Calibration Cylinder Tilt Sensing for Spectacle Lens Blocking
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing spectacle lens manufacturing processes face inefficiencies and inaccuracies in blocking lens blanks due to complex and time-consuming tilt angle adjustments, particularly in high-precision freeform lens production, often requiring multiple surface measurements and leading to potential defects.
Innovation Solution
A spectacle lens blocking system with a block nest and calibration cylinder equipped with an inclination sensor for precise tilt angle determination, allowing for quick and accurate calibration of the block nest, reducing the need for iterative adjustments and minimizing equipment wear.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional blocking methods without inclination sensors are used, then the device complexity is lower, but the manufacturing precision and calibration accuracy deteriorate
Solution Approach 1:
The patent replaces complex mechanical measurement and adjustment systems with electronic inclination sensors that automatically detect and report tilt angles. This substitution eliminates the need for manual surface measurements and iterative adjustments, providing precise digital readings of the block nest's tilt angle while reducing overall system complexity through automation.
Solution Approach 2:
The inclination sensor system enables the blocking device to self-calibrate and self-monitor its tilt angle without requiring external measurement tools or manual intervention. The system automatically detects when the block nest is properly aligned and provides feedback to maintain precise positioning throughout the lens manufacturing process.
2Manufacturing precision
If multiple surface measurements and iterative adjustments are performed, then the manufacturing precision is improved, but the productivity and time consumption deteriorate
Solution Approach 1:
The inclination sensor performs preliminary detection and calibration of the block nest's tilt angle before the lens blocking process begins. By establishing accurate angular positioning in advance, the system eliminates the need for iterative adjustments during manufacturing, allowing operators to proceed directly to lens blocking without time-consuming measurement cycles.
Solution Approach 2:
The inclination sensor provides continuous feedback on the block nest's tilt angle, enabling real-time verification that the blocking surface is properly aligned. This feedback mechanism ensures manufacturing precision is maintained automatically throughout the process, eliminating the need for repeated manual measurements and adjustments that would otherwise be required to maintain quality standards.
3Loss of time
If manual calibration methods are used, then the device complexity is lower, but the calibration time and operational time deteriorate
Solution Approach 1:
The patent replaces manual mechanical calibration procedures with electronic inclination sensing that automatically measures and reports the block nest's angular position. This electronic substitution eliminates the need for manual surface measurements, alignment tools, and iterative adjustments, providing instant digital calibration data that significantly reduces calibration time while maintaining or improving precision through automated detection.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enhances manufacturing throughput by simplifying and speeding up the calibration process, minimizing errors, and reducing downtime, while maintaining high precision in lens production.
Implementation Method 1
the calibration cylinder comprises an inclination sensor configured for determining the tilt angle of the block nest
Implementation Method 2
The lens blank is attached to the blocking piece using a metallic alloy having a low melting temperature
Implementation Method 3
the blocking piece is typically chilled by a cooling device integrated into the blocking device to harden the metallic alloy
Data Source
Figure 1~4
Figure 5~7
Figure 8
AI summary
The present invention relates to relates to the field of manufacturing spectacle lenses and in particular to an arrangement (2) for a spectacle lens blocking system configured for blocking a lens blank (10), the arrangement (2) comprising: a block nest (30) comprising a receptacle (31) configured for receiving a blocking piece (20), wherein a tilt angle of the block nest (30) is adjustable; and a calibration cylinder (40), wherein a contact surface (42) of the of the calibration cylinder is adapted to a shape of the receptacle (31) at least at a reference surface (32) of the receptacle indicative of the tilt angle of the block nest (30), and wherein the calibration cylinder (40) comprises an inclination sensor (43) configured for determining the tilt angle of the block nest (30). Further, a calibration cylinder for an arrangement for a spectacle lens blocking system, a method for calibrating a spectacle lens blocking system, a method of manufacturing a spectacle lens and a computer program product are provided.