The Problem with Passive Assembly
Traditional camera assembly uses "passive alignment": screwing the lens to a fixed mechanical position. The problem is tolerance stacking — lens focal length, threads, washers and sensor placement each carry errors that can push the optical axis off the ideal position by arc-minutes. The consequences:
- Inconsistent FOV across one batch — surround stitching misaligns, ADAS calibration drifts
- MTF drops at center and edges — one side sharp, one side blurry
- Deviations grow further through temperature cycling
How AA Active Alignment Works
Before the lens is glued to the sensor, the AA process runs the module live:
- The module aims at a test chart (concentric circles / star target), computing MTF and optical-axis offset in real time
- A six-DOF micro-adjustment stage moves the lens relative to the sensor based on feedback (X/Y shift, tilt, rotation, and Z for focus)
- When MTF and optical axis both hit target, UV adhesive cures instantly to lock
- Post-cure re-testing rejects out-of-spec units
Because position is adjusted by watching results, mechanical tolerances are eliminated in a closed loop; volume FOV deviation is far smaller than with passive assembly.
Why Automotive Especially Needs AA
- ADAS calibration depends on FOV consistency: one calibration parameter set runs on all production vehicles; large FOV dispersion means per-vehicle calibration costs
- Surround stitching accuracy: viewing-angle deviation among four cameras shows up directly as bird's-eye seam misalignment
- Wide-temperature reliability: after AA curing, the optical axis stays stable through -40℃~+105℃ cycling
TSIMSAFE's AA Line
TSIMSAFE operates AA focusing process zones 1/2/3 with a Class-1000 cleanroom, Class-100 front-stage assembly, curing treatment and a camera test room; 100% imaging tests before shipment. That is the confidence behind our promise that "volume units match the samples." See the ODM Customization Service.
