Optical Lens Blocking with Reference Frame Shift Compensation
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Solution Overview
Problem
Current methods for manufacturing optical lenses face challenges in achieving accurate positioning of the lens surfaces, leading to optical errors due to factors like operator error and machine inaccuracy, which are exacerbated by mechanical shocks and limitations in camera visualization techniques.
Innovation Solution
A method involving a blocker with a movable reference frame and cameras to measure and adjust the positioning of an optical lens member, using detectable features and motors to compensate for positioning shifts, ensuring precise alignment of the lens surfaces based on predetermined parameters like decentration and orientation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operator visualisation or camera observation is used to verify lens positioning, then positioning accuracy can be improved, but the system becomes vulnerable to mechanical shock and operator error
Solution Approach 1:
The patent replaces manual operator visualisation and camera-based observation with an automated coordinate measurement system. The measuring device automatically determines the position of reference features on the lens member and compares it with the blocking device coordinate system, eliminating operator error and camera visualization limitations while maintaining measurement precision under mechanical shock conditions
Solution Approach 2:
The patent implements a feedback mechanism where the measuring device continuously monitors the position of reference features on the lens member and provides real-time positioning data. The system compares measured positions with predetermined blocking parameters and automatically adjusts the blocking device to compensate for positioning shifts, ensuring reliable positioning accuracy even under mechanical shock
2Measurement precision
If manual positioning verification is used during blocking, then positioning accuracy can be corrected, but the process time increases and productivity decreases
Solution Approach 1:
The patent performs preliminary positioning measurements and calculations before the actual blocking operation. The measuring device determines the position of reference features and calculates the blocking parameters in advance, allowing the blocking device to be pre-positioned correctly before the lens member is secured, thereby eliminating post-positioning adjustments and reducing overall process time
Solution Approach 2:
The system performs automated self-measurement and self-correction of positioning errors. The measuring device automatically measures the lens member position, calculates required adjustments, and the blocking device automatically compensates for positioning shifts without requiring manual intervention, thereby maintaining high positioning accuracy while preserving manufacturing productivity
3Measurement precision
If camera visualization techniques are used to measure lens positioning, then positioning can be verified, but the measurement accuracy is limited by mechanical shock and camera resolution
Solution Approach 1:
The patent replaces camera-based optical measurement with a coordinate measurement system that uses reference features directly measurable in the blocking device coordinate system. This substitution eliminates camera resolution limitations and mechanical shock effects on optical visualization, providing stable and accurate measurement of lens positioning
Solution Approach 2:
The patent creates a coordinate system copy by establishing the blocking device coordinate system and mapping the lens member reference features into this coordinate system. This coordinate copying approach allows accurate position determination without relying on camera visualization, thereby overcoming measurement limitations under mechanical shock conditions
Data Source
AI summary
A method and apparatus for blocking an unfinished optical lens member on a blocker for manufacturing an optical lens from the unfinished optical lens member, the latter being provided with a finished surface having a first reference frame, the blocker having a second reference frame, includes: placing the unfinished optical lens member on the blocker; measuring the relative positioning of the first reference frame of the finished surface of the placed unfinished lens member with respect to the positioning of the second reference frame of the blocker; comparing the measured relative positioning with a predetermined relative positioning to determine a relative positioning shift; moving at least the blocker and/or the lens member to change the relative positioning of the first reference frame with respect to the second reference frame to compensate for the relative positioning shift; and blocking the unfinished lens member on the blocker at the changed relative positioning.