Automated Lens Processing System for Prescription Validation

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Solution Overview

Problem

The existing systems for processing eyeglass prescriptions are prone to errors due to incompatibility issues between the various components, leading to a high error rate in manufacturability, particularly in lens production, where errors arise from incorrect specifications of lens products and services, resulting in over 20% of orders being unmanufacturable.

Innovation Solution

A system that generates a work ticket for lens manufacturing by accessing data files for lens and frame specifications, performing calculations to optimize lens thickness, and providing supplemental information through tool tips to laboratory technicians, ensuring accurate selection of manufacturing tools and parameters, thus reducing errors and improving manufacturability.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual processing of eyeglass prescription orders is used, then flexibility in handling custom orders is maintained, but error rate increases due to incompatibility issues between lens components and specifications

Engineering Contradiction:

Improvemanufacturability reliabilityVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent introduces a computer system as an intermediary between the prescription order and the lens manufacturing process. This intermediary automatically checks compatibility between lens components, frame specifications, and patient measurements, generating work tickets that ensure manufacturability before production begins, thereby reducing errors without requiring complex manual verification processes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The patent replaces manual mechanical verification of lens compatibility with an automated computer-based system. The system electronically validates prescription orders against manufacturing capabilities, substituting human judgment and manual checking with algorithmic processing that ensures consistency and eliminates compatibility errors

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Adaptability or versatility

If comprehensive lens specifications and options are provided, then customization capability is improved, but error rate increases due to incompatibility between selected options

Engineering Contradiction:

Improvelens customization capabilityVSAvoidorder manufacturability

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The patent implements a feedback mechanism where the computer system automatically validates selected lens options against compatibility rules and provides real-time feedback. The system checks for incompatibilities between lens materials, coatings, frame types, and patient measurements, generating warnings or rejecting orders that cannot be manufactured, thus maintaining customization while ensuring reliability

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent performs preliminary validation of lens specifications before the manufacturing process begins. The computer system pre-checks compatibility of selected options, verifies frame measurements, and confirms manufacturability in advance, preventing incompatible orders from reaching the production floor and eliminating errors before they occur

Inventive Principle:

Principle #10Preliminary action

3Reliability

If automated computer processing is implemented, then error rate is reduced through automated validation, but initial complexity and setup requirements increase

Engineering Contradiction:

Improveprescription processing accuracyVSAvoidsystem implementation ease

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent designs a universal computer system that handles multiple functions: validating prescription orders, checking lens compatibility, verifying frame measurements, generating work tickets, and providing technician guidance. This multi-functional approach consolidates what would otherwise require multiple separate systems into a single integrated platform, reducing implementation complexity while maintaining high accuracy

Inventive Principle:

Principle #6Universality (Multi-functionality)

Data Source

PatentUS8639372B2Automated optical lens processing system, such as a system for providing supplemental information to laboratory technicians

Publication Date: 2014.01.28 DIGITAL VISION LLC

AI summary

An electronic lens processing system receives a lens prescription and performs lens calculations to create a work ticket for manufacturing the lens. Information that the system used to create the work ticket, such as data files for lens materials and machine settings for controlling lens manufacturing equipment, are stored. The work ticket includes a form that specifies work ticket calculations and/or a graphic of the lens or lenses to be manufactured. The system displays the work ticket on an electronic screen, and a laboratory technician can select elements from the work ticket to receive supplemental information on those elements to aid in processing the lens or determining why a lens prescription is not manufacturable.