Lens Cleaning Machine with Movable Chambers for Contamination Control
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Solution Overview
Problem
Existing lens manufacturing systems face challenges in efficiently cleaning and inspecting lenses, particularly edged lenses, due to complex and costly conveyor systems, high risk of contamination, and inefficient handling, which leads to increased costs and loss of lenses during transit.
Innovation Solution
A machine with a handling unit and movable processing units that integrate cleaning, rinsing, and inspection functionalities, allowing for precise lens transfer and processing within a compact layout, reducing cross-contamination and handling risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a long tunnel conveyor system with multiple cleaning stations is used, then lenses can be cleaned through multiple cleaning processes, but the machine becomes expensive and space-consuming
Solution Approach 1:
The cleaning system is divided into multiple independent cleaning stations arranged in parallel rather than a long sequential tunnel. Each station performs a specific cleaning function (ultrasonic, chemical, rinsing), and lenses pass through multiple stations vertically, reducing the horizontal footprint while maintaining comprehensive cleaning capability.
Solution Approach 2:
The conveyor system transitions from horizontal movement in a long tunnel to vertical movement through stacked cleaning stations. This dimensional change allows multiple cleaning processes to occur in a compact vertical space, reducing the overall machine length and space requirements.
2Reliability
If the main conveyor moves slowly through cleaning stations, then lenses can be properly cleaned, but cleaning liquids are transferred between stations causing contamination
Solution Approach 1:
Each cleaning station is enclosed in a separate sealed chamber with independent access points. The conveyor passes through sealed openings, and each station can be isolated from others, preventing cross-contamination while maintaining proper cleaning time. The sealing mechanisms allow lateral passage of lenses while preventing liquid transfer between stations.
3Ease of operation
If a minimal holding system is used on the conveyor, then uncut lenses with large diameter-to-thickness ratio can be handled, but edged lenses are lost during transit
Solution Approach 1:
The holding system evolves from minimal static supports to dynamic adaptive clamps that adjust their grip based on lens type. Uncut lenses use minimal point contacts, while edged lenses engage with adjustable clamps that conform to the lens periphery, preventing loss during transit through the cleaning stations.
Solution Approach 2:
Different holding mechanisms are applied at different locations along the conveyor based on lens type. Uncut lenses receive minimal support at center points, while edged lenses engage with peripheral clamps, optimizing both handling simplicity and retention for each lens category.
4Productivity
If multiple manual or automatic handling systems are used for lens transfer, then cleaning and inspection can be performed, but lens loss and contamination increase
Solution Approach 1:
Multiple functions (cleaning, rinsing, inspection) are combined into a single integrated conveyor system rather than separate handling stations. The lens remains on the same conveyor throughout the process, eliminating transfers between different handling systems and reducing both loss and contamination risks while maintaining comprehensive processing capability.
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 integrated system ensures thorough and consistent cleaning, reduces contamination, and facilitates real-time inspection, maintaining high-quality standards while minimizing space and resource requirements.
Implementation Method 1
Different cleaning methods, such as ultrasonic cleaning, solvent cleaning, brush cleaning and rinsing with specialized solutions, are known
Data Source
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AI summary
A machine (1) for cleaning lenses, like eyeglass lenses comprising a handling unit (2) for carrying and transferring a lens (L) to be cleaned along a processing path (P), and at least one processing unit (3, 4, 5) having a cleaning chamber (30, 40, 50). The at least one processing unit (3, 4, 5) is arranged such that it can be moved along a movement path (M) between (i) a retracted position in which the lens (L) carried by the handling unit (2) is able to be transferred by the handling unit (2) along the complete processing path (P) outside and relative to the at least one processing unit (3, 4, 5), and (ii) a receiving position in which the lens (L) carried by the handling unit (2) at the processing position (W) is received in the cleaning chamber (30, 40, 50) to allow the lens (L) be processed.