Spectacle Lens Edging Data for Selective Defect Handling
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Solution Overview
Problem
Existing methods for manufacturing spectacle lenses often reject products with defects, leading to waste and inefficiency, without effectively utilizing preliminary or intermediate products that could be repurposed.
Innovation Solution
A method for manufacturing spectacle lenses using a data set of edging data to categorize and process spectacle lens blanks, semifinished products, and finished products based on defect detection and positioning, allowing for the utilization of previously rejected or intermediate products by assigning them to categories for further processing or storage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If spectacle lens blanks with defects are rejected, then product quality is maintained, but material waste increases and production efficiency decreases
Solution Approach 1:
The patent changes the parameter of defect evaluation from binary (defect present/absent) to spatial (defect position relative to edging zone). By introducing edging data and comparing defect positions with the future edging removal zones, the system determines that defects in certain regions can be tolerated and will be removed during edging, thus reducing material waste while maintaining quality
Solution Approach 2:
The patent performs preliminary defect detection and edging data comparison before final product completion. By analyzing defect positions against edging data in advance, the system can identify which defective blanks are still usable, preventing premature rejection and enabling better material utilization
2Reliability
If spectacle lens blanks with defects are rejected, then optical performance is ensured, but production productivity decreases
Solution Approach 1:
The patent transforms the quality assessment parameter from simple defect detection to spatial analysis of defect position relative to edging zones. This parameter change enables automatic classification of blanks into usable and unusable categories, streamlining the production process and improving productivity without compromising optical performance
Solution Approach 2:
The system uses the edging data itself to determine usability of defective blanks. The edging data, which defines the future product geometry and defect removal zones, automatically serves as the criterion for accepting or rejecting defective blanks, eliminating the need for separate quality assessment processes
3Productivity
If detailed defect detection and categorization is implemented, then resource utilization is optimized, but process complexity increases
Solution Approach 1:
The patent makes the edging data serve multiple functions: it defines the future product geometry, identifies defect removal zones, and determines usability of defective blanks. This multi-functionality eliminates the need for separate complex assessment systems, optimizing resource utilization without proportionally increasing process complexity
Solution Approach 2:
The edging data acts as an intermediary that bridges defect detection and quality decision-making. By comparing defect positions with edging data, the system creates a simple decision criterion (defect within edging zone = usable, defect outside = unusable), simplifying the overall process while enabling detailed defect analysis
Data Source
AI summary
A method for manufacturing a spectacle lens according to at least one data set of edging data and a computer program product with instructions for performing the method are disclosed. A spectacle lens blank, semifinished spectacle lens product, or a finished spectacle lens product is inspected for defects and compared to a data set to determine if it can be manufactured into an edged finished spectacle lens that fits into a specific spectacle frame such that the defect is not present in the edged finished spectacle lens.