Ophthalmic Lens Tray Cleaning Station Segmentation
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Solution Overview
Problem
Existing ophthalmic lens tray cleaning systems face challenges in effectively removing dust and debris due to the unique composition and size of lenses, which can lead to contamination of adjacent trays and inefficiencies in cleaning processes, particularly in small, precise production lines where customized lenses are manufactured.
Innovation Solution
A tray cleaning station with a conveyor system that extracts trays from the production line, featuring a rotating base with clamping arms, a vertical cleaning chamber with air and water ducts, and a controller for customized cleaning programs, allowing for individualized cleaning and prevention of cross-contamination.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If high pressure water (around 20Pa) is applied to remove dust from trays, then cleaning effectiveness is improved, but particles are propelled to adjacent trays causing contamination
Solution Approach 1:
The cleaning system is divided into multiple independent cleaning zones, each with its own air supply and suction system. This segmentation allows localized control of cleaning pressure and prevents particles from one zone affecting adjacent zones, resolving the contradiction between effective dust removal and prevention of cross-contamination.
Solution Approach 2:
Air streams are introduced as intermediary elements between the water spray and adjacent trays. The air flow acts as a barrier that contains particles within the cleaning zone while allowing the water spray to effectively clean the tray surface, thus preventing particle propagation to neighboring trays.
2Object-affected harmful factors
If air is used instead of liquid to clean trays, then cross-contamination is reduced, but powder flies and remains suspended in air falling back on trays
Solution Approach 1:
The system merges both air and liquid cleaning methods into a unified process. Water spray is used for primary dust removal while air streams are simultaneously applied to contain and remove particles. This combination leverages the advantages of both methods: liquid for effective cleaning and air for particle containment and removal.
Solution Approach 2:
The system uses pneumatic (air) and hydraulic (water) systems in conjunction. Compressed air is supplied through nozzles to create controlled air streams that work alongside water spray, using the pneumatic force to lift and remove particles while water provides the cleaning action, achieving both effective cleaning and particle containment.
3Object-affected harmful factors
If trays are cleaned individually by extraction, then cross-contamination is prevented and cleaning is optimized, but device complexity increases
Solution Approach 1:
The cleaning chamber is designed as a multi-functional unit that can handle multiple trays simultaneously through segmented zones. Each zone operates independently but uses the same basic cleaning mechanism, allowing the system to process different numbers of trays without requiring fundamentally different equipment, thus managing complexity while maintaining effectiveness.
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
Ensures thorough and efficient cleaning of trays without interfering with the production line, allowing for continuous operation and reducing the risk of re-contamination, while accommodating different tray sizes and optimizing resource use through recycling and adjustable pressure.
Implementation Method 1
The medium directed to the tray should drag the powder away
Implementation Method 2
the pressure applied to the tray by the cleaning medium (water) has to be much greater (around 20Pa)
Data Source
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AI summary
Tray cleaning station (W) for ophthalmic lenses production line (LP), the tray cleaning station (W) comprising a conveyor (T) for the transport of trays (B) supporting the lenses, which comprises extraction means (X) of a tray (B) from the conveyor (T), a chamber (CH) for cleaning the tray (B) and transfer means (TR) of the tray (B) between the extraction means (X) and the chamber (CH). Production line (LP) for manufacturing ophthalmic lenses (L) provided with treatment stations (ET) connected by at least one conveyor (T) for the transport and transfer, between stations (ET) of trays (B) supporting the lenses (L), the production line (LP) comprising at least one tray cleaning station (W) according to any of the preceding claims.