Lens Manufacturing Quality Control via Master Lens Parameter Monitoring
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Solution Overview
Problem
Current lens manufacturing processes, particularly those without molds, face challenges in ensuring quality and efficiency, especially in high-volume, high-yield rapid production, as existing quality control methods are either costly or unreliable, and traditional methods like cast molding suffer from defects such as shrinkage and limited design flexibility.
Innovation Solution
A process involving the regular measurement and recording of parameters from a master lens to monitor the evolution of manufacturing device parameters over time, allowing for reliable quality control of lenses produced without individual lens inspection, utilizing a feedback loop to adjust manufacturing processes and maintain optical and geometrical accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If individual lens inspection is performed to ensure quality, then measurement precision is improved, but productivity deteriorates due to high time cost
Solution Approach 1:
The patent creates a digital copy (virtual model) of the lens manufacturing process and its quality characteristics. Instead of physically inspecting each lens, the system uses a virtual model to predict and evaluate quality, enabling rapid assessment without slowing down production.
Solution Approach 2:
The patent replaces physical mechanical inspection systems with a computational simulation system. The virtual model uses calculated parameters and digital simulations to assess lens quality, eliminating the need for time-consuming physical measurements of each lens.
2Ease of manufacture
If cast molding process is used for lens manufacturing, then ease of manufacture is improved, but manufacturing precision deteriorates due to shrinkage and quality defects
Solution Approach 1:
The patent performs preliminary calculations and simulations before actual manufacturing to optimize the process parameters. By pre-calculating the ideal manufacturing conditions and predicting potential defects, the system can adjust parameters in advance to prevent shrinkage and quality issues before they occur.
Solution Approach 2:
The patent implements a feedback mechanism where the virtual model continuously monitors manufacturing parameters and predicts quality outcomes. This feedback loop allows real-time adjustments to manufacturing parameters to maintain high precision while using simple cast molding processes.
3Manufacturing precision
If digital surfacing process is used for lens manufacturing, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent creates a universal virtual model that can handle multiple lens types, designs, and manufacturing scenarios within a single simulation framework. This multi-functional approach simplifies the overall system by consolidating various specialized tools into one integrated platform.
Solution Approach 2:
The virtual model acts as an intermediary between the complex digital surfacing process and the final lens product. It mediates by simulating and optimizing process parameters before manufacturing, reducing the actual complexity of the physical manufacturing process while maintaining high precision.
4Reliability
If quality control is performed on finished lenses, then reliability is improved, but loss of time increases due to post-manufacturing inspection
Solution Approach 1:
The patent performs quality assessment in advance through virtual simulation before the actual lens is manufactured. By predicting quality outcomes during the design and simulation phase, the system eliminates the need for time-consuming post-manufacturing inspection while ensuring reliability.
Solution Approach 2:
The virtual model provides continuous feedback during the manufacturing process about potential quality issues. This allows real-time corrections to be made during manufacturing rather than requiring time-consuming inspection after completion, maintaining reliability while reducing time loss.
Data Source
AI summary
A process for controlling a lens manufacturing process comprising the steps of: a) manufacturing a master lens according to a manufacturing process using a manufacturing device, b) measuring by using at least a measuring device at least one parameter of the master lens of step a), c) recording the value of the parameter, d) repeating regularly step a) to c) and checking the evolution of the parameter over time, wherein the evolution of at least one parameter of the manufacturing device used during the lens manufacturing process is checked over time and the evolution over time of at least one parameter of the master lens is related with the evolution over time of the at least one parameter of the manufacturing device.