Lens Blank Carrier Transfer With Automated Slot Assignment
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Solution Overview
Problem
The transfer of lens blanks from one carrier to another during the manufacturing process is prone to errors, such as damage, contamination, and incorrect assignment, leading to increased rejects and manufacturing costs due to unintentional swapping and loss of job tickets.
Innovation Solution
A computer-implemented method for providing an occupation order that includes receiving carrier identification information, determining slot arrangements, defining assignments, and providing control signals or instructions for transferring lens blanks between carriers, reducing the need for manual handling and paper-based job tickets.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling and paper-based job tickets are used for transferring lens blanks between carriers, then flexibility and simplicity are maintained, but error rates increase due to damage, contamination, and incorrect assignment
Solution Approach 1:
The patent replaces physical job tickets with electronic data representations. Each lens blank's information is copied into a digital format that travels with the blank through the manufacturing system, eliminating physical handling errors while maintaining information integrity through electronic storage and transmission.
Solution Approach 2:
The patent substitutes manual mechanical handling with automated transfer mechanisms. Robots or automated conveyors replace human operators in transferring lens blanks between carriers, eliminating manual errors in placement and assignment while reducing physical contact that could cause damage or contamination.
2Reliability
If automated transfer mechanisms are implemented to reduce manual handling errors, then transfer accuracy improves, but system complexity and initial costs increase
Solution Approach 1:
The patent designs automated transfer mechanisms with universal capabilities that can handle multiple carrier types and lens blank configurations through a single system. The electronic tracking system serves multiple functions including identification, routing, and quality monitoring, reducing the need for separate specialized systems for each function.
Solution Approach 2:
The patent introduces an electronic identification and tracking system as an intermediary between the automated transfer mechanism and the control system. This intermediary layer manages the complexity by standardizing communication protocols and data formats, allowing the automated hardware to operate reliably without requiring overly complex control logic.
3Manufacturing precision
If electronic tracking and assignment systems are used, then manufacturing precision and error reduction improve, but implementation costs and system complexity increase
Solution Approach 1:
The patent merges the electronic tracking system with the existing carrier design by integrating identification elements directly into the carrier structure. The tracking software is combined with the production management system, eliminating the need for separate complex systems and reducing overall implementation costs while maintaining high assignment accuracy.
Data Source
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AI summary
Provided is a computer-implemented method (200) for providing an occupation order (100) for transferring lens blanks (18) from a first carrier (10) to a second carrier (14). The method (200) comprises receiving (202) carrier identification information about the first carrier (10) having a first number of slots (12) and the second carrier (14) having a second number of slots (16), wherein each of the slots (14) is adapted to carry a lens blank (18). The method further comprises determining (204) an arrangement of the first number of slots (12) at the first carrier (10) and an arrangement of the second number of slots (16) at the second carrier (14) based on the received information. Moreover, the method comprises defining (206) an assignment of at least a part of the first number of slots (12) of the first carrier (10) to a corresponding number of the second number of slots (16) of the second carrier (14), and providing (208) a control signal and/or instructions for transferring multiple lens blanks (18) from at least the part of the first number of slots (12) of the first carrier (10) to the corresponding number of the second number (16) of slots of the second carrier (14) according to the defined assignment.