Optical Lens Manufacturing Data Routing for Low-Latency Machine Retrieval
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Solution Overview
Problem
Existing methods for manufacturing optical lenses are hindered by the need for each manufacturing machine to request complete data sets from a central system for each lens, causing delays and unbalanced workloads due to text-based communication protocols that require conversion of individual values into compound text strings.
Innovation Solution
Implementing a communication protocol based on OPC Unified Architecture (OPC UA) to transmit serialized variables directly to manufacturing machines, allowing pre-distribution of data sets to servers for immediate retrieval, eliminating the need for repeated requests and reducing latency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If each manufacturing machine requests complete data sets from a central system for each lens, then the manufacturing process can be controlled centrally, but delays occur due to repeated requests and text-based communication protocols
Solution Approach 1:
The patent applies preliminary action by pre-distributing data sets to servers before manufacturing machines need them. The system generates and distributes complete data sets containing lens information, machine assignments, and manufacturing steps in advance, so that when a lens arrives at a manufacturing machine, the required data is already available locally, eliminating the need for repeated requests to the central system during manufacturing operations
Solution Approach 2:
The patent introduces servers as intermediaries between the central manufacturing execution system and manufacturing machines. These servers act as local caches that store data sets and provide them to manufacturing machines, reducing the communication load on the central system and eliminating delays caused by text-based protocol conversions at each machine
2Adaptability or versatility
If text-based communication protocols are used to transmit data between central system and manufacturing machines, then compatibility is maintained, but computational overhead increases due to conversion of individual values into compound text strings
Solution Approach 1:
The patent applies segmentation by dividing the data transmission process into two parts: complete data sets are transmitted in bulk to servers in advance using efficient binary protocols, and then individual data elements are retrieved locally from server storage without requiring protocol conversion. This eliminates the need for repeated text string conversions at manufacturing machines, reducing computational overhead while maintaining compatibility through the use of standard OPC UA protocols
3Loss of information
If complete data sets are transmitted to each manufacturing machine for every lens, then data availability is ensured, but network bandwidth is consumed and workloads become unbalanced
Solution Approach 1:
The patent uses servers as intermediaries that act as local data repositories. Complete data sets are transmitted to these intermediary servers in advance using efficient binary protocols, and manufacturing machines retrieve only the specific data they need from local server storage. This approach ensures data availability for all machines without consuming network bandwidth during manufacturing operations and allows for balanced workload distribution across multiple servers
Data Source
AI summary
A method and a device for manufacturing a plurality of optical lenses, a method and a device for providing data sets for the plurality of the optical lenses to at least one manufacturing machine, and a corresponding computer program are disclosed. A data set for a particular optical lens includes a first item of information related to an identifier for the particular optical lens; and a second item of information related to a manufacturing machine configured for performing a manufacturing step for the particular optical lens; or the manufacturing step to be performed for the particular optical lens by using the manufacturing machine. The data set for each optical lens is transmitted to a server configured for operating the manufacturing machine designated for performing the manufacturing step and providing the data set for the particular optical lens to be retrieved by the manufacturing machine for manufacturing the particular optical lens.