Lens Blank Carrier Slot Assignment for Error-Free Transfer
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Solution Overview
Problem
The transfer of lens blanks between carriers during the manufacturing process is prone to errors, such as damage, contamination, and misassignment, leading to increased rejects and manufacturing costs due to the need for manual handling and the risk of swapping job tickets.
Innovation Solution
A computer-implemented method for providing an occupation order that includes determining the arrangement of slots in both carriers, defining assignments, and providing control signals or instructions for automated or semi-automated transfer of lens blanks, reducing the reliance on physical job tickets, and ensuring accurate tracking and updating of process information.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual handling and physical job tickets are used for transferring lens blanks between carriers, then the transfer process can be performed with simple equipment, but the risk of errors such as damage, contamination, and misassignment increases
Solution Approach 1:
The patent replaces physical job tickets with electronic data structures that contain identical identification and tracking information. The occupation order system creates digital copies of the tracking information that accompany lens blanks through automated carriers, eliminating the need for physical paper tickets while maintaining accurate identification and reducing misassignment risks
Solution Approach 2:
The patent replaces manual mechanical handling with automated carrier systems that transfer lens blanks between manufacturing stations. The occupation order system substitutes manual job ticket management with automated electronic tracking, where the system automatically assigns and tracks lens blanks through multiple carriers without human intervention in the transfer process
2Ease of manufacture
If physical job tickets are used to track lens blanks, then the system is simple to implement, but paper usage increases and sustainability decreases
Solution Approach 1:
The patent eliminates physical paper job tickets by creating electronic data structures that serve as digital copies of the tracking information. The occupation order system stores all necessary identification, tracking, and assignment data in electronic form within the manufacturing system, completely replacing paper-based documentation and eliminating paper consumption while maintaining full tracking capability
Solution Approach 2:
The patent changes the fundamental parameter of information storage from physical paper to electronic data. The system transforms the medium of information representation from analog (paper) to digital (electronic), enabling automated processing, reduced material consumption, and improved sustainability while maintaining the same functional capabilities for tracking and identification
3Reliability
If automated carrier transfer systems are implemented, then transfer reliability improves, but the complexity of the manufacturing system increases
Solution Approach 1:
The patent designs the occupation order system as a universal framework that handles multiple functions: identification, tracking, assignment, and verification of lens blanks across different carriers and manufacturing stations. This multi-functional system consolidates what would otherwise require multiple separate systems into a single integrated platform, managing complexity through functional consolidation
Solution Approach 2:
The patent implements feedback mechanisms where the system automatically verifies the status and location of lens blanks during transfer, confirming that occupation orders are correctly executed. The system provides real-time status updates and can detect discrepancies in the transfer process, enabling automatic correction or alerting, thereby improving reliability while managing system complexity through intelligent control
Data Source
AI summary
A computer-implemented method provides an occupation order for transferring lens blanks from a first carrier to a second carrier. A carrier identification information about the first carrier having a first number of slots and the second carrier having a second number of slots is received. Each of the slots is configured to carry a lens blank. An arrangement of the first number of slots at the first carrier and an arrangement of the second number of slots at the second carrier is determined based on the received information. Moreover, at least a part of the first number of slots of the first carrier is assigned to a corresponding number of the second number of slots of the second carrier. A control signal and/or instructions for transferring multiple lens blanks according to the defined assignment are provided.