Optical Member Production: Cane Alignment and Cleaning

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Solution Overview

Problem

The existing method of producing optical members using columnar canes is prone to dust and stain contamination due to dense cane alignment, leading to potential quality deterioration and increased manual error and time in the alignment process.

Innovation Solution

A method involving an alignment step where columnar canes are inserted into a jig with predetermined insertion holes, followed by cleaning and packing steps using specialized apparatuses to automate the alignment and insertion of canes into a mold, ensuring precise alignment and reduced human error.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If canes are cleaned in a dense state, then cleaning efficiency is improved, but dust and stains are not completely removed leading to quality deterioration

Engineering Contradiction:

Improvecleaning efficiencyVSAvoidcleaning quality

Core Design Contradiction:

ProductivityVSManufacturing precision

Solution Approach 1:

The process is segmented into two distinct stages: first, canes are cleaned individually in a sparse state to ensure thorough removal of dust and stains; second, cleaned canes are densely packed for efficient transport and storage. This segmentation allows each stage to optimize for its specific purpose without compromising the other.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Cleaning is performed as a preliminary action before dense packing. By cleaning canes individually first, the process ensures high cleaning quality, and only after cleaning are canes densely packed for transport, thus avoiding contamination during the dense state.

Inventive Principle:

Principle #10Preliminary action

2Ease of operation

If manual alignment of 10,000 or more canes is performed, then flexibility is maintained, but work time becomes long and errors occur

Engineering Contradiction:

Improvealignment flexibilityVSAvoidwork time

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system uses self-aligning fixtures and automated positioning mechanisms that guide canes into correct positions without requiring manual adjustment. The canes are fed automatically and positioned by mechanical guides, reducing both time and human error while maintaining consistent alignment quality.

Inventive Principle:

Principle #25Self-service

Solution Approach 2:

Manual mechanical alignment operations are replaced with automated positioning systems that use mechanical guides, fixtures, and positioning mechanisms to align canes automatically. This substitution eliminates manual labor while maintaining precise alignment through engineered positioning systems.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Adaptability or versatility

If manual handling is used during alignment, then adaptability is maintained, but dust and stains adhere to canes

Engineering Contradiction:

Improvehandling adaptabilityVSAvoiddust and stain contamination

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

Clean rooms or controlled environment chambers are introduced as intermediaries between the external environment and the cane handling process. These controlled environments prevent dust and stain contamination while automated handling systems operate within them, maintaining both cleanliness and adaptability.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The handling process is conducted in a controlled, clean environment that acts as an inert atmosphere relative to contamination. This controlled environment prevents dust and stains from adhering to canes during automated handling, while the system remains adaptable to different cane types and configurations.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

Data Source

PatentUS11787089B2Method of producing an optical member including an alignment of canes into a jig

Publication Date: 2023.10.17 SONY GROUP CORP

AI summary

An information processing apparatus includes a presentation processing unit. The presentation processing unit executes, when a specific sound is generated at another point other than one of a plurality of points, presentation processing for presentation indicating that the specific sound generated at the other point is not a sound generated at the one point. Each of the plurality of points has a telepresence apparatus constituting a telepresence system that performs bidirectional communication of images and sounds for communication between users located at the plurality of points.