A method and system for traceability coding of contact lenses

Abstract

This invention provides a method and system for transferring traceability codes onto contact lenses, belonging to the field of automated contact lens manufacturing. The transfer method comprises five core steps: lens loading and information encoding, pre-transfer fixture positioning and calibration, traceability code transfer operation, online transfer quality detection, and lens sorting and receiving. The traceability code is transferred to the outer ring area of ​​the lens, avoiding the lens's optical zone. This invention also provides a transfer system for executing the above method, comprising multiple functional modules operating collaboratively. This invention solves the problems of insufficient transfer accuracy, low automation, and poor product traceability in existing contact lens production technologies, achieving traceable control throughout the entire contact lens production process, effectively improving transfer production efficiency and product qualification rate, and is suitable for large-scale automated production of contact lenses.

Description

Technical Field

[0001] This invention relates to the field of automated production and manufacturing technology for contact lenses, specifically to a method and system for transferring traceability codes to contact lenses. Background Technology

[0002] With the rapid development of the contact lens industry, the market demand for colored contact lenses continues to grow. These lenses possess both medical and decorative attributes, and quality control during the manufacturing process directly impacts users' eye health and safety. Pad printing is a core process in colored contact lens production, directly determining the lens's appearance quality and production yield. Existing pad printing equipment and processes primarily focus on printing patterns on the lens surface, with a low overall level of automation. Most adopt semi-automated production models, requiring significant manual intervention in process flow and operational control. Problems such as positional misalignment, residual ink on the printing pad, and uneven printing are prone to occur, significantly reducing production efficiency and easily leading to a decrease in product yield. Furthermore, current quality inspection processes in pad printing largely rely on manual offline inspection, with results heavily influenced by personnel condition and operational procedures. This makes it difficult to guarantee the stability and consistency of test results, and hinders the quantitative control and traceability of test data, failing to meet the quality control requirements of large-scale contact lens production.

[0003] As a Class III medical device, contact lenses are subject to stringent national regulations and industry standards regarding the traceability of their entire production process. Currently, most traceability information for contact lenses is only located on the outer packaging, with no corresponding traceability markings on the lens itself. Once a lens is removed from its packaging, traceability and origin confirmation become impossible, failing to meet the traceability and control requirements throughout the product's lifecycle. Furthermore, in current production processes, the manufacturing process data for a single lens cannot be uniquely linked to the lens itself, hindering transparent control of the production process and making it difficult to quickly pinpoint the problem area and scope of impact when quality issues arise. While some existing technologies attempt to print markings on the lens itself, most do not avoid the lens's optical areas, potentially negatively impacting optical performance and wearability. Moreover, the printing process lacks precision and stability, making it incompatible with existing automated production lines and hindering large-scale mass production applications. Summary of the Invention

[0004] To address the aforementioned technical shortcomings, the purpose of this invention is to provide a method and system for transferring traceability codes to contact lenses, which solves the problems of insufficient transfer printing accuracy, low automation, and poor product traceability in the prior art.

[0005] To achieve the above objectives, the present invention adopts the following technical solution:

[0006] A method for transferring traceability codes to contact lenses includes the following steps:

[0007] Step 1: Perform lens loading process, transport the lens to be printed to the preset processing station, collect the basic parameter information of the lens to be printed, encode the collected basic parameter information, and convert it into a traceable code format that can be printed.

[0008] Step 2: Perform pre-printing positioning processing. The position of the printing fixture carrying the lens to be printed is acquired and spatially calibrated by the fixture positioning component. After calibration, the spatial position of the printing fixture is locked and the position data corresponding to this positioning is recorded.

[0009] Step 3: Perform the traceability code transfer operation. The converted traceability code is transferred to the outer ring area of ​​the lens through the transfer mechanism. No traceability code is set in the optical area of ​​the lens.

[0010] Step 4: Perform pad printing quality inspection. Use a vision inspection system to capture full-area images of the completed pad printing lenses, identify the pad printing status of the traceability code, and generate the corresponding quality inspection results for each individual lens.

[0011] Step 5: Perform lens receiving process. Based on the generated quality inspection results, classify, transport, and collect the completed pad-printed lenses.

[0012] Preferably, in step one, the lens to be printed is transported to the preset processing station of the mold tray by an automatic feeding system, the basic parameter information of the lens to be printed is collected by an optical recognition system, the collected basic parameter information is encoded and converted to generate a traceability code graphic file corresponding to each lens.

[0013] Preferably, in step two, the fixture positioning component is activated to collect real-time spatial position data of the pad printing fixture, the real-time spatial position data is compared with preset standard position data, the spatial position of the pad printing fixture is adjusted according to the comparison result, the position deviation of the pad printing fixture is detected by the sensor system, and the positioning is completed when the position deviation meets the preset threshold, and the position data of this positioning is recorded.

[0014] Preferably, in step three, a pad printing plate of the corresponding specification is prepared according to the generated traceability code graphic file. The printing ink corresponding to the traceability code is picked up from the pad printing plate by the pad printing head and transferred to the annular area formed by the outer circle of the lens extending inward from the outer diameter. During the transfer process, the downward pressure of the pad printing head, the printing speed and the printing coordinates are controlled in a closed loop.

[0015] Preferably, in step four, the visual inspection system is activated to acquire a full-area image of the printed lens. The acquired full-area image is analyzed and processed by an image recognition algorithm to identify the graphic integrity and printing clarity of the traceability code. The identification results are compared with preset qualification standards to generate the quality inspection results for the corresponding single lens.

[0016] Preferably, in step five, the quality inspection result corresponding to a single lens is received, lenses that meet the preset qualified standards are transported to the qualified material tray for regular collection, lenses that do not meet the preset qualified standards are transported to the unqualified material tray for isolation collection, and the binding relationship between the quality inspection result of each lens and the corresponding traceability code is recorded simultaneously.

[0017] Preferably, the traceability code includes basic parameter information and internal control information of the lens. The basic parameter information includes lens power, left and right eye identification, material type, and usage period. The internal control information includes an internal identification code corresponding to the lens manufacturing process.

[0018] Preferably, in step two, after the positioning and locking are completed, the recorded position data is synchronously transmitted to the pad printing mechanism. The pad printing mechanism adjusts the pad printing coordinates according to the received position data so that the pad printing position of the traceability code matches the outer ring area of ​​the lens.

[0019] A contact lens traceability code transfer system includes a feeding module, a positioning module, a transfer module, a detection module, and a receiving module;

[0020] The feeding module is used to perform the feeding and conveying of lenses and the collection and processing of basic parameter information of the lenses to be pad-printed;

[0021] The positioning module is used to perform position acquisition, calibration and locking processing of the pad printing fixture;

[0022] The pad printing module is used to perform the preparation of traceability codes and the pad printing operation on the lens surface;

[0023] The detection module is used to perform image acquisition and quality inspection processing of the printed lenses;

[0024] The receiving module is used to perform the sorting, conveying, and collection of lenses after pad printing.

[0025] Preferably, the positioning module establishes a data communication connection with the pad printing module, and the positioning module synchronously transmits the locked pad printing fixture position data to the pad printing module, and the pad printing module adjusts the pad printing coordinates according to the received position data.

[0026] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0027] The lens loading process simultaneously completes the workstation transport, basic information collection, and traceability code encoding conversion, achieving a unique binding between each lens and its corresponding traceability code. This integrates the lens's basic parameter information and production process information into the traceability code, providing a complete data foundation for traceability control throughout the entire lens production process and lifecycle.

[0028] By performing fixture positioning and calibration before pad printing, the position acquisition, deviation calibration, and spatial locking of the pad printing fixture are completed. This effectively ensures the positional accuracy of subsequent pad printing operations, avoids the problem of pad printing position deviation, and greatly improves the stability of pad printing operations and the consistency of batch products.

[0029] The traceability code is transferred to the annular area on the outer edge of the lens, completely avoiding the optical area of ​​the lens. This allows the traceability information to be printed directly onto the lens body without causing any adverse effects on the lens's optical performance or normal wear and use, thus balancing product traceability and safety.

[0030] By conducting an online visual inspection after pad printing is completed, automated online inspection of pad printing quality is achieved, replacing the traditional manual offline quality inspection mode. This effectively reduces the interference of human factors on the inspection results, ensures the stability and quantifiability of the quality inspection results, and enables the binding and storage of inspection data with the corresponding lens traceability code, further improving the traceability and control chain.

[0031] By designing fully automated processes, continuous collaborative operation is achieved in all stages, including material loading, positioning, pad printing, inspection, and material collection. This effectively improves the production efficiency of the contact lens pad printing process, reduces labor costs, and enables transparent control of the production process through the synchronous flow and binding of data from each stage. It also allows for the rapid identification of abnormal processes and improves the overall quality control level. Attached Figure Description

[0032] Figure 1 This is a flowchart of the method of the present invention;

[0033] Figure 2 This is a structural block diagram of the system in this invention. Detailed Implementation

[0034] The invention will now be further described with reference to the accompanying drawings.

[0035] like Figure 1 As shown, a method for transferring traceability codes for contact lenses specifically includes:

[0036] The first step is the lens loading process. An automated loading mechanism continuously transports the lenses to be printed to a pre-set processing station on the mold tray. An optical recognition component collects the basic parameter information of the lenses, encodes and converts this information, and generates a unique traceability code graphic file corresponding to each lens. By completing the collection of individual lens information and the generation of a unique identifier at the initial stage of lens processing, an initial binding relationship is established between the lens and the traceability information. This provides a unique data identifier for subsequent full-process traceability control, while also enabling automated continuous lens loading to meet the cycle time requirements of large-scale mass production.

[0037] After the material loading process is completed, a pre-printing positioning process is performed. The fixture positioning component is activated to collect the real-time spatial position of the printing fixture carrying the lens to be printed. This real-time spatial position is compared with a preset standard position. Based on the comparison results, the spatial position of the printing fixture is adjusted in multiple dimensions. After the position detection component confirms that the positional deviation of the printing fixture meets the preset requirements, the spatial position of the printing fixture is locked, and the corresponding positional data is recorded simultaneously. Precise calibration and locking of the processing benchmark are completed before the printing operation, eliminating positional deviations generated during fixture clamping and transport. This provides a unified and stable positional benchmark for the subsequent accurate printing of traceability codes, effectively avoiding printing position offset issues and ensuring the consistency of printing position across batches of products.

[0038] After positioning and locking are completed, the traceability code transfer printing process is executed. A transfer printing plate of the corresponding specifications is prepared based on the generated traceability code graphic file. A transfer printing head evenly picks up medical-grade printing ink from the surface of the plate and drives it along a preset trajectory, precisely transferring the ink to the outer ring area of ​​the lens. No traceability code transfer operation is performed on the optical area of ​​the lens. The traceability code, containing full traceability information of the lens, is directly printed onto the lens body, achieving a permanent binding between the traceability information and the lens. Simultaneously, the printing area of ​​the traceability code is strictly limited to the non-optical area of ​​the outer ring of the lens, completely avoiding any adverse effects of the printed content on the lens's optical performance and wearability, thus balancing product traceability and safety.

[0039] After the pad printing operation is completed, a pad printing quality inspection process is performed. A vision inspection system is activated to acquire a full-area high-definition image of the lens after pad printing. Image recognition algorithms are used to analyze and process the acquired full-area image, accurately identifying the graphic integrity and printing clarity of the traceability code. The identification results are compared with preset pass / fail standards to generate the corresponding quality inspection result for each lens. Simultaneously, the quality inspection result is bound and stored with the corresponding lens's traceability code. This achieves fully automated online inspection of pad printing quality, replacing the traditional manual offline quality inspection mode. It effectively eliminates the interference of human factors on the inspection results, ensuring the stability and consistency of the quality inspection results. At the same time, it binds the inspection data with the lens's unique traceability code, completing the entire lens traceability data chain. In the event of quality abnormalities, the corresponding lens and production stage can be quickly located.

[0040] After quality inspection, the lens receiving process is executed. The system receives the quality inspection results for each individual lens and drives a sorting and conveying mechanism based on these results. Lenses meeting the standards are transported to the qualified tray for standardized collection, while lenses not meeting the standards are transported to the unqualified tray for isolation and collection. Simultaneously, basic information, traceability codes, production process data, and quality inspection results for all lenses are uniformly archived and stored. Automated sorting and collection of lenses based on quality inspection results effectively separates qualified and unqualified products, preventing unqualified products from flowing into subsequent processes. Furthermore, unified archiving of all production data enables transparent control and full lifecycle traceability of the entire lens production process.

[0041] like Figure 2 As shown, a contact lens traceability code pad printing system includes a feeding module, a positioning module, a pad printing module, a detection module, and a receiving module. Each module establishes a bidirectional data communication connection, enabling synchronous data flow and collaborative operation throughout the entire process. This system architecture, through modular design, allows for independent control and collaborative operation of each process function, facilitating production line debugging, maintenance, and functional expansion. Simultaneously, data interoperability across all modules achieves closed-loop control of the entire production process, improving the automation level and operational stability of the production line.

[0042] The feeding module includes an automatic feeding component and an optical recognition component. The automatic feeding component continuously transports the lenses to be printed and precisely positions them at the workstation. The optical recognition component collects the basic parameter information of the lenses to be printed, encodes and converts the collected basic parameter information, generates a corresponding traceability code graphic file, and synchronously transmits the traceability code graphic file to the printing module. The feeding module achieves simultaneous completion of lens feeding and information collection and encoding, ensuring a unique binding between each lens and a traceability code. It also enables continuous lens feeding, matching the production rhythm of large-scale mass production, reducing manual intervention, and improving production efficiency.

[0043] The positioning module includes a fixture positioning component and a position detection component. The fixture positioning component acquires the spatial position of the pad printing fixture and performs multi-dimensional calibration and adjustment. The position detection component accurately detects the positional deviation of the pad printing fixture and confirms its compliance. After position confirmation, the pad printing fixture is spatially locked, and the positioning data is synchronously transmitted to the pad printing module and the detection module. The positioning module provides a precise positional reference for the entire pad printing process, eliminating positional errors during fixture transport. It also synchronously shares the positioning data with subsequent process modules, ensuring a consistent positional reference across all processes and further improving the accuracy and stability of the pad printing operation.

[0044] The pad printing module includes a steel plate preparation component, a pad printing head component, and a drive control component. The steel plate preparation component prepares a pad printing steel plate of the corresponding specifications based on the received traceability code graphic file. The drive control component adjusts the running trajectory and printing coordinates of the pad printing head component based on the received positioning data. The pad printing head component completes the uniform application of printing ink and precise transfer to the outer ring area of ​​the lens. The pad printing module achieves accurate replication and transfer of traceability code graphics. Through the linkage between the drive control component and the positioning data, dynamic calibration of the printing position is achieved, ensuring the accuracy of the traceability code printing position. It also adapts to the printing needs of different lens specifications and different traceability code graphics, improving the compatibility of the equipment.

[0045] The inspection module includes an image acquisition component and an image processing component. The image acquisition component acquires high-definition images of the entire lens after the pad printing process is completed. The image processing component analyzes and processes the acquired images and accurately identifies the pad printing status of the traceability code, generating a quality inspection result for each individual lens. This result is then synchronously transmitted to the receiving module. The inspection module achieves online automated inspection of pad printing quality, completing the quality verification of all products without manual intervention. This ensures the objectivity and quantifiability of the inspection results and enables real-time transmission of inspection data, providing a data basis for subsequent sorting and receiving.

[0046] The receiving module includes a sorting and conveying component and a tray collection component. The sorting and conveying component accurately sorts and conveys the lenses based on the received quality inspection results. The tray collection component neatly collects qualified and unqualified lenses, and simultaneously archives and stores all production data and traceability information for the entire lens manufacturing process. The receiving module achieves automated sorting, collection, and isolation management of lenses, ensuring product yield. It also archives all production data, providing comprehensive data support for product traceability and enabling transparent and traceable management of the production process.

[0047] This invention addresses the industry pain points of insufficient pad printing accuracy, low automation, and lack of traceability throughout the product lifecycle in the contact lens manufacturing process. It deeply integrates information encoding technology with automated pad printing processes to construct a traceability code pad printing solution with a closed-loop process.

[0048] The core working principle of this invention is as follows: During the lens loading stage, the basic parameter information of each individual lens is collected and its unique traceability code is encoded, establishing a one-to-one correspondence between each lens and the traceability information. Through the fixture positioning and calibration stage before transfer printing, the transfer reference is precisely locked, providing a unified and stable positional reference for subsequent high-precision transfer printing. During the transfer printing operation, the traceability code, which binds all the lens's information, is accurately transferred to the non-optical annular area on the outer ring of the lens, achieving permanent binding of traceability information to the lens body while completely avoiding any impact on the lens's optical performance. Through online visual inspection, the transfer printing quality is automatically verified, and the inspection data is simultaneously bound to the corresponding lens's traceability code, perfecting the entire traceability data chain. Through the sorting and receiving stage, qualified and unqualified products are collected separately, and the entire production data is archived and stored simultaneously. This solution achieves fully automated production of contact lens traceability code transfer printing through continuous collaboration and data exchange between various processes, while simultaneously realizing traceable control throughout the entire lens production process and lifecycle.

Claims

1. A method of pad printing a contact lens traceability code, characterized in that, The method comprises the following steps: Step one, perform lens loading processing, transport the lens to be printed to the preset processing station, collect the basic parameter information of the lens to be printed, encode the collected basic parameter information, and convert it into a traceable code format that can be printed; Step two, perform pre-printing positioning processing, position the printing jig carrying the lens to be printed through the jig positioning assembly, lock the spatial position of the printing jig after calibration, and record the position data corresponding to this positioning; Step three, perform traceable code printing operation, print the converted traceable code to the outer ring area of the lens through the printing mechanism, and the optical area of the lens is not provided with a traceable code; Step four, perform printing quality detection, collect the global image of the printed lens through the vision detection system, identify the printing state of the traceable code, and generate the quality detection result of the corresponding single lens; Step five, perform lens collection processing, classify and transport the printed lens according to the generated quality detection result, and collect it correspondingly.

2. A method for traceability coding of contact lenses by pad printing as claimed in claim 1, characterized in that, In step one, the automatic feeding system transports the lens to be printed to the preset processing station of the mold tray, the optical recognition system collects the basic parameter information of the lens to be printed, and the collected basic parameter information is encoded and converted to generate a traceable code graphic file corresponding to a single lens.

3. A method for traceability coding of contact lenses by pad printing as claimed in claim 1, characterized in that, In step two, the jig positioning assembly collects the real-time spatial position data of the printing jig, compares the real-time spatial position data with the preset standard position data, adjusts the spatial position of the printing jig according to the comparison result, detects the position deviation of the printing jig through the sensor system, and completes the positioning locking when the position deviation meets the preset threshold, and records the position data of this positioning.

4. A method for traceability coding of contact lenses by pad printing as claimed in claim 1, characterized in that, In step three, the traceable code graphic file is used to prepare a printing steel plate of corresponding specifications, the printing ink of the corresponding traceable code is picked up from the printing steel plate through the printing rubber head, and the picked up printing ink is transferred to the annular area formed by the outer diameter extending inwardly from the lens outer circle, and the down pressure, printing speed and printing coordinates of the printing rubber head are closed-loop controlled during the transfer process.

5. A method for traceability coding of contact lenses by pad printing as claimed in claim 1, characterized in that, In step four, the vision detection system collects the global image of the printed lens, analyzes the collected global image through image recognition algorithm, identifies the graphic integrity and printing clarity of the traceable code, compares the identification result with the preset qualified standard, and generates the quality detection result of the corresponding single lens.

6. A method for traceability coding of contact lenses by pad printing as claimed in claim 1, characterized in that, In step five, the quality detection result corresponding to the single lens is received, the lens meeting the preset qualified standard is transported to the qualified tray for regular collection, the lens not meeting the preset qualified standard is transported to the unqualified tray for isolation collection, and the binding relationship between the quality detection result of each lens and the corresponding traceable code is recorded synchronously.

7. A method for traceability coding of contact lenses by pad printing as claimed in claim 1, wherein, The traceable code contains the basic parameter information and internal control information of the lens, the basic parameter information includes lens power, left and right eye identification, material type, and use cycle, and the internal control information includes the internal identification code corresponding to the lens production process.

8. A method for traceability coding of contact lenses by pad printing as claimed in claim 1, characterized in that, In step two, after the positioning and locking are completed, the recorded position data is synchronously transmitted to the pad printing mechanism. The pad printing mechanism adjusts the pad printing coordinates according to the received position data so that the pad printing position of the traceability code matches the outer ring area of ​​the lens.

9. A contact lens trace code pad printing system for performing the contact lens trace code pad printing method of any one of claims 1 to 8, characterized in that, It includes a feeding module, a positioning module, a pad printing module, a detection module, and a receiving module; The feeding module is used to perform the feeding and conveying of lenses and the collection and processing of basic parameter information of the lenses to be pad-printed; The positioning module is used to perform position acquisition, calibration and locking processing of the pad printing fixture; The pad printing module is used to perform the preparation of traceability codes and the pad printing operation on the lens surface; The detection module is used to perform image acquisition and quality inspection processing of the printed lenses; The receiving module is used to perform the sorting, conveying, and collection of lenses after pad printing.

10. A contact lens traceability pad printing system as claimed in claim 9, wherein, The positioning module establishes a data communication connection with the pad printing module. The positioning module synchronously transmits the locked pad printing fixture position data to the pad printing module, and the pad printing module adjusts the pad printing coordinates according to the received position data.

Images