针对某型号头盔显示器光学系统的封装要求，研究了光学镜片的加工、检测及装配工艺特点，提出了一种能很好解决离轴光学系统装配难题的方法，并结合现代制造工艺水平，设计了相应的五自由度装调设备。经误差分析及控制系统对导轨误差的主动补偿，设备的角度调整精度为3.15″，位移调整精度约为1 μm。光学镜筒采用曲面造型，为薄壁对开式结构。选用铝合金材料，装配完成后单个镜筒总质量195 g，最大应力为1.5 MPa，最大变形0.3 μm，满足设计要求。

To meet the assembling requirements of the optical system of a certain Helmet Mounted Display(HMD), features of the lens in manufacturing, testing and assembly were investigated. And finally, an effective way that could solve problems in assembly of off-axis optical system was proposed. With modern production technologies, an adjusting device with five degrees of freedom was designed. After error analysis and active compensation to parallelism error of guide rail, the adjusting precision of angle for the device is 3.15″, while the displacement adjusting accuracy is about 1μm. Furthermore, surface modeling was brought into the design of lens tube, which adopted a thin shell and was divided in two parts, to get compact structure. After comparison, aluminum alloy was selected as the material for lens tube, and some essential analyses were given to the single tube unit. The results showed that the total mass of the tube unit is 195 g, while the maximum stress acting on it is only 1.5 MPa, with the deformation of 0.3 μm. It turned out that the solution satisfied the requirements of design.