Eyeglass Lens Processing Apparatus Two-Step Cup Switching
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Solution Overview
Problem
The existing eyeglass lens processing apparatuses face challenges in reducing axis deviation during the processing of lenses with narrow vertical widths, particularly when using small diameter cups, which can lead to increased rotary moment loads and interference with processing tools, especially in lenses coated with water-repellent substances.
Innovation Solution
The apparatus employs a two-step processing mode that switches from a large diameter cup to a small diameter cup, using corrected roughing path data to avoid interference and manage rotation moment loads, with a processing controller that adjusts the roughing and finishing paths to ensure accurate processing without axis deviation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a small diameter cup is used to process lenses with narrow vertical width, then processing interference is avoided, but holding force decreases and axis deviation increases
Solution Approach 1:
The processing is divided into two distinct stages: roughing processing using a large diameter cup to ensure adequate holding force and minimize axis deviation, followed by finishing processing using a small diameter cup to avoid processing interference. This segmentation allows each stage to use the most appropriate cup size for its specific requirements.
Solution Approach 2:
The system dynamically switches between different cup sizes based on the processing stage. The mode setting unit enables transition from large diameter cup mode during roughing to small diameter cup mode during finishing, optimizing the holding force and interference avoidance characteristics for each phase of processing.
2Reliability
If a large diameter cup is used to ensure holding force, then axis deviation is reduced, but processing interference occurs with narrow vertical width lenses
Solution Approach 1:
The processing sequence is segmented into roughing and finishing stages, with each stage utilizing a different cup size. The large diameter cup is used exclusively for roughing where holding force is critical, while the small diameter cup is used for finishing where interference avoidance is paramount.
Solution Approach 2:
The large diameter cup performs preliminary roughing processing first, removing the majority of material and establishing the basic shape. This preliminary action reduces the subsequent workload for the small diameter cup during finishing, allowing the smaller cup to operate without interference while maintaining precision.
3Ease of operation
If a small diameter cup is used for narrow vertical width lenses, then processing interference is avoided, but rotary moment load increases causing axis deviation
Solution Approach 1:
The processing workload is segmented between two cup sizes. The large diameter cup handles the high rotary moment load during roughing due to its larger attaching area providing better holding force. The small diameter cup then handles the lower-load finishing stage where interference avoidance is the primary concern.
Solution Approach 2:
The large diameter cup performs roughing processing that removes more material than strictly necessary (excessive action in terms of material removal), creating a larger margin. This allows the small diameter cup to complete the precision finishing with reduced rotary moment load, as the remaining material to be removed is less.
Data Source
AI summary
In a two-step processing mode in which a cup for attaching a lens to a chuck axis is changed from a large diameter cup to a small diameter cup on the way of processing, a roughing path data computing unit for computing first roughing path data larger than the target lens shape data by a predetermined finishing margin, and second roughing path data having a radius vector larger by at least Δa than at least radius vector data of the large diameter cup; and a processing controller for roughing the peripheral edge of the lens based on the second roughing path data in response to a processing start signal, thereafter stopping the processing and further resuming the processing. The processing controller performs, when a processing resuming signal is inputted, processing control of either roughing and finishing, or finishing without roughing.