Optical lens manufacturing system and method

Abstract

The invention belongs to the field of optical lens manufacturing, and particularly discloses an optical lens manufacturing system and method.The optical lens manufacturing system comprises a flexible forming device, a defect detecting device, an edge grinding device, a cleaning and drying device, a film coating device, a verifying device, a placing device and a mechanical arm which are sequentially arranged; the mechanical arm can move a lens in processing to a corresponding device within the setting range of the flexible forming device, the defect detecting device, the edge grinding device, the cleaning and drying device, the coating device, the verifying device and the placing device. The production efficiency and the space utilization rate are remarkably improved by integrating the procedures of optical lens forming, defect detection, edge grinding, cleaning and drying, film coating, checking, placing and the like and adopting a mechanical arm to achieve automatic connection of all the devices. And meanwhile, the shape of the mold is accurately adjusted by utilizing a deformable mold technology, full-automatic manufacturing of customized lenses such as plane lenses, spherical lenses, aspheric lenses and free-form lenses is realized, and the capability of processing lenses in different shapes by a production line is improved.

Description

Technical Field

[0001] The present invention belongs to the field of optical lens manufacturing, and particularly relates to an optical lens manufacturing system and method. Background Art

[0002] The processing technology of optical lenses includes steps such as forming, milling, fine grinding, polishing, cleaning, edging, coating, and verification. However, currently, each step corresponds to a separate device. For example, in patent CN204019826U, a fully automatic resin lens casting machine is disclosed; in patent CN207807333U, a fully automatic special grinding machine for glass lenses is disclosed; in patent CN207807332U, a high-precision optical lens fully automatic polishing machine is disclosed. There is no connection between devices, and the processing devices corresponding to each step of optical lenses in the prior art are usually large in size and occupy a large area, making it inconvenient to carry out efficient production in a limited space. And during the optical lens gluing process, a forming device is usually used. However, in existing forming devices, different lenses require different molds. Although some deformable molds have been disclosed, the current mold design has not achieved joint control with the curing and forming process of lens resin. Because, in addition to the influence of the mold on the forming accuracy of the lens, during the curing and forming process of lens resin, cross-linked structures are formed between molecular chains, resulting in a decrease in spacing and a shrinkage phenomenon. As a result, the resin breaks away from the constraint of the mold surface and deforms freely, generating uncontrollable random errors, which also cause a decrease in lens accuracy. Summary of the Invention

[0003] In order to solve the technical problems existing in the prior art, the present invention discloses an optical lens manufacturing system and method.

[0004] In order to achieve the above object, the technical solution adopted by the present invention is as follows: In the first aspect, the present invention discloses an optical lens manufacturing system, including: arranged in sequence A flexible forming device, the flexible forming device includes a flexible mold body, the deformation of the flexible mold body is controlled by a plurality of ejector rods, all the ejector rods are driven by the same driving component, the driving component can move to the position where the ejector rod to be adjusted is located, and drive it to perform a macroscopic linear motion at the millimeter level; at the same time, a micro motion driving device is arranged on each ejector rod, and the micro motion driving device drives the ejector rod to perform a microscopic motion at the micron or nanometer level; A coating device for coating the optical lens; A verification device for verifying the optical lens; A robotic arm, the robotic arm is used to move the optical lens between the flexible forming device, the coating device, and the verification device.

[0005] As a further technical solution, the defect detection device includes a vibration isolation table, on the top of which a gantry bracket is provided, on which an image acquisition device is arranged, and a lens to be detected fixing table is arranged below the image acquisition device.

[0006] As a further technical solution, the flexible forming device includes a first flexible die body and a second flexible die body; a lens forming cavity is formed among the first flexible die body, the second flexible die body and the circumferential baffle. The deformation of the first flexible die body is controlled by a plurality of first ejector rods, and all the first ejector rods are driven by the same first driving component. The first driving component can move to the position where the first ejector rod to be adjusted is located and drive it to perform a macroscopic linear motion at the millimeter level. At the same time, a first micro-motion driving device is arranged on each first ejector rod, and the first micro-motion driving device drives the first ejector rod to perform a microscopic motion at the micron or nanometer level. The deformation of the second flexible die body is controlled by a plurality of second ejector rods, and all the second ejector rods are driven by the same second driving component. The second driving component can move to the position where each second ejector rod is located and drive it to perform a macroscopic linear motion at the millimeter level. At the same time, a second micro-motion driving device is arranged on each second ejector rod, and the second micro-motion driving device drives the second ejector rod to perform a microscopic motion at the micron or nanometer level.

[0007] As a further technical solution, the flexible forming device includes a flexible die body; a lens forming cavity is formed between two flexible die bodies and a support member, or a flexible die body, an initial substrate and a circumferential baffle form a lens forming cavity; the deformation driving device of the flexible die body includes a plurality of annular ejecting members, and the plurality of annular ejecting members are sequentially arranged from the center of the flexible die body to the outer circle, covering the entire flexible die. Each annular ejecting member is driven by at least two driving devices. Each driving device drives the annular ejecting member to perform a macroscopic linear motion before the optical resin is cured, and drives the annular ejecting member to perform a microscopic motion during the curing process of the optical resin.

[0008] As a further technical solution, the flexible forming device further includes a vibration isolation table, on which a support frame, an ultraviolet light source lifting table, a second flexible die body support table and a glue coating linear displacement table are arranged. A glue coating support frame is arranged on the glue coating linear displacement table, and a glue spraying gun is arranged on the glue coating support frame; a first flexible die body lifting table is arranged on the side of the support frame, the first flexible die body is installed on the first flexible die body lifting table, and the second flexible die body is installed on the second flexible die body support table; a light source is arranged on the light source lifting table, and the glue spraying gun and the light source are arranged on both sides of the first flexible die body and the second flexible die body. Positioning marking points are arranged on the second flexible die body support table.

[0009] As a further technical solution, the optical lens manufacturing system further includes a defect detection device for detecting a preliminarily formed optical lens.

[0010] As a further technical solution, the optical lens manufacturing system further includes an edging device for edging the optical lens.

[0011] As a further technical solution, the optical lens manufacturing system further includes a cleaning and drying device for cleaning and drying the optical lens.

[0012] As a further technical solution, the optical lens manufacturing system further includes a placement device for placing the optical lens.

[0013] As a further technical solution, the flexible forming device, the defect detection device, the edging device, the cleaning and drying device, the coating device, the verification device, and the placement device are arranged in a ring in sequence, and the robotic arm is installed inside the ring.

[0014] As a further technical solution, the flexible forming device, the defect detection device, the edging device, the cleaning and drying device, the coating device, the verification device, and the placement device are arranged in a ring in sequence, and the robotic arm is installed inside the ring.

[0015] As a further technical solution, the robotic arm includes a robotic arm body, a negative pressure fixture conversion disk is installed at the end of the robotic arm body, a plurality of inclined negative pressure fixture rigid brackets are arranged on the negative pressure fixture conversion disk, and a flexible contact block is arranged at the end of each negative pressure fixture rigid bracket.

[0016] As a further technical solution, a vacuum negative pressure fixture is installed at the end of the robotic arm, and the vacuum negative pressure fixture includes a rigid bracket and a flexible contact block installed on the rigid bracket.

[0017] As a further technical solution, the optical lens manufacturing system further includes a housing, a material inlet and outlet is arranged on the housing, and a fan filter unit is arranged on the top of the housing.

[0018] As a further technical solution, positioning mark points are arranged on the defect detection device, the edging device, the cleaning and drying device, the coating device, the verification device, and the placement device.

[0019] As a further technical solution, based on the above full-automatic lens manufacturing system, the present invention also discloses a manufacturing method, which is as follows: The flexible forming device forms the optical lens; the robotic arm grabs the formed optical lens and moves it to the defect detection device; the defect detection device checks whether the preliminarily formed optical lens has defects. If there are defects, the optical lens is placed in the recycling device. If there are no defects after inspection, the robotic arm places the inspected optical lens in the edge grinding device; the edge grinding device is used to grind the optical lens, and then the robotic arm places it in the cleaning and drying device, which cleans and dries the optical lens; after cleaning and drying are completed, the robotic arm places it in the coating device, which coats the optical lens; after coating is completed, the robotic arm places it in the verification device, which verifies the optical lens; after verification is completed, the robotic arm places it in the placement device.

[0020] The beneficial effects of the present invention are as follows: The present invention provides an optical lens manufacturing system and method. By integrating key processes such as optical lens forming, defect detection, edge grinding, cleaning and drying, coating, verification, and placement, and using a robotic arm to achieve automatic connection between devices, the production efficiency and space utilization rate are significantly improved; at the same time, the shape of the mold is precisely adjusted using deformable mold technology to realize the full-automatic manufacturing of customized lenses such as planar, spherical, and aspherical lenses, improving the ability of the production line to process lenses of different shapes. In addition, the system is equipped with automatic detection, flexible fixtures, and environmental control devices, further enhancing the flexibility, stability, and product yield of production, with the advantages of high efficiency, high precision, and low cost, and is suitable for large-scale production in a limited space, specifically as follows: Process integration: Integrate multiple key processes (flexible forming, defect detection, edge grinding, cleaning and drying, coating, verification, placement) of optical lens manufacturing into the same system to form a complete closed-loop production process, avoiding problems such as poor connection and complex material transfer caused by the dispersion of each process and independent equipment in the traditional production mode; Automatic connection: With the robotic arm as the core, realize the automatic handling and precise positioning of optical lenses between different devices, ensuring the continuity of the production process, reducing manual intervention, and reducing production interruptions and product quality fluctuations caused by human factors; Modular layout: Each device is arranged in a ring in sequence, and the robotic arm is installed inside the ring. This layout enables the robotic arm to efficiently transfer materials between each device, and at the same time facilitates centralized management and maintenance of each device, improving the overall operation efficiency and maintainability of the production line; Flexible manufacturing: The flexible forming device can adapt to the forming requirements of lenses of different shapes (planar, spherical, aspherical, etc.) through various deformation control methods (e.g., ejector rod control, ring ejector drive), making the production line highly flexible and capable of quickly switching to produce optical lenses of different specifications and shapes to meet diverse market demands; Quality control in advance: Immediately after the forming process, a defect detection device is set up to detect the preliminarily formed optical lenses, promptly discover and eliminate defective products, avoiding ineffective processing of unqualified products in subsequent processes, thereby improving the overall yield rate; Intelligence and data management: The system has the capabilities of automatic monitoring and data analysis, can collect key data in the production process in real time, and dynamically monitor the operating status of equipment, process parameters, and product quality. Through in-depth analysis of this data, the system can automatically optimize the production process, promptly adjust process parameters, ensure the stability and consistency of the production process, thereby improving production efficiency and product quality. At the same time, the intelligent management function can also provide accurate decision-making support for operators, further enhancing the production management level and promoting the development of optical lens manufacturing towards high efficiency, precision, and intelligence; Environmental control and auxiliary guarantee: Environmental control devices such as a housing and a fan filter unit are equipped to provide a stable production environment for optical lens manufacturing, reducing the influence of external factors on the production process and product quality; At the same time, the positioning marking points set on each device provide a reliable basis for the precise positioning and automatic operation of the robotic arm, further enhancing the stability and reliability of the production process; In the mold forming stage of the flexible forming device of the present invention, the driving component is used to achieve the millimeter-level macroscopic linear motion of the ejector rod to realize the macroscopic forming of the mold; during the light curing process of the optical lens, by utilizing the characteristics that the surface shape of the deformable mold is real-time and precisely controllable, combined with the curing characteristics of optical resin or thermosetting resin, during its curing process, the micro motion driving device is used to quickly respond and synchronously adjust the surface shape of the mold, thereby reducing the lens deformation caused by material shrinkage and internal stress, etc., and enabling the high-precision manufacturing of customized lenses. Description of the drawings

[0021] Figure 1 It is the overall structural schematic diagram of the full-automatic lens manufacturing system proposed by the present invention; Figure 2 It is the external schematic diagram of the full-automatic lens manufacturing system proposed by the present invention; Figure 3 It is the distribution schematic diagram of multiple internal modules of the full-automatic lens manufacturing system proposed by the present invention; Figure 4 It is the overall structural schematic diagram of the flexible forming device; Figure 5 It is the upper structural schematic diagram of the flexible forming device; Figure 6 It is the schematic diagram of the first deformation driving device in the flexible forming device; Figure 7 It is the schematic diagram of the second deformation driving device in the flexible forming device; Figure 8It is a top view of the second deformation driving device in the flexible forming device; Figure 9 It is a schematic diagram of the overall structure of the defect detection device; Figure 10 It is a schematic diagram of the upper part of the defect detection device; Figure 11 It is a schematic diagram of the edge grinding device; Figure 12 It is a schematic diagram of the overall structure of the cleaning and drying device; Figure 13 It is a schematic diagram of the upper part of the cleaning and drying device; Figure 14 It is a schematic diagram of the coating device; Figure 15 It is a schematic diagram of the calibration device; Figure 16 It is a schematic diagram of the placement device; Figure 17 It is a schematic diagram of the multi-degree-of-freedom robotic arm; Figure 18 It is a schematic diagram of the negative pressure fixture conversion disk of the multi-degree-of-freedom robotic arm; Figure 19 It is a schematic diagram of the material output port; In the figure: 1. Optical lens manufacturing system; 2. Flexible forming device; 3. Defect detection device; 4. Edge grinding device; 5. Cleaning and drying device; 6. Coating device; 7. Calibration device; 8. Placement device; 9. Industrial control computer; 10. Multi-degree-of-freedom robotic arm; 11. Fan filter unit; 12. Industrial air conditioner; 13. Material output port; 14. Aluminum alloy frame; 15. Acrylic transparent baffle; 16. Positioning mark point; 21. Seismic isolation table; 22. First flexible mold body; 23. Second flexible mold body; 24. Glue application support frame; 25. Glue application linear displacement table; 26. Glue spraying gun; 27. Ultraviolet light source; 28. Ultraviolet light source lifting table; 29. First flexible mold body lifting table; 210. Support frame; 211. Optical resin; 212. Circumferential baffle; 213. Housing; 214. Second ejector rod; 215. First ejector rod; 216. First drive assembly; 217. First support plate; 218. Second support plate; 219. Piezoelectric actuator; 220. Second drive assembly; 221. Outer shell; 222. First two-stage drive device; 223. First annular top piece; 224. Second flexible mold body support table; 225. Support member; 226. Second two-stage drive device; 227. Second annular top piece; 31. Optical seismic isolation table; 32. Lens to be detected; 33. Defect detection camera; 34. Gantry support frame; 35. Lens position adjustment displacement table; 41. Seismic isolation table; 42. Lens edge grinder; 51. Seismic isolation table; 52. Lens ultrasonic cleaner; 53. Lens dryer; 61. Seismic isolation table; 62. Coating umbrella; 63. Coating machine; 71. Seismic isolation table; 72. Lens quality checker; 81. Linear drive guide rail; 82. Lens placement rack; 83. Lens; 101. Manipulator body; 102. Negative pressure fixture conversion disk; 1021. Rigid support; 1022. Flexible contact block; 103. Lens; 104. Positioning camera; 13. Material output port; 131. Material output port opening door; Detailed implementation mode It should be noted that the following detailed description is illustrative and is intended to provide further explanation of the present invention. Unless otherwise specified, all technical and scientific terms used in the present invention have the same meaning as commonly understood by those of ordinary skill in the technical field to which the present invention belongs.

[0022] It should be noted that the terms used herein are only for describing the specific implementation mode and are not intended to limit the exemplary implementation mode according to the present invention. As used herein, unless the present invention clearly indicates otherwise, the singular form is also intended to include the plural form. In addition, it should also be understood that when the terms "include" and / or "comprise" are used in this specification, they indicate the presence of features, steps, operations, devices, components, and / or their combinations; For the convenience of narration, if the words "upper", "lower", "left", and "right" appear in the present invention, they only represent the same directions as the upper, lower, left, and right of the drawing itself, and do not limit the structure. They are only for the convenience of describing the present invention and simplifying the description, rather than indicating or implying that the device or element referred to must have a specific orientation, be constructed and operated in a specific orientation, and therefore cannot be understood as a limitation to the present invention.

[0023] Glossary: Terms such as "installation", "connection", "linkage", and "fixation" in the present invention should be understood in a broad sense. For example, it can be a fixed connection, a detachable connection, or an integral one; it can be a mechanical connection or an electrical connection, a direct connection or an indirect connection through an intermediate medium, an internal connection between two components, or an interaction relationship between two components. For those of ordinary skill in the art, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0024] As Figure 1 , Figure 2 , Figure 3 shown, for the full-process manufacturing of customized lenses (such as spectacle lenses) and serialized lenses (such as VR and AR lenses), this embodiment proposes an optical lens full-automatic rapid manufacturing system and method based on a deformable mold; the system includes an aluminum alloy frame 14, and an acrylic transparent baffle 15 is arranged on the periphery and top of the aluminum alloy frame 14. The acrylic transparent baffle 15 and the aluminum alloy frame 14 together enclose the manufacturing space of the optical lens full-automatic rapid manufacturing system. A flexible forming device 2, a defect detection device 3, an edge grinding device 4, a cleaning and drying device 5, a coating device 6, a verification device 7, a placement device 8, an industrial control computer 9, and a multi-degree-of-freedom robotic arm 10 are arranged in this manufacturing space; and a fan filter unit 11, an industrial air conditioner 12, etc. are also arranged on the top of the system; it should be noted that the defect detection device 3, the edge grinding device 4, the cleaning and drying device 5, and the placement device 8 are optional devices and can be set according to process requirements.

[0025] Specifically, in this embodiment, the flexible forming device 2, the defect detection device 3, the edge grinding device 4, the cleaning and drying device 5, the coating device 6, the verification device 7, and the placement device 8 are distributed in a ring. These devices enclose a complete circle, and the multi-degree-of-freedom robotic arm 10 is arranged inside the complete circle. Through the control of the industrial control computer 9, the multi-degree-of-freedom robotic arm 10 transfers the lens being processed to different devices. Further, the system is also provided with a lens recycling device, which is not shown in the figure, to recycle the lenses that do not meet the requirements; The following is a detailed description of each device: As Figure 4 , Figure 5As shown in the figure, the flexible forming device 2 in this embodiment adopts the forming technology based on a deformable mold, combined with an automatic glue coating structure, a light curing mechanism, etc., to achieve precise and rapid forming of customized and serialized lenses. Through the flexible adjustment of the deformable mold, the system can adapt to the production requirements of lenses of different specifications, ensuring high precision and controllability during the forming process; specifically, the flexible forming device 2 in this embodiment includes a vibration isolation table 21, a first flexible mold body 22, a second flexible mold body 23, a glue coating support frame 24, a glue coating linear displacement table 25, a glue spraying gun 26, an ultraviolet light source 27, an ultraviolet light source lifting table 28, a first flexible mold body lifting table 29, and a support frame 210; A support frame 210, an ultraviolet light source lifting table 28, a second flexible mold body support table 224, and a glue coating linear displacement table 25 are arranged on the vibration isolation table 21. A glue coating support frame 24 is arranged on the glue coating linear displacement table 25, and a glue spraying gun 26 is arranged on the glue coating support frame 24; a first flexible mold body lifting table 29 is arranged on the side of the support frame 210, the first flexible mold body 22 is installed on the first flexible mold body lifting table 29, and the second flexible mold body 23 is installed on the second flexible mold body support table 224; the first flexible mold body 22 and the second flexible mold body 23 are arranged corresponding to each other up and down. An ultraviolet light source 27 is arranged on the ultraviolet light source lifting table 28, and the glue spraying gun 26 and the ultraviolet light source 27 are arranged on both sides of the first flexible mold body 22 and the second flexible mold body 23; in order to realize the positioning between the robotic arm and the flexible forming device 2, a positioning mark point 16 is arranged on the second flexible mold body support table 224; Furthermore, the specific working method is as follows: The industrial control computer 9 controls the deformation driving devices of the first flexible mold body 22 and the second flexible mold body 23 according to the shape requirements of the optical lens, so that the first flexible mold body 22 and the second flexible mold body 23 are deformed according to the shape of the optical lens. The first flexible mold body 22 rises driven by the first flexible mold body lifting table 29 to provide an open area for injecting the photocuring glue. The glue spraying gun 26 approaches the second flexible mold body 23 driven by the glue coating linear displacement table 25. After reaching the specified glue dispensing position, the calculated amount of glue is injected into the lower mold. The glue spraying gun 26 moves away from the second flexible mold body 23 driven by the glue coating linear displacement table 25. The first flexible mold body 22 descends to the height required for the formed lens thickness driven by the first flexible mold body lifting table 29. The ultraviolet light source 27 moves to the photocuring area driven by the ultraviolet light source lifting table 28. The ultraviolet light source 27 is turned on according to the set curing duration to irradiate the glue to cure it and form a lens. After the lens is formed, the first flexible mold body 22 rises driven by the first flexible mold body lifting table 29, and the ultraviolet light source 27 provides an open area for the robotic arm to adsorb the formed lens driven by the ultraviolet light source lifting table 28. At this time, the industrial control computer 9 controls the robotic arm to shift to the open area; Further, there are two deformation driving devices for the first flexible mold body 22 and the second flexible mold body 23 in this embodiment, which are specifically as follows: The first type of deformation driving device is shown in Figure 6, including a first ejector rod 215, a second ejector rod 214, a first driving assembly 216, a second driving assembly 220, a piezoelectric actuator 219, a housing 213, an ultraviolet light source 27, a circumferential baffle 212, etc.; the flexible mold specifically consists of a second flexible mold 23 and a first flexible mold 22, and the two have the same structure, corresponding to the front surface and the rear surface of the optical element respectively, and can be deformed into spherical, aspherical, planar, free-form surface shapes, etc. according to the optical design scheme; the curved surface shape of the second flexible mold 23 is controlled by a plurality of first ejector rods 215 and a first driving assembly 216, and the curved surface shape of the first flexible mold 22 is controlled by a plurality of second ejector rods 214 and a second driving assembly 220; specifically, a first flexible mold 22, a circumferential baffle 212, and a second flexible mold 23 are sequentially installed from top to bottom in the middle of the housing 213, and the first flexible mold 22, the circumferential baffle 212, and the second flexible mold 23 enclose a cavity for forming an optical lens. A plurality of first ejector rods 215 are arranged above the first flexible mold 22, and the first ejector rods 215 are driven by a first driving assembly 216 to move linearly to control the deformation amount of the first flexible mold 22. A plurality of second ejector rods 214 are arranged below the second flexible mold 23, and the second ejector rods 214 are driven by a second driving assembly 220 to move linearly to control the deformation amount of the second flexible mold 23; among them, the position of the first driving assembly 216 is movable, and it can move above any first ejector rod 215 to drive the first ejector rod 215 to move up and down; the position of the second driving assembly 220 is movable, and it can move below any second ejector rod 214 to drive the second ejector rod 214 to move up and down; piezoelectric actuators 219 are arranged on both the first ejector rod 215 and the second ejector rod 214 to control the flexible mold to perform micron- and nanoscale deformations with fast response; specifically, each of the first ejector rod 215 and the second ejector rod 214 includes two sections, and the piezoelectric actuator 219 is arranged between the two sections of the ejector rod, or the piezoelectric actuator 219 is directly arranged at the head positions of the first ejector rod 215 and the second ejector rod 214, and the output end of the piezoelectric actuator 219 is a smooth arc shape.

[0026] Further, the first driving assembly 216 drives a plurality of first ejector rods 215 to perform linear motion, and the second driving assembly 220 drives a plurality of second ejector rods 214 to perform linear motion. The structures of the first driving assembly 216 and the second driving assembly 220 are the same, and each includes: a two-axis driving mechanism, a servo motor, a ball spline shaft, and a clutch. Among them, the two-axis driving mechanism enables the servo motor to move in the X and Y directions in the horizontal plane. The servo motor drives the clutch to perform linear motion through a linear transmission device. In this embodiment, the linear transmission device adopts a driving ball spline shaft structure. The driving ball spline shaft structure realizes linear, rotational, and helical motions, meeting the rotational positioning requirements of the ejector rod. A jaw clutch structure is installed or machined at the front end of the ball spline shaft to realize the torque output to the ejector rod.

[0027] Specifically, the servo motor is carried by the two-axis driving mechanism to the position of the ejector rod that needs to be adjusted. The spline shaft moves linearly until the clutch contacts the ejector rod, and then rotates helically to drive the ejector rod to eject or retract axially. The rotation angle of the spline shaft is monitored during this process. According to the rotation angle and the helix angle of the spline shaft, its axial displacement can be calculated, thereby realizing the accurate control of the axial movement distance of the ejector rod.

[0028] Further preferably, each of the first ejector rod 215 and the second ejector rod 214 includes a plurality of them. A support plate is provided at each of the upper and lower parts inside the housing 213. The first support plate 217 is used to support a plurality of first ejector rods 215, and the second support plate 218 is used to support the second ejector rods 214. Moreover, the thread fit is between the first support plate 217 and the first ejector rod 215, and between the second support plate 218 and the second ejector rod 214. The helix angles of the first support plate 217, the second support plate 218, the first ejector rod 215, and the second ejector rod 214 are less than or equal to the equivalent friction angle, having a self-locking characteristic. By driving the assembly to provide torque, the first ejector rod 215 and the lower top plate generate axial displacement to drive the flexible die body to deform.

[0029] Further preferably, the helix angle of the ejector rod is the same as the helix angle of the helical groove on the ball spline shaft, so as to ensure the motion synchronism.

[0030] Further preferably, the tops of the first ejector rod 215 and the second ejector rod 214 are aspherical, and the maximum curvature radius is less than the maximum curvature radius after the die body deforms.

[0031] Further preferably, a certain vacuum degree can be maintained in the cavity formed by the second flexible die body 23, the first flexible die body 22, and the housing 213, so that a good fit is maintained between the second flexible die body 23, the first flexible die body 22, and the ejector rod; or the ejector rod and the second flexible die body 23, the first flexible die body 22 can also be connected by a flexible hinge. In this case, no vacuum is required to maintain the fit of the flexible die body.

[0032] Further preferably, when the number of ejector rods to be controlled is too large and affects the efficiency, the ejector rods can be partitioned according to the total number of ejector rods, and multiple sets of driving components can be set up to synchronously adjust the ejector rods in different partitions.

[0033] The first deformed driving device drives several ejector rods to move independently through a driving component, realizing the controllable deformation of the flexible mold. Since all the first ejector rods share a first driving component and all the second ejector rods share a second driving component, the space occupied by each ejector rod is reduced. Therefore, compared with the prior art, more ejector rods can be arranged as much as possible within the same area, thereby improving the accuracy of lens forming; at the same time, different-shaped molds can be formed by using the first ejector rod and the second ejector rod, effectively avoiding the high cost of manufacturing different molds required for different optical lens designs, and greatly shortening the product R & D cycle. In the mold forming stage, the driving component is used to realize the millimeter-level macroscopic linear motion of the ejector rod, realizing the macroscopic forming of the mold; in the light curing process of the optical lens, taking advantage of the characteristics of the real-time precise controllability of the surface shape of the deformable mold, combined with the curing characteristics of the optical resin 211, the micro motion driving device is used to quickly respond and synchronously adjust the mold surface shape during the curing process, thereby reducing the lens deformation caused by material shrinkage and internal stress, etc., and realizing the high-precision manufacturing of customized lenses.

[0034] Further, the second deformed driving device provided in this embodiment is shown in Figure 7 、 Figure 8 As shown, it mainly consists of a housing 221, a first flexible mold 22, a first annular ejector 223, a first two-stage driving device 222, a second flexible mold 23, a second annular ejector 227, a second two-stage driving device 226, and a support 225; The first flexible mold 22 and the second flexible mold 23 are arranged up and down, and together with the support 225, they enclose a lens forming cavity; a resin injection port is provided on the support 225, and after the resin is injected, the hole is sealed; The deformation driving device of the first flexible mold 22 includes a plurality of first annular ejectors 223, and the plurality of first annular ejectors 223 are sequentially arranged from the center of the first flexible mold 22 to the outer circle, covering the entire first flexible mold. Each first annular ejector 223 is driven by at least two first driving devices. The first driving device drives the annular ejector to perform millimeter-level macroscopic linear motion before the optical resin 211 is cured, and drives the annular ejector to perform micron- or nanometer-level microscopic motion during the curing process of the optical resin 211; The deformation driving device of the second flexible mold body 23 includes a number of second annular ejectors 227, which are arranged in sequence from the center of the second flexible mold body 23 to the outer circle, covering the entire second flexible mold. Each second annular ejector 227 is driven by at least two second driving devices. The second driving device drives the annular ejector to perform macroscopic linear motion at the millimeter level before the optical resin 211 is cured, and drives the annular ejector to perform microscopic motion at the micron or nanometer level during the curing process of the optical resin 211.

[0035] The second deformation driving device combines the symmetric design characteristics of the aspheric lens and the characteristics of being optimized on a meridian line, uses the annular ejector to drive the cavity surface of the flexible mold body, combines high-precision displacement to meet the contour offset compensation during the mold processing, so as to achieve the effect of one-time rapid forming. And by utilizing the characteristics of high precision, controllable deformability of the deformable mold, it works in coordination with the light curing / thermal curing process, compensates for the resin shrinkage through the deformation of the flexible mold body, and at the same time restricts the shrinkage direction and curing shape to avoid the randomness during the free curing of the resin; confines the shrinkage change within the controllable surface deformation process, improving the surface shape accuracy and the yield rate of the product. The second deformation driving device drives the annular ejector to move through the driving component, realizes the controllable deformation of the flexible mold body, quickly responds to the aspheric optical lens design of different data. After the liquid light-curing glue or optical resin 211 is injected into the mold, it is formed by light curing or thermal curing, and high-quality optical lenses with stable properties can be obtained in batches; effectively avoiding the high cost of manufacturing different molds for different optical lens designs and greatly shortening the product R & D cycle.

[0036] Furthermore, the materials of the above-mentioned second flexible mold body 23 and the first flexible mold body 22 can be selected from conventional mold materials such as nickel-phosphorus alloy. As a further preference, materials with better performance such as amorphous alloy, high-elastic alloy or shape memory alloy can also be selected. When the mold body needs to be deformed again for the surface shape of the next batch of parts after each batch of components is produced, it can be restored to its initial shape by elastic recovery, changing temperature, etc., and then adjusted for deformation again according to the new lens shape.

[0037] Furthermore, in addition to relying on its own elastic deformation or thermal recovery, the recovery of the above-mentioned second flexible mold body 23 and the first flexible mold body 22 can apply negative pressure in the circumferential direction or install springs to assist the flexible mold body to restore its initial shape.

[0038] Furthermore, the above-mentioned first deformation driving device can be used for the processing of forming plane lenses, spherical lenses, aspherical lenses and free-form surface lenses. The difference lies in the different shapes formed by the mold; Furthermore, the above-mentioned second deformation driving device is preferably used for aspherical lenses.

[0039] like Figure 9 , Figure 10 As shown, the defect detection device 3 in this embodiment uses machine vision technology to perform real-time detection on the formed lens, identify and determine whether there are production defects such as bubbles, glue deficiency, scratches, etc. This link can ensure that each lens has good quality in subsequent processing and provide a reliable foundation for subsequent processes, including an optical vibration isolation table 31, a lens to be inspected 32, a defect detection camera 33, a gantry support frame 34 and a lens position adjustment displacement stage 35; a gantry support frame 34 is arranged on the top of the optical vibration isolation table 31, a defect detection camera 33 is arranged on the gantry support frame 34, and a lens position adjustment displacement stage 35 is arranged below the defect detection camera 33; a positioning mark point 16 is arranged on the gantry support frame 34; the function of the positioning mark point 16 is mainly to achieve precise positioning between the robot arm and the defect detection device 3; when the lens to be inspected 32 is placed on the lens position adjustment displacement stage 35, the industrial control computer 9 controls the defect detection camera 33 to start defect detection. If no defects are found, the industrial control computer 9 controls the robot arm to work and take out the lens and place it in the next station; if defects are found, the industrial control computer 9 controls the robot arm to work and take out the lens and place it in the lens recovery station.

[0040] like Figure 11 As shown, the edge grinding device 4 in this embodiment is based on the size requirements of the customized or serialized frame. The system uses a fully automatic edge grinding machine to trim the shape of the optical lens to ensure the compatibility of the optical lens and the frame. This device can adjust the edge grinding accuracy according to the needs to achieve rapid cutting and trimming of different optical lens shapes. Specifically, the edge grinding device 4 includes a seismic isolation platform 41 and a lens edge grinding machine 42; the lens edge grinding machine 42 is provided with a positioning mark point 16; the main function of the positioning mark point 16 is to achieve precise positioning between the robot arm and the edge grinding device 4; like Figure 12 , Figure 13 As shown, the cleaning and drying device 5 in this embodiment includes a shock-isolating platform 51; a lens ultrasonic cleaning machine 52 and a lens dryer 53 are arranged on the shock-isolating platform 51; positioning mark points 16 are arranged on the lens dryer 53 and the lens ultrasonic cleaning machine 52; the positioning mark points 16 are mainly used to achieve precise positioning between the robot arm and the lens ultrasonic cleaning machine 52 and the lens dryer 53; in this device, the lens is thoroughly cleaned by a special cleaning machine to remove residual substances and impurities on the surface, and then dried by a dryer to provide a clean surface environment for the subsequent coating process.

[0041] like Figure 14As shown in the figure, the coating device 6 includes a vibration isolation table 61, a coating umbrella 62, and a coating machine 63. The coating umbrella 62 and the coating machine 63 are arranged on the vibration isolation table 61. A positioning mark point 16 is arranged on the coating machine 63. The main function of the positioning mark point 16 is to achieve precise positioning between the robotic arm and the coating device 6. Lenses are subjected to surface treatments such as anti-reflection and anti-reflective coating in this device to further improve the optical performance and anti-pollution ability of the lenses. This process ensures that the lenses achieve the expected optical effects by precisely controlling the film thickness and uniformity.

[0042] As Figure 15 shown in the figure, the lens verification device 7 includes a vibration isolation table 71 and a lens quality verification machine 72. The lens quality verification machine 72 is arranged on the vibration isolation table 71, and a positioning mark point 16 is arranged on the lens quality verification machine 72. The main function of the positioning mark point 16 is to achieve precise positioning between the robotic arm and the lens verification device 7. This device is responsible for comprehensively detecting the coated lenses, including lens size, diopter, radius of curvature, pupil distance, etc., to ensure that the lenses meet the design specifications and quality requirements.

[0043] As Figure 16 shown in the figure, the placement device 8 includes a linear drive guide rail 81. A lens placement rack 82 is arranged on the linear drive guide rail 81, and a positioning mark point 16 is arranged on the lens placement rack 82. The main function of the positioning mark point 16 is to achieve precise positioning between the robotic arm and the placement device 8. The processed lenses 83 are clamped and placed on this device by the robotic arm, facilitating subsequent manual assembly. The lenses will be transported through the linear drive guide rail at this position and finally sent to the manual assembly device for final assembly with the frame.

[0044] As Figure 17 and Figure 18As shown in the figure, the multi-degree-of-freedom robotic arm 10 in this embodiment includes a robotic arm body 101. A negative pressure fixture conversion disk 102 is installed at the end of the robotic arm body 101. The negative pressure fixture conversion disk 102 automatically adsorbs the lens during processing and transfers the formed lens to the next device. This device ensures the smooth transfer of the lens between devices, reducing the errors and damage risks caused by manual operation. Specifically, three inclined negative pressure fixture rigid brackets 1021 are provided on the negative pressure fixture conversion disk 102, and a flexible contact block 1022 is provided at the end of each negative pressure fixture rigid bracket 1021. The three flexible contact blocks 1022 are installed on their respective corresponding negative pressure fixture rigid brackets 1021, which not only ensures the adsorption stability but also prevents clamping damage to the surface of the workpiece. Moreover, the shapes of the three flexible contact blocks 1022 can be designed into different shapes to meet the adsorption requirements of lenses with different shapes. Further, the inclination angles of the three negative pressure fixture rigid brackets 1021 relative to the negative pressure fixture conversion disk 102 can be set as required. They can be inclined towards the outer ring of the negative pressure fixture conversion disk 102 at the same time, or inclined towards the inner ring of the negative pressure fixture conversion disk 102 at the same time. A robotic arm positioning camera 104 is installed on the robotic arm, and positioning marker points 16 are installed on each work station. The robotic arm takes pictures through the camera and identifies the positioning marker points to accurately locate the position between the robotic arm and each work station. According to the shapes of different lenses 103, a rotating disk type negative pressure fixture is designed at the end of the robotic arm, and different fixtures are switched through program instructions to adsorb different lenses 103.

[0045] Further, the industrial control computer 9 is responsible for running the entire lens production program and providing a human-machine docking interface to facilitate the operator to monitor the production process. The control system includes operations such as discharging and emergency stop to ensure the efficient operation and safety of the production line.

[0046] Further, the sealing cover and the air purification device include a fan filter unit 11, an aluminum alloy frame 14, and an acrylic transparent baffle 15. The entire production system is enclosed by a high-strength aluminum alloy frame 14, with an acrylic transparent baffle 15 as the observation window to ensure the tightness and stability of the processing environment. The system is equipped with a high-efficiency fan filter unit 11 to provide high-cleanliness air, effectively controlling the dust and pollutants in the production environment and ensuring the high quality and high precision of the lens processing process.

[0047] Further, the industrial air conditioner 12 maintains the temperature of the lens manufacturing sealed space at ±1°C. The constant environmental temperature can reduce the manufacturing errors introduced by the deformation of the workpiece and the fixture, and improve the lens manufacturing accuracy.

[0048] Further, as Figure 19As shown, the lens placed by the placement device is transferred out of the manufacturing system through the material output port 13 and is finally adjusted manually. This outlet is only opened briefly during material output and remains closed during the manufacturing process. Specifically, it is achieved by setting a material output port opening door 131 at the material output port 13.

[0049] Furthermore, in order to achieve precise positioning in this embodiment, the positioning fiducial points 16 in this embodiment are composed of two concentric circles. The outer concentric circle provides a clean positioning background for the inner concentric circle to ensure that the positioning camera 104 can accurately capture the image of the inner concentric circle. According to the principle of three points determining a plane, at least 3 positioning fiducial points 16 are installed on each station plane. Then, based on these three (or more) fiducial points, a positioning plane is constructed to achieve the precise positioning of the robotic arm. The camera size, fixture size, the sizes of each station device, the installation position of the fiducial points, and the lens placement position are all input into the robotic arm control system as physical dimensions to achieve the accurate positioning of the lens and the fixture.

[0050] Based on the above manufacturing system, this embodiment also discloses a specific manufacturing method, which is as follows: 1. Lens forming. Specifically, adjust the shape of the deformable mold according to the lens surface shape requirements; the first flexible mold body 22 descends to the upper mold position required by the lens thickness under the drive of the first flexible mold body lifting table 29 to form a glue injection cavity; the glue spraying gun 26 moves to the glue injection device under the drive of the glue coating linear displacement table 25 and injects the calculated volume of glue into the mold cavity according to the target lens volume and the glue shrinkage rate; the glue injection equipment is moved away, and the ultraviolet light source 27 rises to the curing area under the drive of the ultraviolet light source lifting table 28, and the ultraviolet light source 27 is turned on to irradiate the glue to achieve the photocuring forming of the lens; the ultraviolet light source 27 descends under the drive of the ultraviolet light source lifting table 28, and the upper mold rises under the drive of the first flexible mold body lifting table 29 to complete the demolding of the lens; the robotic arm body 101 moves to the lens suction area, and the lens is adsorbed by using the vacuum negative pressure fixture flexible contact block 1022.

[0051] 2. Defect detection. The robotic arm transfers the lens to the defect detection device 3; the defect detection camera 33 takes pictures of the lens 32 to be detected and transmits the data to the industrial control computer 9; automatic detection of defects such as bubbles, lack of glue, and scratches is realized by using defect detection algorithms, etc. Whether the lens is qualified is automatically judged according to the defect threshold. Qualified lenses enter the next process, and unqualified lenses are scrapped and placed in the recycling device. 3. Edge grinding. The robotic arm transfers the qualified lens to the lens edge grinder 42; the edge grinder grinds the lens according to the frame shape to ensure that the lens shape fits the frame shape.

[0052] 4. Cleaning. The robotic arm transfers the edged lens to the lens ultrasonic cleaning machine 52; the lens is ultrasonically cleaned according to the set time parameters to remove surface impurities.

[0053] 5. Drying. The robotic arm transfers the cleaned lens to the lens dryer 53; the lens is dried according to the set time, temperature and other parameters to ensure the surface is dry.

[0054] 6. Coating. The robotic arm transfers the lens to the coating umbrella 62 and places the lens; the robotic arm moves the coating umbrella 62 to the coating machine 63, and the lens is coated according to the set time and other parameters.

[0055] 7. Verification. The robotic arm transfers the coated lens to the lens quality verification machine 72 to detect key parameters such as the outer dimension, diopter, radius of curvature, and pupil distance of the lens; the qualified lens enters the next process, and the unqualified ones are processed manually.

[0056] 8. Lens placement. The robotic arm transfers the verified qualified lens to the placement device 8; it can be decided manually whether to output the verified qualified lens from the stock tray.

[0057] Among them, the processing times of processes such as forming, edging, and coating of lenses with different sizes and shapes are different. The movement of the robotic arm is adjusted according to the actual situation. When a certain process is completed, the lens can be removed and placed on the temporary storage tray beside the device to ensure the efficient utilization of each device in the entire system; the fan filter unit 11 and the industrial air conditioner 12 run continuously to ensure the high cleanliness of the lens processing sealed space.

[0058] The system of the present invention ensures the high precision and high quality of each lens through the automated collaborative operation of multiple devices. During the entire production process, key operations such as the glue injection volume, UV light curing, edging accuracy, defect detection, etc. are all controlled by high-precision automated equipment, minimizing human errors and improving production efficiency. The automatic transfer and operation between each step ensure the smoothness and efficiency of the production process, comprehensively improving the manufacturing quality and consistency of the lens.

[0059] The manufacturing system proposed by the present invention can be applied in multiple fields, including traditional glasses manufacturing, emerging VR / AR devices, etc. These applications put forward higher requirements for the processing accuracy, production efficiency and quality stability of optical lenses.

[0060] The floor area estimation of the optical lens manufacturing system proposed by the present invention is less than 7 square meters. Compared with traditional optical lens processing equipment, it greatly saves space, can be flexibly arranged in different production environments. The fully automatic production method reduces the manual operation links, improves production efficiency and processing accuracy, reduces errors caused by human factors, ensures the stability of lens quality, and helps to achieve large-scale production and standardized production.

Claims

1. An optical lens manufacturing system, characterized in that: Including the following settings: A flexible forming device, wherein the flexible forming device comprises a flexible mold body, wherein the deformation of the flexible mold body is controlled by a plurality of ejector pins, and all ejector pins are driven by the same driving assembly, wherein the driving assembly can move to the position of the ejector pin to be adjusted and drive it to perform millimeter-level macroscopic linear motion; At the same time, each push rod is provided with a micro-motion driving device, which drives the push rod to perform microscopic motion at the micrometer or nanometer level; A coating device, used for coating optical lenses; A validation device, used for validating optical lenses; A robotic arm is used to realize the movement of the optical lens between the flexible forming device, the coating device, and the testing device.

2. The optical lens manufacturing system according to claim 1, characterized in that: The flexible mold body comprises a first flexible mold body and a second flexible mold body; a lens forming cavity is formed between the first flexible mold body, the second flexible mold body and the circumferential baffle; The specific deformation of the first flexible mold is controlled by a plurality of first push rods, all of which are driven by the same first driving assembly, and the first driving assembly can move to the position of the first push rod to be adjusted, and drive it to perform millimeter-level macroscopic linear motion; At the same time, each first push rod is provided with a first micro-motion driving device, which drives the first push rod to perform micro-motion at the micrometer or nanometer level; The specific deformation of the second flexible mold is controlled by a plurality of second push rods, and all the second push rods are driven by the same second driving assembly, and the second driving assembly can move to the position of each second push rod and drive it to perform millimeter-level macroscopic linear motion; At the same time, each second push rod is provided with a second micro-motion driving device, and the second micro-motion driving device drives the second push rod to perform micro-motion at the micrometer or nanometer level.

3. The optical lens manufacturing system as claimed in claim 1, characterized in that: The flexible forming device comprises a flexible mold body; wherein two flexible mold bodies and a support member form a lens forming cavity, or a flexible mold body, an initial base body, and a circumferential baffle form a lens forming cavity; the deformation driving device of the flexible mold body comprises a plurality of annular top pieces, which are arranged in sequence from the center to the outer circle of the flexible mold body, covering the entire flexible mold, and each annular top piece is driven by at least two driving devices, and each driving device drives the annular top piece to perform macroscopic linear motion before the optical resin is cured, and drives the annular top piece to perform microscopic motion during the curing process of the optical resin.

4. The optical lens manufacturing system according to any one of claims 1 to 3, characterized in that: The flexible forming device also includes a seismic isolation platform, on which a support frame, an ultraviolet light source lifting platform, a second flexible mold body support platform and a gluing linear displacement platform are arranged, a gluing support frame is arranged on the gluing linear displacement platform, and a glue spray gun is arranged on the gluing support frame; a first flexible mold body lifting platform is arranged on the side of the support frame, a first flexible mold body is installed on the first flexible mold body lifting platform, and a second flexible mold body is installed on the second flexible mold body support platform; a light source is arranged on the light source lifting platform, and the glue spray gun and the light source are arranged on both sides of the first flexible mold body and the second flexible mold body, and positioning mark points are arranged on the second flexible mold body support platform.

5. The optical lens manufacturing system according to claim 1, characterized in that: The robot arm comprises a robot arm body, a negative pressure fixture conversion disk is installed at the end of the robot arm body, a plurality of inclined negative pressure fixture rigid brackets are arranged on the negative pressure fixture conversion disk, and a flexible contact block is arranged at the end of each negative pressure fixture rigid bracket.

6. The optical lens manufacturing system according to claim 1, characterized in that: The optical lens manufacturing system also includes a shell, a material inlet and outlet are arranged on the shell, and a fan filter unit is arranged on the top of the shell.

7. The optical lens manufacturing system as claimed in claim 1, characterized in that: It also includes a defect detection device for detecting the initially formed optical lens.

8. The optical lens manufacturing system as claimed in claim 7, characterized in that: The defect detection device comprises a vibration isolation platform, a gantry bracket is arranged on the top of the vibration isolation platform, a picture acquisition device is arranged on the gantry bracket, and a lens fixing platform to be detected is arranged below the picture acquisition device.

9. The optical lens manufacturing system as claimed in claim 7, characterized in that: Also included is an edge grinding device for grinding the edge of the optical lens.

10. The optical lens manufacturing system according to claim 9, characterized in that: It also includes a cleaning and drying device for cleaning and drying the optical lens.

11. The optical lens manufacturing system according to claim 10, characterized in that: Also included is a placing device for placing the optical lenses.

12. The optical lens manufacturing system according to claim 11, characterized in that: The flexible forming device, defect detection device, edge grinding device, cleaning and drying device, coating device, verification device, and placement device are arranged in a ring shape in sequence, and the mechanical arm is installed in the ring.

13. The optical lens manufacturing system according to claim 12, wherein: Positioning marking points are arranged on the defect detection device, edge grinding device, cleaning and drying device, coating device, verification device and placement device.

14. The manufacturing method of the optical lens manufacturing system according to claim 13, characterized in that: as follows: The flexible forming device forms the optical lens; the robotic arm grabs the formed optical lens to the defect detection device; the defect detection device checks whether the initially formed optical lens has defects, and if so, the optical lens is placed in the recovery device; if there is no defect after the detection, the robotic arm places the detected optical lens in the edge grinding device; after the edge grinding device is used to edge grind the optical lens, the robotic arm places it in the cleaning and drying device, and the cleaning and drying device cleans and dries the optical lens; after the cleaning and drying are completed, the robotic arm places it in the coating device, and the coating device coats the optical lens; After the coating is completed, the robotic arm places it on the testing device, and the testing device tests the optical lens; after the inspection is completed, the robotic arm places it on the display device.

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