【作者】 段炼；

【导师】 周海波；

【作者基本信息】 中南大学 ， 信息器件制造技术与装备， 2025， 博士

【摘要】 同轴型光电器件作为光通信系统的核心组件,其耦合效率和封装工艺直接影响光子传输质量和系统整体性能。伴随超高速光通信技术快速进步,对器件的封装设备和工艺有了更高要求。现有的封装技术与手段在耦合效率、对准精度及焊接稳定性等方面仍存在不少技术障碍,特别是耦合封装时的光功率衰减问题,极大地限制了器件性能的进一步提高,然而,现有的封装技术和方法在耦合效率、对准精度及焊接稳定性等方面仍存在诸多技术难题,尤其是耦合封装过程的光功率衰减问题严重制约了器件性能的进一步提升。本论文面向同轴型光发射组件等有源光器件的精密封装需求,从单模光纤与激光器耦合理论出发,研究光耦合效率优化、精密耦合对准、焊后偏移行为及图像识别补偿技术,以提高光通信器件光子传输质量为目标,实现光器件的自动化快速耦合对准与精密焊接固定。主要研究内容和结论如下:(1)针对光电器件耦合过程中模场失配和机械误差对光耦合效率的影响,本文研究了单模光纤与激光器模场的分布特性及其匹配机制。本文首先进行了理论建模和数值模拟,分析了光纤高斯模场与激光器椭圆模场在尺寸、形状及相对位置上的匹配规律,发现模场失配是耦合效率下降的内在主要原因,尤其在激光器快轴与慢轴尺寸差异较大时。基于上述理论,设计了球面单透镜与非球面多透镜两种模组优化方案。实验结果表明,非球面多透镜模组可有效缓解模场失配,耦合效率从球面单透镜的22%提升至72%。分析了横向、轴向与角度偏移等机械误差对耦合效率造成的影响,建立起光损耗与机械误差二者的数学关系模型,为后续自动对准和误差补偿工作提供理论支撑。(2)针对光器件封装过程中的精密对准需求,设计并实现了多自由度耦合对准系统。系统采用主动找平的方法降低搜索维度,提高耦合对准效率。结合算法优化,提出了一种基于自适应权重粒子群算法的快速对准方法,通过数值模拟与实验验证,其搜索效率显著优于传统爬山法。进一步优化算法性能,提出基于筛选机制的混沌-粒子群复合算法,利用混沌特性增强初始粒子分布的多样性,提升对准效率与稳定性。实验结果表明,该算法在保持高准确率的同时,搜索效率提升90%,鲁棒性提高50%。该研究实现了光器件的快速、可靠耦合对准,为复杂封装环境下的高精度操作提供了技术支持。(3)针对光电器件焊接过程中热应力引起的焊后偏移问题,建立了基于热弹塑性力学的焊后偏移-光功率光-热-应变耦合模型,研究焊接工艺参数对偏移行为及光耦合效率的影响规律。通过有限元模拟与实验验证,形成同轴型焊接的工艺窗口焊枪位置的离焦量偏移对焊点成形及偏移行为影响最为显著,需将纵向偏差控制在80μm以内,离焦量控制在40μm以内。实验发现焊后偏移方向呈向高能量区域偏移的规律性。最终,通过焊接实验与模拟数据,验证了焊接参数、偏移行为与光损耗之间的数学模型有效性,为焊后偏移的调控提供理论支撑。(4)为解决焊后偏移导致的光功率损耗问题,提出了一种基于图像识别的焊后偏移调控方法。通过搭建图像采集系统并采用畸变矫正技术,精准获取焊前与焊后的光器件位置信息。提出自适应二值化Sobel边缘提取算法,用于复杂背景下光器件边缘的精准识别,边缘识别的无误率达到100%,处理一张图像所花时间仅0.43秒。与深度学习模型MPCGnet相结合,进一步增进复杂背景、多焊点和弱能量焊点的辨识能力,实验结果显示,焊点识别的精确率为77.48%,处理的时长为1.87秒。最后将图像识别技术与焊前焊缝检测、焊后焊点监测相结合,构建了一套实时在线监测与补偿系统,成功将光功率损耗控制在0.5d B以内,偏移补偿精度达到最大耦合效率的10%。图93幅,表27个,公式123个,参考文献144篇更多还原

【Abstract】 As a core component of optical communication systems,coaxial optoelectronic devices have their coupling efficiency and packaging process directly influencing the quality of photon transmission and the overall performance of the system.With the rapid advancement of ultra-high-speed optical communication technology,higher requirements have been placed on the packaging equipment and processes of devices.Despite the existing packaging technologies and methods,there are still many technical obstacles in terms of coupling efficiency,alignment accuracy,and welding stability,especially the issue of optical power attenuation during coupling packaging,which greatly limits the further improvement of device performance.This thesis focuses on the precise packaging requirements of active optical devices such as coaxial optical transmitters,starting from the theory of single-mode fiber and laser coupling,and studies the optimization of optical coupling efficiency,precise coupling alignment,post-welding offset behavior,and image recognition compensation technology,with the goal of improving the photon transmission quality of optical communication devices and achieving automated rapid coupling alignment and precise welding fixation of optical devices.The main research contents and conclusions are as follows:The chapter 2 studies the distribution characteristics and matching mechanism of the mode field of single-mode fiber and laser based on the influence of mode field mismatch and mechanical error on the optical coupling efficiency during the coupling process of optoelectronic devices.Firstly,theoretical modeling and numerical simulation were carried out,and the matching rules of the Gaussian mode field of the fiber and the elliptical mode field of the laser in terms of size,shape and relative position were analyzed.It was found that mode field mismatch is the intrinsic main reason for the decrease in coupling efficiency,especially when the size difference between the fast and slow axes of the laser is large.Based on the above theory,two optimization schemes of spherical singlelens and as-pheric multi-lens modules were designed.The experimental results show that the aspheric multi-lens module can effectively alleviate the mode field mismatch,and the coupling efficiency is increased from 22%of the spherical single-lens to 72%.The influence of mechanical errors such as lateral,axial and angular offsets on the coupling efficiency was analyzed,and a mathematical relationship model between optical loss and mechanical error was established,providing theoretical support for subsequent automatic alignment and error compensation work.In chapter 3,to meet the precision alignment requirements in the pack-aging process of optical devices,a multi-degree-of-freedom coupling alignment system was designed and implemented.The system employs an active leveling method to reduce search dimensions and improve alignment efficiency.By integrating algorithm optimization,a rapid alignment method based on an adaptive-weight particle swarm optimization(PSO)algorithm was proposed.Numerical simulations and experimental validation demonstrated that its search efficiency significantly outperforms traditional hill-climbing methods.Further performance improvements were achieved by introducing a chaoticparticle swarm hybrid algorithm based on a screening mechanism.The chaotic characteristics enhance the diversity of initial particle distribution,improving alignment efficiency and stability.Experimental results showed that this algorithm improved search efficiency by 90%and robustness by 50%while maintaining high accuracy.This research enables rapid and reliable coupling alignment of optical devices,providing technical support for high-precision operations in complex packaging environments.In chapter 4,to address the post-welding offset issue caused by thermal stress during the welding process of optoelectronic devices,a post-welding offset-optical power-light-thermal-strain coupling model based on thermoelastic-plastic mechanics was established.The influence of welding process parameters on the offset behavior and optical coupling efficiency was studied.Through finite element simulation and experimental verification,it was found that the defocus amount of the welding gun position in coaxial welding had the most significant impact on the weld formation and offset behavior.The longitudinal deviation should be controlled within 80,and the defocus amount should be controlled within 40.The experiments revealed that the post-welding offset direction showed a regularity of shifting towards the high-energy area.Ultimately,through welding experiments and simulation data,the validity of the mathematical model between welding parameters,offset behavior,and optical loss was verified,providing theoretical support for the regulation of post-welding offset.In chapter 5,to mitigate optical power losses caused by post-welding offset,an image recognition-based offset control method was proposed.A Sobel edge detection algorithm with adaptive binarization was developed for precise edge recognition of optical devices in complex backgrounds,achieving a 100%edge recognition rate with a processing time of only 0.43seconds per image.Further improvements were made using the deep learning model MPCGnet to enhance recognition capabilities for complex back-grounds,multi-weld points,and low-energy weld points.Experimental results showed a weld point recognition accuracy of 77.48%with a processing speed of 1.87 seconds.By integrating image recognition technology with preweld seam detection and post-weld monitoring,a real-time online monitoring and compensation system was developed,successfully limiting optical power loss to within 0.5 dB and achieving offset compensation accuracy within 10%of maximum coupling efficiency.更多还原