Optical Lens Blank Optimization for Frame Complexity
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Solution Overview
Problem
The increasing trend towards larger and more complex spectacle frames leads to inefficiencies in producing optical lenses, resulting in wastage of material due to the need for larger optical lens blanks, which are not optimized for manufacturing purposes.
Innovation Solution
A method is implemented to optimize the set of optical lens blanks by providing data on contour, surface, and material costs, using a weighted global cost function to minimize supply, lens blank, and material costs, thereby determining the optimal number and contours of lens blanks for efficient manufacturing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If larger optical lens blanks are used to accommodate larger spectacle frames, then the ability to manufacture lenses for complex frame shapes is improved, but material waste increases
Solution Approach 1:
The patent segments the lens blank selection process into multiple categories (e.g., circular blanks, oval blanks, rectangular blanks) with different sizes and shapes. Each category is optimized for specific frame types, allowing the system to select the most appropriate blank size rather than always using the largest available blank, thereby reducing material waste while maintaining adaptability to various frame shapes.
Solution Approach 2:
The patent changes the parameters of lens blanks by defining multiple size variants (e.g., 50mm, 54mm, 60mm diameters) and shapes within each category. This allows the optimization system to select blanks with parameters that closely match the required lens dimensions, minimizing excess material while ensuring sufficient material is available for complex frame shapes.
2Ease of manufacture
If a single large optical lens blank is used for all lens types, then manufacturing simplicity is improved, but the number of different blank sizes increases leading to higher inventory costs
Solution Approach 1:
The patent applies local quality by assigning different blank types to different manufacturing contexts. Instead of using a uniform blank size for all lenses, the system selects from multiple blank types (circular, oval, rectangular) with specific size ranges optimized for particular frame categories. This localized optimization reduces the total variety of blanks needed while maintaining manufacturing efficiency for each specific lens type.
Solution Approach 2:
The patent creates universal blank categories that can serve multiple functions. For example, a set of circular blanks with varying diameters can accommodate round frames, partial edging applications, and serve as a base for various lens designs. This multi-functionality reduces the need for highly specialized blank types, thereby reducing overall inventory complexity while maintaining ease of manufacture for different lens types.
3Adaptability or versatility
If optical lens blanks are not optimized, then manufacturing flexibility is improved, but manufacturing efficiency decreases
Solution Approach 1:
The patent implements preliminary action by pre-categorizing and pre-dimensioning lens blanks into specific size and shape categories before the manufacturing process begins. The optimization system selects the most appropriate blank category based on the required lens parameters, frame type, and material utilization efficiency. This preliminary optimization ensures that the selected blank is closely matched to the final product requirements, improving manufacturing efficiency by reducing material waste and processing time while maintaining flexibility through the availability of multiple pre-categorized options.
Data Source
AI summary
Method implemented by computer for optimizing a set of optical lens blanks used to manufacture a set of optical lenses, each optical lens comprising first and second optical surfaces, the first and second optical surfaces being connected by a external periphery surface, the method comprising: a data providing step during which a set of data for every optical lens of the set of optical lenses is provided, the data comprising at least contour data representative of an external periphery surface of the optical lens, a first dataset representative of the first optical surface of the optical lens and a second dataset representative of the second optical surface of the optical lens; a supply cost function providing step during which a supply cost function is provided, the supply cost function being a function of the number of different optical lens blank comprised in the set of optical lens blanks.