Analysis of the Design and Manufacturing Technology of Liquid Lenses

Liquid lenses represent a groundbreaking advancement in optical technology, providing flexible and high-performance solutions for various industrial applications. One of the notable innovations in this field is the BASSON liquid telecentric lens series. This series is renowned for its exceptional performance characteristics, including high telecentricity, low distortion rate, cost efficiency, and suitability for high magnification and deep depth of field (DOF) measurements. The BASSON series stands out due to its ability to address the rigorous demands of industrial measurement while maintaining compatibility with standard C-mount telecentric lenses and accommodating industrial cameras with sensors up to 2/3" (11.5mm diagonal).

The primary advantage of liquid lenses lies in their innovative design, which harnesses the properties of liquid optics to achieve exceptional performance characteristics. Unlike traditional solid lenses, which use fixed glass or plastic elements, liquid lenses incorporate a liquid droplet as the core optical component. This liquid droplet is enclosed in a flexible, transparent membrane and can be precisely manipulated to adjust the lens's focal length. The ability to dynamically alter the focal length offers unparalleled versatility and precision, making liquid lenses ideal for applications that require rapid and accurate focusing adjustments.

The BASSON series leverages this dynamic adjustment capability to deliver high levels of telecentricity, an essential feature for precise industrial measurements. Telecentric lenses are designed to ensure that light rays entering the lens are parallel, regardless of their position within the field of view (FOV). This design prevents variations in magnification that can occur with traditional lenses, where light rays converge or diverge, leading to image distortion. By maintaining parallel light rays, telecentric lenses eliminate these distortions and ensure that the size and shape of objects are represented accurately across the entire FOV.

In terms of distortion, the BASSON liquid telecentric lens series excels with a distortion rate of less than 0.05%. This low distortion is crucial for applications requiring precise measurements and high image fidelity. By minimizing distortion, the BASSON lenses ensure that the captured images are true to the actual dimensions of the objects being measured, which is essential for quality control and detailed analysis in industrial settings.

Telecentricity is a critical attribute of the BASSON lens series, distinguished by its remarkable specification of less than 0.05°. This high level of telecentricity is essential for ensuring that the lens delivers consistent magnification across the entire field of view (FOV), regardless of the distance between the lens and the object. In conventional lenses, variations in magnification occur due to the convergence or divergence of light rays as they pass through the lens elements. This leads to distortions and inaccuracies, particularly when dealing with objects at varying distances. However, telecentric lenses like those in the BASSON series are engineered to keep light rays parallel, thus eliminating these distortions and ensuring uniform magnification throughout the FOV.

This characteristic is particularly crucial in applications requiring high magnification and deep depth of field (DOF). In such scenarios, even minor fluctuations in magnification can result in substantial measurement errors, compromising the precision of the results. The BASSON lenses, with their exceptionally tight telecentricity, mitigate these issues by providing a stable and consistent view of the object. This ensures that measurements remain accurate regardless of the object's position within the field of view.

The ability to maintain such tight tolerances means that BASSON lenses are exceptionally well-suited for precision tasks in manufacturing and inspection. In manufacturing environments, where parts and components must adhere to strict dimensional specifications, the consistency provided by telecentric lenses is invaluable. Any discrepancies in measurement can lead to defects or quality issues, making the accuracy of the lens paramount. Similarly, in inspection applications, where detailed analysis and verification of components are required, the high telecentricity ensures that inspectors receive a true and undistorted image of the objects being examined.

Moreover, the BASSON lenses’ superior telecentricity contributes to enhanced image quality and reliability, allowing for precise and repeatable measurements. This is particularly beneficial in automated systems and high-throughput environments, where consistent performance and accuracy are essential for maintaining product quality and operational efficiency.

The BASSON liquid telecentric lens series offers a significant advantage in cost efficiency compared to traditional high-performance lenses, primarily due to the innovative use of liquid lens technology. Traditional lenses, particularly those designed for high precision and performance, often involve complex manufacturing processes and high-quality materials, which drive up production costs. These lenses typically require intricate glass or optical elements, precise alignment, and advanced coatings to achieve optimal performance, all of which contribute to their expensive price tags.

In contrast, the BASSON liquid lenses leverage a simpler yet effective approach by using a liquid droplet as the primary optical element. This design reduces the need for multiple high-cost glass elements and complex manufacturing procedures. The liquid lens technology allows for dynamic adjustment of the focal length by altering the shape of the liquid droplet, which can be achieved through relatively straightforward mechanisms. This flexibility in design not only simplifies the manufacturing process but also minimizes material costs, leading to a more affordable production model.

Despite the reduction in manufacturing costs, the BASSON lenses maintain exceptional optical performance. The liquid lens design does not compromise on quality; instead, it offers a high degree of precision and adaptability. This combination of cost savings and superior performance makes the BASSON lenses a compelling option for industrial applications where budget constraints are a key consideration. In fields such as manufacturing, quality control, and inspection, where high-performance optics are necessary but budget limitations are prevalent, the cost efficiency of the BASSON series provides a valuable solution.

The BASSON liquid telecentric lenses offer a notable advantage with their adjustable working distance, a feature that enhances flexibility in diverse measurement applications. Unlike fixed-working-distance lenses, the ability to modify the working distance within specified limits allows users to adapt the lens to varying operational conditions. This adjustability is crucial in scenarios where the distance between the lens and the object can fluctuate, such as in dynamic manufacturing environments or complex inspection setups.

By allowing adjustments to the working distance, the BASSON lenses enable users to optimize the lens performance for specific measurement needs. This means that regardless of whether the object is closer or further away from the lens, users can fine-tune the lens settings to maintain accurate and consistent imaging. This capability ensures that the performance of the lens is not compromised by changes in the distance, which is particularly beneficial for applications requiring precision and adaptability.

Moreover, the flexibility in working distance facilitates easier integration into various systems and setups, providing a versatile solution for different measurement scenarios. Whether the application involves inspecting parts on an assembly line or measuring objects in a lab setting, the ability to adjust the working distance ensures that the BASSON lenses can meet diverse requirements without sacrificing optical quality or accuracy. This adaptability ultimately enhances the lens's utility and efficiency across a range of industrial and scientific applications.

The BASSON series also features TG+ multi-layer coating, which enhances light transmission and reduces reflections. This high transmittance coating ensures that the maximum amount of light reaches the sensor, improving image clarity and brightness. The multi-layer coating also contributes to the overall optical performance of the lens, further reducing distortion and enhancing image quality.

The BASSON liquid telecentric lenses are engineered with industrial-grade waterproofing, a key feature that significantly enhances their suitability for use in demanding environments. This waterproofing is critical for ensuring that the lenses can reliably function even when exposed to moisture, dust, and other harsh environmental conditions. Such robustness is essential for industrial applications where equipment is often subjected to various forms of contamination and physical stress.

The waterproofing technology integrated into the BASSON lenses provides a protective barrier that prevents water and other fluids from entering the lens housing. This protection is crucial for maintaining optical clarity and performance, as moisture ingress can lead to issues such as lens fogging, reduced image quality, or even permanent damage to the optical components. By effectively sealing out moisture, the lenses retain their high performance and accuracy over time, even in environments where exposure to water or cleaning agents is frequent.

Furthermore, the durability of these lenses extends beyond waterproofing. They are constructed to withstand the physical rigors of industrial settings, including temperature fluctuations, vibrations, and potential impacts. This resilience ensures that the BASSON lenses continue to perform reliably under conditions that would challenge less robust optical systems. Their ability to maintain consistent performance and durability in such environments makes them an excellent choice for applications requiring high reliability, such as quality control, automated inspection systems, and other critical industrial processes. Overall, the industrial-grade waterproofing and inherent robustness of BASSON lenses contribute to their dependable operation and long-term value in challenging industrial settings.

In summary, the BASSON liquid telecentric lens series represents a significant advancement in optical technology, combining the flexibility of liquid lenses with high-performance features such as low distortion, high telecentricity, cost efficiency, and adjustable working distance. The series' compatibility with standard C-mount lenses and its suitability for industrial cameras with sensors up to 2/3" diagonal further enhance its versatility and applicability. With its TG+ multi-layer coating and industrial-grade waterproofing, the BASSON series is poised to meet the demanding requirements of various industrial measurement applications, providing reliable and precise optical solutions.

Basson focuses on machine vision products used for precision measurement and defect detection.

Basson not only provides high-precision bi-telecentric lens systems, telecentric lens systems, telecentric light sources, coaxial illuminations and optical lenses, but also offers customized services.

With products designed in Germany, business planned in the UK and products made in China, Basson is able to provide superior products to customers through its global team. Currently, Basson is in preparation of production and assembly of products in Japan.

Dr. Liu Lu, acting as CTO of Basson, is a PhD degree holder of Oxford University.

Production and testing instruments include optical vacuum coating machines manufactured by Satis in Switzerland and Leybold in Germany, a laser interferometer from Zygo in the US, a spectrophotometer from PerkinElmer in the US, a spherometer from Hofbauer Optik in Germany, a centering instrument from Kyoritsu Electric in Japan, a NC grinding device made by Kojima Engineering in Japan and an automatic centering machine made by Shonan in Japan.