Compact Storage System for Lens Shell Molds
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Solution Overview
Problem
Existing storage solutions for shell molds in lens production lines lack a compact and efficient system for storing and retrieving objects with recipe-based access, often resulting in inefficiencies and potential for dirt generation due to mechanical abrasion.
Innovation Solution
A compact storage system featuring a profile frame with metal sheets, a robot with two translational and one rotational degree of freedom, and a detection system, which uses markings and distance sensors to accurately position and orient the gripper for precise storage and retrieval of shell molds, minimizing mechanical contact and ensuring filtered air supply to prevent dirt accumulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If a compact storage system with metal sheets and robot is used, then storage density and space utilization are improved, but mechanical abrasion and dirt generation increase
Solution Approach 1:
The patent introduces an air bearing layer as an intermediary between the metal sheets and the objects being stored. This air cushion prevents direct mechanical contact between the sheets and objects, eliminating abrasion and dirt generation while maintaining the compact storage structure. The air bearing acts as a mediator that enables contactless support and movement.
Solution Approach 2:
The system uses pneumatic air bearings to create a cushion of air between moving parts. Compressed air is supplied through channels in the metal sheets to generate an air bearing layer that supports objects and enables robot manipulation without mechanical contact. This pneumatic approach replaces traditional mechanical support systems.
2Quantity of substance
If multiple metal sheets are stacked for storage, then storage capacity increases, but positioning precision and orientation accuracy become more difficult to maintain
Solution Approach 1:
The patent incorporates preliminary positioning features directly into the metal sheets during manufacturing. Reference markings, alignment pins, and pre-defined storage location geometries are built into each sheet before assembly. This preliminary preparation ensures that when sheets are stacked, their relative positions and orientations are automatically maintained with high precision without requiring complex adjustment mechanisms.
Solution Approach 2:
The system uses optical markers and sensors to detect and measure the precise position and orientation of metal sheets. The markers on the sheets interact with optical sensors to provide feedback on positioning accuracy, enabling the robot to locate and orient itself correctly for each storage location.
3Adaptability or versatility
If a robot with multiple degrees of freedom is used for storage and retrieval, then operational flexibility improves, but system complexity and potential for mechanical contact increase
Solution Approach 1:
The robot system is segmented into distinct functional modules: a multi-axis positioning system for movement, a separate gripper mechanism for object handling, and an integrated detection system for feedback. This segmentation allows each module to be optimized independently while reducing overall system complexity through modular design. The robot has two translational degrees of freedom for positioning and one rotational degree of freedom for orientation.
4Object-affected harmful factors
If filtered air and overpressure are supplied to storage spaces, then cleanliness is improved, but energy consumption increases
Solution Approach 1:
The system establishes a positive pressure environment in the storage spaces before objects are placed or retrieved. Filtered air is supplied in advance to create overpressure, which prevents unfiltered air from entering the storage spaces during operations. This preliminary preparation maintains cleanliness throughout the storage process without requiring continuous high-energy filtration.
Solution Approach 2:
The patent creates a controlled, filtered air environment within the storage system that acts as a protective atmosphere. By maintaining positive pressure with filtered air, the system creates an inert-like environment that prevents contamination from external sources, similar to how inert atmospheres protect sensitive materials.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system enables efficient storage and retrieval of shell molds with reduced mechanical contact, maintaining cleanliness and allowing for semi-automatic or fully automatic operation, thereby enhancing production line efficiency and reducing the risk of contamination.
Implementation Method 1
The memory contains optical markers and sensors to measure the location of the optical markers
Implementation Method 2
a filtration system that supplies filtered air and overpressure to the spaces between the sheets
Data Source
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AI summary
The memory has a profiled frame (1) with multiple metal sheets (2). Each metal sheet has a profiled frame, formed by bending, multiple studs that are provided on the base and a marker and another marker. The studs delimit storage areas for holding objects. Another marker is recessed in the metal sheet, a robot (4) with a gripper (5). The robot has a horizontal and vertical linear displacement shaft (8,9) and a rotational displacement shaft (10).