JP2005070506A - Manufacturing method for optical device, tool for positioning optical axis, manufacturing device for optical device, optical device and rear projector - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for an optical device capable of securing margin amount on a transmission type screen by accurately adjusting the position of an optical axis, a tool for positioning the optical axis, a manufacturing device for the optical device, the optical device and a rear projector. <P>SOLUTION: The manufacturing device 1 for the optical device is equipped with the tool 3 for positioning an optical axis in the device 1. The tool 3 includes a positioning plate 31 being the reference position of a plurality of screen devices 522 constituting the device 1, and having a parting frame symmetrically arranged with an illumination optical axis set in the device 1 as center. The screen devices 522 are moved to a position where the parting frame of the plate 31 is detected before manufacturing the optical device, and initially positionally set at the reference position. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to an optical device manufacturing method, an optical axis positioning jig, an optical device manufacturing apparatus, an optical device, and a rear projector.

2. Description of the Related Art In recent years, a front projector that forms a projected image on the surface side (observer side) of a screen is known as a home theater or the like in a home.
In this front projector, a light beam emitted from a light source lamp is separated into three color light beams R, G, and B by a color separation optical system such as a dichroic mirror, and the separated light beams are colored by three light modulation devices. Each image is modulated in accordance with image information, and a light beam modulated by each light modulation device is synthesized by a cross dichroic prism as a color synthesis optical device to form an optical image. A so-called three-plate type, which is enlarged and projected by an apparatus, is known.
This three-plate projector employs a so-called POP (Panel On Prism) structure in which three light modulation devices are directly attached to the light incident end face of a cross dichroic prism in order to simplify the structure and simplify the assembly process. .

  In the above-described POP structure, when fixing the light modulation device on the light incident end face of the cross dichroic prism, it is necessary to adjust the mutual position with high accuracy in order to prevent image quality deterioration due to pixel shift of each light modulation device. . For this reason, conventionally, in order to adjust the positions of the three light modulation devices, the optical device is manufactured using the manufacturing device described in Patent Document 1.

That is, the manufacturing apparatus is provided with an adjustment screen, an optical axis detection device, and an image detection device. On the other hand, a color separation optical device, a color synthesizing optical device, a light modulation device, and an optical component housing that houses them are combined for adjustment.
As a manufacturing method thereof, first, a projection lens having an average optical characteristic is adopted as a master lens, and this master lens is attached to a manufacturing apparatus. Next, the adjustment target is installed in the manufacturing apparatus, the illumination optical axis to be adjusted is detected by the optical axis detection device, and the image detection device is moved based on the detected illumination optical axis to detect the projected image. Arrange as possible. Since the front projector is provided with a tilt direction, the image detection device is disposed on the tilt direction side with respect to the optical axis of the projection lens. Subsequently, a projection image is formed on the adjustment screen using the light beam emitted from the light source lamp of the manufacturing apparatus, and the position of each light modulation device is adjusted while the projection image is detected by the image detection device. . Then, after the position adjustment, each light modulation device is fixed to the color synthesis optical device.

On the other hand, as a projector, in addition to a front projector, a rear projector that uses a transmissive screen to form a projected image on the back side of the screen and observe an image transmitted through the screen is becoming widespread.
A rear projector generally has an internal unit that projects an optical image, a box-shaped housing that houses a reflection mirror that reflects the optical image projected from the internal unit, and a transmission that is exposed from the front of the housing. And a mold screen. Similar to the front projector, the internal unit includes a light source lamp, a color separation optical device, a light modulation device, a color synthesis optical device, and a projection optical device.

  In view of this, this rear projector is also required to adopt a POP structure such as a front projector in order to simplify the structure and simplify the assembly process, and must be manufactured using conventional devices. Can be considered.

JP 2002-244206 A

However, even if an attempt is made to divert the manufacturing apparatus described in Patent Document 1 to a rear projector, the rear projector is not provided with a tilt direction, so the position of the projected image formed on the adjustment screen is different from that of the front projector. . For this reason, even if an image detection device such as a CCD camera is moved to a position where the projection image can be detected, a projection image is formed beyond the movement range of the image detection device, and the position of the light modulation device is changed. Could not adjust. Even if a structure for expanding the movement range of the image detection device is employed, it is difficult to accurately move the image detection device to the detection position of the projected image.
Further, unlike the front projector, the rear projector has the transmissive screen and the image forming unit housed in the housing, and therefore the position of the projected image on the transmissive screen is required to be positioned with high accuracy. The left and right and top and bottom margins are set small. However, since the manufacturing apparatus described in Patent Document 1 is an apparatus for manufacturing an optical device used for a front projector, the left and right and upper and lower margins can be set relatively large when compared with a rear projector, The positioning of the optical axis is not performed with high accuracy. Therefore, when such a manufacturing apparatus is diverted to a rear projector, a small left / right / top / bottom margin amount cannot be secured due to a slight shift of the optical axis position.

  An object of the present invention is to provide an optical device manufacturing method, an optical axis positioning jig, an optical device manufacturing apparatus, an optical device, which can ensure a margin amount on a transmissive screen by adjusting the optical axis position with high accuracy. And providing a rear projector.

  The optical device manufacturing method of the present invention combines a plurality of light modulation devices that form an optical image by modulating a plurality of color lights for each color light according to image information, and an optical image modulated by each light modulation device. In order to manufacture an optical device including a color combining optical device, an optical image enlarged and projected by a projection optical device through the color combining optical device is projected onto an image forming unit, and the projected optical image is An optical device manufacturing method for positioning and fixing each light modulation device with respect to the color synthesizing optical device based on an image detected by an image detection unit, and before manufacturing the optical device, an optical axis position An optical axis positioning step for positioning an optical axis position in a manufacturing apparatus that manufactures the optical apparatus using an extraction jig, wherein the plurality of image detection units are configured to be movable, and the optical axis The positioning jig is a reference position of the plurality of image detection units. A positioning plate having a parting frame arranged symmetrically with respect to a predetermined position, and the optical axis positioning step is orthogonal to the illumination optical axis set in the manufacturing apparatus and the positioning Positioning plate installation procedure for installing the positioning plate in the manufacturing apparatus so that the center position of the parting frame of the plate coincides with the illumination optical axis, and a position where the parting frame of the positioning plate can be detected And a detection unit initial position setting procedure for moving the plurality of image detection units to set the plurality of image detection units to an initial position.

Here, moving the plurality of image detection units to a position where the parting frame can be detected includes, for example, the following configuration.
For example, with the image forming unit removed, the plurality of image detection units are brought close to the parting frame of the positioning plate, and the plurality of image detection units are directly moved to positions where the parting frame can be detected.
Further, for example, the positioning plate is configured to include a translucent member such as glass, and a parting frame is formed in a scribble shape on the translucent member. Then, the image forming unit is brought close to the positioning plate, and a plurality of image detecting units are moved to positions where the parting frame image projected on the image forming unit can be detected by irradiating the positioning plate with a light beam.

Further, as the image forming unit, for example, a single screen member that projects the entire optical image emitted from the projection optical apparatus may be configured, or a plurality of screen members on which a part of the optical image is projected respectively. You may comprise by.
Furthermore, as the image detection unit, for example, an image sensor such as a charge coupled device (CCD) or a metal oxide semiconductor (MOS) sensor can be employed.
Furthermore, the parting frame only needs to be symmetrically arranged with a predetermined position as the center, and either a configuration that is continuously formed in a frame shape or a configuration that is not continuous but is formed in a frame shape as a whole. It may be adopted. The size of the parting frame is not particularly limited, but may be a reference position for a plurality of image detection units, and may be set in accordance with a predetermined screen size of an optical image projected from the projection optical device, for example. Good.

In the present invention, the optical device manufacturing method includes an optical axis positioning step before manufacturing the optical device. In this optical axis positioning step, the positioning plate is orthogonal to the illumination optical axis set in the manufacturing apparatus in the positioning plate installation procedure, and the center position of the parting frame of the positioning plate matches the illumination optical axis. To be installed in the manufacturing equipment. That is, when the positioning plate is installed in the manufacturing apparatus by this positioning plate installation procedure, the parting frame of the positioning plate is arranged symmetrically with respect to the illumination optical axis. Then, in the detection unit initial position setting procedure, the plurality of image detection units are moved to positions where the parting frame of the positioning plate can be detected, and the initial position is set to the reference position. That is, in this detection unit initial position setting procedure, a plurality of image detection units are arranged symmetrically with respect to the illumination optical axis set in the manufacturing apparatus, and the initial position is set to the reference position. Thus, for example, if the plurality of image detection units are moved by a predetermined dimension from this state, the plurality of image detection units can be arranged at positions corresponding to the screen size of the rear projector on which the optical device to be manufactured is mounted. The plurality of image detection units can reliably detect a part of the optical image projected and projected on the image forming unit by the projection optical device via the color synthesis optical device. And based on this detected image, an optical apparatus can be easily manufactured by adjusting the position of each light modulation apparatus with respect to the color synthesis optical apparatus.
In addition, the optical axis of the optical image projected from the projection optical device is set in the manufacturing apparatus by adjusting the position of each light modulation device with respect to the color synthesizing optical device while detecting the optical image with this image detection unit. It is possible to adjust the position of each light modulation device in a state where it matches the illumination optical axis. As described above, the method of using the master lens as the projection optical device is not adopted, and the projection optical device is included in the adjustment target. Therefore, the position adjustment of each light modulation device can be performed including manufacturing variations of the projection optical device. Therefore, for example, when an optical device and a projection optical device manufactured by this manufacturing method are mounted on a rear projector, the optical device, the projection optical device, and the transmission screen constituting the rear projector are positioned with high accuracy. And the right / left / up / down margins can be appropriately secured.
Further, since the plurality of image detection units are initially set to the reference position in the initial position setting procedure of the optical axis positioning step, for example, the plurality of image detection units are manufactured by moving the plurality of image detection units by a predetermined dimension from this state. A plurality of image detection units can be appropriately arranged at positions corresponding to the screen size of the rear projector on which the target optical device is mounted, and various optical devices can be easily manufactured according to rear projectors having different screen sizes.

  In the method of manufacturing the optical device according to the aspect of the invention, the optical image enlarged and projected by the projection optical device is reflected toward the image forming unit by an optical path adjustment mirror configured to be freely adjustable in posture, An adjustment mirror for adjusting the posture of the optical path adjustment mirror is provided at the center position of the parting frame, and the optical axis positioning jig emits measurement light to the measurement object, and the measurement object A tilt state detection unit that detects the tilt state of the measurement object by detecting return light through the optical axis, and the optical axis positioning step includes light of the measurement light emitted from the tilt state detection unit. An inclination state detection unit installation procedure in which the inclination state detection unit is installed in front of the optical path of the optical path adjustment mirror in the manufacturing apparatus so that the axis coincides with the illumination optical axis, and the optical path adjustment in the inclination state detection unit Measuring light emission procedure for emitting measuring light to the light, return light detection procedure for detecting return light through the optical path adjustment mirror and the adjustment mirror, and return light detected by the return light detection procedure It is preferable that a mirror attitude adjustment procedure for adjusting the attitude of the optical path adjustment mirror based on an inclination state of the optical path adjustment mirror with respect to the illumination optical axis according to the detected position is preferably provided.

Here, the tilt state detection unit can be configured by, for example, an autocollimator or the like. In particular, a laser autocollimator that emits laser light as measurement light is preferable.
By the way, in the rear projector, an optical image is projected on the back side of the transmissive screen by the internal unit housed in the housing, so that the light beam emission direction of the color synthesis optical device and the projection direction of the projection optical device do not necessarily match. Is not limited. On the other hand, in the optical device manufacturing apparatus, in consideration of the adjustment accuracy of the light modulation device, the color synthesis optical device is installed so that the light beam emission direction is the horizontal direction, and the position of the light modulation device from three directions along the horizontal direction. It is easy to carry out the adjustment. Therefore, if the color synthesizing optical device is installed so that the light beam emission direction is horizontal, the projection direction of the projection optical device may not be horizontal.

In the present invention, as the optical axis positioning step, the tilt state detection unit is set to the optical path adjustment mirror so that the optical axis of the measurement light emitted from the tilt state detection unit coincides with the illumination optical axis in the tilt state detection unit installation procedure. Installed in front of the optical path. Further, the measurement light is emitted from the tilt state detection unit to the optical path adjustment mirror in the measurement light emission procedure. Further, return light is detected through the optical path adjustment mirror and the adjustment mirror in the return light detection procedure. Then, the attitude adjustment of the optical path adjustment mirror is performed based on the inclination state of the optical path adjustment mirror with respect to the illumination optical axis according to the return light detection position in the mirror attitude adjustment procedure. As a result, even when the projection direction of the projection optical apparatus is not horizontal, the optical image emitted from the projection optical apparatus is reflected by the optical path adjustment mirror along the illumination optical axis set in the manufacturing apparatus. Can be projected onto the image forming unit. Therefore, the optical axis of the optical image projected from the projection optical device is manufactured by adjusting the position of each light modulation device with respect to the color synthesis optical device while detecting the projected optical image by the image detection unit. The position of each light modulation device can be adjusted in a state where it matches the illumination optical axis set inside. Therefore, for example, when an optical device and a projection optical device manufactured by this manufacturing method are mounted on a rear projector, the positioning of the optical device and the projection optical device and the transmissive screen constituting the rear projector is highly accurate. It can be implemented and the left and right and up and down margins can be secured appropriately.
In addition, if the orientation of the optical path adjustment mirror is appropriately adjusted in accordance with the screen size of the rear projector on which the optical device to be manufactured is mounted, various optical devices can be easily used according to rear projectors with different screen sizes. Can be manufactured.

  In the method of manufacturing an optical device according to the present invention, the optical axis positioning jig emits measurement light to the measurement object, and detects the return light through the measurement object, thereby detecting the tilt state of the measurement object. An optical state emitted from the projection optical device is rectangular, and the image forming unit is composed of a plurality of screen members arranged at corner portions of the optical image. Configured, the plurality of image detection units are integrally disposed on the back surface of each of the plurality of screen members, the screen member and the image detection unit are supported by a support frame configured to be freely adjustable in posture, The support frame is provided with an adjustment mirror at a position corresponding to the illumination optical axis set in the manufacturing apparatus so as to be parallel to the projection surface of the screen member, and the optical axis positioning step Before the positioning plate installation procedure and the detection unit initial position setting procedure, the tilt state detection unit is configured to match the optical axis of the measurement light emitted from the tilt state detection unit with the illumination optical axis. Inclination state detection unit installation procedure installed in front of the optical path of the image forming unit in the manufacturing apparatus, measurement light emission procedure for causing the inclination state detection unit to emit measurement light to the support frame, and adjustment of the support frame A return light detection procedure for detecting return light through the mirror, and the support based on an inclination state of the support frame with respect to the illumination optical axis according to a detection position of the return light detected in the return light detection procedure It is preferable to include a support frame posture adjustment procedure for performing frame posture adjustment.

Here, as the tilt state detection unit, for example, an autocollimator or the like can be employed as in the tilt state detection unit described above.
In the present invention, as the optical axis positioning step, the optical axis of the measurement light emitted from the tilt state detection unit in the tilt state detection unit installation procedure is set before the positioning plate installation procedure and the detection unit initial position setting procedure. The tilt state detection unit is installed in the front stage of the optical path of the image forming unit so as to coincide with the illumination optical axis. Further, the measurement light is emitted from the tilt state detection unit to the support frame that supports the screen member and the image detection unit in the measurement light emission procedure. Further, return light is detected through an adjustment mirror formed at a position corresponding to the illumination optical axis in the support frame in the return light detection procedure. Then, the posture of the support frame is adjusted based on the tilt state of the support frame with respect to the illumination optical axis according to the detection position of the return light in the support frame posture adjustment procedure. Thus, by adjusting the attitude of the support frame with respect to the illumination optical axis, it is possible to further accurately position the image detection unit supported by the support frame with respect to the illumination optical axis. Therefore, by projecting from the projection optical device by adjusting the position of each light modulation device with respect to the color synthesis optical device while detecting the optical image by the image detection unit in which the optical axis positioning is performed with high accuracy. Position adjustment of each light modulation device can be performed with higher accuracy in a state where the optical axis of the optical image matches the illumination optical axis set in the manufacturing apparatus. For this reason, when the manufactured optical device and projection optical device are mounted on a rear projector, the optical device and the projection optical device can be positioned with high accuracy, and the transmissive screen constituting the rear projector can be positioned with high accuracy. The margin amount can be secured more appropriately.

The optical axis positioning jig of the present invention includes a plurality of light modulation devices that form an optical image by modulating a plurality of color lights for each color light according to image information, and an optical image modulated by each light modulation device. An optical axis positioning jig for positioning an optical axis position in a manufacturing apparatus for manufacturing an optical device for manufacturing an optical device including a color combining optical device for combining, A positioning plate having a parting frame symmetrically arranged as a center, and the positioning plate being detachable, perpendicular to an illumination optical axis set in the manufacturing apparatus, and the center position of the parting frame being And a first positioning portion for installing the positioning plate in the manufacturing apparatus so as to coincide with the illumination optical axis.
Here, for example, the positioning plate may be configured by a light shielding member or may include a light transmitting member such as glass. For example, when the light shielding member is used, the parting frame may be formed so as to be directly detectable by, for example, the above-described image detection unit. In addition, for example, in the case of including a light-transmitting member such as glass, a parting frame is formed in a scribble shape on the light-transmitting member, and the positioning plate is irradiated with a light beam, thereby depending on the parting frame. For example, the parting frame image may be projected onto the above-described image forming unit.

According to the present invention, the optical axis positioning jig includes a positioning plate having a parting frame and a first positioning portion that supports the positioning plate. When the positioning plate and the first positioning portion are installed in the manufacturing apparatus, the center position of the parting frame of the positioning plate coincides with the illumination optical axis set in the manufacturing apparatus. That is, the parting frame is arranged symmetrically with respect to the illumination optical axis. By this, for example, if the parting frame is set to be the reference position of the plurality of image detection units installed in the manufacturing apparatus, before manufacturing the optical device, the plurality of image detection units, By moving the parting frame of the positioning plate to a detectable position, the initial position can be set to the reference position by being symmetrically arranged with respect to the illumination optical axis set in the manufacturing apparatus. Therefore, substantially the same operations and effects as those of the method for manufacturing the optical device described above can be obtained.
Further, since the optical axis positioning jig is configured to include a positioning plate on which a parting frame is formed, when performing positioning with respect to the illumination optical axis of a plurality of image detection units, a complicated shape is formed. Even if it does not use the jig | tool which has, it can implement easily with a simple structure.

  In the optical axis positioning jig according to the present invention, an adjustment mirror is provided at the center position of the parting frame of the positioning plate, the measuring light is emitted to the measuring object, and the return light via the measuring object And an optical axis of measurement light emitted from the tilt state detection unit upstream of the optical path of the positioning plate and the first positioning unit by detecting the tilt state of the measurement object. And a second positioning unit that supports and fixes the tilt state detection unit at a predetermined angle in a state in which the tilting state detection unit is aligned with the illumination optical axis, and the tilt state detection unit is supported and fixed to the second positioning unit. In this state, the measurement light is emitted to the measurement object constituting the manufacturing apparatus disposed between the tilt state detection and the positioning plate, and the measurement object and the positioning plate are adjusted via the adjustment mirror. Returned light It detected, it is preferable to detect the inclination of the measurement object relative to the illumination optical axis in accordance with the position of the detected returning light.

Here, similarly to the tilt state detection unit described in the above-described optical device manufacturing method, the tilt state detection unit can be configured by, for example, an autocollimator, and is particularly preferably configured as a laser autocollimator.
In the present invention, the optical axis positioning jig includes an inclination state detection unit and a second positioning unit. The tilt state detection unit is configured so that the optical axis of the measurement light to be emitted coincides with the illumination optical axis set in the manufacturing apparatus at the second positioning unit and the optical path upstream of the positioning plate and the first positioning unit. In this state, it is supported and fixed at a predetermined angle. As a result, for example, when the projection direction of the projection optical device is not horizontal, and the optical path adjustment mirror is installed in the manufacturing apparatus, the tilt state detection unit directs the optical path adjustment mirror to be measured. The measurement light is emitted and the return light is detected via the optical path adjustment mirror and the adjustment mirror of the positioning plate, so that the optical path adjustment mirror is tilted with respect to the illumination optical axis according to the detected return light position. Can be detected. Therefore, based on the detected tilt state of the optical path adjustment mirror with respect to the illumination optical axis, the optical path adjustment mirror can be adjusted to an appropriate posture with respect to the illumination optical axis, and substantially the same operations and effects as the above-described optical device manufacturing method can be enjoyed. it can.

In the optical axis positioning jig of the present invention, it is preferable that the second positioning unit has the angle set according to an optical device to be manufactured.
By the way, in rear projectors having different screen sizes, the angles of optical images emitted from the projection optical device to the reflecting mirrors constituting the rear projector are different. For this reason, when manufacturing an optical device corresponding to a rear projector having a different screen size, it is necessary to appropriately adjust the posture of the optical path adjustment mirror installed in the manufacturing device.
According to the present invention, since the second positioning unit is set at an angle for supporting and fixing the tilt state detection unit according to the optical device to be manufactured, the optical device according to the rear projector having a different screen size. Is manufactured, the optical path adjustment mirror can be appropriately adjusted to a posture corresponding to a predetermined screen size by using the second positioning portion having an angle corresponding to the optical device. Therefore, the second positioning unit can easily manufacture various optical devices corresponding to rear projectors having different screen sizes.

The optical axis positioning jig of the present invention includes a tilt state detection unit that detects the tilt state of the measurement target by emitting the measurement light to the measurement target and detecting return light via the measurement target. The first positioning portion is formed with a support surface that supports and fixes the tilt state detection unit in a state where the optical axis of the measurement light emitted from the tilt state detection unit is aligned with the illumination optical axis. The tilt state detection unit is configured to emit measurement light to a measurement target constituting the manufacturing apparatus disposed downstream of the optical path of the tilt state detection unit in a state where the tilt state detection unit is supported and fixed to the support surface of the first positioning unit. It is preferable that the return light is emitted and detected via the measurement object, and the tilt state of the measurement object with respect to the illumination optical axis is detected according to the position of the detected return light.
Here, as the tilt state detection unit, for example, an autocollimator or the like can be employed as in the tilt state detection unit described above.
In the present invention, the optical axis positioning jig includes an inclination state detection unit. In addition, the first positioning portion is formed with a support surface that supports and fixes the tilt state detection unit in a state where the optical axis of the measurement light emitted from the tilt state detection unit coincides with the illumination optical axis. Thus, for example, when a support frame that supports a plurality of image detection units and a plurality of screen members is installed in the manufacturing apparatus, and an adjustment mirror is provided at a position corresponding to the illumination optical axis of the support frame. In addition, the tilt state detection unit emits measurement light toward the support frame to be measured and detects return light through the adjustment mirror provided on the support frame, thereby detecting the position of the detected return light. Accordingly, the inclination state of the support frame with respect to the illumination optical axis can be detected. Therefore, the support frame can be adjusted to an appropriate posture with respect to the illumination optical axis based on the detected inclination state of the support frame with respect to the illumination optical axis, and substantially the same operations and effects as those of the optical device manufacturing method described above can be enjoyed.

  The optical device manufacturing apparatus according to the present invention includes a plurality of light modulation devices that each have a predetermined illumination optical axis and that modulate a plurality of color lights for each color light according to image information to form an optical image, and each light An optical apparatus manufacturing apparatus that manufactures an optical apparatus including a color combining optical apparatus that combines optical images modulated by a modulation apparatus, the optical axis positioning jig described above, the color combining optical apparatus, And a mounting table on which a projection optical device for enlarging and projecting an optical image via the color synthesizing optical device, an image forming unit on which an optical image emitted from the projection optical device is projected, and a movable configuration. A plurality of image detection units for detecting an optical image projected on the image forming unit from the back side of the image forming unit; and the color combining optics based on the images detected by the plurality of image detection units. Adjusting the position of the plurality of light modulation devices relative to the device; The plurality of image detection units are moved to positions where the parting frame of the positioning plate constituting the optical axis positioning jig can be detected before manufacturing the optical device. The initial position is set to the reference position.

Here, moving the plurality of image detection units to a position where the parting frame can be detected includes, for example, the following configuration as described in the method of manufacturing the optical device.
For example, with the image forming unit removed, the plurality of image detection units are brought close to the parting frame of the positioning plate, and the plurality of image detection units are directly moved to positions where the parting frame can be detected.
Further, for example, the positioning plate is configured to include a translucent member such as glass, and a parting frame is formed in a scribble shape on the translucent member. Then, the image forming unit is brought close to the positioning plate, and a plurality of image detecting units are moved to positions where the parting frame image projected on the image forming unit can be detected by irradiating the positioning plate with a light beam.

Further, as described in the above-described method for manufacturing an optical device, the image forming unit may be configured by a single screen member that projects the entire optical image emitted from the projection optical device, for example. You may comprise by the several screen member by which a part of image is each projected.
Further, as described in the above-described optical device manufacturing method, for example, an image sensor such as a CCD or a MOS sensor can be employed as the image detection unit.
According to the present invention, an optical device manufacturing apparatus includes the above-described optical axis positioning jig, a mounting table, an image forming unit, a plurality of image detecting units, and a position adjusting unit. The plurality of image detection units are moved to a position where the parting frame of the positioning plate constituting the optical axis positioning jig can be detected before the optical device is manufactured, and the initial position is set to the reference position. This makes it possible to enjoy substantially the same operations and effects as those of the optical device manufacturing method described above or the optical axis positioning jig described above.

In the optical device manufacturing apparatus of the present invention, an optical path adjusting mirror that is disposed between the optical paths of the projection optical device and the image forming unit and reflects an optical image emitted from the projection optical device toward the image forming unit. A mirror attitude adjusting unit that adjusts the attitude of the optical path adjusting mirror, and an adjustment mirror is provided at the center position of the parting frame of the positioning plate constituting the optical axis positioning jig, and the optical axis The positioning jig is supported and fixed at a predetermined angle in the state where the optical axis of the measurement light to be emitted coincides with the illumination optical axis, in front of the optical path of the optical path adjustment mirror, in addition to the positioning plate. Inclining state of the optical path adjustment mirror with respect to the illumination optical axis by emitting measurement light to the mirror and detecting return light through the optical path adjustment mirror and the adjustment mirror of the positioning plate An inclination state detection unit for detecting is included, and the mirror attitude adjustment unit is configured to detect the inclination state of the optical path adjustment mirror with respect to the illumination optical axis detected by the inclination state detection unit constituting the optical axis positioning jig. It is preferable to adjust the posture of the optical path adjustment mirror based on the above.
According to the present invention, an optical device manufacturing apparatus includes an optical path adjustment mirror and a mirror attitude adjustment unit. The mirror attitude adjustment unit adjusts the attitude of the optical path adjustment mirror based on the inclination state of the optical path adjustment mirror with respect to the illumination optical axis detected by the inclination state detection unit constituting the optical axis positioning jig. This makes it possible to enjoy substantially the same operations and effects as those of the optical device manufacturing method described above or the optical axis positioning jig described above.

In the optical apparatus manufacturing apparatus according to the present invention, the mirror attitude adjusting unit uses two orthogonal axes that make the optical path adjusting mirror close to and away from the projection optical apparatus as a Z axis and an X axis, When an axis orthogonal to the X axis is the Y axis, an out-of-plane rotation attitude adjustment unit that rotates the optical path adjustment mirror around the Y axis, and a Z axis attitude that moves the optical path adjustment mirror in the Z axis direction It is preferable to include an adjustment unit and an X-axis posture adjustment unit that moves the optical path adjustment mirror in the X-axis direction.
According to the present invention, since the mirror posture adjustment unit includes the out-of-plane rotation posture adjustment unit, the Z-axis posture adjustment unit, and the X-axis posture adjustment unit, the inclined state constituting the optical axis positioning jig Based on the tilt state of the optical path adjustment mirror with respect to the illumination optical axis detected by the detection unit, the posture adjustment of the optical path adjustment mirror can be appropriately performed. In addition, since the optical path adjustment mirror can be adjusted in the direction of rotation about the Z axis direction, the X axis direction, and the Y axis, the attitude of the optical path adjustment mirror can be appropriately adjusted according to rear projectors having different screen sizes.

In the optical device manufacturing apparatus of the present invention, the optical image emitted from the projection optical device is rectangular, and the image forming unit is composed of a plurality of screen members arranged at corner portions of the optical image. The plurality of image detection units are integrally disposed on the back surfaces of the plurality of screen members, a support frame that supports the screen member and the image detection unit, and a support frame that adjusts the posture of the support frame. And an adjustment mirror provided at the position corresponding to the illumination optical axis so as to be parallel to the projection surface of the screen member, and the optical axis positioning jig includes: In addition to the positioning plate, it is supported and fixed in the front stage of the optical path of the support frame in a state where the optical axis of the emitted measurement light coincides with the illumination optical axis, and is measured with respect to the support frame. An inclination state detection unit configured to detect the inclination state of the support frame with respect to the illumination optical axis by emitting light and detecting return light via an adjustment mirror of the support frame, and the support frame posture The adjustment unit preferably adjusts the posture of the support frame based on the tilt state of the support frame with respect to the illumination optical axis detected by the tilt state detection unit constituting the optical axis positioning jig.
According to the present invention, an optical device manufacturing apparatus includes a support frame that supports a plurality of screen members and a plurality of image detection units, and a support frame posture adjustment unit. The support frame posture adjustment unit adjusts the posture of the support frame based on the tilt state of the support frame with respect to the illumination optical axis detected by the tilt state detection unit constituting the optical axis positioning jig. This makes it possible to enjoy substantially the same operations and effects as those of the optical device manufacturing method described above or the optical axis positioning jig described above.

The optical device of the present invention is manufactured by the above-described optical device manufacturing method.
According to the present invention, since the optical device is manufactured by the above-described optical device manufacturing method, it is possible to enjoy the same operations and effects as the above-described optical device manufacturing method.
In addition, the optical device in which the position of each light modulation device is adjusted, including manufacturing variations of the projection optical device, can be projected, and an optical image with an appropriate margin amount can be projected via the projection optical device.

The rear projector according to the present invention includes a light source device, a color separation optical device that separates a light beam emitted from the light source device into a plurality of color lights, the optical device described above, and an optical image formed by the optical device. A projection optical device to project, the light source device, the color separation optical device, the optical device, and a box-shaped housing for housing the projection optical device, and exposed on any side surface of the box-shaped housing. And a transmissive screen for projecting an optical image enlarged and projected by the projection optical device.
According to the present invention, since the rear projector includes the optical device manufactured by the above-described optical device manufacturing method, it can enjoy the same operations and effects as the above-described optical device manufacturing method.
Further, since the rear projector can project an optical image with an appropriate margin amount through the projection optical device onto the transmissive screen, for example, an optical image projected on the transmissive screen by adjusting the attitude of the projection optical device. Adjustment mechanism for adjusting the contour of the optical image, or an adjustment mechanism for adjusting the contour of the optical image projected on the transmission screen by adjusting the posture of the light source device, color separation optical device, optical device, and projection optical device as a whole Can be simplified, the configuration of the rear projector can be simplified, and the manufacturing cost of the rear projector can be reduced.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings.
[Main configuration of rear projector]
FIG. 1 is a cross-sectional view from the side of a rear projector according to an embodiment of the present invention. FIG. 2 is a plan view schematically showing an optical unit including an optical device incorporated in the rear projector.
In FIG. 1, reference numeral 100 denotes a rear projector. The rear projector 100 generates an optical image and projects it, a reflection mirror 300 that reflects the optical image projected from the optical unit 400, and a reflection The transmissive screen 200 that projects an optical image through the mirror 300, and the casing 500 in which the optical unit 400, the reflective mirror 300, and the transmissive screen 200 are arranged are roughly configured.
As shown in FIG. 2, the optical unit 400 includes an integrator illumination optical system 410, a color separation optical device 420, a relay optical system 430, a light modulation device 440, an incident side polarizing plate 451, and an emission side polarizing plate 452. A cross dichroic prism 460 as a color synthesizing optical device, a prism 470, a projection lens 480 as a projection optical device, and a light guide 490.
The integrator illumination optical system 410 includes a light source device 411 including a light source lamp 411A and a reflector 411B, a first lens array 412, a second lens array 413, a polarization conversion element 414, and a superimposing lens 415.

  The light beam emitted from the light source lamp 411A is aligned in the emission direction by the reflector 411B, is divided into a plurality of partial light beams by the first lens array 412, and forms an image in the vicinity of the second lens array 413. Each partial light beam emitted from the second lens array 413 is converted into substantially one type of polarized light by the polarization conversion element 414 and is incident on the superimposing lens 415. Further, the plurality of partial light beams emitted from the superimposing lens 415 are superimposed on three liquid crystal panels 441R, 441G, and 441B that constitute a light modulation device 440 described later.

The color separation optical device 420 includes two dichroic mirrors 421 and 422 and a reflection mirror 423. The dichroic mirrors 421 and 422 have a function of separating a plurality of partial light beams emitted from the integrator illumination optical system 410 into three color lights of red (R), green (G), and blue (B). .
The relay optical system 430 includes an incident side lens 431, a relay lens 433, and reflection mirrors 432 and 434, and has a function of guiding red light, which is color light separated by the color separation optical device 420, to the liquid crystal panel 441R. ing.

The light modulation device 440 includes three liquid crystal panels 441R, 441G, and 441B. The liquid crystal panels 441R, 441G, and 441B use, for example, polysilicon TFTs as switching elements, and the respective color lights separated by the color separation optical device 420 are the three liquid crystal panels 441R, 441G, An optical image is formed by being modulated in accordance with image information by 441B.
The incident-side polarizing plate 451 transmits only polarized light in a certain direction and absorbs other light beams among the respective color lights separated by the color separation optical device 420. The emission-side polarizing plate 452 is a liquid crystal panel. Among the light beams emitted from 441R, 441G, and 441B, only polarized light in a predetermined direction is transmitted and other light beams are absorbed. The incident side polarizing plate 451 and the exit side polarizing plate 452 are set so that the directions of the polarization axes thereof are orthogonal to each other.

The cross dichroic prism 460 has a function of forming a color image by combining images modulated for each color light emitted from the three liquid crystal panels 441R, 441G, and 441B.
The light modulation device 440, the exit-side polarizing plate 452, and the cross dichroic prism 460 described above are configured as an optical device 600 that is integrated into a unit. The incident-side polarizing plate 451 is attached by being slidably fitted into a groove (not shown) formed in the light guide 490.

The prism 470 is disposed on the light emission side of the cross dichroic prism 460, and the color image synthesized by the cross dichroic prism 460 is bent upward in the direction of the projection lens 480, that is, the color image emitted in the forward direction. It is a reflection.
The projection lens 480 enlarges the color image reflected by the prism 470 and projects it on the reflection mirror 300.
Note that the angle of reflection of the prism 470 described above toward the projection lens 480 is appropriately changed in accordance with the manufacturing model of the rear projector 100, for example, the screen size of the rear projector 100. Also, the projection lens 480 is appropriately changed according to the screen size of the rear projector 100.

The light guide 490 is made of, for example, synthetic resin, and arranges the integrator illumination optical system 410, the color separation optical device 420, the relay optical system 430, the optical device 600, and the prism 470 described above at predetermined positions inside. Although not specifically shown, the light guide 490 includes a lower light guide that stores and holds optical components, and an upper light guide that closes an opening of the lower light guide.
The reflection mirror 300 is a general reflection mirror that is disposed on the back side of the casing 500 of the rear projector 100 and is formed in a substantially trapezoidal shape. The reflection mirror 300 reflects the color image projected from the projection lens 480 to the back side of the transmissive screen 200 as shown in FIG.
The transmissive screen 200 is a general rectangular transmissive screen, and includes, for example, a diffusion plate, a Fresnel sheet, a lenticular sheet, and a protective plate from the back side. The transmissive screen 200 projects the color image magnified by the projection lens 480 and reflected by the reflection mirror 300 from the back to the front.

[Configuration of optical device]
FIG. 3 is an exploded perspective view showing a structure for attaching the light modulation device 440 to the cross dichroic prism 460.
The three light modulation devices 440 constituting the optical device 600 are arranged so as to surround the three side surfaces of the cross dichroic prism 460. Specifically, as shown in FIG. 3, each of the liquid crystal panels 441R, 441G, and 441B is housed in a holding frame 443, and transparent resin pins 445 are formed in holes 443A formed at the four corners of the holding frame 443. Is inserted together with an ultraviolet curable adhesive to form a so-called POP (Panel On Prism) structure that is bonded and fixed to the light incident end surface 448 of the cross dichroic prism 460. Here, a rectangular opening 443B is formed in the holding frame 443, and each of the liquid crystal panels 441R, 441G, 441B is exposed through the opening 443B, and this portion becomes an image forming area. That is, each color light R, G, B is introduced into this portion of each liquid crystal panel 441R, 441G, 441B, and an optical image is formed according to image information.

FIG. 4 is a side view showing a mounting structure of the cross dichroic prism 460.
As shown in FIG. 4, a fixing plate 461 is bonded and fixed to the lower surface of the cross dichroic prism 460 with an ultraviolet curable adhesive 462, and a screw fixing hole 461A is formed in the fixing plate 461. . The fixed plate 461 has a spherical bulged portion 461B at the center, and the bulged portion 461B is brought into contact with the lower surface of the cross dichroic prism 460 so that it is not cured between the cross dichroic prism 460 and the fixed plate 461. The position of the cross dichroic prism 460 is adjusted in a state where the UV curable adhesive 462 is filled, and after the position adjustment is completed, the UV curable adhesive 462 is cured by irradiating ultraviolet rays from the upper surface to the lower surface of the cross dichroic prism 460. Let The reason why the spherical bulging portion 461B is formed on the fixed plate 461 is that it is necessary to adjust the position in the tilt direction with respect to the optical axis.

  The optical device 600 in which the light modulation device 440 is fixed to the cross dichroic prism 460 is fixed to a lower light guide (not shown) constituting the light guide 490 by inserting a screw into the hole 461A of the fixing plate 461. The optical unit 400 is configured by combining an upper light guide and a lower light guide (not shown).

  The optical unit 400 having such a configuration first stores and installs the optical components constituting the integrator illumination optical system 410, the color separation optical device 420, the relay optical system 430, the prism 470, and the projection lens 480 in the light guide 490. Keep it. Next, a cross dichroic prism 460 including a fixing plate 461 whose position has been adjusted is mounted in the light guide 490, and the three light modulation devices 440 are fixed to the light incident end surface 448 of the cross dichroic prism 460, and an adhesive for fixing. Install in an uncured state. Then, the light beams emitted from the light sources are used to adjust the positions of the three light modulation devices 440, and finally the adhesive is cured to fix the positioning of the three light modulation devices 440 with respect to the cross dichroic prism 460.

[Structure of optical device manufacturing equipment]
FIG. 5 is a side view showing the manufacturing apparatus 1 of the optical device 600.
FIG. 6 is a plan view showing the manufacturing apparatus 1 of the optical device 600.
The manufacturing apparatus 1 manufactures the optical apparatus 600 by adjusting the relative position between the three light modulation apparatuses 440 and fixing the relative position to the cross dichroic prism 460. The manufacturing apparatus 1 includes an adjustment unit body 2, an optical axis positioning jig 3, and a projection unit body 5.

[Adjustment unit structure]
The adjustment unit main body 2 includes a UV light shielding cover 21, a six-axis position adjustment unit 22 as a position adjustment unit of the three light modulators 440, a clamp jig 23 as a mounting table that supports and fixes the optical unit 400, and a projection The optical path adjustment unit 24 which adjusts the direction of the optical image inject | emitted from the lens 480, and the light source unit 25 for inject | emitting the light beam for adjustment are provided.

The UV light shielding cover 21 includes a support base 211 (FIG. 5) that supports the six-axis position adjustment unit 22, the clamp jig 23, and the light source unit 25, and a bottom plate 212 provided on the support base 211 (FIG. 5). A side plate 213 erected on the outer peripheral portion of the bottom plate 212 and a top plate 214 that closes the upper end portion of the side plate 213 are provided. The side plate 213 is provided with a door 213A (FIG. 6) provided so as to be freely opened and closed, and a transmission window 213B for transmitting the light irradiated from the light source unit 25 and transmitted through the projection lens 480 to the projection unit main body 5. Yes.
The door 213A (FIG. 6) is provided when feeding and removing the optical unit 400 and the optical axis positioning jig 3, and when adjusting the 6-axis position adjusting unit 22, and does not transmit ultraviolet rays. It is formed from an acrylic plate. The support base 211 is provided with a caster 211A (FIG. 5) at a lower portion thereof so that the adjustment unit main body 2 can be easily moved when the apparatus is installed.

A 6-axis position adjustment unit 22, a clamp jig 23, and an optical path adjustment unit 24 are disposed inside the UV light shielding cover 21 of the adjustment unit main body 2. The light source unit 25 is installed below the mounting surface of the optical unit 400 of the clamp jig 23.
Although not shown in the drawings, below the support base 211, a computer, which will be described later, which is a control device for controlling the entire manufacturing apparatus 1, a liquid crystal panel 441R, 441G, A fixing ultraviolet light source device for fixing 441B on the cross dichroic prism 460 is installed.

[Structure of 6-axis position adjustment unit]
FIG. 7 is a side view showing the structure of the 6-axis position adjustment unit 22.
The six-axis position adjustment unit 22 adjusts the arrangement positions of the three light modulation devices 440 with respect to the light incident end surface 448 of the cross dichroic prism 460. The six-axis position adjusting unit 22 includes a planar position adjusting unit 221 that is movably installed along the rail 212 A of the bottom plate 212 of the UV light shielding cover 21, and an in-plane rotation provided at a tip portion of the planar position adjusting unit 221. A position adjustment unit 222, an out-of-plane rotation position adjustment unit 223 provided at a tip portion of the in-plane rotation position adjustment unit 222, and a liquid crystal panel holding unit 224 provided at a tip portion of the out-of-plane rotation position adjustment unit 223. Prepare.

  The planar position adjusting unit 221 is a part that adjusts the advancing / retreating position and the planar position of the cross dichroic prism 460 with respect to the light incident end surface 448, and a base 221A that is slidably provided on the support base 211, A leg portion 221B is provided, and a connecting portion 221C is provided at an upper end portion of the leg portion 221B and to which the in-plane rotational position adjusting portion 222 is connected. The base 221 </ b> A moves in the Z-axis direction (left-right direction in FIG. 7) of the support base 211 by a drive mechanism such as a motor (not shown). The leg portion 221B is moved in the X-axis direction (direction perpendicular to the paper surface of FIG. 7) with respect to the base portion 221A by a driving mechanism (not shown) such as a motor provided on the side portion. The connecting portion 221C is moved in the Y-axis direction (vertical direction in FIG. 7) with respect to the leg portion 221B by a driving mechanism such as a motor (not shown).

  The in-plane rotation position adjustment unit 222 is a part that adjusts the in-plane rotation position of the three light modulation devices 440 with respect to the light incident end surface 448 of the cross dichroic prism 460, and is fixed to the tip portion of the planar position adjustment unit 221. A cylindrical base portion 222A, and a rotation adjusting portion 222B that is rotatably provided in the circumferential direction of the base portion 222A. Then, by adjusting the rotation position of the rotation adjusting unit 222B, the in-plane direction rotation positions of the three light modulation devices 440 with respect to the light incident end surface 448 can be adjusted with high accuracy.

  The out-of-plane rotation position adjustment unit 223 is a part that adjusts the out-of-plane rotation position of the three light modulation devices 440 with respect to the light incident end surface 448 of the cross dichroic prism 460. The out-of-plane rotational position adjustment unit 223 is fixed to the distal end portion of the in-plane rotational position adjustment unit 222, and has a base 223A in which a concave curved surface that is a circular arc in the horizontal direction is formed at the distal end portion, and the base 223A A first adjustment portion 223B is provided on the concave curved surface so as to be slidable along the circular arc, and has a concave curved surface formed in the tip portion in a vertical direction, and the concave curved surface of the first adjustment portion 223B is an arc. And a second adjusting portion 223C provided to be slidable along. When a motor (not shown) provided on the side of the base 223A is rotationally driven, the first adjustment unit 223B slides, and when a motor (not shown) provided on the upper part of the first adjustment unit 223B is rotated, the second adjustment is performed. The part 223C slides, and the out-of-plane rotation position of the three light modulation devices 440 with respect to the light incident end surface 448 can be adjusted with high accuracy.

  The liquid crystal panel holding unit 224 is a portion that holds the three light modulation devices 440 to be adjusted, and is provided at the tip portion of the second adjusting unit 223C. The actuator 223D provided in the second adjusting unit 223C performs Y It is configured to be movable in the axial direction (vertical direction in FIG. 7).

The liquid crystal panel holding unit 224 is formed of a substantially Z-shaped metal plate on the side surface, and includes a suction surface 224A that sucks image forming areas of the liquid crystal panels 441R, 441G, and 441B at the tip portion. Four light beam transmission holes 224B penetrating the front and back surfaces of the holding portion 224 are formed on the 224A.
Such a liquid crystal panel holding unit 224 holds the three light modulation devices 440 in a state where the image forming areas of the liquid crystal panels 441R, 441G, and 441B are sucked onto the suction surface 224A. The adjustment light beam emitted from the light source unit 25 and passing through the light guide 490 along the illumination optical axis is transmitted through the light beam transmission hole 224B and is incident on the image forming regions of the liquid crystal panels 441R, 441G, and 441B. It has become.

[Structure of optical path adjustment unit]
The optical path adjustment unit 24 is disposed in the vicinity of the projection lens 480 and reflects an optical image emitted from the projection lens 480 toward the projection unit main body 5. As shown in FIG. 5, the optical path adjustment unit 24 includes an optical path adjustment mirror main body 241 and an out-of-plane rotation attitude adjustment section 243, a Z-axis attitude adjustment section 244, and an X-axis adjustment section that adjust the attitude of the optical path adjustment mirror main body 241. A mirror posture adjusting unit 242 having an axis posture adjusting unit 245.

8 and 9 are diagrams showing the structure of the optical path adjusting mirror main body 241. FIG. Specifically, FIG. 8 is a view of the optical path adjustment mirror main body 241 as viewed from the front. FIG. 9 is a view of the optical path adjustment mirror main body 241 as viewed from the side. 8 and 9 also show a connection state between the optical path adjustment mirror main body 241 and the out-of-plane rotation posture adjustment unit 243 constituting the mirror posture adjustment unit 242. 8 and 9, two axes orthogonal to each other where the optical path adjustment mirror main body 241 approaches and separates from the projection lens 480 are defined as a Z axis and an X axis, and an axis orthogonal to the Z axis and the X axis is defined as a Y axis. To do.
The optical path adjustment mirror main body 241 reflects the optical image projected from the projection lens 480 of the optical unit 400 to be adjusted toward the projection unit main body 5 while being supported by the mirror attitude adjustment unit 242. That is, the optical path adjustment mirror body 241 has the same function as the reflection mirror 300 of the rear projector 100 described above, and the optical device 600 can be manufactured in the same state as the rear projector 100 by the optical path adjustment mirror body 241. As shown in FIG. 8 or FIG. 9, the optical path adjustment mirror main body 241 includes a plate body 241A and five optical path adjustment mirrors 241B.

The plate body 241A has a substantially rectangular shape in plan view, and is located at portions corresponding to the four corner positions of the optical image projected from the projection lens 480 of the optical unit 400 to be adjusted, and at the optical axis position of the optical image. Five openings 241A1 penetrating the front and back are formed in the corresponding portions. Of these openings 241A1, the opening 241A1 located at the upper left in FIG. 8 has a substantially pentagonal shape in which the lower left corner of the rectangular shape is omitted. Further, the opening 241A1 located at the lower left in FIG. 8 has a substantially rectangular shape. Furthermore, the opening 241A1 located at the optical axis position of the optical image has a substantially circular shape. The openings 241A1 are formed so as to be symmetric with respect to the center line of the plate body 241A in the left-right direction.
Further, three arm portions 241A2 projecting in the out-of-plane direction are formed on the back surface side of the plate body 241A, and a hole 241A3 is formed in the tip portion of the arm portion 241A2 as shown in FIG. Yes.

  The optical path adjustment mirror 241B is installed in each of the five openings 241A1 formed in the plate 241A, and reflects the four corners of the optical image projected from the projection lens 480 of the optical unit 400 to be adjusted toward the projection unit body 5 side. The four optical image reflection mirrors 241B1 and the adjustment reflection mirror 241B2 used when adjusting the posture of the optical path adjustment mirror main body 241 with respect to the illumination optical axis set in the manufacturing apparatus 1.

The mirror attitude adjustment unit 242 adjusts the attitude of the optical path adjustment mirror body 241 while supporting the optical path adjustment mirror body 241. As shown in FIG. 5, the mirror attitude adjustment unit 242 includes an out-of-plane rotation attitude adjustment unit 243, a Z-axis attitude adjustment unit 244, and an X-axis attitude adjustment unit 245.
The out-of-plane rotation attitude adjustment unit 243 supports the optical path adjustment mirror main body 241 and adjusts the attitude of the optical path adjustment mirror main body 241 in the out-of-plane rotation direction that rotates about the Y axis (the direction orthogonal to the paper surface in FIG. 9). To do. As shown in FIG. 8 or 9, the out-of-plane rotation posture adjustment unit 243 includes a support unit 243A, a motor 243B, a joint 243C, and a shaft 243D.

The support unit 243A supports the entire out-of-plane rotation posture adjustment unit 243 while being supported by the Z-axis posture adjustment unit 244 (FIG. 9). The support portion 243A is a plate body having a substantially rectangular shape in plan view extending in the left-right direction in FIG. 8, and protrudes out of the plane at one end side (right end portion in FIG. 8) in the out-of-plane direction. A first support portion 243A1 that supports and fixes 243C is formed. Further, a second support portion 243A2 (FIG. 8) that supports the other end side (left end portion in FIG. 8) of the shaft 243D in a loosely fitted state is formed on the other end side (left end portion in FIG. 8). Yes.
Further, as shown in FIG. 9, a hole 243A3 for fixing to a Z-axis posture adjusting unit 244 described later is formed in the support portion 243A.

  The motor 243B is a commonly used pulse motor, and the motor shaft 243B1 rotates when a predetermined pulse voltage is applied from a motor drive circuit (not shown) under the control of a computer to be described later. In the present embodiment, a pulse motor is employed as the motor 243B. However, the present invention is not limited to this, and other motors such as a servo motor may be employed.

  The joint 243C connects one end of the shaft 243D to the motor shaft 243B1 of the motor 243B. The joint 243C rotates the shaft 243D forward or backward according to the rotation of the motor shaft 243B1 driven by the motor 243B.

  The shaft 243D is formed in a cylindrical shape extending in the left-right direction in FIG. 8, and is inserted into the holes 241A3 (FIG. 9) of the three arm portions 241A2 formed in the plate body 241A in the optical path adjusting mirror body 241 and each arm. It is fixed to the part 241A2 and supports the optical path adjusting mirror main body 241. One end of the shaft 243D is connected to the motor shaft 243B1 of the motor 243B by a joint 243C, and the other end is supported by the second support portion 243A2 of the support portion 243A. The shaft 243D is rotated by the motor 243B via the joint 243C, and rotates the optical path adjustment mirror main body 241 around the rotation axis as indicated by an arrow R1 in FIG.

FIG. 10 is a diagram illustrating a schematic configuration of the Z-axis posture adjustment unit 244. Specifically, FIG. 10 is a view of the Z-axis posture adjusting unit 244 as viewed from the + X-axis direction.
While supporting the out-of-plane rotation posture adjustment unit 243, the Z-axis posture adjustment unit 244 moves the out-of-plane rotation posture adjustment unit 243 in the Z-axis direction (vertical direction in FIG. 9), and moves the optical path adjustment mirror main body 241 to Z. Adjust the posture in the axial direction. As shown in FIG. 10, the Z-axis posture adjusting unit 244 includes a support unit 244A, a motor 244B, a joint 244C, a shaft 244D, and a moving unit 244E.

The support portion 244A supports the entire Z-axis posture adjustment unit 244 while being supported by an X-axis posture adjustment unit 245 described later. The support portion 244A is composed of a plate body having a substantially rectangular shape in plan view, and a first support portion 244A1 substantially similar to the first support portion 243A1 and the second support portion 243A2 of the support portion 243A in the out-of-plane rotation posture adjustment portion 243. In addition, a second support portion 244A2, a fixing hole 244A3 for fixing to an X-axis posture adjusting portion 245 described later, and a rail 244A4 for guiding the movement of the moving portion 244E are formed.
The rails 244A4 are respectively located on the left and right end sides of the support portion 244A, protrude in the out-of-plane direction (+ X axis direction in FIG. 10) of the support portion 244A, and extend in parallel to the left and right end edges of the support portion 244A. Yes.

Since the motor 244B and the joint 244C have substantially the same structure as the motor 243B and the joint 243C in the out-of-plane rotation posture adjustment unit 243, description thereof is omitted.
The shaft 244D is formed in a cylindrical shape extending in the vertical direction in FIG. 10, one end is connected to the motor shaft 244B1 of the motor 244B by a joint 244C, and the other end is supported by the second support portion 244A2 of the support portion 244A. . And although illustration is abbreviate | omitted in shaft 244D, the thread groove is formed in the outer periphery between both ends.

The moving unit 244E is configured by a substantially U-shaped plate in plan view, and moves along the rail 244A4 of the supporting unit 244A while supporting the out-of-plane rotation posture adjusting unit 243.
In the moving portion 244E, a plurality of fixing holes 244E1 are formed in the U-shaped base end portion, and the holes 243A3 (FIG. 9) formed in the support portion 243A in the out-of-plane rotation posture adjusting portion 243 described above. Then, the out-of-plane rotation posture adjusting unit 243 is fixed to the moving unit 244E by inserting the screw and screwing the fixing hole 244E1 with the screw.
Further, in the moving portion 244E, on the back surface side, a sliding portion 244E2 is attached at a position corresponding to the rail 244A4 of the support portion 244A, and a slider 244E3 is attached at a position corresponding to the shaft 244D.
The sliding portion 244E2 has a groove portion (not shown) corresponding to the shape of the rail 244A4. When the rail 244A4 and the groove portion are engaged, the moving portion 244E is guided and slid on the rail 244A4.
The slider 244E3 is formed in a substantially quadrangular prism shape, has female screw holes formed through both opposing end faces, and is screwed into a screw groove (not shown) of the shaft 244D. The slider 244E3 is driven by the motor 244B so that the shaft 244D rotates via the joint 244C, so that the screwed state with the shaft 244D is changed, and the Z axis is moved together with the moving unit 244E according to the rotation direction of the shaft 244D. Move in the direction.

11 and 12 are diagrams showing a schematic configuration of the X-axis posture adjusting unit 245. Specifically, FIG. 11 is a cross-sectional view of the X-axis posture adjusting unit 245 viewed from the + Y-axis direction. FIG. 12 is a cross-sectional view of the X-axis posture adjusting unit 245 viewed from the + X-axis direction.
The X-axis posture adjustment unit 245 moves the Z-axis posture adjustment unit 244 in the X-axis direction (left-right direction in FIG. 11) while supporting the Z-axis posture adjustment unit 244, and the out-of-plane rotation posture adjustment unit 243 and The posture of the optical path adjustment mirror main body 241 is adjusted in the X-axis direction. As shown in FIG. 11 or FIG. 12, the X-axis posture adjusting unit 245 includes a support unit 245A, a motor 245B, a joint 245C, a shaft 245D, and a moving unit 245E.

The support portion 245A is formed of a plate body having a substantially rectangular shape in plan view, is fixed to the top plate 214 of the UV light shielding cover 21, and supports the entire X-axis posture adjustment portion 245.
The lower surface of the support portion 245A includes a first support portion 245A1 and a second support portion 245A2 that are substantially the same as the first support portion 243A1 and the second support portion 243A2 of the support portion 243A in the out-of-plane rotation posture adjustment portion 243. A third support portion 245A3 that supports the moving portion 245E and a rail 245A4 that guides the movement of the moving portion 245E are formed.
The rails 245A4 are respectively positioned on the Y axis direction end side (left and right end sides in FIG. 12) of the support portion 245A, and protrude downward from the lower surface of the support portion 245A (−Z axis direction). It extends in parallel to the Y-axis direction edge of 245A (left and right edge in FIG. 12).
The third support portion 245A3 is composed of three rectangular plate-like bodies extending in the X-axis direction (left-right direction in FIG. 11). And this 3rd support part 245A3 is suspended from the base end part of rail 245A4, and supports the moving part 245E in the upper surface.

Since the motor 245B, the joint 245C, and the shaft 245D have substantially the same structure as the motor 244B, the joint 244C, and the shaft 244D in the Z-axis posture adjustment unit 244, the description thereof is omitted.
The moving portion 245E is configured to have a substantially L shape when viewed from the side by combining three plate bodies of a first plate body 245E1, a second plate body 245E2, and a third plate body 245E3 having a substantially rectangular shape. , While supporting the Z-axis posture adjustment unit 244, the Z-axis posture adjustment unit 244 moves along the rail 245A4 of the support unit 245A.
Further, two reinforcing members 245F having a substantially triangular shape in a side view for reinforcing the moving portion 245E are attached to the inside of the moving portion 245E in a substantially L shape in a side view.

The first plate body 245E1 is a member that supports the Z-axis posture adjusting unit 244. As shown in FIG. 12, a plurality of holes 245E4 are formed through the front and back, and screws and the like are inserted through the holes 245E4. Then, the Z-axis posture adjusting unit 244 is fixed to the first plate body 245E1 by screwing the fixing hole 244A3 formed in the support portion 244A of the Z-axis posture adjusting unit 244 with a screw.
The second plate 245E2 connects the first plate 245E1 and the third plate 245E3, is connected to the upper end portion of the first plate 245E1, and is connected to the lower surface of the third plate 245E3.

  As shown in FIG. 12, the third plate body 245E3 has four projecting portions 245E5 projecting from the lower surface in the out-of-plane direction, and the tip portions of these projecting portions 245E5 are connected to the upper surface of the second plate body 245E2. The protrusions 245E5 form three insertion holes 245E6 between the third plate body 245E3 and the second plate body 245E2, and these insertion holes 245E6 have the third support portion of the support portion 245A described above. 245A3 is inserted, and the weight of the moving part 245E is secured by the third support part 245A3.

In addition, on the upper surface of the third plate body 245E3, a sliding portion 245E7 is attached to a position corresponding to the rail 245A4 of the support portion 245A, and a slider 245E8 is attached to a position corresponding to the shaft 245D.
The sliding portion 245E7 has a groove portion 245E9 corresponding to the shape of the rail 245A4. When the rail 245A4 and the groove portion 245E9 are engaged, the moving portion 245E is guided and slid on the rail 245A4.
The slider 245E8 is formed in a substantially quadrangular prism shape, has female screw holes formed through both opposing end faces, and is screwed into a screw groove (not shown) of the shaft 245D. The slider 245E8 is driven by the motor 245B so that the shaft 245D is rotated via the joint 245C, so that the screwed state with the shaft 245D is changed, and the X axis along with the moving unit 245E is changed according to the rotation direction of the shaft 245D. Move in the direction.

[Structure of light source unit]
FIG. 13 is a side view showing the structure of the light source unit 25.
The light source unit 25 includes a light source for adjusting the positions of the three light modulation devices 440 with respect to the cross dichroic prism 460, and includes a light source unit main body 251 and a light guide unit 252.
The light source unit main body 251 is configured to house a light source lamp 251 </ b> A serving as an adjustment light source in a housing and supply a light beam to the optical unit 400. Although not shown, the casing is provided with an opening for cooling the light source lamp 251A and a cooling fan inside the opening. The light source lamp 251A is turned on and off (shutter) by a computer to be described later.

The light guide unit 252 is configured by a cylindrical body extending vertically, and an opening 252A is formed on the side of the upper end of the light guide unit 252. The interior corresponding to the position of the opening 252A is provided on the opening surface of the opening 252A. On the other hand, a mirror 252B arranged at approximately 45 ° is provided.
In addition, an opening 252C is formed at a position corresponding to the light beam exit portion of the light source lamp 251A of the light source section main body 251, and the inside of the light guide section 252 corresponding to the opening 252C is approximately 45 with respect to the opening surface of the opening 252C. A mirror 252D is provided which is disposed at an angle.

  When the optical unit 400 to be adjusted is adjusted using such a light source unit 25, the upper opening 252A of the light guide 252 and the light source lamp replacement opening of the optical unit 400 are brought into contact with each other. Then, the luminous flux emitted from the light source lamp 251A of the light source section main body 251 is introduced into the light guide 490, and the positions of the three light modulation devices 440 with respect to the cross dichroic prism 460 are adjusted.

[Configuration of optical axis positioning jig]
The optical axis positioning jig 3 is used when positioning the optical axis position in the manufacturing apparatus 1 before manufacturing the optical apparatus 600 to be manufactured. As shown in FIG. 5, the optical axis positioning jig 3 includes a positioning plate 31, a first positioning unit 32, a second positioning unit 33, and an inclined state detection unit 34.

FIG. 14 is a diagram showing a schematic configuration of the positioning plate 31 and the first positioning portion 32. Specifically, FIG. 14 is a view of the positioning plate 31 and the first positioning portion 32 as viewed from the light beam incident direction.
The positioning plate 31 is configured to be attachable to and detachable from the first positioning unit 32, and before the optical device 600 to be manufactured is manufactured, the initial position setting of the screen device described later of the projection unit body 5 and the manufacturing apparatus 1 are performed. This is used when the optical path adjustment unit 24 is positioned with respect to the illumination optical axis set inside. As shown in FIG. 14, the positioning plate 31 includes a plate body 311, a ground glass 312, and an adjustment mirror 313.

The plate body 311 is a metal plate body having a rectangular shape in plan view. Near the four corners, four rectangular openings 311A penetrating the front and back are formed symmetrically at the center position of the plate body. Yes. In addition, although not specifically illustrated, the plate body 311 is formed with six holes for attaching to a predetermined position of the first positioning portion 32.
The ground glass 312 is a predetermined ground glass that is attached to each of the four openings 311A of the plate body 311 and has a parting frame 312A formed on the surface in a scribble shape.

The parting frame 312A serves as a reference position for a screen device 522, which will be described later, of the projection unit body 5. The frame 312A forms four corner portions that are rectangular in plan view. The rectangular area formed by the four parting frames 312A corresponds to a predetermined screen size of the optical image projected from the optical unit 400 having the optical device 600 to be manufactured.
The adjustment mirror 313 is a reflection mirror attached to the central position of the plate body 311 in parallel with the plate surface of the plate body 311, and the optical path adjustment mirror in the optical path adjustment unit 24 with respect to the illumination optical axis set in the manufacturing apparatus 1. This is used when positioning the main body 241.

The first positioning portion 32 is formed in a substantially U-shaped cross section, and six fixing holes 321 are formed on the upper side of the U-shaped base end portion, and are formed in the plate body 311 in the positioning plate 31. For example, a screw or the like is inserted into a hole (not shown), and the screw and the fixing hole 321 are screwed together to support the positioning plate 31 at a predetermined position. Further, the first positioning unit 32 supports the positioning plate 31 at a predetermined position, and at a predetermined position on the bottom plate 212 of the manufacturing apparatus 1 between the optical path adjustment unit 24 of the manufacturing apparatus 1 and the optical path of the projection unit body 5. It is configured to be installable as appropriate. When the first positioning portion 32 supports the positioning plate 31 and is installed at a predetermined position on the bottom plate 212 of the manufacturing apparatus 1, the plate surface of the plate body 311 of the positioning plate 31 is the manufacturing apparatus. 1 and the center position of the plate 311 coincides with the illumination optical axis.
Further, in the first positioning part 32, a support surface 322 for supporting and fixing the tilt state detection part 34 at a predetermined position is formed on the upper U-shaped edge.

  The second positioning unit 33 mounts and fixes the tilt state detection unit 34 at a predetermined angle, and before the optical device 600 to be manufactured is manufactured, the optical path with respect to the illumination optical axis set in the manufacturing device 1 The adjustment unit 24 is used for positioning, and is configured so that it can be appropriately installed on the bottom plate 212 of the manufacturing apparatus 1 before the optical path of the optical path adjustment unit 24 of the manufacturing apparatus 1. The second positioning unit 33 mounts the tilt state detection unit 34 according to the model of the rear projector 100 on which the optical device 600 to be manufactured is mounted, for example, according to the screen size of the rear projector 100. An angle to be fixed is set, and when the optical device 600 is manufactured, an optical device having a predetermined angle corresponding to the optical device 600 is used.

  The tilt state detection unit 34 emits measurement light to a later-described support frame of the optical path adjustment mirror body 241 and the projection unit body 5 of the optical path adjustment unit 24 to be measured, and detects return light, thereby adjusting the optical path. The mirror body 241 and the support frame are detected in an inclined state. The mirror body 241 and the support frame are mounted and fixed on the support surface 322 of the first positioning unit 32 or the second positioning unit 33 as appropriate according to the measurement target for detecting the tilted state. Is done. When the tilt state detection unit 34 is mounted and fixed on the support surface 322 of the first positioning unit 32 or the second positioning unit 33, the optical axis of the measurement light emitted from the tilt state detection unit 34 Corresponds to the illumination optical axis set in the manufacturing apparatus 1.

  The tilt state detection unit 34 is configured, for example, as a laser autocollimator, emits laser light, and adjusts the reflection mirror 241B2 for adjustment of the optical path adjustment unit 24 and the adjustment mirror 313 of the first positioning unit 32, or the projection unit main body 5. The laser beam returned by the adjustment reflecting mirror provided on the support frame described later is detected, and the tilt state of the support frame described later of the optical path adjustment mirror main body 241 of the optical path adjustment unit 24 or the projection unit main body 5 is detected. The tilt state detection unit 34 is electrically connected to a computer to be described later, and the detection position of the return light is recognized by the computer, and the optical path adjustment mirror main body 241 or the projection of the optical path adjustment unit 24 is detected by the detection position. The inclination state of the support frame, which will be described later, of the main body 5 is recognized.

[Projector structure]
The projection unit body 5 is projected from the optical unit 400 including the optical device 600 to be manufactured and detects an optical image via the optical path adjustment unit 24. As shown in FIG. 5 or FIG. 6, the projection unit body 5 includes a dark room 51 and a screen unit 52.
The dark room 51 includes a support base 511 (FIG. 5) that supports the screen unit 52, a bottom plate 512 provided on the support base 511, a side plate 513 erected on the outer periphery of the bottom plate 512, and an upper end of the side plate 513. And a top plate 514 that closes the portion. The side plate 513 is provided with a transmission window 513A for transmitting an optical image projected from the optical unit 400 including the optical device 600 to be manufactured, and the entire projection unit main body 5 is provided below the support base 511. A caster 511 </ b> A (FIG. 5) that can move is provided. In addition, the support frame attitude | position adjustment part which concerns on this invention is corresponded to the caster 511A.

FIG. 15 is a diagram illustrating a schematic configuration of the screen unit 52. Specifically, FIG. 15 is a view of the screen unit 52 as viewed from the front.
The screen unit 52 includes a support frame 521 that can be closely separated from the optical axis positioning jig 3, four screen devices 522 disposed in the vicinity of the four corners of the support frame 521, and supports these screen devices 522. And four moving mechanisms 523 for moving the frame 521 in the in-plane direction.

The support frame 521 supports the screen device 522 and the moving mechanism 523. As shown in FIG. 15, the support frame 521 has a configuration in which a cross-shaped reinforcing member 521B is attached to a rectangular frame 521A in plan view. ing.
In the support frame 521, a screen advance / retreat mechanism 524 is provided at a lower end portion. The screen advance / retreat mechanism 524 is provided on the bottom plate 512 of the dark room 51 so as to extend in a direction orthogonal to the plane of the support frame 521, and is provided on the lower surface of the support frame 521 so as to be movable on each rail 524A. The drive mechanism 524B and a motor (not shown) are provided. The screen advancement / retraction mechanism 524 is driven and controlled by a computer, which will be described later, through a motor drive circuit (not shown), so that the screen unit 52 extends in the direction in which the rail 524A extends, that is, the optical axis positioning jig 3. It is possible to move in the direction of close proximity.
In the support frame 521, an adjustment mirror 521C is attached to a portion where the reinforcing member 521B intersects. This adjustment mirror 521C is projected onto the illumination optical axis set in the manufacturing apparatus 1 using the tilt state detection unit 34 of the optical axis positioning jig 3 before manufacturing the optical apparatus 600 to be manufactured. This is used when positioning the main body 5.

The four screen devices 522 detect the four corner portions of the optical image projected from the optical unit 400 including the optical device 600 to be manufactured while being supported by the moving mechanism 523. These screen devices 522 include a screen member 522A as an image forming unit on which a projection optical image is formed, and a CCD camera 522B as an image detection unit integrally provided on the back surface of the screen member 522A.
The screen member 522A can be configured, for example, by uniformly distributing optical beads on an opaque resin layer. When a light beam is incident from the side where the optical beads are disposed, the optical bead becomes a lens, and the light beam Are ejected to the back side of the screen member 522A.
The CCD camera 522B is an area sensor provided with a charge coupled device as an imaging device, and detects an optical image projected on the screen member 522A from the back side thereof and outputs it as an electrical signal. is there. These CCD cameras 522B are equipped with a zoom / focus mechanism in order to detect a projected image with high accuracy, and the zoom / focus can be freely adjusted by remote control.

The four moving mechanisms 523 are attached to the support frame 521 and move each screen device 522 in the in-plane direction of the support frame 521 (Y-axis direction and Z-axis direction in FIG. 15) while supporting each screen device 522. Let These moving mechanisms 523 include a Y-axis moving unit 523A and a Z-axis moving unit 523B.
As shown in FIG. 15, the Y-axis moving unit 523A is attached to the upper end or the lower end of the support frame 521, and includes a motor 523A1, a joint 523A2, a shaft 523A3, and a slider 523A4.

  The motor 523A1 is a commonly used pulse motor, and is attached to the upper end or the lower end of the support frame 521 so that the motor shaft faces the Y-axis direction. The motor shaft of the motor 523A1 rotates when a predetermined pulse voltage is applied from a motor drive circuit (not shown) under the control of a computer to be described later. In this embodiment, a pulse motor is employed as the motor 523A1, but the present invention is not limited to this, and other motors such as a servo motor may be employed.

  The joint 523A2 connects one end of the shaft 523A3 to the motor shaft of the motor 523A1. Then, the joint 523A2 rotates the shaft 523A3 forward or backward according to the rotation of the motor shaft driven by the motor 523A1.

  The shaft 523A3 is formed in a columnar shape extending in the Y-axis direction, one end is connected to the motor shaft of the motor 523A1 by a joint 523A2, and the other end is supported by a support portion 521D attached to the support frame 521. And although illustration is abbreviate | omitted in shaft 523A3, the thread groove is formed in the outer periphery between both ends.

  The slider 523A4 supports the Z-axis moving unit 523B and moves in the Y-axis direction along the shaft 523A3. The slider 523A4 is formed in a substantially quadrangular prism shape, penetrates both end faces facing in the Y-axis direction, has female screw holes, and is screwed into a screw groove (not shown) of the shaft 523A3. Then, when the shaft 523A3 rotates through the joint 523A2 by driving the motor 523A1, the screwed state of the slider 523A4 is changed with the shaft 523A3, and together with the Z-axis moving unit 523B according to the rotation direction of the shaft 523A3. Move in the Y-axis direction.

The Z-axis moving part 523B is fixed to the slider 523A4 and extends in the Z-axis direction. The Z-axis moving unit 523B engages with the rail 523B1 and is driven by a motor that is driven and controlled by a computer (not shown) via a motor driving circuit (not shown). A slider 523B2 that moves along 523B1 and a placement portion 523B3 that is fixed to the slider 523B2 and places and fixes the screen device 522 are provided.
With the above configuration, the screen device 522 is configured to be movable in the plane of the support frame 521, that is, in the Y-axis direction and the Z-axis direction, and configured to be able to detect an optical image in the detection region 525. .

[Control structure of manufacturing equipment]
FIG. 16 is a diagram schematically showing a control structure of the manufacturing apparatus 1 by the computer 6.
The computer 6 includes a CPU and a storage device, reads a predetermined program stored in the storage device, and controls the entire manufacturing apparatus 1. The computer 6 captures an image captured by the CCD camera 522B of the screen unit 52 through an image capturing device such as a video capture board, performs image processing, and 6-axis positions constituting the adjustment unit main body 2 The adjustment unit 22, the optical path adjustment unit 24 (FIG. 5), the light source unit 25 (FIG. 13), the tilt state detection unit 34 constituting the optical axis positioning jig 3, and the screen advance / retreat mechanism 524 constituting the screen unit 52. (FIG. 15) and the moving mechanism 523 (FIG. 15) are driven and controlled. Therefore, the computer 6 includes the CCD camera 522B, the six-axis position adjustment unit 22, the light source lamp 251A (FIG. 13) that constitutes the light source unit 25, and the tilt state detection unit 34 that constitutes the optical axis positioning jig 3 and the electrical unit. Are connected to each other, and motors 243B, 244B and 245B (FIGS. 8 to 12) in the mirror attitude adjusting unit 242 of the optical path adjusting unit 24 and a screen advance / retreat mechanism 524 constituting the screen unit 52 via a motor drive circuit (not shown). (FIG. 15) and the moving mechanism 523 (FIG. 15) are electrically connected.

[Method for Manufacturing Optical Device]
FIG. 17 is a flowchart for explaining a manufacturing method of the optical device 600.
Next, a method of manufacturing the optical device 600 by the manufacturing apparatus 1 described above will be described with reference to the flowchart of FIG.
First, before installing the optical unit 400 on which the optical device 600 to be manufactured is installed in the manufacturing apparatus 1, the optical axis in the manufacturing apparatus 1 is utilized using the optical axis positioning jig 3 as described below. Positioning is performed (step S1: optical axis positioning step).

FIG. 18 is a flowchart for explaining the positioning of the optical axis position in the manufacturing apparatus 1.
19 to 22 are diagrams for explaining the positioning of the optical axis position in the manufacturing apparatus 1.
First, as shown in FIG. 19, the first positioning portion 32 constituting the optical axis positioning jig 3 is installed at a predetermined position on the bottom plate 212 of the manufacturing apparatus 1, and the first positioning portion 32 is supported. The tilt state detection unit 34 is placed and fixed at a predetermined position on the surface 322 (step S11: tilt state detection unit installation procedure).

After step S <b> 11, the operator operates the computer 6 and calls a predetermined program for adjusting the tilt state of the projection unit body 5. Then, the CPU of the computer 6 reads a predetermined program stored in the storage device, and adjusts the tilt state of the projection unit main body 5 according to this program (step S12).
Specifically, the CPU of the computer 6 outputs a predetermined control signal to the tilt state detection unit 34, causes the tilt state detection unit 34 to emit laser light (step S 121: measurement light emission procedure), and The return light reflected and returned by the adjustment mirror 521C is detected (step S122: return light detection procedure). Then, an electric signal based on the detected return light is input, the return light detection position is recognized, and the tilt state (for example, tilt angle) of the projection unit body 5 is displayed on a display (not shown) connected to the computer 6, for example. (Step S123).
Then, for example, the operator moves the projection unit body 5 by the casters 511A while confirming the tilt state of the projection unit body 5 displayed on a display (not shown), and the adjustment mirror 521C of the projection unit body 5 is tilted. The attitude of the projection unit main body 5 so as to be orthogonal to the laser light emitted from the state detection unit 34, that is, so that the adjustment mirror 521C is orthogonal to the illumination optical axis set in the manufacturing apparatus 1. Adjust. More specifically, the level adjustment screw 511A ′ (FIG. 19) adjusts the inclination of the direction (step S124: support frame posture adjustment procedure).

  After step S12, as shown in FIG. 20, the positioning plate 31 is installed at a predetermined position of the first positioning unit 32 (S13: positioning plate installation procedure), and the second positioning unit 33 is installed in the manufacturing apparatus 1. The inclination state detection part 34 placed on the bottom plate 212 of the first positioning part 32 and placed on the support surface 322 of the first positioning part 32 is removed and placed and fixed on the second positioning part 33 (step S14: inclination state detection). Part installation procedure).

After step S <b> 14, the operator operates the computer 6 and calls a predetermined program for adjusting the posture of the optical path adjustment unit 24. Then, the CPU of the computer 6 reads a predetermined program stored in the storage device, and performs the attitude adjustment of the optical path adjustment unit 24 according to this program (step S15).
Specifically, the CPU of the computer 6 calls the model data registered for each model of the rear projector 100 on which the optical device 600 to be manufactured is mounted, and loads it on the memory of the CPU. This model data includes the design position of the optical path adjustment unit 24 corresponding to the screen size of the rear projector 100 on which the optical device 600 to be manufactured is mounted. Then, the CPU determines the motors 243B, 244B, and 245B of the out-of-plane rotation posture adjustment unit 243, the Z-axis posture adjustment unit 244, and the X-axis posture adjustment unit 245 that constitute the optical path adjustment unit 24 based on the called model data. 8 to 12) are driven and controlled via a motor drive circuit (not shown), and the optical path adjusting mirror main body 241 is arranged at the design position (step S151).

  Further, the CPU of the computer 6 outputs a predetermined control signal to the tilt state detection unit 34 and causes the tilt state detection unit 34 to emit laser light as shown in FIG. 20 (step S152: measurement light emission procedure). The return light reflected and returned by the adjustment reflection mirror 241B2 of the optical path adjustment mirror main body 241 and the adjustment mirror 313 of the positioning plate 31 is detected (step S153: return light detection procedure). Then, an electric signal based on the detected return light is input, and the tilt state of the optical path adjusting mirror main body 241 is recognized from the return light detection position (step S154). Thereafter, based on the recognized inclination state of the optical path adjustment mirror main body 241, the CPU sets the out-of-plane rotation attitude adjustment unit 243, the Z-axis attitude adjustment unit 244, and the X-axis attitude adjustment unit 245 that constitute the optical path adjustment unit 24. The motors 243B, 244B, and 245B (FIGS. 8 to 12) are driven and controlled via a motor drive circuit (not shown), and the optical axis of the light beam reflected by the optical path adjusting mirror body 241 is set in the manufacturing apparatus 1. The attitude adjustment of the optical path adjustment mirror main body 241 is performed so as to match the illumination optical axis (step S155: mirror attitude adjustment procedure).

  After step S15, optical components excluding the liquid crystal panel 441 among the various optical components shown in FIG. 2 are assembled in the light guide 490 to form the optical unit 400. As shown in FIG. It installs in the clamp jig | tool 23 of the main body 2 (step S16). In this embodiment, it is assumed that the position adjustment of the cross dichroic prism 460 with respect to the fixed plate 461 shown in FIG. 4 is performed in advance, and the cross dichroic prism 460 is fixed at a predetermined position of the fixed plate 461.

After step S <b> 16, the operator operates the computer 6 to call a predetermined program for arranging the screen device 522 of the screen unit 52 at the optical image detection position corresponding to the optical device 600 to be manufactured. Then, the CPU of the computer 6 reads a predetermined program stored in the storage device, and places the screen device 522 at the detection position according to this program (step S17). In addition, when implementing this step S17, it implements in the state which removed the screen member 522A of the screen apparatus 522. FIG.
Specifically, the CPU of the computer 6 outputs a predetermined control signal to the light source lamp 251A of the light source unit 25, and turns on the light source lamp 251A (FIG. 13) (step S171).
After step S171, the CPU controls the drive of the screen advance / retreat mechanism 524 and the movement mechanism 523 of the screen unit 52 via a motor drive circuit (not shown). Then, as shown in FIG. 21, the parting frame 312A (FIG. 14) on the ground glass 312 formed on the positioning plate 31 by the light beam emitted from the light source lamp 251A (FIG. 13) and projected through the optical unit 400. The screen device 522 is moved to a position where the CCD camera 522B of the screen device 522 can detect the parting frame image (step S172: detection unit initial position setting procedure). That is, by the movement of the screen device 522, the four screen devices 522 are symmetrically arranged around the illumination optical axis set in the manufacturing apparatus 1, and the initial position is set to the reference position.

  After step S172, the CPU calls the model data registered for each model of the rear projector 100 on which the optical device 600 to be manufactured is mounted, and loads the model data on the memory of the CPU. The model data includes deviation data between the design position of the screen device 522 corresponding to the screen size of the rear projector 100 on which the optical device 600 to be manufactured is mounted and the reference position of the screen device 522. Then, the CPU drives and controls the screen advance / retreat mechanism 524 of the screen unit 52 via a motor drive circuit (not shown) based on the called model data, and arranges the screen unit 52 at the optical image detection position. Further, the CPU drives and controls the Y-axis moving unit 523A and the Z-axis moving unit 523B of the moving mechanism 523 of the screen unit 52 via a motor drive circuit (not shown) based on the deviation data included in the model data, and the screen device The 522 is moved by a predetermined dimension from the reference position in the Z-axis direction and the Y-axis direction, and arranged at a position corresponding to the screen size of the rear projector 100 on which the optical device 600 to be manufactured is mounted (step S173).

  After step S17, the first positioning unit 32, the second positioning unit 33, and the tilt state detection unit 34 are removed from the manufacturing apparatus 1 (step S18). In addition, the screen member 522 </ b> A removed when performing Step S <b> 17 is attached to the screen device 522. In this state, that is, in the state shown in FIG.

  In step S1, after the optical axis positioning in the manufacturing apparatus 1 is performed, the liquid crystal panels 441R, 441G, and 441B are attached to the six-axis position adjustment unit 22 (step S2). The liquid crystal panels 441R, 441G, and 441B are attached by inserting pins 445 coated with an ultraviolet curable adhesive into holes 443A formed at the four corners of the holding frame 443 shown in FIG. Do as the state of.

After step S2, the operator operates the computer 6 to call a predetermined program for causing the optical device 600 to be manufactured. And according to the called program, CPU implements the optical apparatus 600 as shown below (step S3).
Specifically, the CPU calls the model data registered for each model of the rear projector 100 on which the optical device 600 to be manufactured is mounted, and loads the model data on the memory of the CPU. The model data includes design positions of the liquid crystal panels 441R, 441G, and 441B with respect to the cross dichroic prism 460. Then, the CPU outputs a predetermined control signal to the 6-axis position adjustment unit 22 based on the called model data, and the 6-axis position adjustment unit 22 moves the liquid crystal panels 441R, 441G, 441B to move the pins 445 Is installed at an initial position where it contacts the light incident end surface 448 (FIG. 3) of the cross dichroic prism 460 (step S31).

In this state, the light beam emitted from the light source lamp 251A (FIG. 13) and introduced into the optical unit 400 is transmitted from the light beam transmission hole 224B of the liquid crystal panel holding unit 224 of the six-axis position adjustment unit 22 to the liquid crystal panels 441R, 441G, Then, the light enters the lens 441B and a rectangular optical image is projected from the projection lens 480. Then, corner portions of the projected optical image are formed on the screen member 522A of the screen device 522.
In this state, the CPU of the computer 6 outputs an image signal, outputs an image signal including an image pattern for alignment adjustment only to the liquid crystal panel that performs position adjustment with respect to the cross dichroic prism 460, and outputs it to another liquid crystal panel. Outputs an image signal for displaying a black image (step S4). In the present embodiment, first, after adjusting the position of the liquid crystal panel 441G, the position adjustment of the liquid crystal panels 441R and 441B is performed, and accordingly, different image signals are sequentially output. In addition, when adjusting the position of the liquid crystal panels 441R, 441G, 441B, the position of the three liquid crystal panels 441R, 441G, 441B may be adjusted simultaneously using a 3CCD camera as the CCD camera 522B. If so, the adjustment speed can be greatly increased.

  The CPU of the computer 6 outputs a predetermined signal to the CCD camera 522B of the screen device 522, detects a projection image formed on the screen member 522A, and causes the 6-axis position adjustment unit 22 to perform a predetermined operation based on the detected image pattern. The control signal is output, and the focus adjustment of the liquid crystal panel 441G is performed (step S5). When this focus adjustment is completed, the alignment adjustment is performed (step S6). Here, the focus adjustment refers to the Z-axis direction and the X-axis as the center when the direction in which the liquid crystal panel 441G is brought close to and away from the cross dichroic prism 460 is the Z-axis direction, and the two axes orthogonal thereto are the X and Y axes. And the rotation direction (Yθ direction) around the Y axis. The alignment adjustment means adjustment in the X-axis direction, the Y-axis direction, and the rotational direction (θ direction) in the XY plane.

  In Steps S5 and S6, after the position adjustment of the liquid crystal panel 441G is completed, the CPU of the computer 6 drives and controls a fixing ultraviolet light source device (not shown), irradiates ultraviolet rays through the optical fibers 38 and 39, and pins 445 The ultraviolet curable adhesive at the tip is cured (step S7). Thereafter, an image signal is output to start position adjustment of the next liquid crystal panel 441R, and the above steps S4 to S7 are repeated until position adjustment of all the liquid crystal panels 441R, 441G and 441B is completed (step S8). . The ultraviolet irradiation may be performed simultaneously when the focus / alignment adjustment of all the liquid crystal panels 441R, 441G, and 441B is completed.

[Effect of the embodiment]
The embodiment described above has the following effects.
(1) The manufacturing method of the optical device 600 includes the optical axis positioning step S1, and in this optical axis positioning step S1, the positioning plate installation procedure S13 and the detection unit initial position setting procedure S172 are performed. In the initial part position setting procedure S172, the four screen devices 522 can be arranged symmetrically with respect to the illumination optical axis set in the manufacturing apparatus 1, and the initial position can be set as the reference position. Thus, by moving the four screen devices 522 by a predetermined dimension from this state, the four screen devices 522 are arranged at positions corresponding to the screen size of the rear projector 100 on which the optical device 600 to be manufactured is mounted. The four screen devices 522 can reliably detect a part of the optical image projected from the optical unit 400. The optical device 600 can be easily manufactured by driving and controlling the 6-axis position adjustment unit 22 based on the detected image and adjusting the position of each light modulation device 440 with respect to the cross dichroic prism 460.

(2) The position adjustment of each light modulation device 440 with respect to the cross dichroic prism 460 is performed by the six-axis position adjustment unit 22 while detecting the optical images projected from the optical unit 400 by the four screen devices 522. The position of each light modulation device 440 can be adjusted in a state where the optical axis of the optical image projected from the projection lens 480 matches the illumination optical axis set in the manufacturing apparatus 1. As described above, the method of using the master lens as the projection lens 480 is not adopted, and the projection lens 480 is included in the adjustment target. Therefore, it is possible to adjust the position of each light modulation device 440 including manufacturing variations of the projection lens 480. Therefore, when the optical device 600 manufactured by this manufacturing method and the optical unit 400 including the projection lens 480 are installed in the casing 500 of the rear projector 100, the optical unit 400 and the transmissive screen 200 are positioned. It can be carried out with high accuracy, and the left and right and top and bottom margins can be secured appropriately.

(3) Since the initial position of the four screen devices 522 is set to the reference position in the initial position setting procedure S162, the optical device to be manufactured is moved by moving the four screen devices 522 by a predetermined dimension from this state. The four screen devices 522 can be appropriately arranged at positions corresponding to the screen size of the rear projector 100 on which the 600 is mounted, and various optical devices 600 can be easily manufactured according to the rear projector 100 having different screen sizes.

(4) In the optical axis positioning step S1, the tilt state detection unit installation procedure S14, the measurement light emission procedure S152, the return light detection procedure S153, and the mirror attitude adjustment procedure S155 are performed, so the optical path adjustment mirror body 241 is manufactured. Positioning can be performed with respect to the illumination optical axis set in the apparatus 1. Thus, even when the projection direction of the projection lens 480 is not the horizontal direction and the optical image is projected at a predetermined angle with respect to the emission direction of the optical image from the cross dichroic prism 460, An optical image emitted from the projection lens 480 by the optical path adjusting mirror main body 241 can be reflected along the illumination optical axis set in the manufacturing apparatus 1 and appropriately projected onto the screen member 522A of the screen device 522.

(5) In response to the screen size of the rear projector 100 on which the optical device 600 to be manufactured is mounted, the attitude of the optical path adjustment mirror can be adjusted in the mirror attitude adjustment procedure S155, and the rear projector 100 having a different screen size can be used. Accordingly, various optical devices 600 can be easily manufactured.

(6) In the optical axis positioning step S1, before the positioning plate installation procedure S13 and the detection unit initial position setting procedure S172, the inclination state detection unit installation procedure S11, the measurement light emission procedure S121, the return light detection procedure S122, and the support Since the frame posture adjustment procedure S124 is performed, the projection unit body 5 can be positioned with respect to the illumination optical axis set in the manufacturing apparatus 1. Accordingly, by adjusting the attitude of the projection unit body 5 with respect to the illumination optical axis, the screen device 522 supported by the support frame 521 of the projection unit body 5 can be positioned with higher accuracy. it can. Therefore, the position adjustment of each light modulation device 440 with respect to the cross dichroic prism 460 is performed by the six-axis position adjustment unit 22 while the optical image is detected by the screen device 522 in which the optical axis positioning is performed with high accuracy. Thus, the position of each light modulation device 440 can be adjusted with higher accuracy in a state where the optical axis of the optical image projected from the projection lens 480 matches the illumination optical axis set in the manufacturing apparatus 1. For this reason, when the manufactured optical device 600 and the optical unit 400 including the projection lens 480 are installed in the casing 500 of the rear projector 100, the positioning of the optical unit 400 and the transmission screen 200 is further highly accurate. The margin amount on the left, right, top and bottom can be secured more appropriately.

(7) Since the optical axis positioning jig 3 includes the positioning plate 31 having the ground glass 312 on which the parting frame 312A is formed, the optical screen positioning jig 3 performs positioning with respect to the illumination optical axes of the four screen devices 522. In this case, the optical axes of the four screen devices 522 can be easily positioned with the simple structure as described above without using a jig having a complicated shape.

(8) The optical axis positioning jig 3 includes a second positioning unit 33 that supports and fixes the tilt state detection unit 34 at a predetermined angle in the front stage of the optical path of the optical path adjustment unit 24. The second positioning unit 33 has an angle for supporting and fixing the tilt state detection unit 34 according to the optical device 600 to be manufactured. As a result, when manufacturing an optical device corresponding to a rear projector having a different screen size, the second positioning unit 33 having an angle corresponding to the optical device is used, so that the optical path adjustment mirror main body 241 is fixed to a predetermined size. Appropriate adjustments can be made to the posture corresponding to the screen size. Therefore, the second positioning unit 33 can easily manufacture various optical devices corresponding to the rear projector 100 having different screen sizes.

(9) The optical apparatus manufacturing apparatus 1 includes a mirror attitude adjustment unit 242 that adjusts the attitude of the optical path adjustment mirror main body 241. The mirror attitude adjustment unit 242 includes an out-of-plane rotation attitude adjustment unit 243 and a Z-axis attitude adjustment unit. 244 and an X-axis posture adjustment unit 245. Accordingly, the posture adjustment of the optical path adjustment mirror main body 241 is appropriately performed based on the inclination state of the optical path adjustment mirror main body 241 with respect to the illumination optical axis detected by the inclination state detection unit 34 constituting the optical axis positioning jig 3. Can be implemented. Further, since the optical path adjustment mirror main body 241 can be adjusted in the direction of rotation about the Z-axis direction, the X-axis direction, and the Y-axis, the optical path adjustment mirror main body 241 has an appropriate attitude according to the rear projector having a different screen size. Can be adjusted.

(10) The rear projector 100 can project an optical image with an appropriate margin amount secured onto the transmissive screen 200 via the projection lens 480, so that, for example, the projection of the projection lens 480 is adjusted and projected onto the transmissive screen 200. An adjustment mechanism for adjusting the contour of the optical image to be adjusted, or an adjustment mechanism for adjusting the contour of the optical image projected on the transmission screen 200 by adjusting the attitude of the optical unit 400 as a whole is unnecessary. 100 can be simplified, and the manufacturing cost of the rear projector 100 can be reduced.

[Modification of Embodiment]
In addition, this invention is not limited to the said embodiment, Including other structures etc. which can achieve the objective of this invention, the deformation | transformation etc. which are shown below are also contained in this invention.
In the embodiment, when the four screen devices 522 are set to the initial positions, the four screen devices 522 are projected from the optical unit 400 in the vicinity of the positioning plate 31 of the optical axis positioning jig 3. Although the CCD camera 522B is moved to a position where the parting frame image of the parting frame 312A projected by the light beam can be directly detected, the present invention is not limited to this, and the following configuration may be employed.
For example, with the screen member 522A of the screen device 522 attached, the screen device 522 is brought close to the parting frame 312A of the positioning plate 31, and the parting frame image projected on the screen member 522A is moved to a detectable position. It is good also as a structure.
Further, for example, the positioning plate 31 is installed not in the UV light shielding cover 21 of the adjustment unit main body 2 but in a predetermined position in the dark room 51 of the projection unit main body 5. Then, the screen device 522 is moved to a position where the parting frame image of the parting frame 312A projected by the light beam projected from the optical unit 400 can be detected. In such a configuration, for example, the screen device 522 is moved in the Y-axis direction and the Z-axis direction shown in FIG. 15 without moving the screen device 522 close to the positioning plate 31. Can be set to the initial position.

In the embodiment, the image forming unit is configured by the plurality of screen members 522A. However, the image forming unit is not limited thereto, and may be configured by a single screen member that projects the entire optical image projected from the optical unit 400. Good.
In the above-described embodiment, the parting frame 312A has only to be symmetrically arranged around a predetermined position, and a configuration in which the parting frame 312A is continuously formed in a frame shape may be employed. Further, the size of the parting frame 312A only needs to be the reference position of the four screen devices 522, and is not limited to the size described in the above-described embodiment. Further, the positioning plate 31 is provided with a ground glass 312 which is a translucent member, and the parting frame 312A is formed on the ground glass 312. A parting frame may be formed so as to be directly detectable at 522B. With such a configuration, the positioning plate 31 can be easily manufactured.

  In the embodiment, the method for manufacturing the optical device is not limited to the flow shown in FIGS. For example, the positioning plate installation procedure S13 may be performed after the mirror posture adjustment procedure S155. That is, since the positioning with respect to the illumination optical axis of the projection unit body 5 is performed in the support frame posture adjustment procedure S124, the laser light emitted from the tilt state detection unit 34 is reflected for adjustment by the optical path adjustment mirror body 241. The mirror 241B2 and the adjustment mirror 521C of the support frame 521 return to the tilt state detection unit 34, and by detecting this return light, the optical path adjustment mirror body 241 can be positioned with respect to the illumination optical axis.

  In the embodiment, the support frame posture adjustment unit is configured as the caster 511 </ b> A of the projection unit main body 5, but is not limited thereto. For example, if an adjustment mechanism capable of adjusting the posture of the support frame 521 in the tilting direction is provided and the posture adjustment of the support frame 521 is performed by drive control by the computer 6, the position of the support frame 521 relative to the illumination optical axis can be determined. It can be carried out by automatic control without being carried out manually, and the positioning of the support frame 521 with respect to the illumination optical axis can be carried out with high accuracy and speed.

  In the above embodiment, the optical path adjustment mirror 241B is composed of five mirrors, but is composed of a single mirror so that the entire optical image projected from the optical unit 400 is reflected toward the projection unit body 5. May be.

Although the best configuration for carrying out the present invention has been disclosed in the above description, the present invention is not limited to this. That is, the invention has been illustrated and described primarily with respect to particular embodiments, but may be configured for the above-described embodiments without departing from the scope and spirit of the invention. Various modifications can be made by those skilled in the art in terms of materials, quantity, and other detailed configurations.
Therefore, the description limited to the shape, material, etc. disclosed above is an example for easy understanding of the present invention, and does not limit the present invention. The description by the name of the member which remove | excluded the limitation of one part or all of such restrictions is included in this invention.

  The method for manufacturing an optical device and the device for manufacturing an optical device according to the present invention can be used for a rear projector because an optical device capable of securing a margin amount on a transmission screen can be manufactured by adjusting an optical axis position with high accuracy. It is useful as a manufacturing method and a manufacturing apparatus for manufacturing an optical device.

1 is a longitudinal sectional view showing a rear projector on which an optical device according to an embodiment of the present invention is mounted. The figure which shows typically the optical system of the optical unit in the said embodiment. The disassembled perspective view which shows the structure which attaches a liquid crystal panel to the cross dichroic prism in the said embodiment. The side view which shows the attachment structure of the cross dichroic prism in the said embodiment. The side view which shows the manufacturing apparatus of the optical apparatus in the said embodiment. The top view which shows the manufacturing apparatus of the optical apparatus in the said embodiment. The side view which shows the structure of the 6-axis position adjustment unit in the said embodiment. The figure which shows the structure of the optical path adjustment mirror main body in the said embodiment. The figure which shows the structure of the optical path adjustment mirror main body in the said embodiment. The figure which shows schematic structure of the Z-axis attitude | position adjustment part in the said embodiment. The figure which shows schematic structure of the X-axis attitude | position adjustment part in the said embodiment. The figure which shows schematic structure of the X-axis attitude | position adjustment part in the said embodiment. The side view which shows the structure of the light source unit in the said embodiment. The figure which shows schematic structure of the 1st positioning part in the said embodiment. The figure which shows schematic structure of the screen unit in the said embodiment. The figure which shows typically the control structure of the manufacturing apparatus by the computer in the said embodiment. The flowchart for demonstrating the manufacturing method of the optical apparatus in the said embodiment. The flowchart for demonstrating the position adjustment of the optical axis position of the manufacturing apparatus in the said embodiment. The figure for demonstrating the position adjustment of the optical axis position of the manufacturing apparatus in the said embodiment. The figure for demonstrating the position adjustment of the optical axis position of the manufacturing apparatus in the said embodiment. The figure for demonstrating the position adjustment of the optical axis position of the manufacturing apparatus in the said embodiment. The figure for demonstrating the position adjustment of the optical axis position of the manufacturing apparatus in the said embodiment.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Manufacturing apparatus, 3 ... Optical-axis positioning jig, 100 ... Rear projector, 22 ... 6-axis position adjustment unit (position adjustment part), 23 ... Clamp jig (mounting table) , 31 ... Positioning plate, 32 ... First positioning part, 33 ... Second positioning part, 34 ... Inclined state detecting part, 200 ... Transmission screen, 241B ... Optical path adjustment mirror, 242 ... Mirror posture adjustment unit, 243 ... Out-of-plane rotation posture adjustment unit, 244 ... Z-axis posture adjustment unit, 245 ... X-axis posture adjustment unit, 312A ... Frame, 313 ... Adjustment mirror, 322 ... Support surface, 411 ... Light source device, 420 ... Color separation optical device, 440 ... Light modulation device, 460 ... Cross dichroic prism (color) Synthetic optical device), 480... Projection lens ( Imaging optical device), 500... Casing, 511A... Caster (support frame attitude adjustment unit), 521... Support frame, 521C. ) 522B: CCD camera (image detection device), 600: optical device, S1: optical axis positioning step, S11, S14: inclination state detection unit installation procedure, S13: positioning Plate installation procedure, S121, S152 ... Measurement light emission procedure, S122, S153 ... Return light detection procedure, S124 ... Support frame posture adjustment procedure, S155 ... Mirror posture adjustment procedure, S172 ... Detection Initial position setting procedure.

Claims (13)

An optical system comprising a plurality of light modulation devices that form an optical image by modulating a plurality of color lights for each color light according to image information, and a color combining optical device that combines the optical images modulated by the light modulation devices. In order to manufacture an apparatus, an optical image enlarged and projected by a projection optical apparatus through the color synthesis optical apparatus is projected onto an image forming unit, and the projected optical image is detected by a plurality of image detection units, and the detected image is detected. A method of manufacturing an optical device for positioning and fixing each light modulation device with respect to the color synthesis optical device based on
Before manufacturing the optical device, comprising an optical axis positioning step for positioning the optical axis position in the manufacturing apparatus for manufacturing the optical device using an optical axis positioning jig,
The plurality of image detection units are configured to be movable,
The optical axis positioning jig is configured to include a positioning plate having a parting frame that is a reference position of the plurality of image detection units and is symmetrically arranged with respect to a predetermined position.
In the optical axis positioning step, the positioning plate is placed so as to be orthogonal to the illumination optical axis set in the manufacturing apparatus and to make the center position of the parting frame of the positioning plate coincide with the illumination optical axis. Positioning plate installation procedure to be installed in the manufacturing apparatus, and moving the plurality of image detection units to a position where the parting frame of the positioning plate can be detected, and setting the plurality of image detection units to an initial position And a detection unit initial position setting procedure to be set. In the manufacturing method of the optical device according to claim 1,
An optical image enlarged and projected by the projection optical device is reflected toward the image forming unit by an optical path adjustment mirror configured to be freely adjustable in posture,
An adjustment mirror for adjusting the posture of the optical path adjustment mirror is provided at the center position of the parting frame of the positioning plate,
The optical axis positioning jig includes a tilt state detection unit that detects the tilt state of the measurement target by emitting the measurement light to the measurement target and detecting return light via the measurement target. And
In the optical axis positioning step, the tilt state detection unit is arranged in the manufacturing apparatus so that the optical axis of the measurement light emitted from the tilt state detection unit coincides with the illumination optical axis. An inclination state detection unit installation procedure, a measurement light emission procedure for causing the inclination state detection unit to emit measurement light to the optical path adjustment mirror, and return light via the optical path adjustment mirror and the adjustment mirror. Based on the return light detection procedure to be detected and the inclination state of the optical path adjustment mirror with respect to the illumination optical axis according to the detection position of the return light detected in the return light detection procedure A method for manufacturing an optical device, comprising: a mirror attitude adjustment procedure that performs the following. In the manufacturing method of the optical device according to claim 1 or 2,
The optical axis positioning jig includes a tilt state detection unit that detects the tilt state of the measurement target by emitting the measurement light to the measurement target and detecting return light via the measurement target. And
The optical image emitted from the projection optical device is rectangular, the image forming unit is composed of a plurality of screen members arranged at corner portions of the projection optical image, and the plurality of image detection units are: Arranged integrally on the back surface of each of the plurality of screen members,
The plurality of screen members and the plurality of image detection units are supported by a support frame configured to be adjustable in posture,
The support frame is provided with an adjustment mirror so as to be parallel to the projection surface of the screen member at a position corresponding to the illumination optical axis set in the manufacturing apparatus,
In the optical axis positioning step, the optical axis of the measurement light emitted from the tilt state detection unit is made to coincide with the illumination optical axis before the positioning plate installation procedure and the detection unit initial position setting procedure. Inclination state detection unit installation procedure for installing the inclination state detection unit in front of the optical path of the image forming unit in the manufacturing apparatus, and measurement light emission procedure for causing the inclination state detection unit to emit measurement light to the support frame A return light detection procedure for detecting return light via the adjustment mirror of the support frame, and the support frame relative to the illumination optical axis according to the detection position of the return light detected in the return light detection procedure. And a support frame posture adjustment procedure for adjusting the posture of the support frame based on an inclined state. An optical system comprising: a plurality of light modulation devices that form an optical image by modulating a plurality of color lights for each color light according to image information; and a color combining optical device that combines the optical images modulated by the light modulation devices. An optical axis positioning jig for performing positioning of an optical axis position in a manufacturing apparatus for manufacturing the optical apparatus in order to manufacture the apparatus,
A positioning plate having a parting frame arranged symmetrically around a predetermined position;
The positioning plate is made detachable, and the positioning plate is manufactured so as to be orthogonal to the illumination optical axis set in the manufacturing apparatus and so that the center position of the parting frame coincides with the illumination optical axis. An optical axis positioning jig comprising a first positioning unit installed in the apparatus. In the optical axis positioning jig according to claim 4,
An adjustment mirror is provided at the center position of the parting frame of the positioning plate,
A tilt state detector that emits measurement light to the measurement target and detects the tilt state of the measurement target by detecting return light through the measurement target;
The tilt state detection unit is placed at a predetermined angle in a state where the optical axis of the measurement light emitted from the tilt state detection unit coincides with the illumination optical axis in front of the optical path of the positioning plate and the first positioning unit. And a second positioning portion that is supported and fixed by
The tilt state detection unit is measured with respect to a measurement object constituting the manufacturing apparatus disposed between the tilt state detection unit and the optical path of the positioning plate in a state of being supported and fixed to the second positioning unit. Light is emitted, and return light is detected via the measurement object and the adjustment mirror of the positioning plate, and the tilt state of the measurement object with respect to the illumination optical axis is detected according to the position of the detected return light. An optical axis positioning jig characterized by that. In the optical axis positioning jig according to claim 5,
The optical axis positioning jig, wherein the second positioning unit has the angle set according to an optical device to be manufactured. In the optical axis positioning jig according to any one of claims 4 to 6,
A tilt state detector that detects the tilt state of the measurement target by emitting measurement light to the measurement target and detecting return light through the measurement target,
The first positioning unit is formed with a support surface that supports and fixes the tilt state detection unit in a state where the optical axis of the measurement light emitted from the tilt state detection unit is aligned with the illumination optical axis.
The tilt state detection unit is configured to emit measurement light to a measurement target constituting the manufacturing apparatus disposed downstream of the optical path of the tilt state detection unit in a state where the tilt state detection unit is supported and fixed to the support surface of the first positioning unit. An optical axis locating jig that emits light, detects return light through the measurement object, and detects an inclination state of the measurement object with respect to the illumination optical axis according to the position of the detected return light . A predetermined illumination optical axis is set inside, a plurality of light modulators for modulating a plurality of color lights for each color light according to image information to form an optical image, and an optical image modulated by each light modulator An optical device manufacturing apparatus for manufacturing an optical device including a color combining optical device to be combined,
An optical axis positioning jig according to any one of claims 4 to 7,
A mounting table on which the color combining optical device and a projection optical device that magnifies and projects an optical image via the color combining optical device;
An image forming unit on which an optical image emitted from the projection optical device is projected;
A plurality of image detection units configured to be movable and detecting an optical image projected on the image forming unit from a back side of the image forming unit;
A position adjustment unit that performs position adjustment of the plurality of light modulation devices with respect to the color synthesis optical device based on the images detected by the plurality of image detection units;
The plurality of image detection units are moved to a position where the parting frame of the positioning plate constituting the optical axis positioning jig can be detected before the optical device is manufactured, and the initial position is set to the reference position. An optical device manufacturing apparatus. In the manufacturing apparatus of the optical device according to claim 8,
An optical path adjusting mirror disposed between the optical paths of the projection optical device and the image forming unit and reflecting an optical image emitted from the projection optical device toward the image forming unit;
A mirror attitude adjustment unit for adjusting the attitude of the optical path adjustment mirror,
An adjustment mirror is provided at the center position of the parting frame of the positioning plate constituting the optical axis positioning jig,
The optical axis positioning jig is supported and fixed at a predetermined angle in a state where the optical axis of the measurement light to be emitted coincides with the illumination optical axis, in addition to the positioning plate, in front of the optical path of the optical path adjustment mirror. Measuring light is emitted to the optical path adjustment mirror, and the return light through the optical path adjustment mirror and the positioning plate adjustment mirror is detected to detect the tilt state of the optical path adjustment mirror with respect to the illumination optical axis. Including a tilt state detection unit that
The mirror attitude adjustment unit adjusts the attitude of the optical path adjustment mirror based on the inclination state of the optical path adjustment mirror with respect to the illumination optical axis detected by the inclination state detection unit constituting the optical axis positioning jig. An apparatus for manufacturing an optical device. In the manufacturing apparatus of the optical device according to claim 9,
The mirror attitude adjustment unit sets two axes orthogonal to each other to make the optical path adjustment mirror close to and away from the projection optical apparatus as a Z axis and an X axis, and sets an axis orthogonal to the Z axis and the X axis as a Y axis. An out-of-plane rotation attitude adjustment unit that rotates the optical path adjustment mirror around the Y axis, a Z axis attitude adjustment unit that moves the optical path adjustment mirror in the Z axis direction, and the X axis direction. An apparatus for manufacturing an optical device, comprising: an X-axis posture adjustment unit that moves an optical path adjustment mirror. In the manufacturing apparatus of the optical apparatus in any one of Claims 8-10,
The optical image emitted from the projection optical device is rectangular, and the image forming unit is composed of a plurality of screen members arranged at corner portions of the optical image, and the plurality of image detection units are It is integrally arranged on the back surface of each of the plurality of screen members,
A support frame that supports the screen member and the image detection unit; and a support frame posture adjustment unit that adjusts the posture of the support frame.
The support frame is provided with an adjustment mirror at a position corresponding to the illumination optical axis so as to be parallel to the projection surface of the screen member,
In addition to the positioning plate, the optical axis positioning jig is supported and fixed in a stage preceding the optical path of the support frame in a state where the optical axis of the emitted measurement light coincides with the illumination optical axis. A tilt state detector that detects the tilt state of the support frame with respect to the illumination optical axis by emitting measurement light and detecting return light via the adjustment mirror of the support frame,
The support frame attitude adjustment unit adjusts the attitude of the support frame based on an inclination state of the support frame with respect to the illumination optical axis detected by an inclination state detection unit constituting the optical axis positioning jig. An optical device manufacturing apparatus.   An optical device manufactured by the method for manufacturing an optical device according to any one of claims 1 to 3.   A light source device, a color separation optical device that separates a light beam emitted from the light source device into a plurality of color lights, an optical device according to claim 12, and a projection for enlarging and projecting an optical image formed by the optical device. An optical device, a light source device, a color separation optical device, a box-shaped housing for housing the optical device, and the projection optical device, and an exposed side surface of any one of the box-shaped housings A rear projector comprising: a transmission screen that projects an optical image enlarged and projected by the projection optical device.

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