Ophthalmic Lens Edging Control Using Weighted Edger Codes
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Solution Overview
Problem
Traditional ophthalmic lens edging machines lack the capability to adjust their operation based on detailed lens parameters such as radius of curvature, thickness, and treatments, leading to inefficient cutting processes and potential damage to lenses.
Innovation Solution
A flexible edger system that calculates the edging process using a weighted edger code, considering parameters like lens radius, thickness, treatments, and material, to optimize cutting speed and positioning of the diamond abrasive wheel, minimizing damage and optimizing cutting efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional edging machines use fixed cutting parameters, then the device complexity is reduced, but the manufacturing precision and reliability deteriorate due to inability to account for varying lens parameters
Solution Approach 1:
The system performs preliminary calculations of cutting parameters based on lens data before the actual edging process. The calculation module computes optimal cutting speed, feed rate, and other parameters in advance, allowing the edging machine to execute pre-determined precise operations without real-time complexity
Solution Approach 2:
A calculation module acts as an intermediary between the lens data management system and the edging machine. This intermediary processes lens parameters (radius, thickness, material) and translates them into machine-specific cutting parameters, bridging the gap without requiring direct complex integration between all system components
2Productivity
If the edging machine uses a single cutting speed for all lenses, then the ease of operation is improved, but the productivity deteriorates due to inability to optimize for different lens materials and parameters
Solution Approach 1:
The system dynamically adjusts cutting parameters based on lens-specific data. Different lens materials (glass, plastic, polycarbonate) and geometries (radius, thickness) receive optimized cutting speeds and feed rates automatically calculated by the system, allowing high productivity without requiring operator expertise in parameter selection
Solution Approach 2:
The system changes cutting parameters (speed, feed rate, depth of cut) according to lens parameters. The calculation module determines optimal parameter sets for each lens type, enabling the machine to adapt its operation dynamically while maintaining simple interface for the operator
3Loss of substance
If the edging process does not account for lens radius and thickness, then the device complexity is reduced, but the loss of substance increases due to excessive material removal
Solution Approach 1:
The calculation module performs preliminary analysis of lens geometry (radius, thickness, curvature) before edging begins. Based on these pre-calculated parameters, the system determines precise cutting paths and depths that minimize material removal while ensuring proper fit, preventing excessive material waste before the cutting process starts
Solution Approach 2:
The system applies different cutting strategies to different regions of the lens based on local geometry. Areas with varying radius or thickness receive customized cutting parameters, allowing precise material removal only where needed rather than uniform aggressive cutting across the entire lens periphery
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
The system enables precise and efficient edging of ophthalmic lenses by selecting the appropriate macro or speed based on detailed lens data, reducing material waste and improving the accuracy of lens shaping to fit various frames.
Implementation Method 1
an abrasive wheel, such as a diamond abrasive wheel, that is used to remove lens material
Data Source
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AI summary
Systems and methods for controlling an ophthalmic lens edging machine are disclosed. The ophthalmic lens edging machine uses an edger code to select a macro or speed for a requested lens edging job. A system for creating and using the edger code may include a Lab Management System (LMS), a lens calculation system, and a lens edging machine. An edger code may be generated using lens data received from a lens management system and edging machine information identifying one or target lens edging machines. The edger code comprises a plurality of characters. Each character is associated with a different feature of a requested edging job. The features of the requested edging job may include, for example, one or more of: a material type, a lens thickness, an edge type, a frame type, a lens coating, a lens shape, a lens ratio, a lens treatment, and an edging machine block type.