Spectacle Lens Production System with Counter-Flow Transport Tracks
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Solution Overview
Problem
Conventional spectacle lens production systems face inefficiencies due to unequal load distribution and frequent conversions required for processing different lenses, leading to stopped processing and suboptimal device utilization, especially when process devices have varying capacities and fail.
Innovation Solution
A production system with three transport tracks (outer left, outer right, and central) and multiple process devices, where the central transport track operates counter to the outer tracks, allowing for flexible and efficient processing with transfer devices and rotation/transport devices forming a matrix for optimized handling and processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a conventional process line with a predetermined sequence of process devices is used, then the production system is simple to operate, but the system suffers from unequal load distribution and cannot optimally handle different spectacle lens types, leading to frequent conversions and stopped processing
Solution Approach 1:
The patent implements a dynamic process line where the sequence of process devices is not fixed but can be changed based on the spectacle lens type being produced. The control system dynamically reconfigures the process line by activating or deactivating specific process devices and adjusting their parameters, allowing the system to adapt to different production requirements without physical reconfiguration or complete line shutdown
Solution Approach 2:
The patent creates a universal process line that can handle multiple spectacle lens types through a single configured system. Different process devices perform multiple functions depending on their configuration - for example, a process device can be set to perform edging for one lens type and drilling for another. This multi-functionality eliminates the need for separate dedicated lines for different lens types
2Productivity
If process devices are arranged in a linear sequence, then the system layout is simple, but the system cannot achieve optimal load distribution when process devices have different capacities
Solution Approach 1:
The patent incorporates a control system that continuously monitors the load and performance of each process device in real-time. Based on this feedback, the system dynamically adjusts the distribution of workloads, reconfigures the process sequence, and optimizes processing parameters to balance the load across devices with different capacities. This ensures that no single device becomes a bottleneck while maximizing overall system productivity
Solution Approach 2:
The system transitions from a static linear arrangement to a dynamic configurable sequence where process devices can be reordered, activated, or deactivated based on real-time load conditions and device capacities. The control system continuously optimizes the process line configuration to match current production requirements and device availability
3Adaptability or versatility
If a central controller controls all process devices and transport devices, then the system is easy to manage, but any extension or modification requires complete reconstruction and new programming of the central controller
Solution Approach 1:
The patent divides the control system into independent modular units, each controlling specific process devices or transport devices. These modular controllers can be independently configured, modified, or extended without affecting the entire system. Each module communicates with others through standardized interfaces, allowing flexible system expansion and updates while maintaining overall coordination
Data Source
AI summary
Disclosed is a production system for spectacle lenses made from spectacle lens blanks, having a left-hand outer transport track, multiple left-hand processing devices which are arranged on the left-hand side next to the left-hand outer transport track, a right-hand outer transport track, and a central transport track which is arranged between the left-hand outer transport track and the right-hand outer transport track. The transport direction of the left-hand outer transport track and the transport direction of the right-hand outer transport track are identical, and the transport direction of the central transport track is opposite to the transport directions of the left-hand outer transport track and the right-hand outer transport track or can be reversed. The multiple right-hand processing devices are arranged on the right-hand side next to the right-hand outer transport track. A processing device pair made of left-hand and right-hand processing devices is paired with a transfer device.