Lens Gripper Calibration Using a Remote Master Reference
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Solution Overview
Problem
The existing methods for calibrating lens grippers in contact lens manufacturing lines are time-consuming, leading to significant downtime when replacing grippers, as each new gripper requires calibration before use, disrupting the production process.
Innovation Solution
A remote gripper calibration tool with a master gripper and position sensors (Z-directional, X-directional, and Y-directional) allows for off-line calibration of lens grippers, ensuring precise alignment and function testing, enabling quick replacement without on-line calibration, thus minimizing production downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If lens grippers are calibrated on the manufacturing line before use, then calibration precision is ensured, but production downtime increases significantly
Solution Approach 1:
The patent applies preliminary action by calibrating lens grippers in advance on a separate calibration bench before they are installed on the manufacturing line. The calibration process includes mounting the gripper on a calibration bench, adjusting its extension length using a micrometer, and verifying its positioning accuracy. Once calibrated, the gripper is stored ready for installation, eliminating the need for time-consuming calibration during line stoppages and reducing production downtime while maintaining calibration precision
2Productivity
If lens grippers are quickly replaced without calibration, then production continuity is maintained, but gripper functionality and positioning accuracy deteriorate
Solution Approach 1:
The patent resolves this contradiction by performing calibration in advance before the gripper is installed on the manufacturing line. The calibration process includes adjusting the gripper's extension length to match a master gripper's specifications and verifying its positioning accuracy. Calibrated grippers are then stored ready for quick installation, ensuring both production continuity and reliable gripper functionality without compromising on calibration quality
Solution Approach 2:
The patent uses a master gripper with precisely known dimensions as a reference standard. New grippers are calibrated by copying the master gripper's extension length and positioning characteristics using micrometer adjustments and measurement devices. This copying approach ensures that replaced grippers maintain the same functional specifications and positioning accuracy as the master, guaranteeing reliability while enabling quick replacement
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 allows for rapid and precise calibration of lens grippers, reducing manufacturing line downtime by enabling pre-calibrated grippers to be stored and quickly swapped, ensuring continuous production with minimal disruption.
Implementation Method 1
measuring the Z-directional position of the tip of the master gripper with the Z-directional position sensor
Implementation Method 2
measuring the X- and Y-directional positions of the master gripper with the respective X- and Y-directional sensors
Implementation Method 3
measuring the X- and Y-directional positions of the master gripper with the respective X- and Y-directional sensors
Data Source
AI summary
A method for calibrating lens grippers prior to use of the grippers in a lens manufacturing line includes providing a remote gripper calibration tool having an assembly plate and a Z-directional position sensor; providing a master gripper having a length dimension terminating in a tip, the length dimension being predetermined to match a desired final extension length of a lens gripper; mounting the master gripper to the assembly plate; measuring the Z-directional position of the tip of the master gripper with the Z-directional position sensor; unmounting the master gripper from the assembly plate; mounting a lens gripper to be calibrated to the assembly plate, the lens gripper having a tip, and calibrating the lens gripper by adjusting the final extension length of the tip of the lens gripper to a predetermined position relative to the measured Z-directional position of the tip of the master gripper.