Flexible production system and method for orderly dewaxing hard contact lenses

Abstract

According to the flexible production system and method for orderly dewaxing of the hard contact lens, through pretreatment of adjustable ultrasonic frequency, optimized physical auxiliary dewaxing is achieved according to different wax layer characteristics, and it is ensured that the process is safe and controllable while the efficiency is improved. The lenses vertically and directionally fall into one-to-one corresponding collecting units, so that the industrial problem of disordered accumulation of the lenses is thoroughly solved, a foundation is laid for whole-process individualized tracing and automatic processing, and ordering and traceability are realized. Due to the full-automatic / semi-automatic dual-mode design, the same equipment has dual functions of a high-speed mass production line and a flexible research and development platform, and the production flexibility is maximized. The whole process is controlled in a parameterized and programmed mode, and excellent quality consistency and batch stability are ensured.

Description

Technical Field

[0001] This invention relates to the field of eyeglass fitting technology, and in particular to a flexible production system and method for the orderly dewaxing of rigid contact lenses. Background Technology

[0002] In the precision CNC turning process of rigid contact lenses (such as orthokeratology lenses and RGP lenses), the lens blank needs to be temporarily and precisely bonded to a special carrier (mandrel) using water-soluble wax. After the turning process is completed, the water-soluble wax must be completely removed to allow the lens to be safely and without damage.

[0003] Currently, there are two main types of dewaxing technologies in the industry, both of which have significant drawbacks:

[0004] Category 1: Traditional manual ultrasonic dewaxing method. The operator holds a carrier and immerses it in an ultrasonic cleaning tank, relying on ultrasonic vibrations to loosen the wax layer. During this process, the lenses are very prone to prematurely detaching and falling to the bottom of the tank. Under continuous ultrasonic action, they repeatedly impact the hard bottom, causing scratches on the lens surface and rendering them unusable. This method is inefficient, has inconsistent quality, and is entirely dependent on manual operation.

[0005] The second type: Static immersion buffering method (such as the scheme disclosed in Chinese patent document CN119953006A). This scheme lays a buffer layer such as sponge at the bottom of the container, and the wax layer slowly melts by immersion in hot water, allowing the lens to fall onto the buffer layer after detachment. Although this scheme reduces the direct impact between the lens and the hard bottom, it still has the following systemic defects determined by the technical principle:

[0006] Low dewaxing efficiency: It relies entirely on a slow heat conduction process, resulting in a long dewaxing cycle, which becomes a bottleneck in production.

[0007] The process is uncontrollable and undermines product traceability: multiple lenses are scattered and piled up randomly in a limited buffer area after the wax melts. For precision medical devices such as rigid contact lenses that require strict individualized process traceability, this process completely destroys the one-to-one correspondence between the lens and the original carrier station, leading to the need for inefficient and error-prone manual searching, identification, and sorting.

[0008] Unable to achieve automated continuous production: The randomness of the above process and the necessary human intervention make this solution inherently unintegratable into modern fully automated production lines, lacking production flexibility.

[0009] In summary, existing technologies cannot systematically resolve the contradictions between high efficiency, non-destructive operation, orderly process, and flexibility in the dewaxing process. Developing a novel solution that can overcome these contradictions at the level of process principles has become a pressing technical challenge in this field. Summary of the Invention

[0010] To address the technical problems existing in the prior art, the present invention provides the following technical solution:

[0011] On the one hand, a flexible manufacturing method for the orderly dewaxing of rigid contact lenses is provided, comprising the following steps:

[0012] S1. Adjustable ultrasonic pretreatment step: Immerse the lens carrier 3 with the rigid contact lens 7 fixed in it into the first cleaning solution 2 in the ultrasonic cleaner 1 for treatment; during treatment, call the corresponding process formula according to the lens style and specifications. The formula includes at least the appropriate ultrasonic frequency, ultrasonic power and treatment time, so that the water-soluble wax layer 6 fixing the lens 7 is fully softened and structurally loosened, while ensuring that the lens 7 does not fall off at this stage.

[0013] S2, Safe transfer step: The lens carrier 3 after step S1 is transferred from the ultrasonic cleaner 1 to a physical space-independent constant temperature dewaxing collection unit through a transfer mechanism.

[0014] S3, Constant Temperature Hot Melting and Directional Collection Steps: Immerse the lens carrier 3 in the second cleaning solution 13 in the constant temperature dewaxing tank 12 to melt the pre-loosened wax layer 6; the lens 7 falls off vertically and orderly in a static liquid environment and falls precisely into the buffer collection device 8 pre-set in the constant temperature dewaxing tank 12, which corresponds one-to-one with the lens fixing position on the lens carrier 3, to obtain the removed wax-free rigid contact lens 9.

[0015] Preferably, in step S1, the ultrasonic frequency is adjusted within the range of 20 kHz to 200 kHz.

[0016] Preferably, in step S1, the adjustable ultrasonic preprocessing step employs a frequency sweep mode, allowing the ultrasonic frequency to continuously or incrementally change within a specified range of 20 kHz to 200 kHz during a single processing step.

[0017] Preferably, the execution mode of the method includes:

[0018] In response to the fully automatic mode command, steps S1 to S3 are executed automatically and continuously in a loop for continuous production; or,

[0019] In response to the semi-automatic mode command, after receiving a manual feeding confirmation, it automatically executes a complete cycle from step S1 to S3. After completion, it provides an audio-visual prompt and waits for manual feeding.

[0020] Preferably, before performing step S1, the method further includes:

[0021] The lens style and specifications can be determined by selecting the lens specifications through the human-machine interface menu or by scanning the identification code on the lens carrier 3.

[0022] Based on the determined style specifications, the corresponding process formula containing independently adjustable ultrasonic parameters and hot melt parameters is automatically retrieved from a database of multiple pre-stored process formulas.

[0023] Preferably, each formula in the process formula database supports operators in performing parameter adjustments and trial runs in semi-automatic mode, and saves the confirmed valid parameter set as a dedicated standardized process template corresponding to that lens style;

[0024] The system automatically matches and calls the corresponding process template by identifying the unique identification code on the lens carrier 3 or its matching container.

[0025] Preferably, each independent collection unit of the buffer collection device 8 is a modular structure that can be independently disassembled, replaced, or cleaned.

[0026] Preferably, during the execution time of step S3, the control system schedules the material transfer mechanism in parallel to perform at least one preparatory operation from step S1 and / or for preparing a new collection unit for subsequent batches of lenses, thereby achieving multi-station collaboration and intelligent scheduling.

[0027] On the other hand, a flexible production system for implementing the method described above is provided, comprising:

[0028] a. Core process modules, which include:

[0029] The ultrasonic pretreatment unit consists of an ultrasonic cleaner 1 containing a first cleaning fluid 2, which is used to perform controllable ultrasonic pretreatment on a lens carrier 3 with a rigid contact lens 7 fixed on it.

[0030] The constant temperature dewaxing collection unit consists of a constant temperature dewaxing tank 12 containing a second cleaning solution 13, and the constant temperature dewaxing tank 12 is equipped with a buffer collection device 8 for receiving the detached lenses 9.

[0031] And a transfer mechanism for automatically transferring the lens carrier 3 between the ultrasonic pretreatment unit and the isothermal dewaxing collection unit;

[0032] b. The intelligent control system is configured as follows:

[0033] Control the system to respond to fully automatic or semi-automatic mode execution;

[0034] Manage and access multiple sets of process formula databases associated with different lens styles and specifications; each formula contains independently adjustable ultrasonic parameters and thermal fusion parameters.

[0035] Based on the input lens style and specification information, the system automatically retrieves the corresponding process formula from the database to control each module to perform the corresponding operations.

[0036] The transfer mechanism is adapted to lens carriers 3 and buffer collection devices 8 of different sizes;

[0037] While the constant temperature dewaxing and collection unit is processing the current batch, the material transfer mechanism is controlled to perform at least one transfer or preparatory operation for subsequent batches.

[0038] c. A human-machine interface, which has a lens specification selection menu and / or supports scanning the identification code on the lens carrier 3 to automatically identify the lens style and call up the process formula.

[0039] Preferably, the top surface of the buffer collection device 8 is provided with a positioning pin 11, and the bottom of the lens carrier 3 is provided with a positioning groove 4 that cooperates with the positioning pin 11, so as to achieve accurate positioning of the lens carrier 3 in the constant temperature dewaxing tank 12.

[0040] The beneficial effects of the technical solutions provided by the embodiments of the present invention include at least the following:

[0041] Intelligent and controllable process: Through pretreatment with adjustable ultrasonic frequency, the optimal physical-assisted dewaxing is achieved for different wax layer characteristics, improving efficiency while ensuring process safety and controllability.

[0042] Achieving orderliness and traceability: Lenses fall vertically and oriented into corresponding collection units, completely solving the industry problem of disorderly lens accumulation and laying the foundation for end-to-end individualized traceability and automated processing.

[0043] Maximizing production flexibility: The fully automatic / semi-automatic dual-mode design allows the same equipment to function as both a high-speed mass production line and a flexible R&D platform.

[0044] Consistent and reliable quality: Parameterized and programmed control throughout the entire process ensures excellent quality consistency and batch stability. Attached Figure Description

[0045] To more clearly illustrate the technical solutions in the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0046] Figure 1 This is a process flow diagram provided in the embodiments of the present invention;

[0047] Figure 2This is a cross-sectional structural schematic diagram of the ultrasonic preprocessing unit provided in an embodiment of the present invention;

[0048] Figure 3 This is a cross-sectional view of the isothermal dewaxing collection unit provided in an embodiment of the present invention;

[0049] Figure 4 This is a schematic diagram of the UI interface for system mode selection and status area provided in an embodiment of the present invention. Detailed Implementation

[0050] The technical solution of the present invention will now be described with reference to the accompanying drawings.

[0051] In embodiments of the present invention, words such as "exemplarily," "for example," etc., are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" in the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the word "exemplary" is intended to present the concept in a concrete manner. Furthermore, in embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one.

[0052] In the embodiments of this invention, the terms "image" and "picture" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning. Similarly, the terms "of," "corresponding (relevant)," and "corresponding" may sometimes be used interchangeably. It should be noted that, without emphasizing the distinction between them, they convey the same meaning.

[0053] In this embodiment of the invention, sometimes a subscript such as W1 may be mistakenly written as a non-subscript form such as W1. When the difference is not emphasized, the meaning they express is the same.

[0054] To make the technical problems, technical solutions and advantages of the present invention clearer, a detailed description will be given below in conjunction with the accompanying drawings and specific embodiments.

[0055] I. Purpose of the Invention

[0056] The purpose of this invention is to overcome the technical defects of existing dewaxing technology, such as low efficiency, easy damage to lenses, uncontrollable process, fixed process parameters, and lack of production flexibility, and to provide a flexible production method and flexible production system for the orderly dewaxing of rigid contact lenses.

[0057] II. Technical Solution

[0058] To achieve the above objectives, the present invention adopts the following technical solution:

[0059] 1. Core Methodology

[0060] like Figure 1 As shown, a flexible manufacturing method for the orderly dewaxing of rigid contact lenses includes the following steps:

[0061] (1) Adjustable ultrasound pretreatment steps

[0062] The carrier body 3, with the lens (rigid contact lens 7) fixed on it, is immersed in the ultrasonic treatment environment (that is, placed in the ultrasonic pretreatment unit), and the corresponding safety process parameter group is called according to the lens style and specifications.

[0063] The set of safety process parameters includes at least the ultrasonic frequency, ultrasonic power, and processing time adapted to the lens diameter and material.

[0064] The parameter set is configured to use appropriate ultrasonic energy to act on the water-soluble wax layer 6, so as to fully soften it and cause structural loosening, while ensuring that the lens does not fall off at this stage.

[0065] (2) Safe transfer steps

[0066] The pretreated carrier 3 is transferred from the ultrasonic treatment environment to a physically independent isothermal dewaxing environment (that is, transferred to the isothermal dewaxing collection unit).

[0067] In this environment, a buffer collection device 8 is pre-installed, and the layout of its collection units corresponds one-to-one with the lens fixing position of the carrier.

[0068] (3) Constant temperature hot melting and directional collection steps

[0069] Immerse the vehicle in a constant-temperature dewaxing liquid to melt the pre-loosened wax layer;

[0070] The lens falls vertically and orderly in a still, mild liquid environment and falls precisely into the corresponding independent collection unit in the buffer collection device.

[0071] In the above steps:

[0072] The adjustable ultrasonic frequency can be adjusted within the range of 20kHz to 200kHz.

[0073] The adjustable ultrasonic pretreatment step adopts a frequency sweeping mode, which allows the ultrasonic frequency to change continuously or in steps within a certain range during a single treatment process.

[0074] The above method is executed according to the input command of the working mode: if it is in response to the fully automatic mode command, the above steps are executed automatically and continuously in a loop; if it is in response to the semi-automatic mode command, the above steps are executed automatically once based on one manual feeding operation and then stop.

[0075] 2. Flexible production system for implementing this method

[0076] A system for implementing the above-described "flexible production method for ordered dewaxing of rigid contact lenses", the system comprising:

[0077] (1) Core process modules: including an ultrasonic pretreatment unit and a constant temperature dewaxing and collection unit that are physically isolated in space, as well as a transfer mechanism between the two units (any automated equipment that can transfer lenses is acceptable, such as a robotic arm, gantry crane, conveyor belt, or other equivalent implementation schemes that are more cost-effective or more suitable for mass production).

[0078] like Figure 2 As shown, the ultrasonic pretreatment unit includes an ultrasonic cleaner 1 containing a first cleaning solution 2. Inside the ultrasonic cleaner 1, a suspended lens carrier 3 is placed. The bottom surface of the lens carrier 3 has several blind holes, and a downward-facing mandrel carrier 5 is fixedly fitted into each blind hole. The lower end of the mandrel carrier 5 is curved (the upper end, for example, is threaded into the blind hole). The rigid contact lens 7 is bonded to the lower end of the mandrel carrier 5 through a wax layer 6 on its back. Because it is bonded and fixed at this point, the wax layer 6 is softened by ultrasonic pretreatment. The first cleaning solution 2 can be prepared according to the ultrasonic cleaning requirements.

[0079] In order to ensure that the lens carrier 3 is stably placed in the constant temperature dewaxing environment after being transferred, a positioning groove 4 is provided at the bottom of the lens carrier 3, which can cooperate with the positioning pin 11 provided on the top surface of the buffer collection device 8 to prevent shaking.

[0080] like Figure 3 As shown, the constant-temperature dewaxing collection unit includes a constant-temperature dewaxing tank 12 containing a second cleaning solution 13. A buffer collection device 8 is placed on the bottom surface of the constant-temperature dewaxing tank 12. The top surface of the buffer collection device 8 is provided with several collection slots (each collection slot is a collection unit, and each collection unit is a modular structure that can be independently disassembled, replaced, or cleaned). A layer of removable sponge 10 is provided inside the slots. When the lens carrier 3 is transferred to the constant-temperature dewaxing tank 12, its bottom positioning slot engages with the positioning pin 11 for positioning contact. The wax layer is melted by the constant-temperature second cleaning solution 13, after which the rigid contact lens 7 detaches. The detached rigid contact lens 7 falls vertically and orderly into the collection slot. At this time, the rigid contact lens 7 with the wax layer is in the state of a rigid contact lens 9 without a wax layer.

[0081] The unwaxed rigid contact lens 9 can be recycled later.

[0082] (2) Intelligent control system: configured as follows:

[0083] Depending on the selected mode, either fully automatic mode A (continuous production) or semi-automatic mode B (single production) will be executed; for example... Figure 1As shown, the fully automatic mode steps are: receiving production instructions / reading product codes, calling process formulas (database), scheduling materials (e.g., robotic arm picking up materials), ultrasonic pretreatment (according to the formula), safe transfer, hot melting and directional collection, and determining whether production is continuous: if so, continue the cycle from scheduling materials; otherwise, end. The semi-automatic mode steps are: waiting for manual material loading confirmation, confirming process parameters (manual / adjusting formula), automatically executing the complete cycle of the fully automatic mode, providing audible and visual prompts upon completion, waiting for manual material unloading, and repeating the above semi-automatic mode steps after unloading.

[0084] The system stores multiple databases of process formulas associated with different lens styles and specifications. Each formula contains independently adjustable ultrasonic and thermal fusion parameters. (Each formula is configured as follows: operators can adjust and test the equipment in semi-automatic mode. Once the effect is confirmed, the current parameter set can be saved as a standardized process template. Each product style is equipped with a unique identification tray. The system can accurately call the corresponding preset process template by automatically recognizing the tray identification, achieving automated production with a "one product, one policy" approach. Each lens formula has a corresponding standardized process template with a unique identification tray, forming a binding relationship. Later, recognizing the identification will allow the system to retrieve the process formula for that lens.)

[0085] Based on the input lens style and specification information, the corresponding process formula is automatically retrieved (refer to the principle of automatic matching and template retrieval by scanning identifiers in the above system. A process formula intelligent matching and decision-making process is executed: by identifying the unique identifier (such as a QR code) on the carrier, the lens specification information is obtained, and this is used as a key index to retrieve and call the complete process formula that matches the current production context from the pre-stored process formula database).

[0086] The control transfer mechanism adapts to lens carriers 3 and buffer collection devices 8 of different sizes. Here, the carriers and collection devices are universal, with fixed physical dimensions and positioning interfaces; therefore, the transfer mechanism itself requires no adjustment for adaptation. Each lens style's process formula has pre-set all pick-up and drop-off positions and motion paths for this universal carrier and collection device. When the system is working, scanning the QR code on the carrier automatically retrieves the corresponding formula, and then the control transfer mechanism executes according to the coordinates and steps set in the formula.

[0087] The inner liner of the collection compartment of the buffer collection device is a modular design that can be independently disassembled, replaced, and cleaned. This design facilitates thorough cleaning of the inner liner after each dewaxing cycle, or the use of clean inner liners for lenses from different batches or with different levels of contamination, thereby effectively preventing cross-contamination and ensuring the basic cleanliness of the lenses after dewaxing.

[0088] The system's human-machine interface includes a lens specification selection menu (e.g., ...). Figure 4 (as shown), or it can support automatic identification of lens style and call up the corresponding process formula by scanning the identification code on the vehicle.

[0089] In addition, the system is also equipped with an automatic material transfer mechanism. The control system is configured to control the automatic material transfer mechanism to perform at least one transfer or preparatory operation for subsequent batches during the time period when the constant temperature dewaxing collection unit is processing a batch.

[0090] The process of the present invention will be described in detail below with reference to embodiments.

[0091] Example 1: Steady-state operation in fully automated continuous production mode – an efficient dewaxing solution based on multi-station collaboration and intelligent scheduling

[0092] This embodiment, based on the core architecture of "adjustable ultrasonic pretreatment + constant-temperature hot-melt directional collection" in the technical solution, demonstrates the steady-state operation logic of the system in large-scale production. After the equipment starts up and completes initialization (including self-checks of the ultrasonic unit, constant-temperature dewaxing tank, and material transfer mechanism), it enters a continuous production cycle with the constant-temperature hot-melt collection stage as the core and the pretreatment and collection units preparing in parallel. This is achieved through the control system... Figure 3 The coordinated control of the positioning pin 11 and the bearing platform enables seamless connection of processes.

[0093] The core operating logic is as follows:

[0094] At any given moment, while a batch of lenses is undergoing hot melting and directional collection in the constant-temperature dewaxing tank, the system simultaneously performs preparation work for subsequent batches. Specifically, the control system schedules the automatic material transfer mechanism so that two or more of the following operations overlap in time:

[0095] (1) Core Operation (Irrigation and Directional Collection): The current batch of microscope trays is transferred to the isothermal dewaxing tank by a robotic arm. Figure 3 (12) The hot-melt treatment is performed at 65±0.5℃ as specified in Formula A. The system uses a PID temperature control module to maintain the pool liquid temperature fluctuation within ±0.3℃ to ensure uniform melting of the wax layer. After the preset hot-melt time of 180 seconds is reached, the lens naturally detaches in the still liquid and falls through the directional discharge hole at the bottom of the carrier (towards...). Figure 2 The lens is precisely aligned with the positioning slot 4 and falls vertically into the 12-station collection unit below, which has already been aligned (positioning accuracy ±0.1mm), realizing one-to-one correspondence and traceability between the lens and the carrier station.

[0096] (2) Parallel preparatory operation one (ultrasound pretreatment): At the same time, the system will transfer the next batch of lens trays to the ultrasound pretreatment unit. Figure 2(1) Calling Formula A parameters: Perform 180 seconds of assisted loosening treatment at a frequency of 40 kHz (adjustable within the range of 20-200 kHz) and 60% of rated power. The pretreatment tank solution is maintained at 25±2℃ through an independent temperature control loop, in conjunction with... Figure 2 The transducer array of the ultrasonic cleaner 1 shown enables uniform loosening of the wax layer without damaging the lens surface.

[0097] (3) Parallel Preparatory Operation Two (Clean Collection Unit Preparation): The system uses an AGV to transfer the sterilized standby collection unit to the positioning platform, uses a laser alignment system to complete the ±0.05mm accuracy calibration, and then... Figure 3 The removable sponge 10 of the buffer collection device 8 is pre-wetted to ensure the cleanliness and cushioning performance of the lens receiving surface.

[0098] Once the batch in the constant temperature bath has completed dewaxing, the system quickly completes the material handover: empty pallets are removed and full collection units are handed over. Immediately afterwards, the batch that has completed ultrasonic pretreatment is transferred to the constant temperature bath to become the new "core operation," while new preparatory operations are immediately initiated. This cycle repeats continuously, forming an uninterrupted production flow, achieving extremely high equipment utilization and production efficiency.

[0099] The core of this operating logic lies in the intelligent scheduling algorithm of the control system. Specifically, this algorithm is based on multi-sensor data fusion and adaptive control theory, using industrial Ethernet to achieve real-time data interaction between the ultrasonic unit, the constant-temperature dewaxing tank, and the material transfer mechanism. The algorithm employs a three-layer architecture: 1. Data Acquisition Layer: Real-time operating parameters of each unit are acquired via distributed PLC (including ultrasonic frequency scanning data of 100-150kHz, PID feedback values ​​of dewaxing tank temperature of 50±0.3℃, and laser detection data of carrier positioning accuracy of ±0.1mm), with a sampling frequency of 100Hz. 2. Decision Control Layer: A fuzzy PID composite algorithm is used to dynamically correct process parameters based on real-time wax layer thickness detection results (obtained through an infrared spectral sensor). For example, the hot-melt immersion time is adaptively adjusted within the range of 200±10 seconds to ensure precise matching between the wax layer dissolution rate and the lens detachment timing. 3. Execution Feedback Layer: An event-driven task scheduling mechanism is adopted. When the system detects that the pretreatment tank temperature reaches the set value of 30±1℃, it automatically triggers the material transfer mechanism to move the carrier from the positioning tank (…). Figure 2 4) Transfer to a constant temperature dewaxing tank ( Figure 3 (12), and through the positioning pin 11 ( Figure 3 Achieves ±0.05mm repeatability, ensuring that the lens falls accurately into the buffer collection device after orderly dislodgement. Figure 3The system enables real-time data exchange between the ultrasonic unit, the constant-temperature dewaxing tank, and the material transfer mechanism via industrial Ethernet. It supports two configuration modes: ① single-arm serial operation (process overlap is achieved through time window allocation); ② multi-arm parallel operation (different batches are processed independently in physical space). Both modes can achieve continuous production with equipment utilization ≥90% through parametric programming.

[0100] This embodiment can be used for the production operation of formula A or formula B. Two formula examples are as follows:

[0101] Formula A (Orthokeratology lens - standard material, diameter 10.6mm): For the balance parameter settings of methyl methacrylate (PMMA) substrate, the following adjustable parameter combinations are achieved through the "parameter adaptive adjustment module" in the technical solution:

[0102] Adjustable parameters of the ultrasonic pretreatment unit:

[0103] Ultrasonic frequency: 40 kHz (can be set independently within the range of 20-200 kHz);

[0104] Ultrasonic power: 60% (adjustable range: 10%-100%, corresponding to the percentage of the equipment's maximum rated power);

[0105] Processing time: 180 seconds (can be set independently);

[0106] Pretreatment tank liquid temperature: 25°C (set value, the temperature control system can maintain it within ±2°C);

[0107] Adjustable parameters of the isothermal dewaxing collection unit:

[0108] Dewaxing bath solution temperature: 65°C (set value; a high-precision temperature control system can maintain it within ±0.5°C).

[0109] Hot melt soaking time: 180 seconds (can be set independently).

[0110] Formula B (RGP lens - high oxygen permeability material, diameter 11.0mm): This formula addresses the differentiated parameter settings for the silicone acrylate copolymer material. By adjusting the ultrasonic energy and heat-melting temperature to match the material properties, all parameters can be modified and saved in real-time via the human-machine interface.

[0111] Adjustable parameters of the ultrasonic pretreatment unit:

[0112] Ultrasonic frequency: 80 kHz;

[0113] Ultrasonic power: 40%;

[0114] Processing time: 150 seconds;

[0115] Pretreatment tank liquid temperature: 28°C (set value, ±2°C);

[0116] Adjustable parameters of the isothermal dewaxing collection unit:

[0117] Dewaxing bath solution temperature: 58°C (set value, ±0.5°C);

[0118] Hot melt soaking time: 160 seconds.

[0119] This solution enables process collaboration through real-time data interaction and dynamic parameter adjustment: during the constant temperature dewaxing stage, the next batch of ultrasonic pretreatment and clean collection unit preparation work are executed in parallel. Through intelligent scheduling algorithms, continuous production with equipment utilization rate ≥90% is achieved, while meeting the "one product, one policy" process requirements for different lens styles.

[0120] Example 2: Process Development and Cleanliness Management in Semi-Automatic Mode – A Flexible R&D Solution Based on Modular Design

[0121] This embodiment is based on the "flexible production mode" design in the technical solution. By combining manual feeding with automatic process execution, it meets the needs of new product development and small-batch customization, while solving the cross-contamination problem of traditional dewaxing process.

[0122] Process development flow: After the operator selects the semi-automatic mode, the tray containing the new model of prototype lenses is manually placed through the side door of the equipment. Figure 2 (3) and corresponding collection baskets ( Figure 3 (8) Insert the designated interface. The system will automatically identify the vehicle ID and retrieve the basic parameter template. Engineers can set parameters within the following range via the 10.1-inch touchscreen: ultrasonic frequency 20-200 kHz (1 kHz step), power 10%-100% (stepless adjustment), heat fusion temperature 40-80°C (accuracy ±0.1°C), and processing time 30-300 seconds. After startup, the equipment will proceed according to the "Ultrasonic Pretreatment (...)" command. Figure 2 → Robotic arm transfer → Constant temperature dewaxing ( Figure 3The process of "lens collection" is executed automatically, with process data displayed in real time on the interface (including temperature curves and ultrasonic power waveforms). Operators can observe the dewaxing process through a transparent viewing window. After completion, the collection unit is removed for cleanliness testing (residual wax ≤ 0.1 mg / lens) and damage inspection (no scratches under an optical microscope). A customized process formula is generated through parameter iteration and stored in the system database. (Specifically: a customized process formula can be generated through multi-dimensional parameter iteration optimization and stored in the system database. Its technical principle is based on adaptive process modeling and closed-loop feedback control. The implementation process is as follows: 1. Basic parameter initialization: The system presets an initial set of process parameters based on the lens material (such as fluorosilicone acrylate, siloxane, etc.), radius of curvature (8.4-9.2 mm), and wax layer thickness (50-150 μm), including the ultrasonic frequency scanning range (100-150 kHz), pretreatment time (200-280 seconds), and dewaxing temperature (48-52℃); 2. Iterative optimization mechanism: The gradient descent algorithm is used to iterate the key parameters in multiple rounds. During each batch of production, the wax layer dissolution rate data is collected in real time by an infrared spectral sensor (detection accuracy ±2μm). Combined with the lens detachment time difference (target control within ±5 seconds), the parameters are dynamically corrected. For example, when the wax layer residual rate is detected to be >3%, the ultrasonic power is automatically increased by 5%-8% or the soaking time is extended by 10-15 seconds. 3. Formula generation and storage: The optimal parameter combination formed after iteration (including 12 key process parameters) is bound to the lens model (such as orthokeratology lens, RGP) and production batch information to generate a unique formula ID and store it in a distributed database. It supports formula calling, version traceability (retaining modification records of the past 6 months) and cross-production line synchronous updates through the MES system to meet personalized production needs.

[0123] Cleaning and pollution prevention management: Design based on the "removable buffer collection device" in the technical solution ( Figure 3 (8) The system adopts a three-level anti-contamination control: ① The quick-installation interface design of the collection unit and the positioning pin (11) supports the completion of the overall replacement within 30 seconds; ② The surface of the unit is made of medical-grade PP material, which, together with the detachable sponge (10), enables disposable use or high-pressure sterilization at 121℃; ③ After each batch of production, the cleanliness of the spare unit is verified by the ATP bio-fluorescence detector (colony count ≤1 CFU / cm²). When switching to different models of lenses, the operator reads the carrier ID by scanning the barcode, and the system automatically prompts to replace the corresponding model of collection unit, completely eliminating the risk of cross-contamination of the traditional fixed buffer layer.

[0124] Example 3: Adaptive Parameter Adjustment and Special Working Condition Handling – Intelligent Process Optimization Scheme Based on Multi-Sensor Fusion

[0125] This embodiment is based on the "parameter adaptive adjustment module" in the technical solution. By integrating a temperature sensor, an ultrasonic power feedback unit, and a visual inspection system, it achieves dynamic optimization of process parameters under special working conditions.

[0126] For uneven wax layers: When the vision system detects a deviation in lens wax layer thickness exceeding ±5% (via... Figure 2 (Optical imaging is achieved in the positioning slot 4). The system automatically activates the "frequency sweep" ultrasonic mode: linearly scanning at a rate of 5 kHz / second within the range of 20-200 kHz, and matching the vibration frequency of the wax layer with its natural frequency through wide-spectrum excitation, achieving 360° loosening without dead angles. At the same time, the system monitors the change in ultrasonic reflection power in real time. When the power fluctuation is ≤3%, it is determined that the wax layer is loosened uniformly, and the system automatically proceeds to the next process.

[0127] To meet high yield requirements: For ultra-thin custom lenses with a thickness ≤0.05mm, the system utilizes "ultra-safe" formula C, achieving zero damage through the following combination strategy: ① Employing 100-150 kHz high-frequency ultrasound (reducing cavitation effect); ② 20% of rated power (energy density ≤0.5 W / cm²); ③ 50℃ low-temperature heat fusion (15℃ lower than standard process). Combined with... Figure 3 The 8mm thick high-density sponge (10) of the buffer collection device (8) ensures that the impact acceleration of lens falling off is ≤500 G, and the yield rate is increased to 99.9%.

[0128] The system control core has a built-in database of 128 process formulas, covering 16 product categories including orthokeratology lenses, RGP lenses, and astigmatism filters. Through an industrial IoT platform, new formulas can be remotely imported or parameters can be autonomously optimized based on production data using AI algorithms (such as automatically adjusting the hot melt time according to the wax layer thickness), realizing a process upgrade from "experience-driven" to "data-driven".

[0129] Formula C (Ultra-thin Lens - "Ultra-safe" Mode): For polyethersulfone (PES) lenses with a thickness of 0.03-0.05mm, this formula combines parameters of frequency-sweeping ultrasound and low-temperature hot-melt technology.

[0130] This formulation example demonstrates ultra-high safety level parameter settings for extremely high-value or fragile lenses and introduces advanced control modes:

[0131] Adjustable parameters of the ultrasonic pretreatment unit:

[0132] Ultrasound working mode: Frequency sweep mode (can be selected independently; in this mode, the frequency is linearly scanned in the range of 100-150 kHz, and the scan cycle is 20 seconds / scan).

[0133] Ultrasonic power: 20%;

[0134] Processing time: 240 seconds;

[0135] Pretreatment tank liquid temperature: 30°C (set value, ±1°C, achieved using a bipolar temperature control system);

[0136] Adjustable parameters of the isothermal dewaxing collection unit:

[0137] Dewaxing bath solution temperature: 50°C (set value, ±0.3°C, using PID + fuzzy control algorithm);

[0138] Hot melt soaking time: 200 seconds (dynamically corrected by ±10 seconds based on real-time wax layer thickness detection results).

[0139] Therefore, in this embodiment, the system is based on "parameter adaptive adjustment" and uses a three-layer collaborative mechanism to achieve dynamic optimization of process parameters under special operating conditions:

[0140] An integrated high-precision temperature sensor (Pt1000, measurement range 0-100℃, accuracy ±0.1℃) is used to collect the temperature field distribution of the pretreatment tank (30±1℃) and the constant temperature dewaxing tank (50±0.3℃) in real time; an ultrasonic power feedback unit (sampling frequency 1kHz) monitors the actual output power of the transducer (adjustable range 20%-100%); and an industrial vision system (2-megapixel CCD camera + 50mm fixed-focus lens) uses image recognition technology to detect the thickness of the wax layer at the edge of the lens (accuracy ±5μm) and the state of detachment.

[0141] A fuzzy PID composite control algorithm (or a conventional PID algorithm) is adopted to establish a mapping model (or mapping table) between process parameters and wax dissolution rate. The system automatically triggers the adjustment mechanism when it detects the following special conditions: (1) When the temperature fluctuation of the dewaxing tank exceeds ±0.5℃, the power of the heating tube is dynamically corrected by the PID algorithm (response time <2 seconds); (2) When the deviation between the ultrasonic power feedback value and the set value is >3%, the power compensation module is activated; (3) When visual inspection finds that the wax residue rate is >5%, the hot melt soaking time is automatically extended by 5-15 seconds or the ultrasonic frequency is increased by 5-10kHz.

[0142] Adjustment commands are sent to the execution unit in real time via the Profinet bus. For example, when the temperature of the pretreatment pool is below 29°C, the temperature control module automatically switches to bipolar heating mode. After the lens falls off, the vision system triggers the material transfer mechanism to transfer the carrier to the next process, and at the same time sends the adjustment parameters (such as the corrected soaking time of 212 seconds) back to the MES system to form a closed-loop record.

[0143] Those skilled in the art will clearly understand that, for the sake of convenience and brevity, the specific working processes of the devices, apparatuses, and units described above can be referred to the corresponding processes in the foregoing method embodiments, and will not be repeated here.

[0144] In the several embodiments provided by this invention, it should be understood that the disclosed devices, apparatuses, and methods can be implemented in other ways. For example, the apparatus embodiments described above are merely illustrative; for instance, the division of units is only a logical functional division, and in actual implementation, there may be other division methods. For example, multiple units or components may be combined or integrated into another device, or some features may be ignored or not executed. Furthermore, the coupling or direct coupling or communication connection shown or discussed may be through some interfaces; the indirect coupling or communication connection between devices or units may be electrical, mechanical, or other forms.

[0145] The units described as separate components may or may not be physically separate. The components shown as units may or may not be physical units; that is, they may be located in one place or distributed across multiple network units. Some or all of the units can be selected to achieve the purpose of this embodiment according to actual needs.

[0146] In addition, the functional units in the various embodiments of the present invention can be integrated into one processing unit, or each unit can exist physically separately, or two or more units can be integrated into one unit.

[0147] If the aforementioned functions are implemented as software functional units and sold or used as independent products, they can be stored in a computer-readable storage medium. Based on this understanding, the technical solution of this invention, or the part that contributes to the prior art, or a part of the technical solution, can be embodied in the form of a software product. This computer software product is stored in a storage medium and includes several instructions to cause a computer device (which may be a personal computer, server, or network device, etc.) to execute all or part of the steps of the methods described in the various embodiments of this invention. The aforementioned storage medium includes various media capable of storing program code, such as USB flash drives, portable hard drives, read-only memory (ROM), random access memory (RAM), magnetic disks, or optical disks.

[0148] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A flexible manufacturing method for the orderly dewaxing of rigid contact lenses, characterized in that, Includes the following steps: S1. Adjustable ultrasonic pretreatment step: Immerse the lens carrier (3) with the rigid contact lens (7) fixed in the first cleaning solution (2) in the ultrasonic cleaner (1) for treatment; during treatment, call the corresponding process formula according to the lens style and specifications. The formula includes at least the appropriate ultrasonic frequency, ultrasonic power and treatment time, so that the water-soluble wax layer (6) of the fixed lens (7) is fully softened and structurally loosened, while ensuring that the lens (7) does not fall off at this stage. S2, Safe transfer step: The lens carrier (3) after being processed in step S1 is transferred from the ultrasonic cleaner (1) to a physical space-independent constant temperature dewaxing collection unit through a transfer mechanism; S3, Constant Temperature Hot Melting and Directional Collection Steps: Immerse the lens carrier (3) in the second cleaning liquid (13) in the constant temperature dewaxing tank (12) to melt the pre-loosened wax layer (6); the lens (7) falls off vertically and orderly in a static liquid environment and falls precisely into the buffer collection device (8) in the constant temperature dewaxing tank (12) in an independent collection unit corresponding to the lens fixing position on the lens carrier (3) to obtain the removed wax-free rigid contact lens (9).

2. The method according to claim 1, characterized in that, In step S1, the ultrasonic frequency is adjusted within the range of 20kHz to 200kHz.

3. The method according to claim 2, characterized in that, In step S1, the adjustable ultrasonic preprocessing step adopts a frequency sweep mode, which allows the ultrasonic frequency to change continuously or in steps within a specified range of 20kHz to 200kHz during a single processing step.

4. The method according to any one of claims 1 to 3, characterized in that, The execution modes of the method include: In response to the fully automatic mode command, steps S1 to S3 are executed automatically and continuously in a loop for continuous production; or, In response to the semi-automatic mode command, after receiving a manual feeding confirmation, it automatically executes a complete cycle from step S1 to S3. After completion, it provides an audio-visual prompt and waits for manual feeding.

5. The method according to claim 1, characterized in that, Before performing step S1, the following is also included: The lens style and specifications can be determined by selecting the lens specifications through the human-machine interface menu or by scanning the identification code on the lens carrier (3); Based on the determined style specifications, the corresponding process formula containing independently adjustable ultrasonic parameters and hot melt parameters is automatically retrieved from a database of multiple pre-stored process formulas.

6. The method according to claim 5, characterized in that, The process formula database supports operators in semi-automatic mode for parameter adjustment and trial operation of each formula, and saves the confirmed valid parameter set as a dedicated standardized process template corresponding to that lens style; The system automatically matches and calls the corresponding process template by recognizing the unique identification code on the lens carrier (3) or its matching container.

7. The method according to claim 1, characterized in that, Each independent collection unit of the buffer collection device (8) is a modular structure that can be independently disassembled, replaced or cleaned.

8. The method according to claim 1 or 4, characterized in that, During the execution time of step S3, the control system schedules the material transfer mechanism in parallel to perform at least one preparatory operation from step S1 and / or for step S3 to prepare a new collection unit for subsequent batches of lenses, thereby realizing multi-station collaboration and intelligent scheduling.

9. A flexible production system for implementing the method according to any one of claims 1 to 8, characterized in that, include: ‌ a. Core process modules, which include: The ultrasonic pretreatment unit consists of an ultrasonic cleaner (1) containing a first cleaning fluid (2) and is used to perform controlled ultrasonic pretreatment on a lens carrier (3) with a rigid contact lens (7) fixed on it. The constant temperature dewaxing collection unit consists of a constant temperature dewaxing tank (12) containing a second cleaning liquid (13), and the constant temperature dewaxing tank (12) is equipped with a buffer collection device (8) for receiving the detached lenses (9). And a transfer mechanism for automatically transferring the lens carrier (3) between the ultrasonic pretreatment unit and the constant temperature dewaxing collection unit; b. The intelligent control system is configured as follows: Control the system to respond to fully automatic or semi-automatic mode execution; Manage and access multiple sets of process formula databases associated with different lens styles and specifications; each formula contains independently adjustable ultrasonic parameters and thermal fusion parameters. Based on the input lens style and specification information, the system automatically retrieves the corresponding process formula from the database to control each module to perform the corresponding operations. The control mechanism is adapted to lens carriers (3) and buffer collection devices (8) of different sizes; While the constant temperature dewaxing and collection unit is processing the current batch, the material transfer mechanism is controlled to perform at least one transfer or preparatory operation for subsequent batches. c. A human-machine interface, which has a lens specification selection menu and / or supports scanning the identification code on the lens carrier (3) to automatically identify the lens style and call up the process formula.

10. The system according to claim 9, characterized in that, The top surface of the buffer collection device (8) is provided with a positioning pin (11), and the bottom of the lens carrier (3) is provided with a positioning groove (4) that cooperates with the positioning pin (11) so as to achieve accurate positioning of the lens carrier (3) in the constant temperature dewaxing tank (12).

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