Vision System Lens Blank Optic Center Alignment
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Solution Overview
Problem
Existing methods for aligning lens blanks during manufacturing, such as mechanical centering, are slow and inaccurate, limiting the achievable concentricity and resulting in excessive prism in lenses.
Innovation Solution
A method utilizing a precision positioning device, illumination device, and vision system with an image sensor and processor to determine the optic center of a lens blank by identifying known features, allowing for precise alignment and adjustment of the lens blank on a fixture.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical centering is used for blocking the lens blank, then the manufacturing process is simple, but the alignment accuracy and concentricity are insufficient
Solution Approach 1:
The patent replaces the mechanical centering system with an optical vision system that uses image capture and processing to detect lens features and calculate the optic center position. This substitution enables higher alignment accuracy (within 0.05mm) while maintaining manageable system complexity through software-based processing.
Solution Approach 2:
The vision system creates an optical copy (image) of the lens blank and its features, then processes this digital representation to determine the optic center position. This allows precise measurement and alignment without direct mechanical contact, improving accuracy while keeping the physical system relatively simple.
2Productivity
If mechanical blocking is used to hold the lens blank, then the device structure is simple, but the processing speed is slow
Solution Approach 1:
The patent replaces slow mechanical blocking with an automated vision-guided positioning system that rapidly captures images, processes feature coordinates, and calculates the optic center position. This automation significantly increases processing speed while managing complexity through integrated software control.
Solution Approach 2:
The system automatically detects lens features, calculates the optic center position, and guides the blocking operation without requiring manual measurement or adjustment. This self-service capability increases productivity while keeping the overall system complexity manageable through automation.
3Manufacturing precision
If mechanical centering is used, then the system is easy to operate, but the concentricity and prism control are insufficient
Solution Approach 1:
The patent replaces manual mechanical centering with an automated vision system that captures lens images, identifies features, and calculates the optic center position programmatically. This achieves high concentricity (within 0.05mm) while maintaining ease of operation through automated processing and minimal manual intervention.
Solution Approach 2:
The vision system provides feedback by detecting the actual position of lens features and calculating the optic center location, which then guides the blocking operation. This closed-loop feedback ensures high concentricity and prism control while keeping the operation simple through automated adjustment.
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 method enables high-precision alignment of lens blanks, improving concentricity and reducing prism, thereby enhancing the accuracy and efficiency of lens manufacturing.
Implementation Method 1
The illumination device may be configured to illuminate the lens blank from sides of the lens blank. The illumination device may be a low angle ring lighting device.
Implementation Method 2
The pick head may be configured to hold the lens blank using a vacuum.
Data Source
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AI summary
A method comprises providing a lens blank, a precision positioning device, an illumination device, and a vision system, wherein the lens blank includes at least one feature whose position is known relative to a position of an optic center of the lens blank, and wherein the vision system comprises an image sensor and a processor; mounting the lens blank on the precision positioning device; illuminating the lens blank with the illumination device; viewing the lens blank with image sensor of the vision system; determining the position of the at least one feature using the processor; and determining the position of the optic center of the lens blank based on the position of the at least one feature using the processor.