Turret Lens Processing Machine for Continuous Multi-Step Machining
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current lens processing machines in plastic material require multiple dedicated machines for each operation, leading to reduced operational flexibility and increased downtime due to limited axes of movement, which complicates cutting, drilling, milling, engraving, and loading/unloading processes.
Innovation Solution
A multi-axis machine integrating cutting, drilling, milling, engraving, and loading/unloading operations with a turret system and articulated arms, allowing for flexible tool positioning and independent lens handling, reducing downtime and enabling operations at various angles without affecting productivity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple dedicated machines are used for each lens processing operation, then each operation can be performed with specialized equipment, but the production cycle time increases due to long downtime between processes
Solution Approach 1:
The patent combines cutting, drilling, milling, and engraving operations into a single integrated machine platform. The machine includes a cutting device with a first spindle, a drilling device with a second spindle, a milling device with a third spindle, and an engraving device with a fourth spindle, all mounted on the same machine structure. This allows multiple operations to be performed sequentially or simultaneously on the same lens without removing it from the machine, thereby reducing downtime between processes while maintaining the specialized capabilities of each operation.
Solution Approach 2:
The machine is designed as a universal processing center that can perform multiple different operations on lenses. The control unit coordinates the cutting device, drilling device, milling device, and engraving device to execute various processing sequences based on the lens type and required operations. This multi-functional approach eliminates the need for multiple dedicated machines while preserving the quality benefits of specialized equipment for each operation type.
2Device complexity
If a three-axis cutting tool is used with limited rotation axes, then the machine structure is simplified, but the operational flexibility is reduced and shaped tools are required which limit cutting angles
Solution Approach 1:
The patent adds rotational freedom to the cutting tool by enabling the first spindle to rotate around a first rotation axis that is different from the cutting direction. This allows the cutting tool to approach the lens from various angles and perform complex cutting operations that were previously impossible with fixed three-axis tools. The same dimensional enhancement is applied to the drilling, milling, and engraving devices, giving each tool the ability to operate at multiple angles without requiring complex shaped tooling.
Solution Approach 2:
The machine incorporates dynamic positioning capabilities where the spindles can rotate and reposition during operation. The first spindle can rotate around the first rotation axis, and similarly the second, third, and fourth spindles have their own rotation axes. This dynamic adjustment allows the tools to adapt to different lens geometries and cutting requirements in real-time, providing the flexibility of shaped tools without the limitations of fixed tool geometries.
3Adaptability or versatility
If drilling, engraving, and milling operations are added to the cutting machine, then operational flexibility increases, but the production cycle is slowed down
Solution Approach 1:
The machine is designed to perform cutting, drilling, milling, and engraving operations in a continuous sequence without interrupting the production flow. The control unit coordinates all four devices to operate efficiently in sequence, and the turret mechanism allows for quick tool changes and positioning. Additionally, the machine can hold multiple lenses in position simultaneously, allowing operations to be performed on different lenses at different stages of the process, thereby maintaining continuous productive action rather than idle waiting time.
Solution Approach 2:
The machine includes a turret that can pre-position multiple lenses and tools in advance. Before the actual processing begins, the system can prepare the next lens or tool in the sequence, reducing setup time between operations. The control unit can also pre-program the sequence of operations based on the lens type and required processing, allowing for optimized routing and timing of each operation to minimize cycle time.
4Device complexity
If loading and unloading operations are integrated with processing operations, then the machine structure is simplified, but the processing efficiency is reduced due to operational interference
Solution Approach 1:
The patent separates the loading/unloading function from the processing function by incorporating a turret mechanism that can independently hold and present lenses to the processing devices. The turret acts as an intermediate buffer that decouples the loading/unloading operations from the actual cutting, drilling, milling, and engraving processes. This allows lenses to be loaded onto the turret while other lenses are being processed, and finished lenses can be unloaded from the turret without interrupting the processing of other lenses, thereby maintaining processing efficiency while using a relatively simple integrated structure.
Data Source
Figure 1
Figure 2
Figure 3~4
AI summary
The invention concerns a machine (1) for processing lenses, comprising: - an apparatus (10) for loading and storing raw lenses that comprises a lens exit portion (11); - a lens cutting system (20) that comprises: a first lens housing seat (200) and a first spindle-holder head (210) for a cutting tool positionable at said first seat (200) by means of a first articulated arm (211); - a lens drilling-milling-engraving system (30) that comprises: a second lens housing seat (300) and a second spindle-holder head (310) for at least one drilling-milling-engraving tool positionable at said second seat (300) by means of a second articulated arm (311); - a processed lens unloading zone (40); - a lens transfer apparatus (50) which is suitable to pick up one lens at a time from said apparatus 10 for loading and storing to bring it sequentially into the first lens housing seat (200) of said lens cutting system (20), into the second lens housing seat (300) of said lens drilling-milling-engraving system (30) and into the processed lens unloading zone (40); and - a management and control unit (100). The lens exit portion (11), the first lens housing seat (200), the second lens housing seat (300) and said processed lens unloading zone (40) constitute four operating stations of said machine (1). Said lens transfer apparatus (50) comprises a turret (51) having four suction-cup seats (51a,b,c,d) each of said transport seats being suitable to receive a single lens. Said lens transfer apparatus (50) comprises first motor means (52) suitable to rotate said turret around a turret axis (X) so as to cyclically bring each transport seat (51a,b,c,d) in sequence at said four operating stations of the machine (1) which are arranged on a circumference centered on said turret axis (X) in angular positions spaced 90° apart from each other.