Optical Lens Processing Layout for Automated Deblocking Flow
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Solution Overview
Problem
Existing lens processing installations are inefficient and lack optimal throughput, particularly in deblocking eyeglass lenses, as they are large and do not allow for efficient automation in processing and material handling.
Innovation Solution
A facility and method with multiple independently-operating processing devices and a transport system for conveying lenses on carriers, including a commissioning device for fitting lenses and block pieces, a return-conveying device for block pieces, and optical examination and cleaning devices, enabling a fully-automated and optimized process sequence.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a strip-like conveying system with tempered water bath and multiple cleaning systems is used for deblocking lenses, then the lenses can be deblocked and cleaned, but the installation becomes relatively large and does not allow for optimal throughput
Solution Approach 1:
The installation is divided into multiple independently-operating processing devices, each capable of performing specific processing steps on lenses. This segmentation allows for parallel processing and optimizes throughput while reducing the overall installation footprint by eliminating the need for a single large sequential system.
Solution Approach 2:
The patent introduces a vertical arrangement of processing devices and multi-level transport systems, utilizing the vertical dimension to organize the processing flow. This dimensional change allows multiple processing steps to occur simultaneously at different levels, increasing throughput without proportionally increasing the horizontal installation area.
2Productivity
If multiple processing devices for the same processing steps are added to increase throughput, then productivity improves, but device complexity increases
Solution Approach 1:
The transport carriers are designed with universal features including integrated information carriers (barcodes) that can be read by multiple devices, standardized interfaces for different processing devices, and modular designs that can accommodate various processing operations. This universality allows multiple processing devices to work together efficiently without proportionally increasing system complexity.
Solution Approach 2:
The system incorporates information carriers on transport carriers that provide feedback about lens identity, processing status, and routing instructions. This feedback mechanism enables automated control and coordination between multiple processing devices, reducing the complexity of managing parallel processing operations through intelligent rather than purely mechanical control.
3Extent of automation
If a commissioning device for fitting transport carriers with lenses and block pieces is implemented, then automation is improved, but device complexity increases
Solution Approach 1:
The commissioning device performs preliminary actions by pre-attaching block pieces to transport carriers and pre-positioning lenses before they enter the main processing line. This preliminary preparation simplifies subsequent processing steps and enables full automation of the manufacturing process, as the complex assembly tasks are completed upfront in a dedicated station.
Solution Approach 2:
The system uses information carriers on transport carriers that enable self-identification and self-routing of lens batches through the processing line. The commissioning device reads these information carriers to automatically determine processing parameters and routing, eliminating the need for manual programming or complex external control systems.
Data Source
AI summary
An installation and a method for processing optical lenses, whereby transport carriers and block pieces are conveyed backward after use in each case to a commissioning device or blocking device, and the lens carriers are fitted by machine with unblocked or blocked lenses in order to make possible an automated and optimized process sequence.