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Bausch & Lomb Automated Lens Measurement System Project #05427
Executive Summary
Bausch & Lomb brought this project to R.I.T. in order for the Senior Design team
to develop the most cost effective non-contact method of evaluating the center thickness
of a contact lens.
In order to produce a contact lens, a mold is produced, the lens is cast and cured,
then it is hydrated, inspected and packaged for shipment. The current process during the
inspection uses a mechanical contact gauge to determine the center thickness. Once this
measurement is performed, the lens must be discarded. The new requirements specified
by Bausch & Lomb maintain that the new system must be non-contact in order to
eliminate the discarding of any good product.
As stated above, the requirements were determined after consulting with the
Bausch & Lomb Project Coordinator and Sponsor. After this was finalized all of the
other appropriate documentation was put into place. The team could then begin
researching concepts.
This project is different than most because it was extremely research intensive.
The team was required to spend a significant amount of time conducting research into
various technologies and companies that currently exist and could provide the proper
equipment. It is outside of the scope of the project for the team to construct its own
device from scratch, so the research was critical to find appropriate vendors that could be
evaluated.
After the initial large grouping of companies was narrowed down to the top eight
that might be capable of meeting the projects needs, a feasibility assessment was
conducted. This feasibility confirmed the teams’ opinion of what the top three companies
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were that should be pursued further. On a parallel track, all of the companies were sent
testing samples. The results from the vendor testing would aid the team in determining
what the top companies were. The top scoring companies from the teams’ opinion,
feasibility assessment and testing results were Lumetrics, Micro-Epsilon, and
Panametrics – NDT.
These top companies will have their units brought into Bausch & Lomb for the
team to conduct an analysis of how capable they are. This analysis, along with final
recommendations, cost benefit analysis, and a manufacturing integration package are
slated to be completed at the end of Senior Design II. In order to accomplish all of these
goals given the one-quarter remaining, the team has adopted a very aggressive timeline in
order to ensure the projects success. As a whole, the team is very proud of the progress
to date, is determined in achieving success, and confident in the path that lies ahead.
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EXECUTIVE SUMMARY.......................................................................................................11.0 INTRODUCTION.............................................................................................................5
1.1 BACKGROUND.....................................................................................................51.1.1 Current Measurement Method..........................................................................51.1.2 Desired Method..................................................................................................61.1.3 Possible Points of Integration...........................................................................6
1.2 CONFIDENTIALITY AND PROTECTION OF INTELLECTUAL PROPERTY..................72.0 NEEDS ASSESSMENT................................................................................................8
2.1 NEEDS ASSESSMENT OVERVIEW..............................................................................82.2 REQUIREMENTS – MEASUREMENTS........................................................................8
2.2.1 Non-Contact.......................................................................................................92.2.2 Integration........................................................................................................102.2.3 PLC Interface...................................................................................................102.2.4 User Interface..................................................................................................112.2.5 Extensibility / Flexibility..................................................................................11
2.3 MISSION STATEMENT.............................................................................................112.4 GOALS & OBJECTIVES...........................................................................................122.5 TEAM CHARTER......................................................................................................122.6 CONSTRAINTS..........................................................................................................132.7 RISK ASSESSMENT..................................................................................................152.8 BUDGET...................................................................................................................15
3.0 CONCEPT RESEARCH..................................................................................................163.1 POSSIBLE TECHNOLOGIES AND DISCOUNTED TECHNOLOGIES...........................16
3.1.1 Capacitance Method........................................................................................163.1.2 Laser Triangulation.........................................................................................173.1.3 Optical Spectrometer........................................................................................173.1.4 Laser (Autofocus)............................................................................................183.1.5 Ultrasonic.........................................................................................................193.1.6 Vision System...................................................................................................203.1.7 Mechanical Contact System............................................................................20
3.2 LONG LIST/SOURCES..............................................................................................213.3 SHORT LIST.............................................................................................................223.4 REASONS NOT TO PURSUE CERTAIN COMPANIES................................................223.5 METHOD FOR GATHERING TECHNOLOGY AND COMPANY INFORMATION.........243.6 PATENT SEARCH.....................................................................................................24
3.6.1 Patent Information..........................................................................................253.7 PRODUCT SPECIFICATION RESEARCH...................................................................28
3.7.1 Contact Lens Quick Reference Guide.............................................................283.7.2 Radius of curvature.........................................................................................293.7.3 Mold Information............................................................................................293.7.4 Cost Research...................................................................................................293.7.5 Centration of Lens...........................................................................................30
4.0 FEASIBILITY................................................................................................................31
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4.1 THE SHORT LIST REVISITED.................................................................................314.2 JUDGING CRITERIA.................................................................................................324.3 WEIGHTING CRITERIA...........................................................................................324.4 SCORING..................................................................................................................334.5 SAMPLE TEST RESULTS..........................................................................................344.6 THE TOP THREE.....................................................................................................36
5.0 DESIGNS.......................................................................................................................375.1 LUMETRICS.............................................................................................................375.2 MICRO-EPSILON.....................................................................................................395.3 PANAMETRICS.........................................................................................................43
6.0 CONCLUSION...............................................................................................................456.1 SUMMARY................................................................................................................456.2 GOALS FOR SENIOR DESIGN II..............................................................................456.3 ACTION PLAN TO ACHIEVE GOALS.......................................................................45
7.0 References...................................................................................................................47
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1.0 Introduction
With increased demand for contact lenses, Bausch & Lomb has seen a need to
ramp up its production. To do so, Bausch & Lomb is in the process of building new fully
automated production lines. To ensure every product meets their high quality standards,
lens measurements, including center thickness, are conducted as part of the production
process. The team has been requested to research and evaluate methods and devices
available to perform an automated, non-contact central thickness measurement. Based on
the teams technical and cost benefit evaluations of the methods/devices available, the
design team will build an offline station to functionally test the capabilities of the
measurement system(s) chosen.
Figure 1.0 – Process flow for contact lens production
1.1 Background
The center thickness of the contact lens is critical to maintain the correct optical
properties as well as to ensure comfort for the consumer. If the lens is too thin it will not
perform properly and may rip. If the lens is too thick, the optical properties will be
compromised and the consumer will not be comfortable wearing the lens. Therefore,
verifying that the product has the proper center thickness is critical to maintain the
product integrity.
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1.1.1 Current Measurement Method
Bausch & Lomb currently performs this lens central thickness measurement on a
manual offline station, which mechanically contacts the lens to perform the measurement.
The lens is in the wet state at the time of measurement. After the measurement has been
made, the lens must be discarded as the mechanical contact that the measurement device
makes with the lens may impose defects on the surface of the lens. Since lenses must be
thrown out after the current measurement is performed, lens central thickness is
monitored at an audit level of between 1 and 1.5 percent, rather than at 100 Percent of
Lenses Made (PLM).
1.1.2 Desired Method
Bausch & Lomb would like the design team to develop an automated, non-contact
measurement system for numerous reasons. A non-contact method would allow B&L to
measure the central thickness without discarding product. Since no contact would be
made with the lens surface, there would be no possibility of damaging the surface of the
lens. The automated system would also lower production costs and increase quality. The
system would not require an operator, so the non-value added labor cost would be
decreased substantially. A non-contact device would allow B&L to measure every lens’s
central thickness, which would insure a higher quality product.
1.1.3 Possible Points of Integration
In order to reduce costs further we will also determine the manufacturing process
step at which it is best to perform the central thickness measurement. During the
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manufacturing process the lens is either in the dry state or the wet state. In the dry state,
there are three scenarios where the lens central thickness can be measured, including:
while both mold halves are still assembled, after the mold has been de-capped, and after
the lens has been released from the mold. Since the lens starts off in the dry state, it
would be beneficial to perform the measurement at some point during the dry stage, as it
would allow bad product to be discarded at an earlier stage of production.
In the wet state, the lens can be measured in either the final blister or the wet cell
used for cosmetic inspection. Although we do not see inspecting in the blister as a cost-
effective method, we will keep it as a possible point of integration in case a measurement
cannot be performed elsewhere in the process.
As part of our development process, we will consider each of the scenarios
mentioned above, and evaluate the pros and cons of each. We will attempt to find
systems capable of measuring in more than one of the process steps above.
1.2 Confidentiality and Protection of Intellectual Property
Given the highly competitive nature of the contact lens manufacturing industry,
Bausch & Lomb has required that a Bausch & Lomb representative, prior to its public
release, review all information disclosed in any publication regarding this project. With
that being said, it is to be understood that certain portions of this report may not contain
all information that was discovered during the research and concept development phases
of this design project.
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2.0 Needs Assessment
2.1 Needs Assessment Overview
In performing a needs assessment for this project, the team in cooperation with
Bausch & Lomb representatives outlined and agreed to the requirements of the
Automated Lens Measurement System. With these requirements an overall mission
statement was formed along with team goals and objectives. The team then broke up the
member roles and responsibilities.
2.2 Requirements – Measurements
The first requirements specify the thickness range to be measured. The range for
this project is 50 – 250 μm. As a frame of reference, a typical human hair is
approximately 50 μm and standard sheet of 8.5 x 11 printer paper is approximately 185
μm. The thickness requirement is born out of the need to measure different products such
as single power correction, multifocal correction or toric lenses and their range of Stock
Keeping Units (SKU’s).
The tolerance specified for the measurement is ±10 μm. This requirement is
based around the optical properties of the lens and the comfort realized by the consumer.
Since these characteristics are directly related to its center thickness, the specified
tolerance must be held.
A gauge repeatability and reproducibility less than 18% is also required. This is a
Bausch & Lomb quality requirement, which insures both precision and accuracy of the
measurement are maintained at an acceptable level.
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The measurement area of the system is not to exceed 1.0 square mm. This is due
to the lens geometry, specifically the anterior and posterior curvatures as well as the
thickness profile across the lens. A limit of 1.0 square mm holds the measurement to the
central point of the lens.
2.2.1 Non-Contact
Bausch & Lomb stressed the non-contact requirement from the beginning. It has
greatly impacted the project by increasing both complication of making the measurement
and cost. This requirement is a quality/yield based. The word contact is similar to bump,
crash, jolt and strike as found in a thesaurus. This is undesirable from a quality
standpoint, regardless of how gentle the contact is. The underlying theme remains the
same, the more lens handling, and the more chances there are for cosmetic defects to
occur. Lenses are extremely brittle and easily subject to cosmetic defects in the dry state.
While the lens is more durable in the wet state, there is still a possibility of causing
cosmetic defects.
There also exists the possibility of causing a mark on the lens visible to process
machine vision systems. These systems are trained to find actual defects on lenses and
are antagonized by non-defect process signatures, which appear similar to actual cosmetic
defects. Elimination of a contact method further limits the possibility of false rejects at
the inspection point.
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2.2.2 Integration
The end goal of the project is to have a fully functional standalone test station,
similar to the current station used by operators. Bausch & Lomb does not expect and is
not requiring the team to integrate the new process into any of its current manufacturing
lines due to the implications and complications of doing such. However, Bausch &
Lomb is requiring that the system be designed with integration and extensibility in mind.
To accomplish this goal, the team is requiring the system to meet the current
shortest cycle time of Bausch & Lomb’s manufacturing line with the intent to measure
every lens. Design of the standalone test station will be focused around the point of
integration on the manufacturing line. Design for manufacturing will be implemented in
designing the system such that as many common parts as possible will exist between the
test station and the integrated system.
As required by Bausch & Lomb, a plan for line integration will be provided. The
plan will include all drawings, part numbers, instructions and bill of materials needed to
integrate and implement a fully functional system.
2.2.3 PLC Interface
With lot integrity and line integration in mind, the system must be able to
communicate to a Programmable Logic Controller (PLC). A PLC interface will allow
Bausch & Lomb to record line data for process control, development and improvement.
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2.2.4 User Interface
On both the standalone test station and the proposed integrated solution a user
interface is required. This requirement will allow the test station operator to view and
record the last measurement made. On the integrated solution, a user interface will allow
the line operator to aide in monitoring the process. The user interface will also allow line
technicians to easily set up and calibrate the system.
2.2.5 Extensibility / Flexibility
While it is impossible for Bausch & Lomb to know what the characteristics of
future products will be, it is requiring that the system be extensible and flexible enough to
process these new products. Possible influences could be the tint/opaqueness of the lens,
the monomer used, different molding materials and new lens geometry. It is impossible
for the team to guarantee this requirement can be satisfied indefinitely, but the team will
focus on this requirement when evaluating technologies. It is realistic that the team can
satisfy this requirement within the designed lifespan of the system.
2.3 Mission Statement
With a high level view of the project in mind, the team agreed on the following
mission statement:
“To provide Bausch & Lomb with the most cost effective non contact solution for
accurately measuring the central thickness of a contact lens.”
The team would like to focus on meeting the requirements with the most cost
effective solution possible. Certainly a low cost system may give up some of the
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flexibility desired by Bausch & Lomb and a high-end system may satisfy and exceed all
requirements. The team would like to find the best overall solution, as expressed in the
mission statement.
2.4 Goals & Objectives
Besides meeting the requirements set forth by Bausch & Lomb, the team
developed goals and objectives to help provide them with the best overall solution.
The first goal of the team was to research all non-contact methods for thickness
measurements. After researching various technologies, the team evaluated the pros and
cons as applicable to a make vs. buy solution within the given constraints.
As stated in the mission statement, the system should be cost effective. This will
allow Bausch & Lomb to justifiably integrate the system into its manufacturing lines.
The system, and more specifically the device used to measure the central
thickness should have customer support as needed. In the event that a solution with
highly developed components and/or software is implemented, the team wants Bausch &
Lomb to have the best resources possible for using the system.
The team will also design any and all needed fixturing. As part of the design
process and project budget, the team will design as much of the system as reasonably
possible.
2.5 Team Charter
The team established guidelines on how to best conduct business in the most
efficient manner possible while promoting involvement from all team members. Team
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members are expected to attend and be on time to all meetings or have a reasonable
exception. Members will be respectful of each other and of all ideas. Constructive
criticism will be used at all times. Meeting minutes will be emailed out by midnight of
the next day. The next tentative meeting will be announced at the end of each meeting.
Assignments will be completed on time. In the event that an emergency arises or
an assignment cannot be completed on time, the group member will notify the team so
that proper arrangements can be made.
Emails will be responded to within 24 hours or by assigned date. Team members
will print out emails to aide in documenting the project. The team charter is a living
document subject to amendment upon ratification of all team members.
2.6 Constraints
This project is faced with many constraints, which will influence the overall
success of the project. After doing some initial research, the team decided to perform a
make vs. buy rational analysis.
In performing this analysis, the team came to the realization that the optimum
solution would be to integrate a developed technology into a system rather than attempt
to reinvent the wheel. This decision was influenced by many factors.
The first limiting factors are the timeline, whereby the project needs to be finished
by early/mid May 2005 and the size/experience of the team. The team is neither large
enough nor proportioned correctly with its knowledge base to develop a non-contact
solution accurate to the micron range.
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Requirements set down by Bausch & Lomb leave a narrow margin of
technologies capable of performing the measurement. To develop a laser, spectrometer
or ultrasonic technology to a level of sophistication to meet Bausch & Lomb’s
requirements is unrealistic.
Furthermore, while patent searches did not reveal much prohibiting their use in
the contact lens thickness measurement application, there exists numerous patents around
the individual technologies themselves. This barrier alone would have greatly slowed
down or stopped the project, had the team opted to design a solution.
By deciding to integrate a purchased solution, the team has been and will continue
to be constrained by vendors. Before going into too much detail with vendors,
confidentiality agreements need to be established. This process has consumed
approximately forty percent of Senior Design I. This has impacted the project further do
to the constraints on lead times for sample reports. The ripple effect produced by this
will delay final decisions as to which vendors should be tested in house first. Delays in
designing and ordering fixturing are also expected.
Fixturing constraints exist due to the fine tolerances needed. Lenses will need to
be located with extreme accuracy and repeatability to meet requirements. As a result, a
Bausch & Lomb approved machine shop will be contracted to manufacture the fixturing
designed by the team.
Bausch & Lomb has agreed to support the team with the process development
personnel and resources it has. Due to the number of projects and involvement in these,
the team may be constrained by the timing and amount of available support.
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While the team is sufficiently funded, budgetary constraints also exist. The team
will need to manage funds to be able purchase fixturing and pay for trial lease periods of
systems.
2.7 Risk Assessment
The requirements propose the greatest risk to the project. An initial bin of
vendors was quickly narrowed down because they did not feel they could perform. Due
to the arrangement of the senior design project and graduation of team members, there
exists a hard deadline by which all work must be completed. Any delays pose a risk to
the entire project. This has lead the team to pursue a very aggressive schedule in hopes
of having time for a couple delays which will surely occur. All lead times present a risk
to the team. Future risks for the team include finding the most suitable vendor, being
able to design and obtain fixturing for the system, producing a fully functional test station
and publishing an integration plan. The project is being worked on in a parallel fashion
whenever possible to mitigate the risk of missing deadlines.
2.8 Budget
Bausch & Lomb is sufficiently funding the project to achieve success. With a
well-managed budget, the team will be able to purchase fixturing and bring systems in
house on lease or demo for full evaluation. The responsibility to allocate funding and
purchase a complete system will rest with Bausch & Lomb.
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3.0 Concept Research
3.1 Possible Technologies and Discounted Technologies
This section will outline the various concepts that have been researched.
3.1.1 Capacitance Method
The capacitance method utilizes a parallel plate capacitor by inserting the material
to be measured between the plates to act as a dielectric. The material will change the
voltage characteristics of the capacitor. As long as the material properties of the lens are
known, a correlation can be found between the voltage characteristics and the thickness
of the lens. The lens must be characterized with known thicknesses to create a look up
table as a reference for the device.
Advantages of the Capacitance Method:
The accuracy of this method tends to be very high.
Disadvantages of the Capacitance Method:
The operating distance of the plates may be too close to fit a curved material. The lenses must be characterized with known thicknesses. This may prove
difficult without destroying the lens. The lens must be positioned exactly perpendicular to the plates of the capacitor. The plates of the capacitor must be fixed which would complicate the positioning
of the lens. It would be impossible to measure the lens in the mold with this method. The effects of a curved material inside of a capacitor are unknown.
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3.1.2 Laser Triangulation
The laser triangulation method uses a laser source oriented at an angle to the lens.
The laser both reflects off of the top surface and travels through to the bottom surface of
the lens where it is reflected for a second time. A laser sensor is situated opposite of the
laser source. This sensor is able to detect the reflection of the laser from both the top and
bottom surface of the lens. Data is passed to a software system that can measure the
thickness of the lens based on the refractive index of the material as well as the distance
between the two laser signals.
Advantages of Laser Triangulation Method:
Only one measurement of the lens is required. The accuracy of the systems is very high. Measurements can be done both in and out of mold. Sensor and receiver are very compact. Systems are relatively inexpensive.
Disadvantages of Laser Triangulation Method:
May be difficult for laser to find surface of lens. Measurement time may be too long because of high accuracy. Refractive index may not be constant on some lenses.
3.1.3 Optical Spectrometer
The optical spectrometer method uses a multi-chromatic light source oriented
perpendicular to the lens. The light source reflects off of the top surface and travels
through to the bottom surface of the lens where it is reflected for a second time. The
reflected light is fed into a spectrometer where the wavelengths of light are separated.
Light bands of a certain wavelength will appear that relate to the top and bottom surface
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reflection. The software system can measure the thickness of the lens based on the
refractive index of the material as well as the wavelengths that have been returned from
the lens.
Advantages of Optical Spectrometer:
Only one measurement of the lens is required. The accuracy of the systems is very high. Measurements can theoretically be done both in and out of mold. Sensor and receiver are very compact. Vendor is very confident based on past experience.
Disadvantages of Optical Spectrometer:
May be difficult for Optical Spectrometer to find surface of lens. Characterization of angularity tolerance may be difficult
3.1.4 Laser (Autofocus)
The autofocus laser method uses a laser and lens system similar to a DVD player
in that it measures the distance from the sensor to a reflective surface. The distance to the
top surface is subtracted from the distance to the bottom surface to obtain a thickness.
This data must be manipulated manually because neither the software nor the hardware
was designed for thickness measurements. These systems are also designed for highly
reflective surfaces.
Advantages of Autofocus Laser:
The accuracy of the systems is very high. Measurements can theoretically be done both in and out of mold. Sensor and receiver are very compact.
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Disadvantages of Autofocus Laser:
Reflectivity of lens may not be enough for sensor to find both top and bottom surfaces.
Two measurements are required. System not designed for thickness measurements. Z-axis movement of either lens or sensor may cause system to be outside of
tolerance. Z-axis movement may drive up cost of system.
3.1.5 Ultrasonic
The ultrasonic system is similar to a sonar system that uses a high frequency
transducer to map the position and surfaces of the lens. This system requires exact
positioning of the lens in a wet environment. The ultrasonic system that we are
considering was designed and built with contact lenses in mind, although it has never
been used in an automated setting. The system is being considered as a wet alternative to
the dry systems.
Advantages of an Ultrasonic system:
The accuracy of the systems is very high. System designed and built for contact lenses.
Disadvantages of an Ultrasonic system:
Not currently used in an automated setting. Measurement required in a wet environment, which is not desired by
Bausch & Lomb. Difficult to implement across all manufacturing platforms. High frequency transducer may drive up cost of system.
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3.1.6 Vision System
The vision system uses a high-resolution camera to take a digital picture of each
lens. The picture is then analyzed by a computer to determine the thickness of the lens
based on the number of pixels that the lens occupies. The accuracy of this system is
dependant on the quality of the camera that is being used to photograph the lenses. This
system is similar to the current vision system.
Advantages of Vision System:
Similar to current utilized technology.
Disadvantages of the Vision System:
Software intensive system. Camera may not be able to see profile of lens. High quality camera may drive up cost of system. May be difficult to accurately photograph the lens while in the mold or mold half. The sensor (camera) may be large.
3.1.7 Mechanical Contact System
The mechanical contact method involves automating the current procedure for
measuring the central thickness of the lens. Lowering a probe onto the lens that is resting
on a pedestal does this. The current procedure is done in the wet state on an offline
manual station and is performed by a technician. This system is used on an audit basis
and the lenses must be destroyed after being measured.
Advantages of mechanical contact system:
The optical properties of the lens will not affect the system.
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The function and accuracy of this system are already known with respect to the
manual station.
Disadvantages of mechanical contact system:
Every lens cannot be tested because of quality issues.
Bausch & Lomb has specified a non-contact system.
This method has not been attempted in the dry state.
This method cannot be done in the mold or half mold.
3.2 Long List/Sources
After the initial needs assessment, research was done to gather companies and
technologies that were available and could handle measuring the contact lens to Bausch
& Lomb’s specifications. Individual Internet research was completed and compiled.
Several sources were used such as Google, Thomas Registrar, Global Spec., and Bausch
&Lomb Experts. The companies that were discovered consists of: Lumetrics, Keyence,
Elektrophysik, FRT of America, Mission Peak Optics, Micro-Photonics, Filmetrics,
Thermo Electron Corp., ABB, Adetech, Onosokki, MTI Instruments Inc., LMI
Technologies, Micro-Epsilon, Beta Laser Mike, ORYX, Panametrics, AccuSentry,
Norman N. Axelrod and Associates, Dr. Schenk Inspection Systems, Optical Data
Associates, LLC., and Solve TECH Inc. The companies offered a wide range of
technologies that were discussed in section 3.1.
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3.3 Short List
Researched companies were contacted to obtain a technical representative to
initially assess if it was feasible for the company to handle the given application. In
addition, to obtain recommendations on which device(s) would be the best to use. After
the initial screening the long company list developed into the following short list:
Lumetrics (Low Coherence Intferometry) Mission Peak Optics (Optical Gauge) Filmetrics (Spectrometer) MTI Instruments (Fotonic Sensor/Triangulation Laser) LMI Technologies (Triangulation Laser) Micro-Epsilon (Spectrometer/Polychromatic White Light) ORYX (Optical Gauge) Panametrics (High Frequency Ultrasonics)
3.4 Reasons Not to Pursue Certain Companies
The companies that did not make the short list had several reasons as to why they
would not be able to handle the application of measuring the central thickness of a
contact lens.
Beta Laser Mike had a device that consisted of a transmit and receive laser. The
Focal diameter would be too big for the application. This type of device is only good for
flat applications.
FRT of America was not able to handle the application either. They were not
confident they could measure a curved surface such as a contact lens. Micro-Photonics
could only measure up to a maximum of 50 microns.
SolveTech’s capacitive method would require a much larger spot size than
required (>1mm). Also, a fixture would need to be developed to position the lens
accurately between two plates with a separation distance significantly smaller than the
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overall height of the lens. The method's accuracy was also questionable for the given
application.
Keyence’s device was incapable of measuring the size and accuracy needed.
AccuSentry’s technology is essentially a camera or vision system that is used to inspect
products. The entire concept of a vision system was discarded due to the current lack in
adequate technology. Norman N. Axelrod and Associates was not pursued any further
because they do not sell a specific technology. Instead they would come in, analyze the
problem, and custom develop a solution. In this case, it would defeat the purpose of
Senior Design.
Dr. Schenk Inspection Systems sell products to measure thin films. Meaning, that
all of their products are meant to be installed on a high speed manufacturing line and take
a measurement based on the profile view of the thin film. Due to those characteristics
this was not a viable technology to pursue. Optical Data Associates, LLC is a small
testing company that specializes in high precision inspection of various components for
their optical properties and so forth. This company is just a testing firm and therefore
would not be able to help or sell any technology that would meet the needs of the
application.
Onosokki is only in the business of contact method systems for measurement and
this would not meet the applications requirement of a non-contact method requested by
Bausch & Lomb.
Adtech, ABB and Thermoelectron were all companies researched, but no
response was ever heard from them. Therefore, they were not looked into any further.
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3.5 Method for Gathering Technology and Company Information
A teleconference or onsite visit was scheduled with each of the resulting
companies. An on-site visit to Lumetrics occurred on Tuesday (1/11/05). The remaining
companies had teleconferences with the team on Wednesday (1/12/05) and Friday
(1/14/05). The information gathered from each company was the device measurement
range, measurement tolerance, angularity tolerance, spot size, number of measurements
required, device output, cycle time, system cost, device model number, working height,
lens state for measurement, sensor/controller ratio, sample lead time, demo lead time,
length of demo period, and system lead time. After all the information was collected
each team member revised their notes and created a list of their top company choices.
3.6 Patent Search
Several patents were found that are within the realm of the given application. The
topics varied from a contact probe that measured the actual thickness of a contact lens, to
automated visual inspections of a contact lens. Since the application that is being dealt
with is more process oriented on the measurement of the central thickness of a contact
lens, the patents listed below are not being infringed upon by our application. Each will
be discussed in further detail as to why they do not impact our project. Please see
Appendix A to view all patent abstracts for further reference.
4,665,624 4,403,420 5,205,076 6,134,342 6,765,661 6,301,005 6,490,028 6,847,458
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6,822,745 6,815,947 6,791,691 6,775,003 6,791,696
3.6.1 Patent Information
Patent number 4,665,624 deals with a soft contact lens analyzing apparatus. This
apparatus utilizes a fixturing device and several measurement scales to determine the
diameter, sagittal depth and central thickness of a contact lens. All of the scales use
probes that must come into contact with the actual lens. Therefore this describes a
mechanical, contact system which is not what our application calls for.
Patent number 4,403,420 is about a digital gauge for measuring the sagittal depth
and thickness of a lens, and the related systems and methods to do so. This method
involves a fixture and several linear encoders to measure the diameter, sagittal depth and
central thickness of a lens. Each of the encoders is connected to some type of probe that
needs to come into contact with the lens. Again, this is a mechanical contact system in
which our application will not infringe on.
Patent number 6,134,342 talks about a visual inspection method and apparatus for
a contact lens. The method described is automated. The visual inspection system is
looking for defects such as foreign material, scratches, breakage and so forth. The actual
system does not perform any quantitative dimensional measurements and therefore does
not have to do with our application.
Patent number 5,206,076 is for a self aligned manufacturing system and method.
This method does not pertain to the metrology of contact lenses. It describes a method on
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how to actually produce contact and intra-ocular lenses. Since this is describing the
manufacturing process and not a measurement process our application does not conflict.
Patent number 6,765,661 describes a lens (such as contact lens) inspection
method. This system looks for such flaws as tears or surface defects. Again, this system
does not perform any quantitative dimensional measurements and therefore our
application will not infringe with this patent.
Patent number 6,301,005 deals with an inspection system for optical components.
This system contains a device to hold the optical component in place. Also, it has the
means to inspect the optical component for any apparent defects. Given that this system
does not take into account quantitative dimensional measurements the compared
application is not the same and will not infringe.
Patent number 6,490,028 is for a variable pitch grating diffraction range finding
system. What is described is a very precise method to determine the range or distance
from a reference point to an object. Utilizing a variable pitch grating achieves this high
precision. This system uses a completely different methodology than any of the
apparatuses the team has evaluated for the given application.
Patent number 6,847,458 refers to a method and apparatus for measuring the
shape and thickness variation of polished opaque plates. In this system dual
interferometers are used. One is placed on each side of the plate to perform its surface
mapping and other calculations. Since the system is attempting to measure opaque plates
two interferometers must be used. This system is different from any of the researched
systems that have been evaluated because it is a dual interferometer system. All of the
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systems researched use only one interferometer. Also, this is for measuring opaque
substances, as our application is to measure optically clear lenses.
Patent number 6,822,745 talks about optical systems for measuring form and
geometric dimensions of precision engineered parts. This patent does describe a similar
technology that we will be utilizing. However, it describes the specific equipment and
not the overall process of the measurement. Whichever piece of equipment is chosen to
be used in our application should be protected by that respective company’s patent. No
process issues are present that would violate this patent.
Patent number 6,815,947 deals with a method and system for thickness
measurements of thin conductive layers. This system utilizes an electrically conductive
method known as eddy current. Extremely thin films that also have conductive properties
are the only applicable item that may be measured using this system. Due to its
limitations, the team ruled out this technology initially. None of the systems being
evaluated use this or any related technology.
Patent number 6,791,691 refers to a measuring method that uses attenuation in
total reflection. This patent describes a similar technology that we will be utilizing.
Furthermore, it describes the specific equipment and not the overall process of measuring
the object. That respective companies patent should protect whichever piece of
equipment the team decides to use in our application. No process issues are present.
Patent number 6,775,003 is about an apparatus and method for total internal
reflection spectroscopy. This also describes a similar technology that is being evaluated.
Again, although it has a similar technology it does not describe the process. Therefore,
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the researched technologies respective companies patent should protect the equipment in
the end that the team decides to put into use. No process issues are present.
Patent number 6,791,696 talks about an automated optical measurement apparatus
and method. This patent describes the method to measure lens properties, such as central
thickness, utilizing a wave front analysis. None of the technologies researched involve
this type of technology. For this reason, our application will not infringe on this patent.
3.7 Product Specification Research
This section highlights how the characteristics of a contact lens were researched
and captured.
3.7.1 Contact Lens Quick Reference Guide
Research was completed to create a reference guide for Bausch & Lomb’s contact
lens specifications. The specifications include product line, lens type, monomer,
diameter and tolerance of the lenses, wet central thickness range and tolerance of the
lenses, sagittal depth range and tolerance of the lenses, power range of each lens,
refractive index of each lens, if the lens had tint, and the document number of the
Finished Product (FP) specification. This guide was referred to when vendors were
contacted. Due to proprietary information this chart cannot be appended.
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3.7.2 Radius of curvature
During research the radius of curvature (base curve) was questioned by some of
the vendors as this could potentially pose a problem in obtaining the central thickness
measurement. This is another area where experts at Bausch & Lomb were able to inform
the team of the dimension. This dimension varies across all product lines. Due to
proprietary information this dimensional information cannot be released.
3.7.3 Mold Information
During the early stages of the project the mold material was introduced as
Polypropylene and PVC depending on which contact lens it will contain. The theoretical
refractive index of the materials are known, however the actual refractive index of the
molds is unknown. This is confidential information that cannot be disclosed.
3.7.4 Cost Research
Research was done to identify what the overall cost is to actually manufacture a
contact lens. Cost was broken down by each stage of the lens manufacturing process.
Also, the cost of material and operator labor and benefits were gathered. If the apparatus
was eventually integrated into the line as an automated system, in order to cost justify the
equipment, such costs would need to be known. This material will be covered further in
section 6.0.
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3.7.5 Centration of Lens
In order to properly present the lens to the sensor, and to take the various lens
profiles into account, a centration requirement was determined. If the measurement spot
size is less than 50 microns in diameter, than the measurement must be offset at a
distance from center equal to spot diameter plus 10 microns, in both the x and y
directions. If the spot size is larger than 50 microns in diameter, the measurement can be
taken directly in the center of the lens, at a distance of +/- 500 microns in either the x or y
direction.
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4.0 Feasibility
This section outlines how the team determined the feasibility of the companies,
and their respective technologies.
4.1 The Short List Revisited
Once the companies were eliminated due to their inability to meet the
requirements of the project, the team was left with eight companies to evaluate. Again,
these companies were:
Lumetrics Panametrics – NDT MTI ORYX Mission Peak Optics Micro-Epsilon LMI Filmetrics
All of these companies seemed capable of meeting the project requirements. The
team also had a good feel for the true potential of each company. After such extensive
research and learning from various technology experts, the team had a solid
understanding of the technical details to make effective decisions. With this knowledge,
the team had an idea of the top three companies that should be evaluated, but that idea
needed to be confirmed with evidence. Constructing a Feasibility Matrix did this. Please
see Appendix B for the complete matrix.
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4.2 Judging Criteria
The criteria by which the remaining companies would be evaluated were
determined by the project requirements (Appendix C). The primary technical criterion
was determined, but there was additional information the team felt was important that
should be included. While this data would not be scored, it was still listed on the
Feasibility Matrix for reference and to keep in mind when evaluating the companies. The
criterion is listed below:
Technical Criteria (Scored) Informational Criteria (Not Scored)
Measurement Range Device Model Number
Measurement Tolerance Working Height
Angularity Tolerance Lens State for Measurement
Spot Size Sensor/Controller Ratio
Number of Measurements Required Sample Lead Time
Device Output Demo Lead Time
Cycle Time Length of Demo Period
System Cost System Lead Time
Team Opinion
Table 1.0 Technical and Informational Criteria for the Feasibility Matrix
4.3 Weighting Criteria
Once the technical criterion that the companies would be evaluated for was
identified, it was necessary to weight the criteria. The criterion must be weighted
because some are more important than others. The most important criterion would have a
weight of five, and the least important criterion would have a weight of one. No criteria
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were given a weight of one, and the majority had a weight of five. The reason for this is
that there are multiple critical factors that the systems must be able to meet in order to
work effectively. The criterion that was slightly less important was given weights of four
and three.
4.4 Scoring
Once the companies, criterion, and weight were all identified the scoring could begin.
This was done with a fairly simple system outlined below:
Companies received a score of 1 if they might be close to meeting the requirements, but it would require some additional engineering to get the system to be able to achieve that specific criterion.
Companies received a score of 2 if they met the requirements. Companies received a score of 3 if they exceeded the requirements.
Two examples of the scoring system are outlined below:
System Cost Scoring Device Output Scoring
If the system cost more than $10,000, the
company received a 1.
If the system had an analog output, the
company received a 1.
If the system cost $10,000, the company
received a 2.
If the system had a digital output, the
company received a 2.
If the system cost less than $10,000, the
company received a 3.
If the system had a digital output and some
type of software bundle, the company
received a 3.
Table 2.0 Technical and Informational Criteria for the Feasibility Matrix
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These scores were then multiplied by the respective criterion weight and summed
to find the overall score for each company. The top three scores then identified the best
three companies and technologies that are able to successfully meet the projects needs.
4.5 Sample Test Results
Samples of contact lenses in three different states were sent to all vendors to
evaluate. The rationale was that this would once again confirm the teams’ decisions and
insure that all of the decisions being made were sound. Please note that LMI would not
evaluate samples, so there is no report from them. Please also note that all vendors
(except Panametrics – NDT) were given contact lenses still sealed in the mold, contact
lenses in the mold but decapped and dry contact lenses. Panametrics – NDT was given
wet contact lenses in solution to evaluate. Below is a summary of the testing results from
each vendor. The full reports can be found in Appendix D.
Lumetrics
Lumetrics conducted a sample analysis of the contact lens in various states and
evaluated the systems ability to accurately and repeatedly measure the center thickness.
Since they could measure the lens in the wet state, in addition to dry, it is easy to compare
the results they provide to the results acquired from the same lens using the current
manual process. For all trials conducted, their results had excellent agreement with the
current process.
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MTI
The technology utilized by MTI is only able to measure the lens in the dry state.
The team has not received an official report from them, but has conversed with their
representative on multiple occasions. The general consensus so far seems to be that they
are not able to achieve repeatable results with any of their systems. They are however
continuing their attempts and the team is moving forward while awaiting the data from
them.
ORYX
The team has not received an official report from ORYX. The preliminary results
given via e-mail and phone calls show that they are able to measure the lens in any of the
various dry states. The only issue that they may have is the cycle time requirement, since
their sensor takes longer than any other to acquire the returned signal and calculate the
thickness. The team feels comfortable with what ORYX is capable of and is awaiting
their final report.
Panametrics – NDT
Panametrics measures the lens in the wet state only due to their ultrasonic
technology. Therefore, it is very easy for the team to confirm their results and see how
well they relate to the current process. All of the results show excellent agreeability with
the current process. All measurements from Panametrics were verified to be within two
microns when the same lens was measured with the current manual station.
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Micro-Epsilon
The team does not have an official test report from Micro-Epsilon, but the vendor
has come and performed a demonstration. This demonstration showed their technology
and how it works, and they were able to accurately measure several lenses in the various
dry states. These initial demonstration measurements show good compatibility with
results acquired from the current process.
Mission Peak Optics
Mission Peak Optics was only able to measure the dry lens in its free state. Their
report was quickly returned to the team within one day of receiving the samples. The
results from their testing look promising and have good agreement when compared to the
current process.
4.6 The Top Three
The top three companies identified by the matrix confirmed the teams’ opinion on
what the best companies were. The three companies are:
Lumetrics
Micro-Epsilon
Panametrics
These three companies will have their units brought in house to Bausch & Lomb for the
team to do extensive testing on the units. The team will determine these units’ abilities to
meet the projects needs and will make a final recommendation to Bausch & Lomb from
these companies.
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Figure 2.0 Light Reflections bounced back to the DI 330 OPTIGAUGE for a single-layer film and a two-layer film with adhesive.
Bausch & Lomb Automated Lens Measurement System Project #05427
5.0 Designs
This section outlines the designs of the vendors, as well as our preliminary design
and placement plan. Additional information from each company’s website can be found
in Appendix E.
5.1 Lumetrics
The DI 330 OPTIGAUGE FILM THICKNESS MEASUREMENT SYSTEM
employs advanced optical technology originally developed by Eastman Kodak to monitor
its polyester film manufacturing operation for thickness uniformity. The DI 330 system
operates using the principle that light incident on a translucent film will reflect a portion
of that light. In fact, a reflection will occur at every surface interface. So, a single-layer
film will have two reflections, one from the upper surface
(R1) and one from the lower surface (R2). A two-layer film
with an adhesive in-between will have four reflections; one
from the upper surface (R1), one from the first layer-
adhesive interface (R2), one from the second layer-
adhesive interface (R3), and finally one from the lower
surface (R4).
The different reflections carry information about layer
thickness based upon the distance that the reflections have
traveled. Using advanced digital processing and proprietary
software, the DI 330 OPTIGAUGE system analyzes each
reflection and then calculates the exact thickness of each
layer.
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Features of DI 330 OPTIGAUGE
Reduce maintenance expenses with unique optical technology that is non-toxic, and non-radioactive.
Decrease inspection costs and scrap with non-contact, non-destructive gauging system
Improve customer satisfaction and profits through the highest guaranteed accuracy of ± 0.1 micron (± 0.004 mil)
Decrease scrap costs with instantaneous feedback and a measurement rate of 30 Hz
Lower inspection costs with a wide range of measurement from 12 microns to 9 mm
Decrease inspection time with simultaneous measurement of multiple layers Flexible system measures specialty multi-layer films, medical packaging,
adhesives and laminates Portable enough to inspect and measure lenses, flats, assemblies, ball lenses
with no system changes Works with a multitude of solids, liquids and coatings
The DI 330 OPTIGAUGE seems to be the most versatile sensor of our final three.
It is able to measure with both halves still on the lens, as well as with the bottom half of
the mold still attached to the lens, and the freestanding lens. Of course we would like to
place the sensor as far up the line as we can. The optimum place for this sensor would be
immediately after the monomer that makes up the lens has set into its solid form. This
takes place after the lens has gone through an Ultraviolet (UV) curing process.
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The lenses are placed in a single file on a conveyer after the UV cure process.
This position in the line would allow the sensor to measure before the top of the mold has
been removed. The size of the sensor should not be a problem if it is placed before the
machine that removes the top of the mold.
5.2 Micro-Epsilon
optoNCDT 2400 is a confocal displacement sensor for extremely precise
applications. Polychromatic light (white light) is focused onto the target surface by a
multi-lens optical system. The lenses are arranged such that the light is broken down into
monochromatic spectra by controlled chromatic deviation. A certain distance is assigned
to each wavelength by a factory calibration. The light reflected from the target surface is
passed via an optical arrangement to the receiver optical system, which detects and
processes the spectral changes.
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Figure 2.1 - Casting Machine: The lenses exit the UV curing stage of the casting machine and are in their solid state for the first time.
Bausch & Lomb Automated Lens Measurement System Project #05427
Figure 3.0 optoNCDT 2400: In-Focus Displacement and Position Measurement
Characteristics
Measuring principle: Confocal Measuring range: 0.08/0,35/1/3/10/24 mm0.003/0.014/0.039/0.118/0.39/0.94 inch Linearity: ±0.1 % FSO (full scale output) Resolution: 0.004 % FSO Measuring rate (selectable): 30/10/300/1000 Hz
Applications
Figure 3.1 Thickness of transparent materials
Figure 3.2 Distances to glossy and transparent surfaces
Figure 3.3 Measurements in holes (hole depth)
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Figure 3.4 Measurement of surface contours
After speaking with a representative of the company, and from the data that has been
returned to us from the testing procedure, the team has decided that there are two logical
places for the sensor.
After the top of the mold has been removed.
After the lens has been released completely from the mold
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Figure 3.5 Lens Release Machine: This machine removes the lens from the bottom half of the mold.
Bausch & Lomb Automated Lens Measurement System Project #05427
The optical sensor for the optoNCDT 2400 is very compact and could be
positioned in the 4-6 inch space before the mold release machine. The data collection
box can be positioned at the bottom of the machine where there is more room.
It would be more desirable to take the measurement while the lens is still in the
bottom mold half (for centering purposes). If it is found that the optoNCDT 2400 can
take more accurate measurements while the lens is completely free of the mold, then the
sensor will be implemented on one of the lens handling spindles. The picture above
shows a machine that is not surrounded by close quarters creating a good location for the
sensor and data acquisition box. This is the last place in the lens release machine that the
lenses are being processed on an individual basis. After this they are placed on the tray
shown in the picture until they are packaged.
The positioning of the lens may cause some design issues if the lens has already
been released from the mold. The mold would be easier to center and would also be
further up the line.
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Figure3.6 Lens Release Machine: The lenses pass through this section of the machine without any pieces of the mold before they are placed in the tray at the far end of the picture.
Bausch & Lomb Automated Lens Measurement System Project #05427
5.3 Panametrics
Panametrics-NDT 25 MULTI PLUS
ultrasonic thickness gage for multilayer
materials offers several unique
measurement capabilities. In addition to
making thickness measurements on metal,
plastic and many other materials with
varying thickness ranges, the 25 MULTI
PLUS can calculate and simultaneously
display as many as four separate
measurements. The Summation Mode accurately displays the total thickness of selected
layers.
Features of the 25 MULTI PLUS:
Calculates and simultaneously displays thickness measurements of as many as
four layers, and displays the total thickness of selected layers
Measures thickness of barrier layers in applications such as plastic fuel tanks
and bottle pre-form
A-Scan display for waveform verification
Wide thickness range: 0.004 to 20 in (0.100 to 508 mm)
Resolution up to 0.0001 in (0.001 mm)
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Figure 4.0 Panemetrics-NDT 25 MULTI PLUS
Bausch & Lomb Automated Lens Measurement System Project #05427
Internal alphanumeric file-based datalogger stores 18,000 thicknesses or 1,750
waveforms
The Barrier Layer Mode feature makes it possible to measure critical barrier
layers in multilayer plastic parts such as gas fuel tanks and bottle pre-forms. This special
mode displays the thickness of thin barrier layers that are typically too difficult to
measure with conventional ultrasonic thickness gages. This is because of lack of
separation between the echo from the front and back of the barrier layer.
The Panametrics sensors would require that the lens be in the wet state. While
this is not the most desirable state to measure the lens in, it may be an acceptable
alternative to the dry methods discussed in previous sections. Panametrics has disclosed
that the 25 MULTI PLUS has been used before for measuring of contact lenses in a non-
automated environment and is a proven technology for our application. Unfortunately,
there may be a problem with measuring lenses that are less than one hundred microns
thick as that is the lower limit that the device can theoretically measure. This problem
could be remedied with a higher frequency transducer. This high frequency transducer
may raise the cost of the system significantly.
Precise positioning of the lens in a wet environment would require the design of a
wet cell. Positioning inside the wet cell may also increase our cycle time. This system
would also severely limit the possible placement of the sensor on the line. The desire to
measure the lens in the dry state further up the production line is driven heavily by the
logistics of manipulating a lens in the wet state. The cost savings of doing this
measurement in the dry state in relation to the wet state is relatively small.
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6.0 Conclusion
This section will wrap up the outcome of Senior Design I, and outline the goals of
Senior Design II.
6.1 Summary
Senior Design I has focused mainly on researching technologies and devices
available. The team started with 22 companies, and narrowed the list down to 8
companies. After performing a feasibility assessment, the team was able to separate its
top three choices. With these top vendors the team plans to go on to Senior Design II and
accomplish all its goals.
6.2 Goals for Senior Design II
The final goal for Senior Design II is to present to Bausch & Lomb the teams
compiled in-house test data and final recommendations of the top units. Once the final
unit is chosen, the team plans to create a fully functional offline system. The team will
also develop an implementation plan, for Bausch & Lomb to integrate the system online.
6.3 Action Plan to Achieve Goals
The scheduling of the following action items is outlined in Appendix F. To
accomplish these goals the action plan is to start by bringing in demonstration units from
the top vendors. The team will perform a DOE and a Gauge R&R on each device to
determine if the device will meet Bausch & Lomb’s standards.
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The team plans to do a full cost benefit analysis. From preliminary calculations,
it is anticipated that all 8 of the devices from the feasibility matrix will prove to be cost
effective.
With drawings from the top three vendor units, the team plans to start designing
fixtures needed to secure the unit, as well as fixtures to correctly orient the contact lens.
From testing, the cost analysis, and all the data gathered from Senior Design I, the
team will present to Bausch & Lomb their final recommendations on each device. Once
the final system has been chosen, the team will work on creating a fully functional offline
station.
The various product lines at Bausch & Lomb will be thoroughly evaluated, and an
implementation plan will be developed to integrate a system onto the line chosen by
Bausch & Lomb. The plan will include where the device should be positioned on the
line, and how and where contact lenses that failed will be discarded. As well as how the
device will be connected to the existing PLC interface.
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7.0 References
This section gives the citation for the sources of information utilized while compiling
this report.
Global Spec 16 Jan 2005 <http://www.globalspec.com/>
Google 16 Jan. 2005 <http://www.google.com/>
Lumetrics 12 Feb. 2005 < http://lumetrics.net/>
Micro-Epsilon 12 Feb. 2005 <http://www.micro-epsilon.com/index_en.html>
Micro Format Inc. 10 Feb. 2005 <http://www.paper-paper.com/weight.html>
Mission Peak Optics 12 Feb. 2005 <http://www.missionpeakoptics.com/>
The World of Hair 10 Feb. 2005 <http://www.pg.com/science/haircare/hair_twh_141.htm>
Thomas Register 16 Jan 2005 <http://www.thomasregister.com/>
United States Patent and Trademark Office 14 Jan. 2005 <http://www.uspto.gov/patft/index.html>
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8.0 Appendix
Document AppendixPatent Abstracts AFeasibility Matrix BProject Requirements CVendor Testing Reports DVendor Website Literature ETimeline for Senior Design II F
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Appendix A – Patent Abstracts
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Appendix B – Feasibility Matrix
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Appendix C – Project Requirements
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Appendix D – Vendor Testing Reports
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Appendix E – Vendor Website Literature
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Appendix F – Timeline for Senior Design II
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