Modular Ophthalmic Lens Production Line with Transfer Robots
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Solution Overview
Problem
Existing ophthalmic lens production lines are inflexible, requiring significant downtime and laborious processes for changing lens geometries or materials, as they are configured for specific processes and cannot easily adapt to new lens types without interrupting production.
Innovation Solution
A modular production line comprising separate manufacturing, inspection, and packaging modules with reusable molds and transfer robots, allowing for easy exchange of manufacturing units and addition of treatment stations, enabling flexible production processes and 'lot change on the fly' without production interruption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the production line is configured for a specific process with fixed stations, then manufacturing precision and efficiency are improved, but adaptability to change lens geometries or materials deteriorates
Solution Approach 1:
The production line is divided into separate functional modules (mold exchange module, dosing module, closing module, forming module, extraction module, inspection module, packaging module) that can be independently configured and exchanged. This segmentation allows the system to maintain high precision for each specific process while enabling easy adaptation to different lens types by reconfiguring individual modules without affecting the entire production line.
Solution Approach 2:
The production line incorporates dynamic elements including automated mold exchange mechanisms, transfer robots that can reposition components, and configurable station arrangements. These dynamic features enable the system to adapt to different lens geometries and materials by adjusting the configuration of individual modules while maintaining continuous operation and high manufacturing precision.
2Productivity
If the production line uses fixed stations configured for specific processes, then productivity is improved, but loss of time during line clearance and reconfiguration increases
Solution Approach 1:
By dividing the production line into independent modules, the system can perform selective reconfiguration of only the affected modules rather than clearing the entire line. This reduces the scope of downtime operations and allows continuous production to resume more quickly after changes are implemented.
Solution Approach 2:
The system includes preliminary action mechanisms such as pre-positioned replacement modules and automated mold exchange systems that prepare components in advance. This allows for rapid switching between different lens types by having ready-made configurations available, minimizing the time required for line clearance and reconfiguration.
3Productivity
If the production line is specifically adapted for one process, then manufacturing efficiency is improved, but ease of operation for changing processes deteriorates
Solution Approach 1:
The modular architecture allows operators to easily change lens types by simply exchanging specific modules rather than reconfiguring the entire production line. Each module is designed with standardized interfaces and automated connection mechanisms, making the changeover process straightforward and minimizing operational complexity while maintaining high manufacturing efficiency.
Solution Approach 2:
The production line modules are designed with universal interfaces and standardized configurations that allow them to perform multiple functions. For example, the mold exchange module can accommodate different mold types, and the transfer robots can handle various component configurations. This multi-functionality simplifies the operation of changing lens types while preserving the manufacturing efficiency of the optimized process.
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 modular design enables quick and efficient changes in lens manufacturing processes and materials, reducing downtime and increasing production flexibility, allowing for continuous operation while adapting to different lens types and processes.
Implementation Method 1
Each transfer robot of the plurality of transfer robots is arranged at a location between two said individual manufacturing units between which the respective transfer robot is arranged and is configured to transfer the reusable molds from one of the two individual manufacturing units between which the respective transfer robot is arranged to the other one of the two individual manufacturing units between which the respective transfer robot is arranged
Implementation Method 2
the lens forming material enclosed in the mold cavity is polymerized and/or crosslinked to form the contact lens
Implementation Method 3
solvents contained in the lens forming material which are also contained in the contact lens formed therefrom as well as any non-polymerized and/or non-crosslinked lens forming material need to be extracted from the contact lens
Implementation Method 4
a coating can be applied to the contact lens in order to improve lubricity of the contact lens
Implementation Method 5
a foil is placed onto the shell and is heat-sealed thereto
Data Source
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AI summary
A modular production line for the production of ophthalmic lenses comprises at least three separate modules: - a manufacturing module (MM), - an inspection module (IM), and - a packaging module (PP). The modular production line further comprises fixedly arranged transfer interfaces between the individual modules (MM, IM, PP) for transferring the lenses from a preceding module to a subsequent module. The manufacturing module (MM) comprises a plurality of manufacturing stations (300, 301, 302, 310, 320, 321, 322, 330, 331, 340, 341, 342, 350, 351, 352) which are grouped to form a plurality of individual manufacturing units (30; 31; 32; 33; 34; 35) arranged in a closed loop. Reusable male and female molds (212, 112) are transported through the manufacturing stations of the manufacturing units, and each manufacturing unit (30; 31; 32; 33; 34; 35) comprises a plurality of the manufacturing stations (300, 301, 302, 310, 320, 321, 322, 330, 331, 340, 341, 342, 350, 351, 352). A plurality of transfer robots (36) is provided, each transfer robot (36) of the plurality of transfer robots (36) being arranged at a location between two manufacturing units (30; 31; 32; 33; 34; 35) to transfer the reusable molds from one manufacturing unit to the other manufacturing unit.