Optical Lens Positioning Optimization in Lens Blanks
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Solution Overview
Problem
The increasing trend towards larger spectacle frames complicates the production of optical lenses, leading to material wastage and increased manufacturing costs due to the need for larger lens blanks and complex machining processes, especially when machining prisms require frequent changes in machining devices.
Innovation Solution
A method implemented by computer means to optimize the position of the optical lens within the lens blank by evaluating a manufacturing prism cost function, which minimizes the amount of manufacturing prism used, simplifying the process and reducing costs through virtual positioning and evaluation steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Area of stationary object
If larger lens blanks are used to accommodate larger spectacle frames, then the lens can be manufactured to meet frame size requirements, but material wastage increases
Solution Approach 1:
The patent applies preliminary action by performing virtual positioning and evaluation of manufacturing prism cost functions before actual machining. The method calculates optimal lens positions and evaluates manufacturing complexity in advance, allowing selection of the best positioning strategy before material is removed, thereby minimizing material wastage.
Solution Approach 2:
The patent uses virtual positioning to create a digital copy or simulation of the lens positioning process. By virtually positioning the lens in the blank and evaluating cost functions computationally, the method determines optimal positions without physically moving or removing material during the evaluation phase, reducing material wastage.
2Adaptability or versatility
If manufacturing prism is increased to accommodate asymmetric frame shapes, then the lens can be manufactured for complex frames, but manufacturing complexity increases
Solution Approach 1:
The patent applies parameter changes by introducing and optimizing the manufacturing prism cost function with multiple parameters including prism amounts, lens positions, and orientation angles. By adjusting these parameters computationally to minimize the cost function, the method achieves adaptability to various frame shapes while keeping the actual machining process simpler through optimized parameter selection.
Solution Approach 2:
The patent performs preliminary evaluation of manufacturing prism cost functions for different positioning scenarios before actual machining. By calculating and comparing cost functions in advance, the method determines the optimal positioning strategy that accommodates asymmetric frame shapes while minimizing the complexity of the subsequent machining operations.
3Manufacturing precision
If frequent changes in machining devices are made to accommodate large manufacturing prism, then the lens can be manufactured with required precision, but manufacturing time increases
Solution Approach 1:
The patent applies preliminary action by evaluating manufacturing prism cost functions and determining optimal lens positioning before actual machining begins. This pre-calculation identifies the positioning strategy that achieves required precision while minimizing the need for device changes during manufacturing, thereby improving productivity.
Solution Approach 2:
The patent uses feedback by iteratively evaluating the manufacturing prism cost function for different lens positions and orientations, using the evaluation results to refine and optimize the positioning strategy. This feedback loop ensures that the final positioning achieves required precision while minimizing manufacturing complexity and time.
Data Source
AI summary
A method includes: providing lens blank data relating to the first, second and peripheral blank surfaces of the lens blank; providing optical lens data relating to the first, second and peripheral optical surfaces of the optical lens; virtually positioning the optical lens in the lens blank in a position so that at least one of the first optical surface or the second optical surface is included within the lens blank; evaluating a manufacturing prism cost function, the machining prism cost function corresponding to a weighed sum of the first manufacturing prism to be used when blocking the lens blank on the second surface to machine the first optical surface and of the second manufacturing prism to be used when blocking the lens blank on the first optical surface to machine the second optical surface. The positioning and evaluation steps are repeated so as to minimize the manufacturing prism cost function.