Ophthalmic Lens Image Registration Without Production Downtime
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Solution Overview
Problem
Existing methods for inspecting ophthalmic lenses, particularly contact lenses, require interruptions in the manufacturing process to update the registration function for image registration, leading to inefficiencies and unnecessary downtime.
Innovation Solution
A method and system that uses imaged reference marks on a lens carrier to register and update the registration function during the automated lens manufacturing process, compensating for changes in optical imaging devices without interrupting production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the registration function is updated by acquiring images of a registration object, then the accuracy of image registration is improved, but the manufacturing process must be interrupted causing loss of time
Solution Approach 1:
The method uses imaged reference marks that are already present on the lens carrier from previous manufacturing steps. These reference marks were created during the lens manufacturing process itself, so no separate preliminary action of acquiring registration object images is needed. The reference marks are reused for registration function updates without interrupting production.
Solution Approach 2:
The lens carrier serves dual purposes: it carries the ophthalmic lens for manufacturing and inspection, and simultaneously provides reference marks for registration function updates. The system uses the existing imaged reference marks on the lens carrier to update the registration function, making the lens carrier self-sufficient for both manufacturing and registration update functions without requiring external registration objects.
2Reliability
If the registration function is updated frequently to compensate for changes in optical imaging devices, then the reliability of defect detection is improved, but unnecessary computational expenses are incurred when no changes have occurred
Solution Approach 1:
The system updates the registration function during normal lens inspection by comparing imaged reference marks with their expected positions. The feedback mechanism determines whether an update is actually needed based on detected deviations, allowing the system to maintain reliability by updating only when changes in optical imaging devices are detected, rather than performing unnecessary updates.
3Measurement precision
If multiple images of different types are acquired for comprehensive defect detection, then the measurement precision of defect identification is improved, but the device complexity increases
Solution Approach 1:
The registration function serves multiple purposes: it registers different types of images (bright-field, dark-field, phase-contrast) to a common frame, and simultaneously updates itself using imaged reference marks from the lens carrier. This multi-functional approach allows comprehensive defect detection across multiple image types while using a single integrated registration system rather than separate systems for each image type.
Data Source
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AI summary
A method (6) for inspecting an ophthalmic lens (2), in particular a contact lens such as a soft contact lens (2), in an automated lens manufacturing process is disclosed. The method comprises the steps of acquiring (60) a plurality of images containing the ophthalmic lens (2) to be inspected as an imaged ophthalmic lens (2), wherein each image (4) of the plurality of images is of a different image type, registering (63) the plurality of images by applying a registration function to each image (4) of the plurality of images to obtain registered images, determining (64), based on the registered images, whether the ophthalmic lens (2) complies with predetermined specifications, and updating (62) the registration function to compensate for possible changes in the acquisition of the plurality of images. Updating (62) the registration function is performed during the automated lens manufacturing process.