Optical Lens Surfacing Compensation for Yield and Power Accuracy
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Solution Overview
Problem
Optical prescription laboratories face challenges in achieving precise optical power and design in lens manufacturing due to deviations in the surfacing process, leading to reduced yields and the scrapping of lenses outside predetermined tolerances, with current methods relying on manual statistical analysis that is cumbersome and limited.
Innovation Solution
A real-time calculation system that uses statistical analysis to determine compensation factors for lens manufacturing processes, optimizing yields by continuously monitoring and adjusting equipment performance, integrating with Lens Design Systems (LDS) to centralize monitoring and control across multiple production lines.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If manual statistical analysis is used to determine compensation factors, then the process can be performed with simple equipment, but the analysis is cumbersome and time-consuming
Solution Approach 1:
The patent replaces manual statistical analysis with an automated calculation system that computes compensation factors using measured deviations from lens surfacing equipment. This substitution of manual mechanical analysis with an automated computational system eliminates the time-consuming nature of manual work while maintaining the ability to determine appropriate compensation factors.
Solution Approach 2:
The calculation system performs self-service by automatically computing compensation factors based on measured lens deviations without requiring manual statistical analysis. The system takes measured data as input and autonomously determines the compensation factors needed for future manufacturing runs, freeing operators from cumbersome manual analysis tasks.
2Productivity
If real-time calculation system is implemented to compute compensation factors, then yields are increased and productivity improves, but device complexity increases
Solution Approach 1:
The patent implements a feedback mechanism where the calculation system continuously receives measured deviations from lens surfacing equipment and computes compensation factors that are applied to future manufacturing runs. This closed-loop feedback system automatically adjusts manufacturing parameters based on actual performance data, improving yields while managing complexity through systematic automation.
Solution Approach 2:
The system performs preliminary calculation of compensation factors based on measured deviations before future manufacturing runs occur. By pre-computing the necessary compensation adjustments, the system enables improved productivity in subsequent production without requiring complex real-time adjustments during manufacturing operations.
3Device complexity
If statistical analysis is performed manually by process engineers, then no automated system is needed, but the analysis is limited to far vision optical power deviations and requires good understanding of optical product industrial performances
Solution Approach 1:
The patent creates a universal calculation system that can handle multiple types of lens deviations and manufacturing scenarios through a single automated platform. The system is designed to work with different lens surfacing equipment and compute compensation factors for various deviation types, eliminating the limitations of manual analysis that was restricted to far vision optical power deviations and required specialized expert knowledge.
4Device complexity
If compensation factors are statically defined in Lens Design System, then the system is simple to implement, but it cannot adapt to changing manufacturing deviations and trends
Solution Approach 1:
The patent transitions from static compensation factors defined in the Lens Design System to dynamic compensation factors that are continuously updated based on measured manufacturing deviations. The calculation system computes updated compensation factors using recent measurement data, allowing the system to adapt to changing manufacturing conditions and deviation trends while maintaining operational simplicity through automated updates.
Data Source
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AI summary
A system and a method for compensating deviations in an optical lens manufacturing process, wherein the user provides a lens prescription to the Lab Management System (LMS 101), the Lens Design System (LDS 103) computes the manufacturing parameters on which the lenses are manufactured and an analyzer is configured to compute deviations in one or more surfaced optical lenses based upon nominal optical prescription values and parameters measured on one or more lenses output from lens surfacing equipment, the analyzer further configured to compute compensation factors for one or more future optical lens manufacturing runs based upon the deviations. The system uses statistical analysis to determine the compensation factors that can be applied to given products, Semi-Finish, materials, or lens designs to increase the lab yields. Using a monitoring and configuration system, the user tracks the evolution of the laboratory's performance and identifies areas in which yields are impacted. The user defines how the calculation system will optimize the laboratory's performance, such as by defining how the compensation factors will be calculated and applied.