CN111377598B - Apparatus and method for manufacturing molded lens - Google Patents
Apparatus and method for manufacturing molded lens Download PDFInfo
- Publication number
- CN111377598B CN111377598B CN201811620140.3A CN201811620140A CN111377598B CN 111377598 B CN111377598 B CN 111377598B CN 201811620140 A CN201811620140 A CN 201811620140A CN 111377598 B CN111377598 B CN 111377598B
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- press
- pressing
- curve
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- slope
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Classifications
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B11/00—Pressing molten glass or performed glass reheated to equivalent low viscosity without blowing
- C03B11/16—Gearing or controlling mechanisms specially adapted for glass presses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B11/00—Pressing molten glass or performed glass reheated to equivalent low viscosity without blowing
- C03B11/06—Construction of plunger or mould
- C03B11/08—Construction of plunger or mould for making solid articles, e.g. lenses
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/32—Component parts, details or accessories; Auxiliary operations
- B29C43/58—Measuring, controlling or regulating
- B29C2043/5808—Measuring, controlling or regulating pressure or compressing force
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
- C03B2215/00—Press-moulding glass
- C03B2215/40—Product characteristics
- C03B2215/44—Flat, parallel-faced disc or plate products
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/50—Glass production, e.g. reusing waste heat during processing or shaping
- Y02P40/57—Improving the yield, e-g- reduction of reject rates
Abstract
An apparatus and method for manufacturing a molded lens. The substrate is positioned between the first die core and the second die core, and the first die core is moved to enable the substrate to form a lens. The distance sensor sends out a plurality of pressing distance parameters for moving the first die core, and the plurality of pressing distance parameters can form a pressing curve. The difference between the press curve and the reference press curve is compared by a processor and a comparator. The processor determines whether the difference is within the error range.
Description
Technical Field
The present invention relates to a molding technique, and more particularly, to a device and method for manufacturing molded lenses with quality monitoring.
Background
Because the press curve can only identify whether the press is generated or not due to the differences among different dies, lenses and manufacturing processes in different lens manufacturing processes, the variation in the press process and the actual press depth of the lenses cannot be identified. The existing press forming curve can only identify whether press forming is performed or not, and cannot identify the process variation in the press forming process and the actual press forming depth of the lens, so that the subsequent quality control cost is derived.
Disclosure of Invention
The embodiment of the invention provides a manufacturing device and a manufacturing method for a molded lens, which can identify lenses with abnormal quality in different lens pressing processes so as to improve the quality.
In the method for manufacturing the molded lens, the substrate is positioned between the first mold core and the second mold core, and the first mold core is moved to enable the substrate to form a lens. The distance sensor sends out a plurality of pressing distance parameters for moving the first die core, and the plurality of pressing distance parameters can form a pressing curve; comparing, by the processor and the comparator, the difference of the compaction curve with the reference compaction curve; and determining, by the processor, whether the difference is within the error range.
The manufacturing equipment of the molded lens of the embodiment of the invention carries out a pressing manufacturing process on a substrate, and the manufacturing equipment comprises: the molding cavity, wherein the first die core or the second die core can move in the molding cavity, and the substrate is positioned between the first die core and the second die core; a distance sensor adjacent the molding chamber; a processor coupled to the distance sensor; the pneumatic cylinder is coupled with the processor and can enable the first die core or the second die core to move; the pressure regulating valve is coupled with the processor and the pneumatic cylinder and can regulate the pressure of the pneumatic cylinder; the pressure gauge is coupled with the processor and the pneumatic cylinder and can display the pressure of the pneumatic cylinder; the power meter is coupled with the processor and the pneumatic cylinder and can measure the power of the heater; a heater coupled to the processor for heating the molding chamber; the temperature controller is coupled with the processor and the heater and can control the temperature of the heater; the comparator is coupled with the processor, wherein the distance sensor sends out a plurality of pressing distance parameters of the pressing process, the plurality of pressing distance parameters can form a pressing curve, and the processor and the comparator compare the difference between the pressing curve and a reference pressing curve; and a memory device, wherein the reference press-making curve data is placed in the memory device.
Based on the above, the embodiment of the invention can monitor the actual pressing depth and the variation of the pressing process in real time, thereby eliminating defective products and reducing the subsequent quality control cost.
The foregoing description is only an overview of the present invention, and is intended to be implemented in accordance with the teachings of the present invention, as well as the preferred embodiments thereof, together with the following detailed description of the invention, given by way of illustration only, together with the accompanying drawings.
Drawings
Fig. 1 is an external view schematically showing an apparatus for manufacturing a molded lens according to an embodiment of the present invention.
Fig. 2 is a block diagram of an apparatus for manufacturing a molded lens according to an embodiment of the present invention.
FIG. 3 is a flow chart of a method of manufacturing a molded lens according to an embodiment of the invention.
FIG. 4 is a schematic diagram of a press-fit curve according to an embodiment of the present invention.
FIG. 5 is a schematic diagram of an adjusted curve according to an embodiment of the invention.
FIG. 6 is a flow chart of finding a slope turning point according to an embodiment of the present invention.
FIG. 7 is a diagram illustrating finding a slope turning point according to an embodiment of the present invention.
FIG. 8 is a graph illustrating real-time (in-situ) monitoring of quality anomalies according to another embodiment of the present invention.
Detailed Description
Fig. 1 is an external view schematically showing an apparatus for manufacturing a molded lens according to an embodiment of the present invention. Referring to fig. 1, the apparatus for manufacturing a molded lens includes a first mold core 101 and a second mold core 102. A molding chamber 104 is formed in a space between the first mold core 101 and the second mold core 102. A substrate 103 is disposed in the molding chamber 104, so that the substrate 103 is pressed through the first mold core 101 and the second mold core 102. The substrate 103 may be made of glass or a polymer material such as plastic.
Fig. 2 is a block diagram of an apparatus for manufacturing a molded lens according to an embodiment of the present invention. Referring to fig. 2, the apparatus for manufacturing a molded lens includes a processor 210, a comparator 215, a storage device 220, an alarm 225, a distance sensor 230, a pneumatic cylinder 240, a pressure regulating valve 250, a pressure gauge 260, a power gauge 270, a heater 280, and a temperature controller 290.
The processor 210 may be implemented using a central processing unit (Central Processing Unit, CPU), a physical processing unit (Physics Processing Unit, PPU), a programmable Microprocessor (Microprocessor), an embedded control chip, a digital signal processor (Digital Signal Processor, DSP), an application specific integrated circuit (Application Specific Integrated Circuits, ASIC), or other similar devices.
The comparator 215 may be implemented as a voltage comparator, a current comparator, or other similar device, etc.
The storage device 220 is any type of fixed or removable random access Memory (Random Access Memory, RAM), read-Only Memory (ROM), flash Memory (Flash Memory), secure digital card (Secure Digital Memory Card, SD), hard disk, or other similar device or combination of devices. The memory device 220 stores therein modules of one or more program code segments, which are executed by the processor 210 to implement the method for manufacturing a molded lens described below.
The distance sensor 230 is adjacent to the molding chamber 104, coupled to the processor 210, and configured to sense a distance between the first mold core 101 and the second mold core 102. The pneumatic cylinder 240 is coupled to the processor 210 and configured to move the first mold core 101 or the second mold core 102 within the molding chamber 104. The pressure regulating valve 250 is coupled to the processor 210 and the pneumatic cylinder 240, and is configured to regulate the pressure of the pneumatic cylinder 240. The pressure gauge 260 is coupled to the processor 210 and the pneumatic cylinder 240, and is configured to display the pressure of the pneumatic cylinder 240. The power meter 270 is coupled to the processor 210 and the heater 280 and configured to measure the power of the heater 280. The heater 280 is coupled to the processor 210 and is configured to heat the molding chamber 104. The temperature controller 290 is coupled to the processor 210 and the heater 280, and is configured to control the temperature of the heater 280.
FIG. 3 is a flow chart of a method of manufacturing a molded lens according to an embodiment of the invention. Referring to fig. 1-3, in step S305, the distance sensor 230 sends out a plurality of press-fit distance parameters for the lens manufacturing process, and the plurality of press-fit distance parameters can form a press-fit curve. Next, in step S310, the difference between the compaction curve and the reference compaction curve is compared by the processor 210 and the comparator 215. The reference press curve data is placed in the storage device 220. In step S315, the processor 210 determines whether the difference is within the error range. If the difference is within the error range, as shown in step S325, it is determined that the quality is not abnormal. If the difference is not within the error range, in step S320, a warning signal is sent out through the warning device 225. The warning signal is, for example, an audio signal or a video signal. For example, the warning sound effect can be played through the speaker, or a warning message can be displayed in the display.
Here, the press-molding curve data can be formed by the following steps. The processor 210 receives a plurality of press parameters corresponding to the lens manufacturing process from the distance sensor 230 to obtain a plurality of pre-press curves. Because of different mold cores, different machine stations or different pressing setting parameters (temperature, pressure, speed and torsion), the distances for pressing molding are different.
The function of the compaction parameter satisfies one of the following conditions:
(1)F(T，P，V)＝f{T(t)，P(w，a)，V(t，g)}；
wherein F represents the thickness of the substrate, T represents the temperature of the molding cavity, P represents the pressure of the pneumatic cylinder, V represents the moving speed of the first mold core or the second mold core, T represents the molding time, w represents the acting force of the first mold core or the second mold core on the substrate, a represents the stressed area of the substrate, and g represents the interval between the first mold core and the second mold core; and
(2)F(T，W)＝f{T(t)，W(w，d)}；
wherein F represents the thickness of the substrate, T represents the temperature of the molding chamber, W represents the work, T represents the molding time, W represents the acting force of the first mold core or the second mold core on the substrate, and d represents the moving distance of the first mold core or the second mold core.
FIG. 4 is a schematic diagram of a press-fit curve according to an embodiment of the present invention. Fig. 4 shows 6 press curves corresponding to the same lens process, but obtained from different mold cores, different tools or different press setting parameters (temperature, pressure, speed, torque). For the lowest press curve, H is the lens press depth. The original press-made curve cannot be used for distinguishing whether an abnormal lens exists or not. Therefore, the pressing curve is further adjusted to make the pressing points the same, so that whether the lens with abnormality exists can be easily distinguished.
Finding out the slope turning point in the pre-adjustment pressing curve, setting the slope turning point of the pre-adjustment pressing curve as a datum point, and using the datum point as a pressing starting point to obtain the pressing curve again. The processor 210 obtains a plurality of slopes from the pre-adjustment press-making curves, and the comparator 215 compares the obtained slopes with a threshold value one by one to find a slope turning point in each pre-adjustment press-making curve. Here, the slope is obtained from two coining distances of two adjacent units of time.
The reference press curve data may be formed by the following steps: receiving a plurality of press-making distance parameters corresponding to a plurality of lens processes from the distance sensor 230 to obtain a plurality of pre-press-making curves; finding slope turning points in the early-stage pressing curves, setting the slope turning points of each early-stage pressing curve as a datum point, and using the datum point as a pressing starting point to obtain a plurality of adjusted early-stage pressing curves again; and forming a reference press-formed curve by overlapping a plurality of the previous press-formed curves. The step of finding the slope turning point in each compaction curve comprises the following steps: and obtaining a plurality of slopes from each early-stage compaction curve, and comparing the obtained slopes with a threshold value one by one to find out slope turning points in each early-stage compaction curve.
FIG. 5 is a schematic diagram of an adjusted curve according to an embodiment of the invention. In fig. 5, after the slope turning point is found from the press-manufactured curve of fig. 4, the slope turning point is set as a reference point, the reference point is set as 0, and the adjusted curve is retrieved with the reference point as the press-manufactured starting point.
Referring to fig. 5, the difference between the end line segment of the adjusted curve a and the standard is beyond the error range, which indicates that the quality of the lens pressed by the lens process corresponding to the adjusted curve a is abnormal. Accordingly, the processor 210 sends out an alarm signal to inform the user through the alarm 225.
In addition, the processor 210 may also calculate the lens press depth from the adjusted curve. For example, the lens press depth can be obtained by subtracting the press distance corresponding to the end line segment from the press distance corresponding to the press start point of the adjusted curve.
An example of how to find the slope turning point is described below. FIG. 6 is a flow chart of finding a slope turning point according to an embodiment of the present invention. Referring to fig. 6, in step S605, it is determined whether the slope is less than or equal to a threshold value. Here, the slope is obtained from two coining distances of two adjacent unit times. When the slope is smaller than or equal to the threshold value, the corresponding pressing distance is the slope turning point, and the corresponding pressing distance is taken as the pressing starting point.
In addition, in other embodiments, two different thresholds may be utilized to find the slope turning point. In fig. 4, the pressing distance is rapidly decreased in a very short time from the beginning, and it can be first determined whether the slope is greater than 100 (the first threshold). After the slope is determined to be greater than 100, the slope is compared with a second threshold (e.g., 20) one by one to find a point where the slope suddenly decreases.
FIG. 7 is a diagram illustrating finding a slope turning point according to an embodiment of the present invention. As shown in fig. 7, the intersection point B of the pressing distance curve and the pressing slope curve is the slope turning point.
In addition, FIG. 8 is a graph illustrating real-time (in-situ) monitoring of quality anomalies according to another embodiment of the present invention. Fig. 8 shows an adjusted curve, in which the real-time molding data is compared with the same mold reference molding curve, and the abnormality of the adjusted curve C can be clearly identified in fig. 8. Therefore, the abnormal pressed product can be effectively and timely monitored.
In summary, the present invention finds out the pressing start point as a reference, and can analyze the real-time pressing data to reject defective products and save the labor for quality control.
While the invention has been described with respect to preferred embodiments, it will be understood by those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention, and that any such changes and modifications as described in the above embodiments are intended to be within the scope of the invention.
Claims (6)
1. A method of manufacturing a molded lens, comprising:
a substrate is positioned between a first die core and a second die core;
moving the first mold core to form a lens on the substrate;
a distance sensor sends out a plurality of pressing distance parameters for moving the first die core, and the plurality of pressing distance parameters form a pressing curve; wherein, the pressing curve data is formed by the following steps:
finding a slope turning point in a pre-adjustment pressing curve, setting the slope turning point of the pre-adjustment pressing curve as a reference point, and taking the reference point as a pressing starting point to obtain the pressing curve, wherein the step of finding the slope turning point in the pre-adjustment pressing curve comprises the following steps: obtaining a plurality of slopes from the pre-adjustment pressing curve, and comparing the obtained slopes with a threshold one by one to find out the slope turning points in the pre-adjustment pressing curve, wherein each slope is obtained by two pressing distances of two adjacent unit times;
comparing, by a processor and a comparator, the difference of the press-fit curve with a reference press-fit curve; wherein, the reference pressing curve data is formed by the following steps:
receiving a plurality of pressing distance parameters corresponding to the first mold core moving process from the distance sensor to obtain a plurality of early pressing curves;
finding a slope turning point in each of the pre-press curves, setting the slope turning point of each of the pre-press curves as a reference point, and using the reference point as a press forming point to retrieve a plurality of adjusted pre-press curves, wherein the step of finding the slope turning point in each of the press curves comprises: obtaining a plurality of slopes from each of the pre-press curves, and comparing the obtained slopes with a threshold value one by one to find the slope turning point in each of the pre-press curves, wherein each slope is obtained by two press distances of two adjacent unit times; and
forming the reference press-making curve by overlapping a plurality of the pre-press-making curves; and
and judging whether the difference is within an error range by the processor.
2. The method of claim 1, wherein an alarm signal is sent by an alarm when the difference exceeds the error range.
3. The method of any one of claims 1 to 2, wherein the reference press-molding curve data is stored in a storage device.
4. An apparatus for manufacturing a molded lens, which performs a press-molding process on a substrate, comprising:
a molding cavity, a first mold core or a second mold core can move in the molding cavity, wherein the substrate is positioned between the first mold core and the second mold core;
a distance sensor adjacent to the molding chamber;
a processor coupled to the distance sensor,
a pneumatic cylinder coupled to the processor for moving the first mold core or the second mold core;
the pressure regulating valve is coupled with the processor and the pneumatic cylinder and used for regulating the pressure of the pneumatic cylinder;
the pressure gauge is coupled with the processor and the pneumatic cylinder and used for displaying the pressure of the pneumatic cylinder;
a heater coupled to the processor for heating the molding chamber;
a power meter coupled to the processor and the pneumatic cylinder for measuring the power of the heater;
a temperature controller coupled to the processor and the heater for controlling the temperature of the heater;
a comparator coupled to the processor, wherein the distance sensor sends out a plurality of pressing distance parameters of the pressing process, the plurality of pressing distance parameters form a pressing curve, and the processor and the comparator compare the difference between the pressing curve and a reference pressing curve; wherein, the pressing curve data is formed by the following steps:
finding a slope turning point in a pre-adjustment pressing curve, setting the slope turning point of the pre-adjustment pressing curve as a reference point, and taking the reference point as a pressing starting point to obtain the pressing curve, wherein the step of finding the slope turning point in the pre-adjustment pressing curve comprises the following steps: obtaining a plurality of slopes from the pre-adjustment pressing curve, and comparing the obtained slopes with a threshold one by one to find out the slope turning points in the pre-adjustment pressing curve, wherein each slope is obtained by two pressing distances of two adjacent unit times; and
the reference press-making curve data is formed by the following steps:
receiving a plurality of press-making distance parameters corresponding to a plurality of lens manufacturing processes from the distance sensor to obtain a plurality of early-stage press-making curves;
finding a slope turning point in each of the pre-press curves, setting the slope turning point of each of the pre-press curves as a reference point, and using the reference point as a press forming point to retrieve a plurality of adjusted pre-press curves, wherein the step of finding the slope turning point in each of the press curves comprises: obtaining a plurality of slopes from each of the pre-press curves, and comparing the obtained slopes with a threshold value one by one to find the slope turning point in each of the pre-press curves, wherein each slope is obtained by two press distances of two adjacent unit times; and
forming the reference press-making curve by overlapping a plurality of the pre-press-making curves; and
a memory device, wherein the reference compaction curve data is placed in the memory device.
5. The apparatus for manufacturing a molded lens of claim 4, wherein the substrate comprises glass or a polymer material.
6. The apparatus for manufacturing a molded lens of claim 4, wherein the function of the molding distance parameter satisfies one of the following conditions:
(1)F(T，P，V)＝f{T(t)，P(w，a)，V(t，g)}；
wherein F represents the thickness of the substrate, T represents the temperature of the molding chamber, P represents the pressure of the pneumatic cylinder, V represents the moving speed of the first die core or the second die core, T represents the molding time, w represents the acting force of the first die core or the second die core on the substrate, a represents the stress area of the substrate, and g represents the interval between the first die core and the second die core; and
(2)F(T，W)＝f{T(t)，W(w，d)}；
wherein F represents the thickness of the substrate, T represents the temperature of the molding chamber, W represents work, T represents molding time, W represents the acting force of the first mold core or the second mold core on the substrate, and d represents the moving distance of the first mold core or the second mold core.
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201811620140.3A CN111377598B (en) | 2018-12-28 | 2018-12-28 | Apparatus and method for manufacturing molded lens |
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| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201811620140.3A CN111377598B (en) | 2018-12-28 | 2018-12-28 | Apparatus and method for manufacturing molded lens |
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| CN111377598A CN111377598A (en) | 2020-07-07 |
| CN111377598B true CN111377598B (en) | 2023-08-04 |
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| Publication number | Publication date |
|---|---|
| CN111377598A (en) | 2020-07-07 |
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