major concern for module assembly. And (3) following the requirements of customers on the medical module, such as clear imaging of the determined near-focus distance and the determined far-focus distance, drawing corresponding Mark points of the chart and determining corresponding resolution thresholds according to the corresponding near-focus far-focus distance. At this time, only FFL (Z axis direction) is calibrated, tilt (X and Y directions) is not calibrated, and a compromise FFL position is found so that the far and near focus can reach a threshold (the far and near Jiao Quanchong is set according to the change curve of the far and near focus analysis along with FFL).
S6-5: and respectively carrying out the steps of photoresist painting, UV irradiation and MTF value check. The steps are the same as the traditional mobile phone lens module assembly mode.
S7: the actively calibrated lens module 4 is inspected. And performing quality inspection on the concrete modules after the AA is assembled according to corresponding requirements.
The foregoing is merely exemplary of the present application, and the specific structures and features well known in the art are not described in detail herein, so that those skilled in the art will be aware of all the prior art to which the present application pertains, and will be able to ascertain all of the prior art in this field, and with the ability to apply the conventional experimental means prior to this date, without the ability of those skilled in the art to make various embodiments with the benefit of this disclosure, without the ability to develop and practice the present application, certain typical known structures or methods should not be considered as an obstacle to the practice of the present application by those skilled in the art. It should be noted that modifications and improvements can be made by those skilled in the art without departing from the structure of the present application, and these should also be considered as the scope of the present application, which does not affect the effect of the implementation of the present application and the utility of the patent. The protection scope of the present application is subject to the content of the claims, and the description of the specific embodiments and the like in the specification can be used for explaining the content of the claims.
Claims (10)
1. An AA assembling method for a medical lens module, which is characterized by comprising the following steps: the method comprises the following steps:
s1: acquiring depth of field data of a lens according to the actual shooting distance of the lens module to obtain a plurality of AA object distances;
s2: designing a plurality of chart artwork according to the AA object distance and the size of the sensor;
s3: obtaining distortion data of a lens;
s4: performing anti-distortion processing on the chart original image according to the distortion data of the lens to obtain a plurality of anti-distortion chart images;
s5: superposing a plurality of anti-distortion chart images;
s6: and carrying out multi-distance AA calibration on the lens module according to the superimposed anti-distortion chart.
2. The AA assembling method for a medical lens module of claim 1, wherein: the step S3 comprises the following steps:
s3-1: using an instrument to test the optical distortion value of the lens at each view field position;
s3-2: and simulating and outputting a distortion value by adopting software for the position of which the test distance is lower than the limit of the instrument.
3. The AA assembling method for a medical lens module of claim 1, wherein: the step S4 comprises the following steps:
s4-1: inputting distortion data, and automatically fitting by software to generate a distortion model;
s4-2: on the basis of a distortion model, ideal image height of a lens is subjected to homogeneous transformation of coordinates to obtain ideal coordinates which are paved on pixel points of the whole sensor, and an inverse distortion model matched with the lens is obtained by combining a negative value of the actual image height of the lens;
s4-3: processing the coordinates of Mark points in the chart through an anti-distortion model to obtain anti-distortion coordinates;
s4-4: and importing the anti-distortion coordinates into the chart original drawing to obtain the anti-distortion chart.
4. A method of AA assembly for a medical lens module as recited in claim 3, wherein: in the distortion model in S4-1, the distortion model of the conventional lens is described by adopting the first two terms of Taylor series expansion, and the distortion model of the fisheye lens is described by adopting the first three terms of Taylor series expansion.
5. The AA assembling method for a medical lens module of claim 1, wherein: the step S5 comprises the following steps:
s5-1: manufacturing a hollow cone instrument according to the size of the field angle of the lens;
s5-2: and respectively placing the anti-distortion chart in the appliance according to the corresponding AA object distance, and placing the appliance in a corresponding position of the machine.
6. The AA assembling method for a medical lens module of claim 5, wherein: the material of the anti-distortion chart is transparent glass, and Mark points of the anti-distortion chart are filled in black.
7. The AA assembling method for a medical lens module of claim 6, wherein: the device is designed to be of a size according to a field angle corresponding to the furthest field of view where the Mark point of the anti-distortion chart is located, and an edge area is arranged at the position where the anti-distortion chart is placed.
8. The AA assembling method for a medical lens module of claim 1, wherein: the step S6 comprises the following steps:
s6-1: turning on a light source, wherein the illuminance position of the light source enables Mark points of a plurality of anti-distortion chart to be imaged in a plane without interference and can be grasped by an AA machine;
s6-2: any AA object distance is selected to draw a '0' visual field Mark point, and active calibration OC is carried out;
s6-3: selecting a central view field and a peripheral view field of the middle distance between the near focus and the far focus to actively calibrate tilt;
s6-4: setting an analysis threshold value corresponding to the distance between the near focus and the far focus to actively calibrate the FFL;
s6-5: and respectively carrying out the steps of photoresist painting, UV irradiation and MTF value check.
9. The AA assembling method for a medical lens module of claim 8, wherein: and the AA object distance selected in the step S6-2 is the AA object distance of the middle distance.
10. The AA assembling method for a medical lens module of claim 1, wherein: further comprising S7: and checking the actively calibrated lens module.
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