Optical Lens Processing Layout With Vertical Container Buffering
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Solution Overview
Problem
Existing optical lens processing systems require extensive design effort and space due to the need for complex conveyor loops and manual handling, leading to inefficiencies and increased costs, as well as challenges in accessing and servicing processing machines safely.
Innovation Solution
A processing machine with a container buffer storage and transport device that allows for buffering and prioritization of containers, enabling a compact layout where machines can be lined up linearly, reducing the need for conveyor loops and facilitating easier access for personnel and maintenance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conveyor loops branching off horizontally from a main conveyor line are used to connect processing machines, then automated transport of containers is achieved, but the layout becomes very wide and long requiring large space
Solution Approach 1:
The patent transitions from horizontal conveyor loop layouts to a vertical stacking arrangement where containers are buffered in multiple levels. This dimensional change from 2D horizontal expansion to 3D vertical utilization significantly reduces the floor space required while maintaining automated transport functionality.
Solution Approach 2:
The patent implements nested container buffering where multiple containers are stacked vertically in a buffer storage system. This nesting approach allows multiple containers to occupy the same horizontal footprint by utilizing vertical space, thereby reducing the overall layout area while preserving automated handling capabilities.
2Productivity
If conveyor loops with machine-specific conveyor speeds are used, then different throughput times of processing machines are compensated, but the design effort and complexity increase
Solution Approach 1:
The patent introduces a vertical buffer storage system as an intermediary between processing machines with different throughput times. This buffer acts as a decoupling mechanism that absorbs timing differences without requiring complex speed-controlled conveyor loops, thereby simplifying the overall system design while maintaining productivity balance.
Solution Approach 2:
The patent segments the continuous conveyor loop into discrete vertical buffer positions, allowing independent control and timing adjustment at each buffer level. This segmentation enables flexible accommodation of different machine throughput times through simple vertical positioning rather than complex continuous speed control.
3Extent of automation
If processing machines are arranged in a Christmas tree-like layout with conveyor loops, then automated processing is enabled, but accessibility for operation and service becomes difficult
Solution Approach 1:
The patent rearranges the processing layout from a horizontal Christmas tree configuration to a linear arrangement with vertical buffer stacking. This dimensional reorganization places all processing machines in a single file with uniform spacing, making all machines equally accessible from the front while maintaining automated vertical buffer operations.
4Adaptability or versatility
If the main conveyor line is made very long to accommodate branching conveyor loops, then all processing machines can be connected, but the installation becomes complex and requires numerous custom-made components
Solution Approach 1:
The patent replaces the long horizontal main conveyor line with a compact linear arrangement of processing machines connected by simple horizontal conveyors, while utilizing the vertical dimension for buffer storage. This eliminates the need for numerous branching loops and custom components, significantly simplifying installation while maintaining the ability to connect multiple machines.
Data Source
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AI summary
The invention relates to a processing machine (1) for processing optical lenses (101, 102), which is formed by a component (2). It has a horizontally oriented conveyor (10) for transporting containers (100) containing at least one optical lens (101, 102), the conveyor (10) extending from an entry side (3) to an opposite exit side (4) of the component (2). The processing machine (1) also has a container buffer (20) and a container transport device (30), the latter being configured to remove containers (100) from the conveyor (10) and store them in the container buffer (20), as well as to transport containers (100) back to the conveyor (10). Additionally, a workpiece handling station (40) with at least one storage position (41, 42, 43, 44) for each container (100) is provided.The container transport device (30) is designed to transport containers (100) from the container buffer storage (20) to one or at least one of the storage locations (41, 42, 43, 44). The workpiece handling station (40) has a handling device (50) with which the optical lenses (101, 102) are removed from a container (100) located at one or more of the storage locations (41, 42, 43, 44) and transferred to a processing station (60). The invention also relates to a production plant (200) with two such processing machines (1, 1a).