Optical System Manufacturing Decoupling Stock and Precision
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Solution Overview
Problem
Current methods for manufacturing progressive power lenses rely on specific semi-finished optical systems that are tailored to individual prescriptions, limiting flexibility and stock management, as they depend on the characteristics of the finished optical system, making it challenging to adapt and manage semi-finished stock independently.
Innovation Solution
A method involving the generation of a virtual optical system using computer calculations, where a virtual function is modified to create a semi-finished optical system that can be adapted to different optical functions by modifying encryption functions, allowing the same semi-finished system to produce multiple optical systems with varying optical functions, thereby decoupling the stock management from the specific optical system characteristics.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If semi-finished progressive lens blanks are tailored to individual prescriptions, then manufacturing precision is improved, but adaptability and stock management flexibility deteriorate
Solution Approach 1:
The optical system is divided into two independent parts: a first part (front surface) that defines the optical function and a second part (back surface) that is customized to individual prescriptions. This segmentation allows the first part to be standardized for stock management while the second part maintains precision customization, resolving the contradiction between manufacturing precision and adaptability.
Solution Approach 2:
The first part of the optical system is designed as a universal component that can be used across multiple prescriptions. By standardizing this part, the system achieves versatility in stock management while the second part is customized to maintain manufacturing precision for each specific prescription.
2Manufacturing precision
If semi-finished optical systems are customized for specific optical functions, then manufacturing precision is improved, but device complexity and production time increase
Solution Approach 1:
The production process is segmented into two independent manufacturing steps: first manufacturing the standardized first part, then adding the customized second part. This segmentation reduces overall process complexity by allowing parallel processing and independent optimization of each step, while maintaining high manufacturing precision through specialized processing of each part.
Solution Approach 2:
The first part of the optical system is manufactured in advance as a standardized component, allowing preliminary preparation and stockpiling. This preliminary action reduces production time and complexity for final customization, as the base component is already prepared and only requires addition of the prescription-specific second part.
3Reliability
If encryption functions are applied to modify virtual equations, then data security is improved, but calculation complexity increases
Solution Approach 1:
Encryption functions are introduced as intermediary elements that transform the virtual equations representing optical surfaces. These encryption functions act as mediators between the raw optical data and the final manufactured product, providing data protection while maintaining the mathematical relationships needed for manufacturing. The complexity is managed by keeping the encryption functions as separate, well-defined transformation layers.
Data Source
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AI summary
The invention relates to a method of calculating an optical system (OS), the optical system (OS) being identified by a function (OF), the optical system (OS) comprising a first part (Fl) defined by a first equation (EFl) and a second part (F2) defined by a second equation (EF2), the method comprising: - a generating step (GEN), in which a virtual optical system (VOS) is used to generate a virtual function (VOF); - a modification step (MOD), in which the virtual function (VOF) is modified so as obtain the function (OF); - a calculation step (CAL), in which the second equation (EF2) is calculated from the function (OF), and the first equation (EFl). The invention relates also to a method of manufacturing an optical system (OS).