Universal Lens Basket Geometry for Automated Optical Handling
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Solution Overview
Problem
Existing lens baskets are unsuitable for automated manufacturing processes due to non-uniform and unbalanced receiving points, causing mechanical stresses and astigmatism, which compromise the optical quality of lenses.
Innovation Solution
A universal basket assembly with a planar base and tilted lens holders, each comprising a central arm and angled arms defining a tilted plane, allows for consistent and automated loading and unloading of lenses, reducing mechanical stresses and astigmatism.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional lens baskets with multiple lens holder configurations are used to accommodate various lens dimensions, then the baskets can receive different types of lenses, but the receiving points become non-uniform and unbalanced, making automated handling impossible
Solution Approach 1:
The patent changes the geometric parameters of the lens holder by introducing a tilted plane configuration at a specific angle (e.g., 45 degrees) relative to the base. This parameter change creates uniform receiving points that maintain geometric consistency across all lens holders, enabling automated robotic arms to load and unload lenses consistently while still accommodating various lens dimensions through the standardized tilted interface.
Solution Approach 2:
The tilted plane lens holder design serves as a universal interface that can accommodate multiple lens types and dimensions. The standardized geometry of the tilted plane and support members creates a multi-functional receiving structure that maintains uniformity across all positions in the basket, allowing a single automated handling system to service all lens holders regardless of the specific lens being processed.
2Adaptability or versatility
If lenses are positioned in traditional baskets, then various lens geometries can be held, but mechanical stresses are applied causing astigmatism and compromising optical quality
Solution Approach 1:
The patent applies local quality by providing targeted support at specific locations on the lens through the tilted plane configuration and support members. Instead of uniform support across the entire lens, the support members contact the lens at precise local points on the tilted plane, distributing mechanical stresses locally in a controlled manner that prevents astigmatism while maintaining the ability to hold various lens geometries.
Solution Approach 2:
The tilted plane configuration creates an equipotential support surface where lenses of various geometries can be positioned. The angled plane ensures that lenses rest in a consistent gravitational and mechanical equilibrium position, reducing unwanted mechanical stresses and preventing astigmatism by maintaining uniform support conditions across different lens types and orientations.
3Ease of operation
If lens holders are not configured to keep lenses stationary, then lenses can be easily loaded, but lenses shift around during manufacturing causing quality issues
Solution Approach 1:
The tilted plane configuration introduces asymmetry in the lens holder design, creating a unique angular orientation that allows lenses to be easily inserted during loading. Once positioned, the asymmetric geometry of the tilted plane and support members creates mechanical engagement that prevents lenses from shifting during manufacturing processes, thus maintaining position stability while preserving ease of loading.
Data Source
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AI summary
A basket assembly for holding optical article, the basket comprising: a planar base; and a plurality of lens holders tilted relative to a reference plane that is perpendicular to the planar base, each lens holder comprising: a central arm, first and second angled arms disposed on opposite sides of the central arm, wherein: the first and second angled arms extend from the central arm at a common angle and from a common point of intersection, and the first and second angled arms and the central arm collectively define a tilted plane that is tilted at an angle relative to the reference plane. Also presented is a method of loading and unloading the basket that is configured to hold optical articles.