Ophthalmic Lens Edge Profiling With 3D Laser Scanning
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Solution Overview
Problem
Existing systems fail to accurately provide a full 3D outer peripheral edge profile of ophthalmic lenses, leading to inaccuracies in machining and coating processes due to reliance on incomplete or inaccurate geometric data.
Innovation Solution
A machine and method utilizing a laser scanner unit to determine the 3D profile of the outer peripheral edge of ophthalmic lenses, combined with a lens holder unit and a UV light curing unit for precise application of coatings, employing a multi-axis system for accurate scanning and coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tactile measurement method is used to measure lens edge positions, then the measurement process is simple, but the measurement precision is insufficient and only provides Z axial information
Solution Approach 1:
The patent replaces the tactile/mechanical measurement system with an optical measurement system. A laser beam is projected onto the lens edge and reflected back to a sensor, enabling non-contact measurement of the 3D edge profile. This substitution provides complete geometric data (X, Y, Z coordinates) without mechanical contact, resolving the contradiction between measurement precision and device complexity.
Solution Approach 2:
The patent transitions from 1D axial measurement to 3D spatial measurement. By projecting a laser beam and detecting its reflection at different positions along the lens perimeter, the system captures complete 3D edge profile data including radial distance, axial position, and angular location, providing full geometric information about the lens edge.
2Loss of information
If existing tracer systems are used, then some lens edge information can be obtained, but the geometric data is incomplete and does not provide full 3D outer peripheral edge profile
Solution Approach 1:
The patent replaces existing tracer systems with a laser-based optical measurement system. The laser beam projects onto the lens edge and the reflected light is detected by a sensor, enabling accurate capture of the complete 3D edge profile. This provides full geometric data including radial distance from the optical axis, axial position, and angular location around the perimeter.
Solution Approach 2:
The patent achieves complete 3D measurement by capturing data in multiple spatial dimensions simultaneously. The laser scanning system measures the radial distance, axial position, and angular position of the lens edge, providing comprehensive 3D geometric information that existing 2D tracer systems cannot obtain.
3Manufacturing precision
If inaccurate edge profile data is used, then the processing speed is maintained, but the manufacturing precision of lens fitting and coating is compromised
Solution Approach 1:
The patent performs the 3D edge profile measurement at the beginning of the processing sequence, before machining and coating operations. By obtaining accurate geometric data of the lens edge in advance, the system enables precise planning of subsequent processing steps, ensuring high manufacturing precision without compromising processing efficiency.
Solution Approach 2:
The patent uses the measured 3D edge profile data as feedback to control subsequent machining and coating operations. The accurate geometric information about the lens edge is fed back to the processing system to adjust tool positions, cutting parameters, and coating application, ensuring precise manufacturing while maintaining efficient processing speeds.
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
Enables the generation of an accurate 3D-profile of the outer peripheral edge for subsequent processing, ensuring precise fitting and coating of ophthalmic lenses, improving the accuracy of machining and coating processes.
Implementation Method 1
A laser scanner unit is provided for determining a profile of the outer peripheral edge of the ophthalmic lens when mounted to the lens holder unit
Data Source
AI summary
A machine for processing an edge profile of an ophthalmic lens. The machine is defined by mutually perpendicular X, Y and Z axes. The machine comprises a machine frame, a lens holder unit for selectively holding the ophthalmic lens, a laser scanner unit for determining an edge profile of the ophthalmic lens mounted to the lens holder unit, and a main controller operatively connected to each of the lens holder unit and the laser scanner unit. The lens holder unit is configured to selectively rotate the ophthalmic lens around a C-axis of the lens holder unit, tilt the ophthalmic lens relative to the laser scanner unit and move rectilinearly relative to the machine frame in the directions of the Y axis. The laser scanner unit is selectively moveable rectilinearly relative to the machine frame in the directions of the X and Z axes.