Modular Lens Processing Layout for Higher Throughput
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Solution Overview
Problem
Existing lens processing devices face inefficiencies in terms of processing time and throughput, particularly in edge processing of spectacle lenses, due to the sequential nature of measurement and processing steps, which leads to prolonged overall processing times.
Innovation Solution
A modular device with operatively connected measuring and processing units via conveyor devices, allowing for flexible configuration and decoupling of measurement and processing steps, enabling lenses to be processed in any order and allowing for simultaneous handling of multiple lenses, thereby optimizing throughput.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If lenses are processed sequentially through measurement and edge processing devices, then processing accuracy is maintained, but processing time increases and throughput decreases
Solution Approach 1:
The system divides the lens processing workflow into independent modules: multiple measuring devices, multiple edge processing devices, and conveyor devices that transfer lenses between them. This segmentation allows parallel processing of multiple lenses simultaneously, increasing throughput while maintaining measurement accuracy through dedicated measuring stations.
Solution Approach 2:
Lenses are pre-measured and pre-positioned on conveyor devices before being transferred to edge processing devices. This preliminary action ensures that measurement data is captured and lenses are properly oriented before processing begins, maintaining accuracy while enabling continuous flow processing that improves throughput.
2Productivity
If multiple processing devices are added to increase throughput, then productivity improves, but device complexity increases
Solution Approach 1:
The conveyor devices are designed as multi-functional units that can transfer lenses between different measuring devices and different edge processing devices. This universal transfer capability allows the system to handle multiple lenses in various sequences without requiring dedicated transfer mechanisms for each device pair, thus improving throughput while controlling complexity.
Solution Approach 2:
Conveyor devices act as intermediary elements between measuring devices and edge processing devices. These intermediaries buffer and coordinate the flow of lenses, allowing independent operation of measuring and processing stations while maintaining system synchronization, thereby enabling parallel processing without proportionally increasing overall system complexity.
3Manufacturing precision
If lenses with longer processing times are handled, then comprehensive processing is achieved, but it delays processing of other lenses
Solution Approach 1:
The system maintains continuous processing by having multiple edge processing devices operating in parallel. When one device is processing a lens that requires longer processing time, other devices simultaneously process different lenses. The conveyor devices continuously feed lenses to available processing stations, ensuring that useful action continues without interruption across the system, thereby maintaining quality while minimizing overall waiting time.
Solution Approach 2:
The system dynamically assigns lenses to different processing devices based on current workload and processing requirements. If a lens requires extended processing, the control system can redirect subsequent lenses to different processing stations, balancing the load dynamically. This dynamic allocation ensures comprehensive processing of complex lenses while preventing bottlenecks that would delay other lenses.
Data Source
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AI summary
The present invention relates to a device for lens processing, comprising at least one receiving device for at least one transport box, at least one measuring device, and at least one processing device. According to the invention, it is provided that at least one conveying device is provided between the at least one measuring device and the at least one processing device, that at least one handling device or handling apparatus is provided between the at least one receiving device, the at least one measuring device and the at least one conveying device, such that the at least one measuring device, the at least one conveying device and the at least one processing device can be arranged or are arranged in any number and/or orientation with respect to one another. The present invention further relates to a corresponding method for lens processing and to a processing device for lenses.