Spectacle Lens Cleaning and Coating Automation
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Solution Overview
Problem
The manufacturing of spectacle lenses is hindered by inadequate cleaning processes, which can lead to defects in coatings and increased processing times due to human error and the need for manual handling, as well as lenses being left in waiting loops, affecting the quality and efficiency of the manufacturing process.
Innovation Solution
A method involving a combination of pre-cleaning and deep cleaning steps, including warm water washing, rinsing, and high-pressure deionized water treatments, followed by degassing and anti-reflective coating in a vacuum environment, to ensure lenses are properly cleaned and prepared for coating without human intervention, reducing errors and processing time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a single thorough cleaning step is performed after polishing, then the cleaning process is simple and fast, but the cleaning effectiveness is insufficient due to temperature effects and waiting time
Solution Approach 1:
The cleaning process is divided into two distinct steps: a first cleaning step performed immediately after polishing while the lens is still warm, and a second cleaning step performed after the lens has cooled. This segmentation allows each cleaning step to address specific contamination issues at different temperatures, thereby improving overall cleaning effectiveness without requiring complex equipment modifications.
Solution Approach 2:
The first cleaning step is performed as a preliminary action immediately after polishing while the lens blank is still warm. This timing is critical because the warmth of the lens enhances the effectiveness of the cleaning solution in removing polishing residues and contaminants that would be difficult to remove once the lens cools down.
2Ease of operation
If manual handling is used for charging and discharging optical elements, then flexibility and adaptability are maintained, but human error and processing time increase
Solution Approach 1:
The system employs automated robotic arms that autonomously charge and discharge optical elements between processing stations. The robotic system includes sensors and control mechanisms that enable it to self-regulate the handling process, eliminating the need for manual intervention while maintaining operational flexibility and significantly reducing processing time and human error.
3Productivity
If optical elements are left in waiting loops between processing steps, then batch optimization is possible, but surface contamination and coating quality deteriorate
Solution Approach 1:
The system maintains continuous movement of optical elements through automated conveyance mechanisms between processing stations. Optical elements are kept in constant motion or held in controlled environments that prevent surface contamination during transfer, ensuring that the surface remains ready for coating application without deterioration even during batch processing transitions.
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
This method enhances the cleaning efficiency of spectacle lenses, reduces the risk of coating defects, minimizes human error, and streamlines the manufacturing process, allowing for faster production and improved quality of lenses that meet prescription specifications.
Implementation Method 1
a first cleaning step with a cleaning solution
Implementation Method 2
rinsing, and high-pressure deionized water treatments
Implementation Method 3
degassing and anti-reflective coating in a vacuum environment
Implementation Method 4
applying an AR-coating in a vacuum box coater
Data Source
AI summary
A manufacturing facility for manufacturing an optical element according to a prescription includes a first station configured for surfacing and polishing a second face of a lens blank and pre-cleaning the second face of the lens blank including a finishing drying which allows the lens blank to be put on hold, a second station configured for deep cleaning the second face of the lens blank and hard coating the second face of the lens blank, a tunnel oven configured to degas the lens blank, a vacuum box coater configured to apply an antireflection (AR)-coating, and a third station configured to deblock the processed lens blank from the block piece.