Spectacle Lens Tool Wear Detection With External Optical Sensing

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Solution Overview

Problem

Existing devices for processing optical workpieces, such as spectacle lenses, face challenges in reliably recognizing tool wear without prolonging processing times or increasing complexity, particularly due to issues with visual inspection methods and barcode-based systems that are prone to errors and contamination.

Innovation Solution

A device with a compact design featuring contactlessly operating sensor equipment that includes a laser and light-section sensor, allowing for wear recognition by comparing actual and desired geometries of the tool, and is protected from contamination and mechanical damage, enabling reliable wear detection without extending processing times.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Device complexity

If visual inspection methods or barcode-based systems are used for wear recognition, then the device complexity is reduced, but the reliability of wear detection deteriorates due to errors and contamination

Engineering Contradiction:

Improvedevice complexityVSAvoidreliability of wear detection

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent replaces mechanical/visual inspection methods and barcode-based systems with a sensor equipment comprising optical sensors (such as cameras or laser scanners) that contactlessly detect the processing region of the tool. This substitution eliminates the reliability issues of visual inspection and barcode systems while maintaining relatively simple device complexity, as the sensor system integrates directly into the processing device without requiring complex external inspection equipment.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Reliability

If sensor equipment is placed inside the work chamber for continuous monitoring, then the reliability of wear detection is improved, but the sensor equipment is exposed to contamination and mechanical damage

Engineering Contradiction:

Improvereliability of wear detectionVSAvoidcontamination and mechanical damage to sensor

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent positions the sensor equipment outside the work chamber and uses the opened opening of the work chamber to detect the tool's processing region. This preliminary positioning prevents the sensor from being exposed to harmful factors inside the chamber while still enabling detection before processing begins or during pauses in processing.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent uses the opening of the work chamber as an intermediary access point, allowing the sensor to detect the tool without being physically present inside the contaminated environment. The opening serves as a mediator that enables optical or electromagnetic detection while maintaining physical separation between the sensor and harmful factors.

Inventive Principle:

Principle #24Intermediary (Mediator)

3Object-affected harmful factors

If the sensor arrangement is moved outside the work chamber, then the sensor is protected from contamination, but the detection capability through the opened opening is limited

Engineering Contradiction:

Improveprotection from contaminationVSAvoiddetection precision through opening

Core Design Contradiction:

Object-affected harmful factorsVSMeasurement precision

Solution Approach 1:

The patent employs sensors capable of detection through the opening from an external position, utilizing optical or electromagnetic fields that can penetrate or pass through the opening space. This dimensional approach allows detection without direct contact or presence inside the chamber, maintaining both protection and precision.

Inventive Principle:

Principle #17Another dimension (Dimensionality change)

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 solution provides reliable and accurate wear recognition of polishing tools, preventing damage to workpieces by identifying unacceptable deviations from desired geometries, thus ensuring tool integrity and reducing wastage, all while maintaining a compact and efficient processing setup.

Implementation Method 1

sensor equipment with at least one contactlessly operating sensor arrangement... adapted to detect... at the processing region of the tool

Methodology Applied

Scientific EffectLight reflection: Reflection

Data Source

PatentUS11633827B2Device for processing optical workpieces, particularly spectacle lenses

Publication Date: 2023.04.25 SATISLOH AG

AI summary

A device for processing spectacle lenses has a work chamber, which is accessible by way of an opening and in which a workpiece mount and at least one tool mount are opposite one another and movable relative to one another so that a processing region of a tool held at the tool mount can be brought into processing engagement with a workpiece held at the workpiece mount and in processing engagement can be guided over the workpiece. For recognition of wear at the tool, a sensor equipment with at least one contactlessly operating sensor arrangement is provided and is movable outside the work chamber between a protected rest position and a detecting position. In the detecting position the sensor equipment is constructed to detect at the processing region of the tool held at the tool mount an unacceptable deviation beyond a predetermined amount from a desired geometry.