Building optical systems
Overview
This standard identifies the competences you need to build an optical system, in accordance with approved procedures. You will be required to handle and assemble high precision components to carry out the tasks. You will be expected to use a variety of assembly methods and techniques. From the process carried out, you will be expected to record assembly data relating to the optical system you have built.
Your responsibilities will require you to comply with organisational policy and procedures for the build/assembly activities undertaken, and to report any problems with these activities, or with the tools and equipment used that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying build/assembly practices for optical systems. You will understand the various assembly techniques used, and their application. You will know how to apply and interpret information obtained from the build drawings/specifications, in adequate depth to provide a sound basis for carrying out the assembly activities, identifying and correcting faults and ensuring that the completed assembly meets the specification requirements.
You will understand the safety precautions required when carrying out the assembly activities. You will be required to demonstrate safe working practices throughout, and will understand your responsibility for taking the necessary safeguards to protect yourself and others in the workplace.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow the relevant instructions, assembly drawings and any other specifications
- ensure that the specified components are available and that they are in a usable condition
- use the appropriate methods and techniques to assemble the components in their correct positions
- secure the components using the specified connectors and securing devices
- check the completed assembly to ensure that all operations have been completed and that the finished assembly meets the required specification
- complete the required production documentation
- deal promptly and effectively with problems within your control and report those that cannot be solved
Knowledge and Understanding
You need to know and understand:
- how to work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- regulations with regard to the substances used in the assembly process
- the hazards associated with producing optical assemblies, and how to minimise them and reduce any risks
- the personal protective equipment (PPE) and clothing to be worn during the assembly activities
- how to extract and use information from engineering drawings, specifications, manufacturers' manuals (to include symbols and conventions to appropriate standards) in relation to work undertaken
- how to extract the necessary information in order to fit and align the various optical assemblies and electrical and electronic components
- the general principles of optical, electrical and electronic assembly techniques; the purpose and function of the components (including identification systems such as colour codes, manufactures specification)
- preparations to be undertaken on the optical, electrical and electronic components prior to fitting them into the assembly
- the correct component handling procedures (including relevant handling equipment and procedures to avoid electrostatic discharge (ESD))
- the assembly and securing methods and procedures to be used, and the importance of adhering to these procedures
- how the components are to be routed, aligned, adjusted and positioned prior to securing, and the tools and equipment that are used for this
- the importance of using the specified optical, electrical and electronic components and securing devices for the assembly, and why you must not use substitutes
- the quality control procedures to be followed during the assembly operations
- how to conduct any necessary checks to ensure the accuracy, position, security, function, completeness and electrical continuity of the assembly
- how to detect assembly defects, and what to do to rectify them
- how to check that the tools and equipment to be used are correctly calibrated and are in a safe and serviceable condition
- the importance of ensuring that all tools are used correctly and within their permitted operating range
- the importance of ensuring that all tools, equipment and components are returned to their correct location on completion of the assembly activities
- problems with the assembly operations, and the importance of informing appropriate people of non- conformances
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
Scope/range
Scope Performance
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- Carry out all of the following during the assembly activities:
- obtain and interpret correctly the documentation for the type of optical system being assembled
- adhere to procedures or systems in place for risk assessment, personal protective equipment and other relevant laser safety regulations and procedures to realise a safe system of work
- check that all tools and test equipment to be used are within their calibration dates
- provide and maintain safe access and working arrangements for the work area
- carry out the assembly activities using safe and approved techniques and procedures
- return all tools and equipment to the correct location on completion of the assembly activities
- leave the equipment and work area in a safe and clean condition on completion of the assembly activities
- dispose of any waste items in a safe and environmentally acceptable manner
- Carry out the assembly of one of the following types of optical system:
- sensing
- measuring
- data
- imaging
- display
- other specific optical system
- Use six of the following types of component in the assembly:
- cables and wires
- sensors
- earthing devices
- instrumentation
- plugs
- motors
- circuit boards
- relays
- sockets
- lamps/lighting
- optical components
- mechanical components
- switches
- junction boxes
- electronic modules
- other specific component
- Prepare for the assembly activities, to include carrying out all of the following:
- obtain all the required optical system components and check that they are undamaged and fit to use
- obtain all the required tooling and assembly jigs/fixtures
- preparation and alignment of fixtures to correct accuracy using an appropriate metrology method
- obtain and prepare any necessary adhesives for the assembly operation
- obtain and prepare any cleaning materials required for the assembly operation
- Assemble an optical system, to include carrying out eight of the following:
- positioning the housing, ensuring correct seating
- setting up the correct datums, using an appropriate metrology
- positioning and locating the optical components along the optical axis, avoiding generating debris, and ensuring correct seating
- performing any alignment checks required (such as centring)
- priming any surfaces to be bonded
- applying the adhesive according to the approved method
- monitoring the components during the curing of the adhesive
- removing any excess adhesive and performing a final clean
- making further alignment checks and tests
- fitting appropriate mechanical fastening devices, tightened to the required torque
- making all required electrical connections and correctly routeing cables and wires
- Carry out the required checks, using the correct tools and equipment, to include all of the following:
- completeness of the assembly
- freedom from damage or foreign objects
- position and alignment of optical components
- component security
- electrical inputs and outputs
- electronic inputs and outputs
- assembly function
- Assemble optical imaging systems in compliance with one of the following standards:
- standards and procedures
- customer (contractual) standards and requirements
- company standards and procedures
- specific equipment requirements/manufacturer's data
- recognised compliance agency/body's standards
- other accepted international standards