Optical Lens Container Buffering for Compact Modular Machining
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Solution Overview
Problem
The existing manufacturing systems for machining optical lenses and/or optical lens blanks are complex, requiring large setup areas, labor-intensive operation, and complex networking of machining apparatuses, leading to inefficient throughput and accessibility issues for operators and maintenance personnel.
Innovation Solution
A modular machining apparatus with a horizontally aligned conveyor section, container buffer store, and container transport device that allows buffering and prioritization of containers within the module, enabling a compact layout and easy access, eliminating the need for extensive conveying loops and bespoke engineering.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If individual machining apparatuses are connected by additional conveyor sections forming conveying loops, then automated transport of lens containers is achieved, but the setup area becomes very large and device complexity increases
Solution Approach 1:
The manufacturing system is divided into independent modular machining apparatuses, each capable of autonomous operation with its own container buffer store. This segmentation eliminates the need for extensive interconnecting conveyor loops, as each module handles its own container flow independently, significantly reducing the overall setup area while maintaining automation.
Solution Approach 2:
The patent transitions from a two-dimensional layout with horizontal conveying loops to a three-dimensional arrangement by stacking machining apparatuses vertically. Multiple modules can be arranged in layers, with containers transferred between levels, thereby compacting the footprint and reducing the horizontal setup area while preserving automated functionality.
2Extent of automation
If machining apparatuses are placed in conveying loops branching from a main conveyor section, then automated transport is achieved, but accessibility for operators and maintenance personnel deteriorates
Solution Approach 1:
By segmenting the system into independent modular apparatuses, each module can be accessed individually from multiple sides without requiring personnel to navigate through or around extensive conveyor loops. This modular arrangement improves accessibility for both operation and maintenance while preserving automated container transport within each module.
3Extent of automation
If extensive conveying loops and bespoke engineering are used to network machining apparatuses, then automated transport is achieved, but device complexity and installation complexity increase
Solution Approach 1:
The system is segmented into self-contained modular apparatuses, each with integrated container buffer stores and transport mechanisms. This eliminates the need for complex bespoke engineering to create extensive interconnecting conveying loops, as each module operates independently with standardized interfaces, thereby reducing overall device complexity while maintaining automated functionality.
Solution Approach 2:
Each modular machining apparatus is designed as a universal unit that can perform multiple functions: machining operations, container buffering, and automated container transport. This multi-functionality eliminates the need for separate specialized conveying systems between different types of apparatuses, simplifying the overall system architecture and reducing device complexity.
4Loss of time
If containers are buffered on conveying loops between machining apparatuses, then throughput time differences are compensated, but the conveying loops become very long and setup area increases
Solution Approach 1:
Container buffering is segmented and localized within each modular machining apparatus rather than being distributed along extensive conveying loops. Each module has its own container buffer store that can hold multiple containers, allowing the apparatus to continue operating at its own pace and compensating for throughput time differences without requiring long interconnecting loops, thereby reducing setup area.
Data Source
AI summary
A machining apparatus for machining optical lenses has a horizontally aligned conveyor section for transporting containers containing at least one optical lens, the conveyor section extending between an entry and opposite exit side of a module. The machining apparatus has a container buffer store and a container transport device, the latter being designed to retrieve containers from the conveyor section and to store said containers in the container buffer store and to transport containers back onto the conveyor section. A workpiece handling station having at least one parking space is provided for one container. The container transport device transports containers from the container buffer store to at least one parking space. A handling device of workpiece handling station retrieves optical lenses from a container standing on a parking spaces and transfers said container to a machining station. Moreover, the invention relates to a manufacturing system having two such machining apparatuses.