As space resources become increasingly constrained, the major space-faring nations are establishing large space target monitoring systems. There is a demand for both the number and the detection capability of space-based optical monitoring equipment. The detection range (i.e., field of view) and parasitic capability (lightweight and small size) of a single optical payload will largely reduce the scale and cost of the monitoring system. Therefore, in this paper, the optic-mechanical system of an ultra-lightweight and ultra-compact space camera and the optical alignment method are investigated around a fully freeform off-axis triple-reversal large field of view (FOV) optical system. The optic-mechanical system optimisation design is completed by adopting the optic-mechanical integration analysis method, and the weight of the whole camera is less than 10 kg. In addition, to address the mounting problems caused by the special characteristics of the freeform surface optical system, a dual CGH coreference alignment method is innovatively proposed. The feasibility of the method is verified by the mounting and testing test, and the test results show that the system wavefront difference is better than 1/10 λ. The imaging test of the space camera and the magnitude test results meet the design requirements of the optical system. The optic-mechanical system design method and alignment method proposed in this paper are instructive for the design and engineering of large field of view full freeform optical loads.
Keywords: freeform optical systems; integrated optomechanical analysis; space optical camera.