Ophthalmic Lens Transfer Position Verification
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Solution Overview
Problem
In the automated mass production of ophthalmic lenses, particularly contact lenses, there is a challenge in accurately transferring lenses from inspection cuvettes to primary packaging containers due to positional deviations, leading to incorrect placement and reduced production yield.
Innovation Solution
A method and apparatus that utilize a camera to image the lens position relative to the concave inner surface of the inspection cuvette, determine deviations from a predetermined set transfer position, and use a processor to decide whether to transfer the lens to the packaging container based on predetermined maximum deviations or eccentricity thresholds, ensuring proper alignment before pick-up and release.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a transfer gripper with suction openings is used to pick up the lens, then the lens can be transferred from the inspection cuvette to the packaging container, but the lens may not be picked up correctly or may be placed at unwanted locations due to positional deviations
Solution Approach 1:
The system performs preliminary imaging and position determination of the lens before the transfer operation. The camera captures the lens position relative to the concave inner surface, and the processor calculates the deviation from the set transfer position in advance, allowing the system to predict and prevent placement errors before they occur.
Solution Approach 2:
The system establishes a feedback loop where the camera continuously monitors lens position, the processor compares actual position with the set transfer position, and the transfer gripper adjusts its operation based on this feedback. The system determines whether to transfer based on whether the deviation is within acceptable thresholds, creating a closed-loop control system.
2Speed
If the lens position is not verified before transfer, then the transfer process is faster, but lenses are placed at unwanted locations reducing production yield
Solution Approach 1:
Position verification through imaging is performed as a preliminary action before the transfer operation. This quick optical check and computational assessment of lens position allows the system to determine transfer suitability instantaneously, preventing wasted transfer operations on mispositioned lenses while maintaining rapid throughput.
Solution Approach 2:
The patent replaces complex mechanical positioning and verification systems with an optical imaging and computational approach. Instead of using mechanical sensors or complex alignment mechanisms, the system uses a camera to capture lens position and processes the image data computationally to determine transfer suitability.
3Manufacturing precision
If a camera and processor are added to determine lens position, then lens placement accuracy is improved, but device complexity increases
Solution Approach 1:
The patent replaces complex mechanical positioning systems with a simpler optical and computational system. Instead of using multiple mechanical sensors, actuators, and physical alignment mechanisms, the system uses a single camera to capture lens position and processes the image data computationally to determine transfer suitability.
Solution Approach 2:
The camera acts as an intermediary between the lens and the transfer gripper, providing optical information about lens position without requiring direct mechanical interaction. The processor serves as another intermediary, translating the optical data into transfer decisions, thereby decoupling the measurement and execution functions.
Data Source
AI summary
In a method of handling an ophthalmic lens contained in an inspection cuvette and immersed in an inspection liquid the lens is arranged at an actual position relative to a concave inner surface of a bottom glass of the inspection cuvette;The method comprises the steps of:positioning the inspection cuvette in a handling position without pivoting the inspection cuvette;through the viewing glass obtaining an image of the lens;from the obtained image determining a deviation of the actual position of the lens from a set transfer position;comparing the deviation with a predetermined maximum deviation;determining that the lens is arranged at a proper transfer position when the deviation is less than the maximum deviation,in case of the proper transfer position, transferring the lens from the inspection cuvette to the primary packaging container.