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Precision mechanics: exact down to the μ

One example: Precision Mechanics for Higher Level Systems

Application: double camera system for day and night vision

The system must conform to the highest demands of the higher level system in the orientation of both optical axes to each other (parallelism) and to mechanical references (perpendicularity).

Examples for required characteristics:

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Axis parallelism of +/- 1 mrad even under vibration and shock load
Perpendicularity of both optical axes to the reference of the higher level system (HLS) of +/- 300 μrad even under vibration and shock load
Perpendicularity of light-sensitive sensor surface to the optical axes of lenses <3 mrad even under vibration and shock load
Focus upon a defined distance with the highest possible resolution
Temperature stability of optical axes to each other < 0.12 mrad/10 C°
Temperature stability of the optical axes as a reference of the higher level system < 0.4 mrad/10 C°
Temperature range -32 C° to +70 C°

Important approaches:

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Cost-utility analysis
Installation optimization in the higher level system using 3D data exchange
Iterative optimization using modal analysis
Environmental tests during development (temperature and vibration tests)
Mock-ups (e.g. 3D print)

From highly complex to ultracompact

Kappa’s Precision Mechanics area doesn’t only produce the hardened mechanical designs of extremely resistant cameras. The engineers’ core assignments range from highly precise to complex system design.

To name a few examples, cameras are constructed for chassis controls on airplanes and aerodynamic compact models for integration into outer doors of vehicles. Among topics addressed are optical axes, mechanical apertures, motorized drive, vibration isolation,
and temperature stabilization.

Measurement accuracy of 1 μm along all axes are the order of the day. This is true for sensor positioning, but also for mechanical system interfaces as well. Proprietary fixture and measurement equipment construction, for internal as well as external processes at suppliers, fall within the spectrum of tasks as well.

 

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