Six-Axis Transport Device for Precision Spectacle Lens Blocking
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Solution Overview
Problem
Existing devices for blocking spectacle lenses lack the necessary degrees of freedom to accurately position lenses during the blocking process, leading to potential errors and requiring additional calculations and adaptations in downstream processing machines.
Innovation Solution
A device with six position-controlled movement axes, including three linear and three rotational axes, allows for precise positioning of spectacle lenses relative to a block piece, ensuring accurate blocking without touching the block piece and enabling universal use without specific processing machine requirements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If only two position-controlled movement axes are used in the transport device, then the device complexity is reduced, but the positioning precision and manufacturing precision deteriorate because six degrees of freedom are required to fully position a workpiece in a 3D coordinate system
Solution Approach 1:
The transport device is designed with six position-controlled movement axes (three linear axes and three rotational/tilting axes) that can be dynamically adjusted to provide the full six degrees of freedom required for precise positioning. This dynamic capability allows the system to adapt to different workpiece positioning requirements while maintaining manufacturing precision.
2Manufacturing precision
If manual lens mapping and alignment station with operator adjustments are used, then the device complexity is reduced, but the productivity and manufacturing precision deteriorate due to manual operation and potential human error
Solution Approach 1:
The patent replaces manual mechanical alignment operations with an automated computer-controlled system. The computer calculates the desired position based on job data and automatically controls the transport device's six movement axes to position the workpiece with high precision, eliminating manual operator intervention and associated errors.
Solution Approach 2:
The system performs self-alignment through automated computer control. The computer automatically determines the workpiece position, calculates required adjustments, and controls the movement axes without requiring operator intervention, enabling the system to service itself in terms of positioning and alignment operations.
3Manufacturing precision
If the workpiece touches the block piece or mold during blocking, then the device complexity is reduced, but the manufacturing precision and reliability deteriorate because the workpiece must be held without contact to maintain positioning accuracy
Solution Approach 1:
The holding head serves as an intermediary between the transport device and the workpiece. It provides contactless or minimal contact holding of the workpiece during transport and positioning, allowing the workpiece to be held in a defined position relative to the block piece without direct contact that would compromise positioning accuracy.
4Adaptability or versatility
If correction data must be sent to downstream processing machines to compensate for positioning errors, then the blocker simplicity is maintained, but the adaptability and ease of operation worsen because downstream machines must adapt to the blocker
Solution Approach 1:
The system performs preliminary positioning using all six degrees of freedom before the blocking operation. By pre-positioning the workpiece with high accuracy using the six movement axes, the system eliminates the need for downstream machines to perform compensation calculations or adaptations, making the blocker universally applicable to various downstream processing machines.
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 solution provides accurate and universal blocking capabilities, reducing errors and the need for additional calculations in subsequent processing, particularly beneficial for complex lenses like progressive lenses, and avoids prismatic defects.
Implementation Method 1
the transport device has four further position-controlled movement axes, i.e. a total of six position-controlled movement axes, namely three position-controlled linear axes that are essentially perpendicular to one another and three rotation or tilting axes about the linear axes that are controlled in terms of the angle of rotation
Implementation Method 2
a blocking station in which the workpiece is fixed by means of a temporarily deformable, namely light-curing or thermoplastic block material on a block piece can be blocked
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention discloses a device (10) for blocking workpieces, particularly spectacle lenses (L), for the processing and/or coating thereof, comprising a support surface for positioning the workpiece to be blocked, a blocking station (14) in which the workpiece can be blocked on a blocking piece (S) by means of a temporarily deformable blocking material, and a transport device (18) which has a retaining head (16) for the workpiece and by means of which a relative movement can be created between the workpiece being retained at the retaining head, and the support surface and the blocking station. In order to enable a use of the blocking device that is as universal as possible, the transport device has at least four position-controlled movement axes (X, Y, Z, A, B, C), by means of which the workpiece can be positioned in a defined manner in consideration of the orientation and geometric information relative to a blocking piece located in the blocking station, and can be retained in the defined relative position to the blocking piece during blocking while leaving a blocking material accommodation gap between the workpiece and the blocking piece.