Ophthalmic Lens Zoning for Optical-Safe Machining Parameters
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Solution Overview
Problem
Traditional methods for producing ophthalmic lenses lack flexibility in selecting machining parameters, leading to increased manufacturing times, costs, and lower quality lenses due to inadequate consideration of aesthetic and optical quality, as well as the presence of components and optically-sensitive portions.
Innovation Solution
A method and system that identify and differentiate zones within a lens blank based on their characteristics, allowing for the selection of specific machining parameters such as rotational speed, translational speed, and depth of cut, to prioritize aesthetic and optical quality while minimizing risk of defects and machining time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional predefined machining parameters are used for the entire lens blank, then the manufacturing process is simple and fast, but the aesthetic and optical quality of the lens is compromised
Solution Approach 1:
The lens blank is divided into multiple zones (optically-sensitive zones and non-optically-sensitive zones) with different machining parameter requirements. The processor identifies and differentiates these zones, applying less aggressive parameters to optically-sensitive zones and more aggressive parameters to non-optically-sensitive zones, thereby resolving the contradiction between quality and complexity.
Solution Approach 2:
Different machining parameters are applied to different zones of the lens blank based on their optical sensitivity. Optically-sensitive zones receive parameters optimized for quality (lower rotational speed, lower translational speed), while non-optically-sensitive zones receive parameters optimized for efficiency (higher rotational speed, higher translational speed), achieving local optimization of both quality and productivity.
2Productivity
If aggressive machining parameters are used to decrease manufacturing time, then productivity increases, but the risk of defects and damage to the lens increases
Solution Approach 1:
The lens blank is segmented into zones with different vulnerability characteristics. Unsupported zones are identified and assigned less aggressive machining parameters to prevent vibration marks and defects, while supported zones can tolerate more aggressive parameters, thus maintaining reliability while improving overall productivity.
Solution Approach 2:
Machining parameters are locally adjusted based on the structural characteristics of each zone. Zones with better support receive more aggressive parameters for faster material removal, while unsupported or thin zones receive gentler parameters to prevent damage, achieving a balance between productivity and reliability.
3Adaptability or versatility
If uniform machining parameters are applied across the lens blank, then the machining process is straightforward, but zones with different characteristics (supported vs unsupported, optically-sensitive vs non-sensitive) are not adequately addressed
Solution Approach 1:
The lens blank is divided into multiple zones based on their characteristics (supported/unsupported, optically-sensitive/non-sensitive). The processor identifies each zone and assigns appropriate machining parameters, enabling the system to adapt to different zone requirements while maintaining efficient manufacturing through automated parameter selection.
Solution Approach 2:
The machining parameters are dynamically adjusted based on the zone being machined. The system transitions between different parameter sets depending on the current zone's characteristics, allowing optimal parameters to be applied to each zone without manual intervention, thus achieving adaptability without significant time loss.
Data Source
Figure 1A~1B
Figure 2
Figure 3A~3B
AI summary
This disclosure includes a method and a system for producing ophthalmic lenses. The method includes identifying a plurality of zones (226a, 226b) within a spatial representation (126) of a lens blank (10), selecting, for each of the zones (226a, 226b) one or more parameters for producing the lens (14), and producing the lens (14) by removing material from the lens blank (10) according to the one or more parameters of each of the zones.