Lens Processing Turret for Integrated Cutting and Drilling
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Solution Overview
Problem
Current lens processing machines in plastic material require multiple dedicated machines for cutting, drilling, engraving, and milling operations, leading to reduced operational flexibility and increased production time due to lengthy downtimes between processes.
Innovation Solution
A multi-functional machine integrating cutting, drilling, milling, engraving, and loading/unloading operations with advanced articulated arms and a turret system, allowing simultaneous performance of these tasks and independent lens handling, while using non-shaped tools and creating angled cuts not achievable by traditional machines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple dedicated machines are used for cutting, drilling, engraving and milling operations, then each operation can be performed with specialized equipment, but the production time increases significantly due to lengthy downtimes between processes
Solution Approach 1:
The patent combines cutting, drilling, engraving, and milling operations into a single integrated machine system. The machine includes a cutting unit with a cutting tool, a drilling unit with a drilling tool, an engraving unit with an engraving tool, and a milling unit with a milling tool, all mounted on a common base structure and capable of processing lenses sequentially without removal between operations. This eliminates the downtime associated with transferring lenses between separate dedicated machines.
Solution Approach 2:
The machine is designed as a multi-functional processing system that can perform multiple different operations (cutting, drilling, engraving, milling) on the same lens within a single setup. The universal base structure supports multiple tool units that can be positioned and activated as needed, allowing one machine to replace multiple specialized machines while maintaining operational reliability for each specific function.
2Reliability
If separate machines are used for cutting operations and drilling/engraving/milling operations, then each machine can be optimized for its specific function, but the operational flexibility is reduced
Solution Approach 1:
The machine integrates multiple functional units (cutting, drilling, engraving, milling) into a single system with a common base structure. Each unit maintains its specialized functionality while the overall system provides operational flexibility to perform any combination of operations on the same lens without repositioning or resetup, thereby achieving both functional reliability and operational versatility.
Solution Approach 2:
The machine employs dynamic positioning capabilities where the tool units can be moved and positioned as needed on the base structure. The lens support system allows for dynamic adjustment of lens position and orientation, enabling the machine to adapt to different operation sequences and configurations, thereby enhancing operational flexibility while maintaining the specialized functions of each tool unit.
3Ease of manufacture
If a three-axis tool system is used for cutting operations, then the cutting can be performed with linear movement and rotation, but the operational flexibility is limited and shaped tools are required
Solution Approach 1:
The patent enhances the traditional three-axis system by adding rotational capabilities to the tool units. The cutting tool, drilling tool, engraving tool, and milling tool can all rotate around the lens in addition to moving along linear axes. This adds a dimensional aspect of rotation that enables angled cuts and diverse operation angles without requiring shaped tools, thereby maintaining ease of manufacture while significantly improving cutting angle flexibility and operational versatility.
Data Source
AI summary
A machine for processing lenses includes an apparatus for loading and storing raw lenses having a lens exit portion, a lens cutting system including a first lens housing seat and a first spindle-holder head for a cutting tool positionable at the first seat by a first articulated arm, a lens drilling-milling-engraving system including a second lens housing seat and a second spindle-holder head for a drilling-milling-engraving tool, a processed lens unloading zone, a lens transfer apparatus, and a management and control unit. The lens exit portion, the first and second lens housing seats, and the processed lens unloading zone constitute four operating stations. The lens transfer apparatus includes a turret having four suction-cup seats to receive a single lens. A first motor rotates the turret to cyclically bring each transport seat in sequence to the four operating stations.