Calculation system for manufacturing an ophthalmic lens

Abstract

A calculation system (1) for manufacturing an ophthalmic lens. A set of calculation modules (M.sub.1, M.sub.2, M.sub.3, M.sub.4) is associated to partial calculation in relation with manufacturing process of said ophthalmic lens. A managing unit (MU) is configured to: receive input data, and calculate output data through one or several iteration(s) of: determining one or several calculation module(s) to be activated, determining an order of activation of the one or several calculation module(s), and activating the determined one or several calculation module(s), in accordance with the determined order of activation. The managing unit transmits an indication that the output data have been calculated.

Claims

1. A calculation system for manufacturing an ophthalmic lens, comprising: a processor; a set of calculation modules 1 to N, N being an integer higher than 1, each calculation module being implemented by the processor and associated to a partial calculation in relation with a manufacturing process of said ophthalmic lens, each calculation module activated independently and asynchronously from another calculation module, a managing program implemented by a memory and the processor, wherein the memory stores sequences of instructions that are accessible to the processor and executed by the processor, causes the processor to: receive input data from a remote device, the input data being related to the manufacturing process of said ophthalmic lens and/or to an ophthalmic lens manufacturing system that manufactures the ophthalmic lens, calculate output data related to the manufacturing process of said ophthalmic lens from the input data, through one or several iteration(s) of: determining several calculation modules to activate, determining an order of activation of the several calculation modules to be activate, activating the determined several calculation modules, in accordance with the determined order of activation, and transmit, to the ophthalmic lens manufacturing system, an indication that the output data have been calculated, and make the output data available to the ophthalmic lens manufacturing system, the ophthalmic lens manufacturing system manufacturing the ophthalmic lens based on the output data received by the ophthalmic lens manufacturing system.

2. The calculation system according to claim 1, wherein the managing program is embedded in a master module, each calculation module being a slave calculation module activated by the master module.

3. The calculation system according to claim 1, comprising N managing programs, each calculation module comprising one of the said N managing programs, one calculation module being determined as managing module for an output data calculation, depending on the received input data.

4. The calculation system according to claim 1, wherein the set of calculation modules comprises at least one optical calculation module that calculates values of optical parameters related to the ophthalmic lens that is manufactured, the optical parameters comprising geometrical parameters related to the ophthalmic lens.

5. The calculation system according to claim 4, wherein the input data comprise a request to calculate values of the optical parameters, the input data further comprising prescription data for a wearer of the ophthalmic lens.

6. The calculation system according to claim 1, wherein the set of calculation modules comprises at least one manufacturing calculation module that calculates values of ophthalmic lens manufacturing process parameters.

7. The calculation system according to claim 6, wherein a request to calculate values of the ophthalmic lens manufacturing process parameters specifies several manufacturing step(s) to be performed.

8. The calculation system according to claim 6, wherein a manufacturing calculation module returns, in response to its activation, a list of parameters values, and/or indication that the calculation is impossible to perform for the said one or several manufacturing step(s).

9. The calculation system according to claim 4, wherein the set of calculation modules comprises at least one manufacturing calculation module, that calculates values of ophthalmic lens manufacturing process parameters, wherein the input data comprises a request to calculate values of the optical parameters and values of the manufacturing process parameters, the input data further comprising prescription data for a wearer of the ophthalmic lens.

10. The calculation system according to claim 1, wherein the input data comprises measurement data measured during the manufacturing process of the ophthalmic lens.

11. The calculation system according to claim 1, wherein the input data comprises operation state data related to an equipment of the ophthalmic lens manufacturing system.

12. The calculation system according to claim 1, wherein the input data comprises process change data related to a change in the manufacturing process of said ophthalmic lens.

13. The calculation system according to claim 1, wherein the processor further determines the order of activation of the several calculation modules to be activated, through several iteration(s) of: determining a first calculation module impacted by the input data, and determining a second calculation module impacted by a parameter value calculated by the first calculation module.

14. The calculation system according to claim 1, wherein the processor further uses predetermined priority rules related to the one or several calculation modules to determine the order of activation of the several calculation modules to be activated.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) Non limiting embodiments of the invention will now be described with reference to the accompanying drawing wherein:

(2) FIG. 1 is a functional view of a calculation system according to an embodiment of the invention;

(3) FIG. 2 is a functional view of a calculation system according to another embodiment of the invention;

(4) FIG. 3 is schematic view showing dependences of calculation modules in respect with parameters values calculated by other calculation modules; and

(5) FIG. 4 is a flow chart showing steps of a calculation method for manufacturing an ophthalmic lens according to an embodiment of the invention.

DETAILED DESCRIPTION OF THE DRAWINGS

(6) Elements in the Figures are illustrated for simplicity and clarity and have not necessarily been drawn to scale. For example, the dimensions of some of the elements in the figures may be exaggerated relative to other elements to help improve the understanding of the embodiments of the present invention.

(7) FIG. 1 shows a calculation system 1 for manufacturing an ophthalmic lens according to an embodiment of the invention.

(8) In the context of the present invention, the term ophthalmic lens can refer to a lens blank, an uncut lens, or a semi-finished lens.

(9) The calculation system 1 comprises a set of calculation modules M.sub.1 to M.sub.N, N being an integer higher than or equal to 1. According to the example embodiment represented in FIG. 1, N=4.

(10) Each calculation module M.sub.1 to M.sub.4 is associated to a partial calculation in relation with manufacturing process of said ophthalmic lens. In the context of the present invention, the term partial calculation refers to a portion of the complete manufacturing process of the ophthalmic lens. When the calculation system 1 comprises a single calculation module M.sub.1 (N=1), the term each calculation module refers to the calculation module M.sub.1.

(11) Each calculation module M.sub.i is configured to be activated independently and asynchronously from another calculation module M.sub.j, with i an integer such as 1?i?N, and j an integer such as 1?j?N and j?i.

(12) The set of calculation modules M.sub.1 to M.sub.4 may comprise one or several optical calculation module(s), and/or one or several manufacturing calculation module(s). For instance, the calculation system 1 may comprise one optical calculation module M.sub.1 and three manufacturing calculation modules M.sub.2 to M.sub.4.

(13) An optical calculation module M.sub.1 is configured to calculate values of optical parameters related to the ophthalmic lens to be manufactured.

(14) A manufacturing calculation module M.sub.2, M.sub.3, M.sub.4 is configured to calculate values of ophthalmic lens manufacturing process parameters. The manufacturing calculation module M.sub.2, M.sub.3, M.sub.4 may be associated to the manufacturing side. It may be arranged for instance in the ophthalmic lab comprising the manufacturing apparatus.

(15) The set of calculation modules M.sub.1 to M.sub.4 may further comprise one or several other calculation module(s), for instance a control data calculation module, a process validation calculation module, a Job Ticket managing calculation module, a statistical calculation module, a calculation system related data calculation module, and/or any type of calculation module in relation with manufacturing process of the ophthalmic lens.

(16) The calculation system 1 further comprises at least one managing unit MU.

(17) According to the embodiment of the invention represented in FIG. 1, the managing unit MU is embedded in a master module MM. In this embodiment, each calculation module M.sub.1 to M.sub.N is a slave calculation module configured to be activated by the master module MM.

(18) According to another embodiment of the invention represented in FIG. 2, the calculation system 1 comprises N managing units MU.sub.1 to MU.sub.N, each calculation module M.sub.i comprising one managing units MU.sub.i. In this embodiment, when the calculation system 1 comprises several calculation modules M.sub.1 to M.sub.4, one of the calculation modules M.sub.1 to M.sub.4 is determined as managing module for an output data calculation. For instance, the calculation module M.sub.1 to M.sub.4 determined as managing module for an output data calculation is the first calculation module M.sub.1 to M.sub.4 receiving, from a remote device 2, input data related to the output data calculation.

(19) In this embodiment, when the managing module receives input data, it determines a list of calculation modules to be activated and an order of activation, or it determines whether a predetermined list has to be updated. If a predetermined list has to be updated, the managing module updates the predetermined list.

(20) Then, the managing module determines whether it has to perform a calculation. If it has to perform a calculation, the managing module performs the said calculation, updates the input data, and determines whether the list has to be updated.

(21) Then, the managing module transmits the input data, or the updated input data, to the next calculation module to be activated according to the current list.

(22) Then, the calculation module receiving the data performs the corresponding calculation, updates the input data, and determines whether the list has to be updated. The data are updated and transmitted in the same way until the last calculation has been performed. Then, the output data are made available to the ophthalmic lens manufacturing system, as disclosed below.

(23) Each managing units MU.sub.1 to MU.sub.N is similar to the managing unit MU of FIG. 1.

(24) The managing unit MU comprises receiving means configured to receive input data. The input data are received from a remote device 2, which may be, for instance, a managing entity (LMS) of the ophthalmic lab, or an ophthalmic lens calculator of a remote ophthalmic lens designer.

(25) The input data may comprise calculated data and/or measured data. The input data may be related to the manufacturing process and/or to an ophthalmic lens manufacturing system configured to manufacture the ophthalmic lens.

(26) The manufacturing process related data may comprise optical and/or manufacturing calculation request. The type of calculation requests which can be handled by the calculation system 1 depend on the calculation modules M.sub.1 to M.sub.4 included in the calculation system.

(27) For instance, when the set of calculation modules M.sub.1 to M.sub.4 comprises at least one optical calculation module, the input data may comprise an optical calculation request. When the set of calculation modules M.sub.1 to M.sub.4 comprises at least one manufacturing module, the input data may comprise a manufacturing calculation request. When the set of calculation modules M.sub.1 to M.sub.4 comprises at least one optical calculation module and at least one manufacturing calculation module, the input data may comprise an optical and/or manufacturing calculation request.

(28) The manufacturing calculation request may specify one or several manufacturing step(s) to be performed.

(29) The manufacturing process related data further comprises the data which are useful for performing the optical and/or manufacturing calculation, for instance order request data, optical data, manufacturing process data, and/or measurement data.

(30) The order request data comprise at least prescription data of the wearer of the ophthalmic lens. The prescription data comprise a set of optical characteristics such as spherical power, cylindrical power, cylinder axis, addition power, and prescribed prism, determined by an ophthalmologist in order to correct the vision defects of the wearer. The order request may further comprise other wearer's parameters, such as a head/eye movement coordination parameter and/or an eye rotation center position.

(31) The optical data comprise geometrical data related to the ophthalmic lens to be manufactured. The geometrical data may comprise data related to a front surface of the ophthalmic lens, data related to a back surface of the ophthalmic lens, data related to a relative position of the front and back surfaces, and/or data related to a shape of the ophthalmic lens.

(32) The measurement data comprise data measured during the manufacturing process of the ophthalmic lens.

(33) The ophthalmic lens manufacturing system refers to a combination of a management entity (LMS) and associated manufacturing equipments or apparatus. The ophthalmic lens manufacturing system may also include an ordering system, for instance an ordering system of an eye care practitioner or an ordering system based on an individual internet access.

(34) The ophthalmic lens manufacturing system related data may comprise operation state data related to an equipment of the ophthalmic lens manufacturing system, and/or process change data related to a change in the manufacturing process.

(35) The operation state data may comprise data related to a wear state of an equipment of the ophthalmic lens manufacturing system.

(36) The process change data may comprise data related to a change of process decided by the manufacturer, for instance data related to a change of topcoat to be used.

(37) The managing unit MU further comprises calculation means configured to calculate, from the input data, output data related to the manufacturing process. The output data may be calculated by:

(38) determining one or several calculation module(s) M.sub.1 to M.sub.N to be activated,

(39) determining an order of activation of the one or several calculation module(s) M.sub.1 to M.sub.N to be activated, and

(40) activating the determined one or several calculation module(s) M.sub.1 to M.sub.N, in accordance with the determined order of activation.

(41) The determination of an order of activation aims at calculating the manufacturing process data associated with each equipment in chronological order. This order is important because of the dependences of certain process steps on the previous.

(42) For example, the surfacing, polishing and engraving steps depend on how the lens was blocked (e.g. initial and final thicknesses, orientation of the lens member). This implies that the blocking parameters must be calculated first in order to calculate the remaining steps of the process.

(43) In the same way, the polishing calculation depends on a lens surface state parameter, which may have a value calculated by a surfacing module.

(44) In the same way, the engraving calculation depends on a coloration process parameter, which may have a value calculated by a coloration module.

(45) FIG. 3 represents a general illustration of these dependences. We consider here that the calculation module M.sub.1 is configured to calculate values of parameters A, B, C and D, the calculation module M.sub.2 is configured to calculate values of parameters E, F, G and H, the calculation module M.sub.3 is configured to calculate values of parameters I and J, and the calculation module M.sub.4 is configured to calculate values of parameters K and L.

(46) In the represented example, the calculation module M.sub.2 depends on the values of the parameters A, C and D calculated by the calculation module M.sub.1, as symbolized by the arrows F.sub.1, F.sub.2 and F.sub.3. The calculation module M.sub.3 depends on the value of the parameter D calculated by the calculation module M.sub.1, as symbolized by the arrow F.sub.4. The calculation module M.sub.2 depends on the value of the parameter K calculated by the calculation module M.sub.4, as symbolized by the arrow F.sub.5. The calculation module M.sub.3 depends on the value of the parameter E calculated by the calculation module M.sub.2, as symbolized by the arrow F.sub.6. And the calculation module M.sub.4 depends on the value of the parameter J calculated by the calculation module M.sub.3, as symbolized by the arrow F.sub.7.

(47) To manage these multiple dependences, the output data may be calculated through one or several iteration(s). For instance, the order of activation of the one or several calculation module(s) to be activated may be determined through one or several iteration(s) of:

(48) determining a first calculation module impacted by the input data,

(49) determining a second calculation module impacted by a parameter value calculated by the first calculation module.

(50) Referring to FIG. 3, we are considering that the input data comprise measured data related to the parameter A.

(51) During a first iteration, it is determined that the module M.sub.2 is a first module impacted by the input data. Then, it is determined that the module M.sub.3 is a second module impacted by the value of the parameter E recalculated by the module M.sub.2.

(52) During a second iteration, it is determined that the module M.sub.4 is a third module impacted by the value of the parameter J recalculated by the module M.sub.3.

(53) The number of iterations is not limited. It is thus possible to determine a subset of calculation modules impacted by any type of input data, and to activate these calculation modules, in a suitable order. Consequently, it is possible to improve the precision of the calculation process, without having to perform a complete recalculation for each new input data.

(54) When two calculation modules M.sub.1 to M.sub.4 are impacted during a same iteration, the order of activation may be determined by further using predetermined priority rules related to the calculation modules M.sub.1 to M.sub.4.

(55) According to some embodiments of the invention, a manufacturing calculation module M.sub.1 to M.sub.4 is configured to return, in response to its activation, a list of parameters values, and/or indication that the calculation is impossible to perform for the said one or several manufacturing step(s). This feature aims at being alerted as soon as possible when a calculation is impossible to perform.

(56) The managing unit MU further comprises transmitting means configured to transmit, to the ophthalmic lens manufacturing system, an indication that the output data have been calculated, and to make the output data available to the ophthalmic lens manufacturing system.

(57) The output data may be made available by transmitting the output data to the ophthalmic lens manufacturing system, directly or via another device.

(58) Alternatively, the output data may be made available by storing the output data in a calculation module M.sub.1 to M.sub.4, or in the master module MM, or in another device. In this alternative, an indication that the output data are available may be sent to the ophthalmic lens manufacturing system.

(59) The output data may further specify one or several manufacturing step(s) to be performed.

(60) FIG. 4 represents steps of a calculation method for manufacturing an ophthalmic lens, according to an embodiment of the invention. The method may be implemented by the calculation system 1 disclosed above. The method comprises:

(61) a first receiving step S1,

(62) a calculating step S2,

(63) a first transmitting step S3,

(64) a second receiving step S4,

(65) a recalculating step S5, and

(66) a second transmitting step S6.

(67) During the receiving step S1, input data are received at a managing unit MU.

(68) When the calculation system 1 comprises a master module MM, the managing unit MU is embedded in the master module MM.

(69) When each calculation modules M.sub.1 to M.sub.4 comprise a managing unit MU, the calculation module M.sub.i associated to the managing unit MU that first receives the input data is determined as being the managing module for the steps S2 and S3.

(70) During the calculating step S2, the output data related to the manufacturing process are calculated from the input data.

(71) As explained above, the calculating step S2 may comprise one or several iteration(s) of:

(72) determining one or several calculation module(s) to be activated,

(73) determining an order of activation of the one or several calculation module(s) to be activated, and

(74) activating the determined one or several calculation module(s), in accordance with the determined order of activation.

(75) During the transmitting step S3, the output data are made available to the ophthalmic lens manufacturing system, and an indication that the output data have been calculated is transmitted to the ophthalmic lens manufacturing system.

(76) During the second receiving step S4, updated input data are received at a managing unit MU. The updated input data are, for instance, data measured during the manufacturing of the ophthalmic lens. The updated input data may for instance comprise blocking position error data measured after the blocking step of the lens, measured prism deviation, or measured blocking material thickness error.

(77) When each calculation modules M.sub.1 to M.sub.4 comprise a managing unit MU, the calculation module M.sub.j associated to the managing unit MU that first receives the input data in step S4 may be different than the calculation module M.sub.i determined as being the managing module in step S1.

(78) During the second calculation step S5, the output data dependent of the measured data are recalculated from the actual measured data. For instance, the blocking data dependent of the blocking position, such as the blocking material quantity, may thus be recalculated from the actual position data. The second calculation step S5 is similar to the calculation step S3, but is performed based on updated input data.

(79) During the transmitting step S6, the updated output data are made available to the ophthalmic lens manufacturing system, and an indication that the output data have been calculated is transmitted to the ophthalmic lens manufacturing system.

(80) Many further modifications and variations will suggest themselves to those skilled in the art upon making reference to the foregoing illustrative embodiments, which are given by way of example only and which are not intended to limit the scope of the invention, that being determined solely by the appended claims.

(81) In the claims, the word comprising does not exclude other elements or steps, and the indefinite article a or an does not exclude a plurality. The mere fact that different features are recited in mutually different dependent claims does not indicate that a combination of these features cannot be advantageously used. Any reference signs in the claims should not be construed as limiting the scope of the invention.