Alignment system and method

An alignment system comprising:

• a base having a feature that accepts a first optical element that emits light;
• a first eccentric element having a through hole that accepts an eccentric assembly comprising:
• (a) a second eccentric element having a feature that accepts a second optical element and the second optical element is attached to the second eccentric element via second attachment means;
• and
• (b) a lens retained inside the second eccentric element through hole wherein the second optical element and the lens form a fixed optical axis for the eccentric assembly;
• wherein
• a. the first eccentric element is engaged with the base via first attachment means;
• b. optical alignment between the first optical element and the fixed optical axis of the eccentric assembly is achieved by rotationally adjusting at least one of the eccentric elements relative to the base;
• and
• c. optical alignment of the entire alignment system is achieved with no greater than two axis of adjustment.

An alignment system comprising:

• a base having a first through hole that accepts a first optical element that emits light;
• a first eccentric element having a second through hole that accepts an eccentric assembly, wherein
• (a) the first eccentric element includes an outward lip and an inside surface lip;
• (b) the second through hole includes a first section, a second section, a third section;
• (c) axis of the third section is eccentric with respect to axis of the second section;
• (d) axis of the second section is eccentric with respect to axis of the first section;
• (e) the first eccentric element is engaged with the base via first attachment means comprising:
• (i) a raised collar and a raised outer lip on the base wherein the first section engages the raised collar;
• (ii) a clamp washer having at least two through holes wherein the clamp washer's outer edge engages the raised outer lip and the clamp washer's inner edge engages the outward lip wherein the clamp washer includes an unsupported region between the outer edge and the inner edge;
• and
• (iii) clamping bolts run through the clamp washer's through holes exert clamping pressure on the clamp washer causing the first eccentric element to be attached to the base;
• wherein
• (f) the first section has an inner diameter that engages with outer diameter of the raised collar and there is sufficient mechanical overlap between the raised collar and the first section to create a physically coupling;
• (g) the second section has an inner diameter that engages with outer surface of the eccentric assembly;
• and
• (h) the third section has an inner diameter that allows a portion of the eccentric assembly to pass through;
• (i) the eccentric assembly is comprising:
• (i) a second eccentric element having a third through hole that accepts a second optical element;
• and
• (ii) a lens retained inside the third through hole;
• (j) the second optical element and the lens form a fixed optical axis for the eccentric assembly;
• (k) the second eccentric element is attached to the second optical element via a nut wherein the nut engages with threads on outer diameter of the second eccentric element;
• (l) the second eccentric element further includes a nose that fits inside and engages the first through hole;
• (m) the nose includes a first nose section with an outer diameter that engages with the second section;
• and a second nose section with an outer diameter that passes though the second through hole and engages with the inside surface lip;
• (n) optical alignment between the first optical element and the fixed optical axis of the eccentric assembly is achieved by rotationally adjusting at least one of the eccentric elements relative to the base;
• and
• (o) optical alignment of the entire alignment system is achieved with no greater than two axis of adjustment.

A method for aligning a set of components comprising:

• providing the alignment system comprising:
• (a) a base having a feature that accepts a first optical element that emits light;
• (b) a first eccentric element having a through hole that accepts an eccentric assembly comprising:
• (i) a second eccentric element having a feature that accepts a second optical element and the second optical element is attached to the second eccentric element via second attachment means;
• and
• (ii) a lens retained inside the second eccentric element through hole wherein the second optical element and the lens form a fixed optical axis for the eccentric assembly;
• wherein the first eccentric element is engaged with the base via first attachment means;
• optical alignment between the first optical element and the fixed optical axis of the eccentric assembly is achieved by rotationally adjusting at least one of the eccentric elements relative to the base;
• and optical alignment of the entire alignment system is achieved with no greater than two axis of adjustment;
• and
• aligning the alignment system by rotationally adjusting at least one of the eccentric elements relative to the base.

A method of making the alignment system of claim 1 comprising:

• providing a base, a first optical element, a second optical element and an eccentric assembly wherein:
• (a) the base includes a feature that accepts the first optical element;
• (b) the first eccentric element includes a through hole that accepts the eccentric assembly;
• (c) the eccentric assembly includes a lens and a second eccentric element having a feature that accepts a second optical element;
• (d) the lens is retained inside the second eccentric element through hole;
• and
• (e) the second optical element and the lens form a fixed optical axis for the eccentric assembly;
• attaching the base to the first eccentric element via first attachment means;
• attaching the eccentric assembly to the second optical element via second attachment means;
• and
• connecting the first eccentric element to the eccentric assembly;
• wherein optical alignment between the first optical element and the fixed optical axis of the eccentric assembly is achieved by rotationally adjusting at least one of the eccentric elements relative to the base;
• and optical alignment of the entire alignment system is achieved with no greater than two axis of adjustment.