U.S. patent application number 10/834719 was filed with the patent office on 2004-11-25 for container for and use of the latter in a production center for manufacturing individual spectacle lenses on prescription.
Invention is credited to Lack, Oswin.
Application Number | 20040235397 10/834719 |
Document ID | / |
Family ID | 32981215 |
Filed Date | 2004-11-25 |
United States Patent
Application |
20040235397 |
Kind Code |
A1 |
Lack, Oswin |
November 25, 2004 |
Container for and use of the latter in a production center for
manufacturing individual spectacle lenses on prescription
Abstract
A container (10) for a production center for manufacturing
individual spectacle lenses (L) on prescription, known as a
prescription workshop, is disclosed, which prescription workshop
has a number of workstations between which the spectacle lenses can
be transported by means of transport boxes (K) which are each
designed to receive one right and one left spectacle lens and
possibly associated processing tools. According to the invention,
the container is designed to receive a number of transport boxes in
order to transport the latter between at least two workstations of
the prescription workshop, the container having an insertion and
output device (14) for the transport boxes, by means of which the
transport boxes can be inserted into the container and a specific
transport box can be output from the container when selected. The
invention also comprises the use of the container according to the
invention in a prescription workshop. As a result, a logistic
system for a prescription workshop is provided by means of which an
optimized material flow of the transport boxes can be ensured in a
flexible manner and largely independent of the size of the
prescription workshop and the structural conditions thereof.
Inventors: |
Lack, Oswin; (Huttenberg,
DE) |
Correspondence
Address: |
Steven L. Permut
RESING, ETHINGTON, BARNES, KISSELLE, P.C.
P.O. Box 4390
Troy
MI
48099-4390
US
|
Family ID: |
32981215 |
Appl. No.: |
10/834719 |
Filed: |
April 29, 2004 |
Current U.S.
Class: |
451/41 |
Current CPC
Class: |
B65G 65/00 20130101;
B65G 1/127 20130101; B65G 37/02 20130101 |
Class at
Publication: |
451/041 |
International
Class: |
B24B 001/00 |
Foreign Application Data
Date |
Code |
Application Number |
May 2, 2003 |
DE |
103 19 944.6 |
Claims
I claim:
1. Container (10) for a production center (12) for manufacturing
individual spectacle lenses (L) on prescription, claim 22 for which
production center has a number of workstations (A-H) between which
the spectacle lenses (L) can be transported by means of transport
boxes (K) which are each designed to receive one right and one left
spectacle lens (L) and possibly associated processing tools,
characterized in that the container (10) is designed to receive a
number of transport boxes (K) in order to transport the latter
between at least two workstations (A-H) of the production center
(12), the container (10) having an insertion and output device (14)
for the transport boxes (K), by means of which the transport boxes
(K) can be inserted into the container (10) and a specific
transport box (K) can be output from the container (10) when
selected.
2. Container (10) according to claim 1, characterized in that the
insertion and output device (14) has a store (38) for the transport
boxes (K).
3. Container (10) according to claim 2, characterized in that the
store (38) is formed by a tray conveyor, by means of which a number
of receiving trays (42) for in each case at least one transport box
(K) are circulated in a paternoster-like manner.
4. Container (10) according to claim 3, characterized in that the
insertion and output device (14) has a conveying device (40) by
means of which a transport box (K) can be moved from an outer
position on the container (10) to an inner end position in the
store (38) of the container (10) and vice versa.
5. Container (10) according to claim 4, characterized in that the
conveying device (40) has a longitudinal conveyor (62) by means of
which a transport box (K) can be moved from the outer position on
the container (10) to an inner intermediate position in the
container (10) and vice versa, and has a gripper device (64) by
means of which the transport boxes (K) can be moved from the inner
intermediate position in the container (10) to the inner end
position in the store (38) of the container (10) and vice
versa.
6. Container (10) according to claim 5, characterized in that the
insertion and output device (14) has a recognition device (76) by
means of which a marking (78) that is provided on each transport
box (K) and identifies the respective transport box (K) can be
detected.
7. Container (10) according to claim 6, characterized in that the
recognition device (76) is a reader by means of which a barcode
(78) fitted on each transport box (K) can be detected.
8. Container (10) according to claim 6, characterized by a control
device (74) which is effectively connected to the store (38) and
the conveying device (40) and which in turn is effectively
connected to the recognition device (76) and in which information
regarding the marking (78) of the transport boxes (K) that is
detected by the recognition device (76) can be stored, the store
(38) and the conveying device (40) being controllable by the
control device (74) in order to output a specific transport box (K)
from the container (10) upon a corresponding request, taking into
account the information regarding the marking (78) of the transport
boxes (K) that is stored in the control device (74).
9. Container (10) according to claim 8, characterized by a
transmitting and receiving device (88), which is effectively
connected to the control device (74), for communication between the
container (10) on the one hand and a workstation (A-H) and/or a
host control system (92) of the production center (12) on the other
hand.
10. Container (10) according to claim 9, characterized by a
signaling device (82) for the filling level of the container (10)
and/or the processing status of the spectacle lenses (L) contained
in the transport boxes (K) accommodated in the container (10).
11. Container (10) according to claim 9, characterized by a cooling
unit (98) for cooling the spectacle lenses (L) contained in the
transport boxes (K) accommodated in the container (10).
12. Container (10) according to claim 9, characterized by a drying
unit (100) for drying the spectacle lenses (L) contained in the
transport boxes (K) accommodated in the container (10).
13. Container (10) according to claim 9, characterized by a power
supply unit (52) for the power consumers that are present in the
container (10).
14. Container (10) according to claim 9, characterized in that the
container (10) can be rolled, for which purpose the container (10)
is equipped with a number of wheels or rollers (34).
15. Container (10) according to claim 2, characterized in that the
insertion and output device (14) has a conveying device (40) by
means of which a transport box (K) can be moved from an outer
position on the container (10) to an inner end position in the
store (38) of the container (10) and vice versa.
16. Container (10) according to claim 15, characterized in that the
conveying device (40) has a longitudinal conveyor (62) by means of
which a transport box (K) can be moved from the outer position on
the container (10) to an inner intermediate position in the
container (10) and vice versa, and has a gripper device (64) by
means of which the transport boxes (K) can be moved from the inner
intermediate position in the container (10) to the inner end
position in the store (38) of the container (10) and vice
versa.
17. Container (10) according to claim 1, characterized by a
signaling device (82) for the filling level of the container (10)
and/or the processing status of the spectacle lenses (L) contained
in the transport boxes (K) accommodated in the container (10).
18. Container (10) according to claim 1, characterized by a cooling
unit (98) for cooling the spectacle lenses (L) contained in the
transport boxes (K) accommodated in the container (10).
19. Container (10) according to claim 1, characterized by a drying
unit (100) for drying the spectacle lenses (L) contained in the
transport boxes (K) accommodated in the container (10).
20. Container (10) according to claim 1, characterized by a power
supply unit (52) for the power consumers that are present in the
container (10).
21. Container (10) according to claim 1, characterized in that the
container (10) can be rolled, for which purpose the container (10)
is equipped with a number of wheels or rollers (34).
22. Method of manufacturing individual spectacle lenses (L) on
prescription in a production center (12) having a number of
workstations (A-H), in which the spectacle lenses (L), possibly
together with associated processing tools, are transported between
the workstations (A-H) by means of transport boxes (K) which are
each designed to receive one right and one left spectacle lens (L)
and possibly the associated processing tools, characterized in that
the transport boxes (K) are transported between at least two
workstations (A-H) of the production center (12) by means of a
container (10) having a number of workstations (A-H) between which
the spectacle lenses (L) can be transported by means of transport
boxes (K) which are each designed to receive one right and one left
spectacle lens (L) and possibly associated processing tools,
characterized in that the container (10) is designed to receive a
number of transport boxes (K) in order to transport the latter
between at least two workstations (A-H) of the production center
(12), the container (10) having an insertion and output device (14)
for the transport boxes (K), by means of which the transport boxes
(K) can be inserted into the container (10) and a specific
transport box (K) can be output from the container (10) when
selected.
Description
BACKGROUND OF INVENTION
[0001] The present invention relates to a container for a
production center for manufacturing individual spectacle lenses on
prescription, according to the preamble portion of claim 1. The
invention also relates to a method of manufacturing individual
spectacle lenses on prescription, according to the preamble portion
of claim 15.
[0002] The workstations or processing stations in production
centers for manufacturing individual spectacle lenses from
conventional materials (polycarbonate, mineral glass, CR 39,
Hi-index, etc.) on prescription, also referred to as prescription
workshops, are usually highly automated, with transport boxes being
used as transport medium during manufacture. These transport boxes,
also known as prescription boxes or "job trays", form the subject
for example of the German standard DIN 58763.
[0003] Accommodated in the transport boxes are in each case the
right and the left spectacle lens of an order and possibly the
associated precision-grinding or polishing tool for the respective
spectacle lens. Moreover, such a transport box has a compartment
for the written, internal order. This usually bears a marking in
the form of a barcode or the like. The transport boxes themselves
are often also equipped with so-called "transponders", i.e.
semiconductor elements for storing and transmitting information, by
means of which identification of the respective order and of the
current processing status of the spectacle lenses is possible.
[0004] By means of the transport boxes, spectacle lenses made of
various materials must be fed to various workstations or machines,
at which the spectacle lenses are processed using various
auxiliaries and fuels (e.g. polishing agents, polishing pads) and
various process parameters. The following process steps are usually
carried out when manufacturing individual spectacle lenses on
prescription:
[0005] (A) removing a suitable right and left spectacle lens blank
from a semi finished product store and placing it in a transport
box ("blank picking"). Semi finished means that the usually round
or oval, as seen in plan view, spectacle lens blanks which have not
yet been rimmed have already been processed on one of their two
optically active surfaces.
[0006] (B) Then, the spectacle lens blanks are prepared for the
blocking process, namely by applying a suitable protective tape
("taping") or a suitable protective lacquer ("protective
lacquering") to protect the already processed optically active
surface.
[0007] (C) The next step is the so-called "blocking" of the
spectacle lens blanks. Here, each spectacle lens blank is
associated with a suitable block, for example a block according to
the German standard DIN 58766. For this purpose, the block is
firstly brought into a predefined position with respect to the
protected, already processed surface of the spectacle lens blank
and then, in this position, the space between block and spectacle
lens blank is filled with molten material (Wood's metal or
wax).
[0008] (D) Following the blocking process, there is a cooling phase
for solidifying the filling material. Following solidification of
the filling material, the block forms a seat for processing the
respective spectacle lens blank.
[0009] (E) Only then can the spectacle lens blanks be preprocessed,
depending on the material, by means of grinding, milling or turning
("generating"), with the previously unprocessed optically active
surface of the respective spectacle lens blank being given its
macro geometry according to the prescription.
[0010] (F) After this preprocessing at the latest, the
corresponding tool for precision-grinding or polishing of the
respective spectacle lens is placed in the transport box ("tool
picking").
[0011] (G) The fine processing of the spectacle lenses
("finishing") then takes place, in which the preprocessed optically
active surface of the respective spectacle lens is given the
desired micro geometry. Depending on, inter alia, the material of
the spectacle lenses, the fine processing is subdivided into a
precision-grinding process and a polishing process that follows on
therefrom, or comprises, if a polishable surface has already been
produced during preprocessing, merely a polishing process.
[0012] (H) After the polishing process, each spectacle lens is
removed from the respective block ("deblocking").
[0013] (I) This is finally followed by cleaning steps and possibly
further refining steps, e.g. an antireflection coating or hard
coating of the spectacle lenses.
[0014] The process steps described above are usually carried out in
a largely automated mode of operation, according to the "first
in/first out" principle in which a transport box arriving at a
workstation first also leaves the latter first. The workstations
are fixedly linked to one another via conveyor belts, transverse
roller devices for the transverse transfer out of the material
flow, lifting devices, shunts and the like. Only for the cooling
phase following blocking are suitable buffer zones provided, for
instance in the form of automated shelves with bent-arm robots or
linear drives, in which the transport boxes await their further
processing.
[0015] One disadvantage of the rigid linking of the workstations by
means of belts or similar transport devices for the transport boxes
is in particular that these stationary transport devices have to be
adapted individually to the size of the prescription workshop and
to the structural conditions thereof. Changes in the predefined
material flow, for instance if further workstations, e.g. new or
other processing machines, are to be used to expand the capacity or
to process spectacle lenses made of different materials, are always
associated with a considerable outlay.
[0016] The alternative of manual transport of the transport boxes,
on the other hand, in which the transport boxes are stacked and
carried by one person from one workstation to the next workstation,
in particular has the disadvantages that it is very staff-intensive
and thus cost-intensive and is also dangerous on account of the
high degree of strain on the staff.
[0017] There are known from the prior art separate devices for
delivering articles (e.g. DE 34 24 988 A1), in which the articles
are received in boxes that are stacked on top of one another or are
placed on trays that are stacked on top of one another, individual
devices for receiving and conveying collecting boxes for series
parts that are to be gathered into batches (e.g. DE 41 21 844 C2),
in which there are successive consoles between endless conveyors in
the flow direction, said consoles having horizontal bearing
surfaces for receiving the collecting boxes, and also separate
intermediate workpiece stores (e.g. DE 197 49 396 A1) having
receiving troughs guided in a paternoster-like manner for
workpieces arriving at timed intervals; however, these are not
suitable for a prescription workshop, i.e. a production center for
manufacturing individual spectacle lenses, but rather only for
series- and mass-produced parts.
SUMMARY OF THE INVENTION
[0018] It is an object of the invention to provide a logistic
system by means of which a material flow of the transport boxes in
a prescription workshop that is as optimal as possible can be
ensured in a flexible manner and largely independent of the size of
the prescription workshop and the structural conditions
thereof.
[0019] This object is achieved by the features given in claims 1
and 15. Advantageous and/or expedient developments of the invention
form the subject of claims 2 to 14.
[0020] According to one aspect of the invention, a container for a
production center for manufacturing individual spectacle lenses on
prescription, which production center has a number of workstations
between which the spectacle lenses can be transported by means of
transport boxes which are each designed to receive one right and
one left spectacle lens and possibly associated processing tools,
is designed to receive a number of transport boxes in order to
transport the latter between at least two workstations of the
production center, the container having an insertion and output
device for the transport boxes, by means of which the transport
boxes can be inserted into the container and a specific transport
box can be output from the container when selected.
[0021] According to a further aspect of the invention, there is
furthermore provided a method of manufacturing individual spectacle
lenses on prescription in a production center having a number of
workstations, in which the spectacle lenses, possibly together with
associated processing tools, are transported between the
workstations by means of transport boxes which are each designed to
receive one right and one left spectacle lens and possibly the
associated processing tools, wherein the transport boxes are
transported between at least two workstations of the production
center by means of a container according to the invention.
[0022] By means of the container according to the invention, or by
means of the use thereof according to the invention in a
prescription workshop, the transport boxes known for example from
the German standard DIN 58763 can be transported between the
individual workstations of the prescription workshop either
individually or in batches in a manner that is simple, easy for the
staff, cost-effective, space-saving and in particular very
flexible, without the transport being subjected to greater
restrictions on account of the size and/or the structural
conditions of the prescription workshop. Because the containers in
this case are equipped with an insertion and output device for the
transport boxes, by means of which the transport boxes can be
inserted into the containers and a specific transport box can be
output from the container when selected, the container may
optionally operate in a "first in/first out" mode or in any other
operating mode, depending on what is necessary for an optimized
material flow, so that the container can be used in a very varied
and multifunctional manner. Moreover, when using the containers
according to the invention, there is no need for the high outlay in
terms of individual planning, set-up and change that is necessary
in the case of the rigid conveying systems described above. As a
result, the container according to the invention is particularly
suitable for prescription workshops which have to date not
automated their manufacturing operations on account of the
above-described disadvantages of the rigid conveying systems, which
have been subject to limitations with regard to the use of
conventional conveying systems on account of the size and/or
structural conditions of their workshop area, which already use
universally rigid conveying systems, but want to or have to expand
manufacture by further workstations in as cost-effective a manner
as possible, or which have to date only automated part of their
manufacture (or wish to do so in the future) because, for example,
relatively old processing machines that cannot be automated or can
be automated only with difficulty are used (and are to continue to
be used). One particular advantage of the use of containers
according to the invention is also in this case that the logistic
system of a prescription workshop can easily "grow" with the output
of spectacle lenses it produces, simply by using additional
containers. Finally, the container according to the invention, on
account of its modular character, can be made in an outstandingly
standardized manner and/or to form the subject of a container
modular products system, which helps to considerably lower the
costs of the logistic system for a prescription workshop.
[0023] Preferably, the insertion and output device of the container
has a store for the transport boxes. The store may be, for
instance, shelves fitted in a fixed position in the container, on
which shelves the transport boxes can be placed in a defined manner
by means of a lifting device that is provided. Nevertheless, a
design is preferred in which the store is formed by a tray
conveyor, by means of which a number of receiving trays for in each
case at least one transport box are circulated in a
paternoster-like manner.
[0024] It is further preferred when the insertion and output device
of the container has a conveying device by means of which a
transport box can be moved from an outer position on the container
to an inner end position in the store of the container and vice
versa. Advantageously, for this purpose the conveying device may
have a longitudinal conveyor by means of which a transport box can
be moved from the outer position on the container to an inner
intermediate position in the container and vice versa, and also a
gripper device by means of which the transport boxes can be moved
from the inner intermediate position in the container to the inner
end position in the store of the container and vice versa.
[0025] It may furthermore be provided that the insertion and output
device has a recognition device by means of which a marking that is
provided on each transport box and identifies the respective
transport box can be detected. In one simple refinement, the
recognition device may only have one input option, for instance in
the form of a keyboard, via which information regarding the marking
on the transport box, which may for example be a written
manufacturing order that is placed in a suitable receptacle on the
transport box at the start of the prescription manufacturing
operation, can be manually input. In one preferred refinement of
the container, however, the recognition device is a reader by means
of which a marking in the form of a barcode fitted on each
transport box in a preferably detachable manner can be detected,
preferably automatically. Such a barcode may for example be printed
on the written manufacturing order such that it can be seen from
outside. It is furthermore conceivable in this case that the
recognition device is adapted to recognize, as box marking, a
"transponder" that is known per se and is fitted on the transport
box, in order to identify the transport box and read information
regarding the respective manufacturing order and/or processing
status of the spectacle lenses contained in the respective
transport box.
[0026] In one advantageous assembly stage, the container may be
provided with "intelligence", for which purpose the container has a
control device which is effectively connected to the store and the
conveying device and which in turn is effectively connected to the
recognition device and in which information regarding the marking
of the transport boxes that is detected by the recognition device
can be stored, the store and the conveying device being
controllable by the control device in order to output a specific
transport box from the container upon a corresponding request,
taking into account the information regarding the marking of the
transport boxes that is stored in the control device.
[0027] When the container furthermore has, in an advantageous
further assembly stage, a transmitting and receiving device, which
is effectively connected to the control device, for communication
or data transfer between the container on the one hand and a
workstation and/or a possibly present host control system of the
prescription workshop on the other hand, firstly information
regarding the marking of the transport boxes and thus the
respective manufacturing order can be forwarded for manufacturing
purposes to the respective workstation or processing machine and/or
the host control system of the prescription workshop. Secondly, a
workstation or processing machine and/or the host control system of
the prescription workshop can transmit in a simple manner a request
signal to output a specific transport box on the container. In
principle, the transmitting and receiving device of the container
may be formed by a container-side plug or a container-side socket
which makes contact with a complementary counterpart on the
workstation or processing machine when the container is brought
into a defined relative position with respect to the workstation or
processing machine. Particularly with regard to a possibility of
communication between the container and the host control system of
the prescription workshop that is as uncomplicated as possible,
however, a transmitting and receiving device is preferred which
operates without wires and cables, for example by radio or an
infrared interface.
[0028] The container may expediently have a signaling device for
the filling level of the container and/or the processing status of
the spectacle lenses contained in the transport boxes accommodated
in the container, for instance in the form of a multicolored
indicator light and/or an indicator unit that operates
acoustically, so that the staff in the prescription workshop can
receive information, even from a distance, about the status of the
container or of the spectacle lenses stored or transported
therein.
[0029] In further assembly stages, the container may advantageously
have one or more further functional units which serve to act upon
the spectacle lenses contained in the transport boxes accommodated
in the container. For instance, the container may be equipped with
a cooling unit in order for example to shorten the dwell time
following blocking, with it being possible for solidification of
the filling material between block and spectacle lens blank to be
accelerated by means of the cooling. Furthermore, the container may
have a drying unit for drying the spectacle lenses contained in the
transport boxes accommodated in the container, whereby for example
the protective lacquer applied to the already processed optically
active surface prior to blocking can be dried in order that the
spectacle lenses can be fed to the blocking process more rapidly.
The drying unit may in this case comprise a fan and/or heating.
[0030] It is furthermore advantageous when the container has a
dedicated power supply unit for the power consumers present in the
container, for instance the drives for the store and/or the
conveying device, the recognition, control and/or signaling devices
and also possibly the further functional units, so that the
container is self-sufficient and does not have to have an external
supply by way of power supply lines and/or cables. Expediently,
this is an electrical power supply unit having at least one
accumulator, for instance a car battery. In this case, electrical
connection means are to be furthermore advantageously provided on
the container, by means of which the container can be connected to
an external power supply and/or can be charged up by the
accumulator in buffer zones, so that said container is not
subjected to unnecessary load and does not have to be removed for
charging purposes.
[0031] Finally, if the container is equipped with a number of
wheels or rollers so that it can be rolled, the container may be
moved to the various workstations of the prescription workshop
without any problems by one person. In further assembly stages, an
automotive drive of the container would also be conceivable in this
case, so that the container may be moved from workstation to
workstation by remote control. Rail systems on the floor or ceiling
of the prescription workshop are likewise possible, on which it may
also be possible for the containers to be moved automatically,
which allows for the structural conditions of the prescription
workshop and is also desired despite the restricted flexibility of
movement in the case of rail systems with respect to a free
mobility of the containers.
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] Hereinbelow, the invention is described in more detail on
the basis of preferred embodiments with reference to the attached
drawings that are shown in a partially schematic manner, where
identical or similar parts bear the same reference signs. In the
drawings:
[0033] FIG. 1 shows a partially cut-away, perspective illustration
of a container for receiving and transporting the prescription
boxes in a prescription workshop according to a first embodiment of
the invention,
[0034] FIG. 2 shows a schematic illustration of a container for
receiving and transporting the prescription boxes in a prescription
workshop according to a second embodiment of the invention, where
the container is docked at a processing machine of the prescription
workshop, said processing machine likewise only being shown
schematically,
[0035] FIG. 3 shows a schematic illustration of two containers for
receiving and transporting the prescription boxes in a prescription
workshop according to a third embodiment of the invention, where
the containers are docked at a blocking station of the prescription
workshop, said blocking station likewise only being shown
schematically, and
[0036] FIG. 4 shows the layout of a prescription workshop, in which
containers according to the invention for transporting the
prescription boxes between the individual workstations of the
prescription workshop are used.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] FIGS. 1 to 3 show details of containers 10 for use in a
production center, shown by way of example in FIG. 4, for
manufacturing individual spectacle lenses L on prescription,
referred to as prescription workshop 12, which has a number of
workstations A to H and possibly I that are known per se and were
discussed in the introduction. Between the workstations A to I, the
spectacle lenses L are transported by means of transport boxes K
that are known per se, as described for example in the German
standard DIN 58763. Each transport box K is designed to receive one
right and one left spectacle lens L and possibly associated
processing tools. It is essential that, as will be described in
more detail below, the container 10 is designed to receive a number
of transport boxes K in order to transport the latter between at
least two of the workstations A to I of the prescription workshop
12, the container 10 having an insertion and output device 14 for
the transport boxes K by means of which the transport boxes K can
be inserted into the container 10 and a specific transport box K
can be output from the container 10 when selected.
[0038] As shown in FIG. 1, the container 10 has a basic frame 16
which is made up of rack profiles in the manner of a framework,
said rack profiles preferably being made of an aluminum alloy. The
base of the container 10 is formed by an essentially square lower
rack consisting of a front and a rear lower rack profile 18 and two
lateral lower rack profiles 20, in which there is fixedly inserted
a flat base plate 22 with sufficient inherent rigidity, made for
example of sheet steel. The top of the container 10 is in turn
formed by an essentially square upper rack which consists of a
front and a rear upper rack profile 24 and two lateral upper rack
profiles 26 and on which there is fastened a flat top plate 28 with
sufficient inherent rigidity, which may likewise be made of sheet
steel. The base and the top of the container 10 are fixedly
connected to one another by means of four longitudinal struts 30,
one longitudinal strut 30 being fitted at each corner of the upper
and lower racks. Furthermore, the basic frame 16 is reinforced
about halfway up the longitudinal struts 30 by transverse struts
32, only one of which is in each case provided at the sides and in
the rear region of the container 10, whereas in the front region of
the container 10 there are provided two transverse struts 32 that
are spaced apart in the vertical direction and delimit a kind of
window for the insertion and outputting of the transport boxes K
into and from the container 10. The upper of the front transverse
struts 32 is shown in a broken manner in FIG. 1. All the transverse
struts 32 run perpendicular to the longitudinal struts 30 and are
attached to the latter in a suitable manner. Not shown in FIG. 1,
in order to make it possible to see into the container 10, are
further casing parts and doors that are preferably made of aluminum
sheet or plastic, which are fastened to the basic frame 16 in a
manner such that they can be detached or opened for assembly and
repair purposes and in the assembled state of the container 10
largely screen off the interior of the container 10 from the
surrounding environment. In accordance with the requirements in
each case, the further casing parts and doors may possibly be
isolated from one another and sealed off from one another and from
the basic frame 16 in a particular way in order where necessary to
allow use of the container 10 in a clean-room environment, said
container being essentially cuboid-shaped as seen from outside. In
this case, filters or the like may also be provided in the
container 10, although these are not shown in the present case.
[0039] In the embodiment shown, the container 10 is designed such
that it can be rolled, for which purpose four wheels or rollers 34
are provided, two of which are in each case fitted on each lateral
lower rack profile 20, namely in each case in a front and a rear
region of each lateral lower rack profile 20, in a manner such that
they can rotate. The rollers 34 may be conventional rollers, e.g.
those having a plastic hub covered with a hard rubber tire. In
order to be able to move the container 10 by hand, there is fitted
on the rear side of the container 10 a U-shaped sliding or grab
rail 36 which extends from longitudinal strut 30 to longitudinal
strut 30 at the level of and parallel to the rear transverse strut
32 and is attached to the longitudinal struts 30 in a suitable
manner.
[0040] Inside the container 10, there are fitted on the basic frame
16, in a manner not shown in any more detail here, as parts of the
insertion and output device 14, a store 38 for the transport boxes
K and a conveying device 40 by means of which a transport box K can
be moved from an outer position on the container 10 to an inner end
position in the store 38 of the container 10 and vice versa. In the
embodiment shown, the store 38 is formed by a tray conveyor by
means of which a number of receiving trays 42 for in each case at
least one transport box K, in this case for in each case four
transport boxes K, are circulated or guided in a loop in a
paternoster-like manner. For this purpose, the store 38 has, on
both sides of the receiving trays 42, guides 44 for the receiving
trays 42, which guides run in a looped manner and extend almost
over the entire height of the container 10, in which the receiving
trays 42 are connected in a suitable manner, for example by means
of a chain drive that is not shown in any more detail, to one
another and to a drive, of which there is shown in FIG. 1 a drive
motor 46, an angular gear 48 and a drive pinion 50 that can be
driven by the drive motor 46 via the angular gear 48. In the
embodiment shown, the drive motor 46 is an electric motor which is
supplied with electrical power by an accumulator 52 arranged on the
base plate 22--said accumulator being formed, in the embodiment
shown, by two car batteries connected in parallel or in series,
depending on requirements--as power supply unit for the power
consumers present in the container 10.
[0041] At each longitudinal end, each receiving tray 42 has a side
flank 54 on which there is fastened a pin 56 or the like which in
turn is guided in the associated guide 44 and is connected for
drive purposes, in a suitable manner, to the chain drive that is
not shown in any more detail here. The side flanks 54 of each
receiving tray 42 are connected by means of a bearing plate 58 for
the transport boxes K, said bearing plate having sufficient
inherent rigidity or being suitably reinforced, which bearing plate
extends almost over the entire width of the container 10 while
leaving enough space for the drive and guiding elements of the
store 38. On the upper side of each bearing plate 58 there are
fitted, at regular spacings, guide beads 60 for the transport boxes
K, which guide beads extend transversely over the bearing plate 58.
The spacings of the guide beads 60 with respect to one another and
with respect to the side flanks 54 can be found for example in the
German standard DIN 58763, which in particular forms the standard
regarding the dimensions of transport boxes K.
[0042] In the embodiment shown, the conveying device 40 has a
horizontally aligned longitudinal conveyor 62 in the form of a
commercially available, preferably electrically driven conveyor
belt, which extends through between the front transverse struts 32
so that a transport box K can be moved from an outer position on
the container 10 to an inner intermediate position in the container
10 and vice versa. Furthermore, the conveying device 40 has a
gripper device 64 which serves to move the transport boxes K from
the inner intermediate position on the longitudinal conveyor 62 in
the container 10 to the inner end position in the store 38 of the
container 10 and vice versa.
[0043] In the embodiment shown, the gripper device 64 has a
horizontal portal 66 which is aligned parallel to the front
transverse struts 32 of the basic frame 16 and to the receiving
trays 42 and is formed by a commercially available, preferably
electrically operated linear unit. A commercially available,
preferably electric gripper drive 68 comprising two parallel
grippers 70 for the transport boxes K can be moved along the portal
66 in the horizontal, i.e. lateral, direction, as shown by the
associated double arrow in FIG. 1. The grippers 70 may be moved
towards and away from one another, as shown by the double arrows in
FIG. 1, in order to grasp/clamp a transport box K and release the
latter, respectively. Furthermore, the portal 66 is mounted at each
of its longitudinal ends on in each case a commercially available,
preferably electrically operated linear unit 72. By means of the
linear units 72 which extend parallel to one another and to the
lateral transverse struts 32 of the basic frame 16 in the
horizontal direction, the portal 66 and thus the gripper drive 68
can be moved forwards and backwards in a horizontal direction, i.e.
between two end positions, as shown by the associated double arrow
in FIG. 1.
[0044] The linear unit forming the portal 66, the gripper drive 68
and the lateral linear units 72 and also the longitudinal conveyor
62 are also supplied with electrical power by the accumulator 52.
The drive motor 46 of the store 38, by means of which the receiving
trays 42 of the store 38 can be moved predominantly in the vertical
direction, as shown by the associated double arrow in FIG. 1, and
also the linear units 66, 72, the gripper drive 68 and the
longitudinal conveyor 62 of the conveying device 40 are coupled to
one another for control purposes via a control device 74 in the
form of a PC which has appropriate control plug-in cards (SPS, CNC,
etc.) and is likewise arranged on the base plate 22 of the basic
frame 16. It is obvious to the person skilled in the art that the
transport boxes K can thus be placed in the store 38 at a specific
location on a specific receiving tray 42 by suitable horizontal
movement by means of the conveying device 40 and by suitable
vertical movement of the receiving trays 42. In the same way, by
means of the conveying device 40, a specific transport box K can be
removed from the store 38 and output from the container 10.
[0045] As electric drives for the store 38 and the conveying device
40, it is also possible to use cost-effective electric drives from
the automobile sector (windscreen wiper motor, window opening
drives, etc.), provided that this is technically possible. It is
also conceivable, although this is not shown here, that a small
compressor with air accumulator is provided in the container 10, as
a result of which pneumatic drives could also be used for the store
38 and the conveying device 40.
[0046] As shown in FIG. 1, the insertion and output device 14 of
the container 10 furthermore has a recognition device 76 which in
this case is arranged on the longitudinal conveyor 62 of the
conveying device 40, by means of which recognition device a marking
that is provided on each transport box K and identifies the
respective transport boxes K can be detected. In the embodiment
shown, the recognition device 76 is a commercially available reader
(barcode scanner), by means of which a barcode 78 placed on each
transport box K as marking can be detected. More specifically, in
this case each transport box K has a suitable receptacle in which
there may be placed a written manufacturing order 80 that bears the
barcode 78 among other things.
[0047] Like the store 38 and the conveying device 40 of the
container 10, the recognition device 76 is also effectively
connected in a suitable manner, not shown in FIG. 1, to the control
device 74, so that information regarding the marking of the
transport boxes K, in this case effected by means of the barcode
78, that is detected by the recognition device 76 can be stored in
the control device 74. As a result, the store 38 and the conveying
device 40 of the container 10 can be controlled by the control
device 74 in order to output a specific transport box K from the
container 10 upon a corresponding request, which is input into the
control device 74 for example manually by an operator via a
keyboard (not shown here) on the container 10 or automatically by a
workstation or processing machine of the prescription workshop 12,
taking account of the information regarding the marking 78 of the
transport boxes K that is stored in the control device 74.
[0048] In FIGS. 2 and 3, containers 10 are shown schematically in
further assembly stages. These too have an insertion and output
device 14 in a suitably designed basic frame 16, e.g. as shown in
FIG. 1, which can be moved by means of rollers 34, which insertion
and output device 14 has a store 38 and a conveying device 40 that
may be designed as described with reference to FIG. 1. Store 38 and
conveying device 40 are in this case, along with a recognition
device 76 for identifying the transport boxes K, connected to one
another for control purposes via a control device 74. In these
examples of embodiments too, these components are supplied with
electrical power by an accumulator 52 in the container 10.
[0049] Compared to the container 10 shown in FIG. 1, the container
10 shown in FIG. 2 has three additional functional components,
whereas the container shown in FIG. 3 has a further two compared to
the latter. Before describing these functional components in more
detail, it should be pointed out at this point that these
functional components may be provided individually or in any
desired combination on a container 10, depending on
requirements.
[0050] Firstly, the containers 10 shown in FIGS. 2 and 3 have a
signaling device 82 which can output for example a signal that is
representative of the filling level of the container 10 and/or of
the processing status of the spectacle lenses L contained in the
transport boxes K accommodated in the container 10. In the
embodiment shown, the signaling device 82 is a multicolored
indicator light that is connected to the control device 74.
[0051] Furthermore, the containers 10 shown in FIGS. 2 and 3 have a
transmitting and receiving device 84 with associated antenna 86,
which transmitting and receiving device is effectively connected to
the respective control device 74. In the embodiment shown in FIG.
2, the container 10 can communicate, by means of the transmitting
and receiving device 84, with the respective workstation of the
prescription workshop 12, in this case the processing machine E for
preprocessing the spectacle lenses L, for instance in order that
the workstation can request a specific order, i.e. transport box K,
from the container 10 or else that the container 10 can inform the
workstation about processing data in respect of a specific
transport box K that is yet to be output or has already been
output, said processing data relating to the spectacle lenses L
contained therein. The respective workstation accordingly likewise
has a transmitting and receiving device 88 which is connected to a
control device 90 of the workstation. Besides communication between
container 10 and respective workstation, the container 10 shown in
FIG. 3 can also communicate with a host control system 92 of the
prescription workshop 12 for further manufacturing control
purposes, which host control system is likewise equipped for this
purpose with a transmitting and receiving unit 94. In this
connection, FIG. 3 finally also shows an optional item of hand-held
equipment (PDA) 96 which can communicate with the containers 10,
the workstations of the prescription workshop 12 and the host
control system thereof for control and/or monitoring purposes.
[0052] Furthermore, the container 10 shown in FIG. 2 and the
container 10 shown in the right in FIG. 3 have a commercially
available cooling unit 98 for cooling the spectacle lenses L
contained in the transport boxes K accommodated in the container
10, by cooling the air inside the container 10. This may shorten,
for example, the dwell time following blocking of the spectacle
lenses L, by accelerating, by means of the cooling, the
solidification of the filling material between block and spectacle
lens blank. The cooling unit 98 may be designed so that it can be
regulated such that the cooling times and/or temperatures can be
selected to be different for different filling materials or
spectacle lens materials.
[0053] Instead of a cooling unit, the container 10 shown on the
left in FIG. 3 has a drying unit 100 for drying the spectacle
lenses L contained in the transport boxes K accommodated in the
container 10. As drying unit 100, use may be made for example of a
commercially available electrical heater comprising fans. The
drying unit 100 serves for example to dry the protective lacquer
that is applied to the already processed optically active surface
of the spectacle lens L prior to blocking. It should also be noted
here that the cooling unit 98 and the drying unit 100 are
advantageously arranged within the paternoster loop of the store
38.
[0054] As further functional components, the containers 10 shown in
FIG. 3 also have an input device 102, for instance in the form of a
keyboard, and a display device 104, for example an LCD display,
which are connected to the control device 74 of the container 10
and by means of which for example processing data in respect of the
orders, i.e. transport boxes K, that are placed in or are to be
placed in the container 10 can be input, requested and
displayed.
[0055] FIGS. 2 and 3 finally also illustrate how the containers 10
can be used at the workstations of the prescription workshop 12.
Whereas in FIG. 2 the horizontal arrows show that the respective
order, i.e. transport box K, is removed from the container 10 via a
conveying device 106 of the workstation E and after processing of
the spectacle lenses L at the workstation this transport box K is
placed back into the same container 10, FIG. 3 shows (cf. once
again the horizontal arrows) that the respective order, i.e.
transport box K, is removed from the container on the left in FIG.
3 via the conveying device 106 of the workstation C and this
transport box K is then placed into the container 10 on the right
in FIG. 3 following processing of the spectacle lenses L at the
workstation C.
[0056] FIG. 4 shows, by way of example, the layout of a
prescription workshop 12 in which the above-described containers 10
are used. In terms of the function of the individual workstations A
to H of the prescription workshop 12, for the sake of clarity
reference may firstly be made at this point to the introduction to
the description. The main material flow between the workstations A
to H is shown by arrows in FIG. 4.
[0057] In the layout example shown here, two different container
types are used: firstly a container without a cooling
unit--referenced 10--and secondly a container with a cooling
unit--referenced 10'. Whereas the containers 10 are used in almost
all areas of the prescription workshop 12, the containers 10' are
used only in the area between the blocking station C and the
preprocessing station E in order to allow rapid cooling of the
blocked spectacle lenses L. These containers 10', which are
somewhat more complex, therefore circulate between the finished
part side of the blocking station C and the unfinished part side of
the preprocessing station E. In order to ensure sufficient solidity
of the blocking material, a buffer zone D is provided between the
blocking station C and the preprocessing station E, in which buffer
zone the containers 10' can dwell and cool.
[0058] The individual workstations A to H of the prescription
workshop 12 are then linked flexibly by means of the containers 10,
10' as follows:
[0059] At A, transport boxes K are filled from a semi finished
product store with semi finished spectacle lenses L in accordance
with the prescription order. These transport boxes K are placed in
a container 10.
[0060] As soon as a container 10 has been filled, said container is
docked at the unfinished part side of the protective tape station B
(taping), which may be designed as described for example in DE 199
25 087 C2. Alternatively, a protective lacquer station may be
provided here. There is an empty container 10 for receiving the
transport boxes K comprising coated spectacle lenses L at the
opposite side of the protective tape station B. The protective tape
station B itself operates completely automatically and for this
purpose has a dedicated charging device comprising tape (not
shown).
[0061] As soon as this container 10 containing transport boxes K
comprising coated spectacle lenses L has been filled, it is brought
by an operator to the unfinished part side of the blocking station
C. Blocking is effected either manually or completely
automatically. On the finished part side of the blocking station C
there is an empty container 10' with integrated cooling unit, for
receiving the transport boxes K comprising the blocked spectacle
lenses L.
[0062] When this container 10' is completely full, the container
10' is fed, following some intermediate storage in the buffer zone
or waiting zone D, to the unfinished part side of the preprocessing
station E. The preprocessing station E usually operates completely
automatically and for this purpose has a dedicated charging system
110 comprising a conveyor belt for the supply and discharge of the
transport boxes K. An empty container 10 is docked on the finished
part side of the preprocessing station E, for receiving the
transport boxes K comprising the preprocessed spectacle lenses
L.
[0063] Again, as soon as this container 10 has been filled, it is
brought by an operator to the making-ready station F, in which the
appropriate tools for fine processing, i.e. precision-grinding
and/or polishing, from a tool store 112 are placed in each
transport box K.
[0064] Once all transport boxes K have been equipped with the
necessary processing tools, this container 10 is brought to the
unfinished part side of the finishing station G, which in the
layout example shown comprises a number of polishing machines. The
transport boxes K are fed in succession to the polishing machines.
The operator places tool and spectacle lens L into the polishing
machine and starts the latter. The placing of the spectacle lenses
L and tools into the precision-grinding or polishing machines is
usually not automated, although this is also possible in principle.
The finished spectacle lenses are then placed back in their
transport box K together with the tools and said transport box is
placed into an empty container 10.
[0065] As soon as this container 10 has in turn been filled, it is
brought to the deblocking station H, in which the spectacle lenses
L are removed from the blocks. From here, the spectacle lenses L
are fed to the further cleaning and refining processes. The blocks,
tools and transport boxes K are finally briefly cleaned before they
are taken back to their starting station (blocking station C, tool
store 112 and transport box shelf, respectively).
[0066] A container for a production center for manufacturing
individual spectacle lenses on prescription, known as a
prescription workshop, is disclosed, which prescription workshop
has a number of workstations between which the spectacle lenses can
be transported by means of transport boxes which are each designed
to receive one right and one left spectacle lens and possibly
associated processing tools. According to the invention, the
container is designed to receive a number of transport boxes in
order to transport the latter between at least two workstations of
the prescription workshop, the container having an insertion and
output device for the transport boxes, by means of which the
transport boxes can be inserted into the container and a specific
transport box can be output from the container when selected. The
invention also comprises the use of the container according to the
invention in a prescription workshop. As a result, a logistic
system for a prescription workshop is provided by means of which an
optimized material flow of the transport boxes can be ensured in a
flexible manner and largely independent of the size of the
prescription workshop and the structural conditions thereof.
[0067] Other variations and modifications are possible without
departing from the scope and spirit of the present invention as
defined by the appended claims.
* * * * *