Ophthalmic Surface Pre-Compensation for Blocking Deformation
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Solution Overview
Problem
Existing ophthalmic device manufacturing methods face challenges in accurately producing surfaces with predetermined optical functions due to deformation defects caused by blocking during machining, leading to optical power errors and reduced precision.
Innovation Solution
A method that selects an initial ophthalmic surface, identifies a reproducible surface defect caused by blocking, uses a predictive compensation model to determine a surface defect value, and transforms the surface to compensate for these defects, ensuring the machined surface conforms to the initial design by adjusting parameters like clamping force, bonding force, and material constraints.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If blocking is applied to hold the ophthalmic device during machining, then the device stability is improved, but deformation defects are introduced due to clamping forces
Solution Approach 1:
The method applies preliminary action by calculating and applying a compensatory transformation to the initial ophthalmic surface before machining. The transformation pre-compensates for the deformation that will occur during blocking and machining, so that after the blocking-induced deformation occurs, the final surface matches the desired target surface.
Solution Approach 2:
The method applies preliminary anti-action by introducing a compensatory transformation that counteracts the expected deformation from blocking. The transformation creates an opposite effect to the blocking-induced deformation, ensuring that the two effects cancel each other out and the final surface achieves the desired precision.
2Stability of the object's composition
If clamping force is increased to reduce device movement during machining, then machining stability is improved, but deformation defects increase
Solution Approach 1:
The method applies parameter changes by adjusting the clamping force parameters to optimal values that minimize deformation. The system determines appropriate clamping force levels and applies transformations that account for the specific deformation characteristics at these force levels, achieving a balance between stability and precision.
3Measurement precision
If blocking force is increased to prevent device movement, then positioning accuracy is improved, but optical power errors increase
Solution Approach 1:
The method applies preliminary action by pre-calculating the deformation that will occur at the intended blocking force level and applying a compensatory transformation to the initial surface. This allows the use of sufficient blocking force for positioning accuracy while pre-compensating for the resulting optical power errors.
Solution Approach 2:
The method applies feedback by using measured or modeled deformation data from blocking operations to refine the compensatory transformation. The system incorporates information about blocking-induced deformations and adjusts the transformation parameters to optimize both positioning accuracy and optical power accuracy.
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
This approach effectively compensates for deformation phenomena during machining, limits optical power errors, and enhances the accuracy of ophthalmic devices by accounting for blocking effects and material characteristics, resulting in a more precise final product.
Implementation Method 1
the reproducible surface defect is a deformation defect which is due to the blocking the ophthalmic device when a face of which is machined
Data Source
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AI summary
The disclosure relates to a method for manufacturing by machining an ophthalmic device, comprising selecting (100) an initial ophthalmic surface of the ophthalmic device intended to be manufactured, selecting (110) a manufacturing method intended to be implemented for machining the ophthalmic device and which introduces a reproducible surface defect, providing (120) a surface defect value which is function of the initial ophthalmic surface and reproducible surface defect and which would be introduced if the initial ophthalmic surface were produced by said manufacturing method, transforming (130) said initial ophthalmic surface into a transformed ophthalmic surface by compensating said surface defect, machining (150) by said manufacturing method the transformed ophthalmic surface in order to obtain an ophthalmic surface which substantially conforms to the initial ophthalmic surface, wherein said manufacturing method comprises blocking (140) the ophthalmic device to be machined and the reproducible surface defect is a deformation defect which is due to the blocking the ophthalmic device when a face of which is machined for obtaining the ophthalmic surface.