Method and apparatus for grinding lenses

Abstract: Method and apparatus for edge grinding a lens (2) comprising the grinding of a safety bevel on the lens using a third grinding wheel (7) which contacts the lens under gravity or a resilient bias and is automatically brought into operation once the lens has been ground to the required size and shape.

Description: This invention relates to a method and apparatus for grinding lenses and more particularly to grinding the edge or periphery of a lens for fitting into a pair of spectacle frames. The normal procedure for fitting a person with a pair of spectacles is for an optician to prescribe the appropriate lenses following an eye test and then for the person to choose a pair of frames into which the prescribed lenses are to be fitted. There is a wide range of sizes sand shapes of frames and in order to accommodate these, the lens manufacturer produces oversize lenses to a variety of prescriptions, whether single or bi-focal, and an ophthalmic laboratory or the like will shape the required lenses to fit the chosen spectacle frames. Lenses are shaped on a so-called lens edging machine which grinds the periphery of a lens to the required shape using a physical or electronically-memorised replica of the required shape. These lens edging machines can handle both glass lenses and lenses of synthetic plastics material and it is known first to grind a lens to the required shape using a grinding wheel, and then to finish the lens by exposing it to a V-shaped grinding wheel in order to produce an outwardly-extending, peripheral ridge or apex on the lens, which ridge is received by the associated frame, whereby each lens is located and retained in position in the pair of frames. Such a machine is disclosed, for example, in GB-A-2,001,267. After a period of use, the flat grinding wheel wears and develops an inwardly-extending peripheral groove with the result that a lens if ground marginally oversize until the grinding wheel is changed, which in turn means that the V-shaped grinding wheel has to remove more material than otherwise required and is thus subjected to increased wear. According to a first aspect of the present invention there is provided a method of edge grinding a lens (2) comprising the steps of:- a. grinding the periphery of a lens (2) to the required basic size and shape using first grinding means (5), and b. producing an outwardly-extending peripheral ridge or an inwardly-extending peripheral groove on the lens (2) using second grinding means (6) the grinding face of which is suitably contoured to provide said ridge or groove, characterised in that it comprises the further steps of c. automatically providing a safety bevel on the lens using pivotally mounted third grinding means (7) by moving the third grinding means from an inoperative to an operative position and in so doing allow the third grinding means to pivot into contact with the lens. When a peripheral groove is formed for so-called rimless or supra spectacles, steps b and c of this first aspect of the invention are reversed. Preferably, the third grinding means contacts the lens under gravity so that it is free to follow the contour of the lens as opposed to being forced into contact with the lens. The step of producing the safety bevel is incorporated as an automatic step in the sequence of grinding the edge of a lens with the third grinding means being brought into contact with the lens for a predetermined period. According to a second aspect of the present invention there is provided a lens edging machine comprising first grinding means (5) operable to grind a lens to a required basic size and shape, second grinding means (6) operable to grind an outwardly-extending peripheral ridge or an inwardly-extending peripheral groove on the lens, and control means operable to control automatically the operation of the first and second grinding means, characterised in that it further comprises third pivotally mounted grinding means (7) operable to grind a safety bevel on the lens, the third grinding means being controlled automatically by the control means and being movable from an inoperative position to an operative position in which the third grinding means pivots into contact with the lens. As with the first aspect of the invention, the safety bevel is formed be fore the peripheral groove in rimless or supra spectacles. The third grinding means preferably is arranged to contact the lens under gravity, whereby it can readily follow the contour of the lens. Furthermore, the third grinding means is preferably arranged to be operable as part of the normal lens edging operation, whereby the lens is first exposed in turn to the first, second and third grinding means, whereby there is no operator involvement as regards lens handling other than placing the oversize lens in the machine and removing the entirely finished lens from the machine. The first and second grinding means may be mounted on a common shaft and movable generally axially of the shaft so as to bring one or other grinding means into contact with the lens, as is conventional. The third grinding means is preferably arranged to be in a rest position until required and then movable to an operative position. The third grinding means may be in the form of a grinding wheel mounted on the output shaft of a motor which is mounted on an actuator which in turn is mounted on a carrier. The carrier is operable to move the third grinding means from the rest position towards the operative position, the actuator then being operated so as to extend the drive shaft of the grinding means so that as the carrier continues to move, the grinding wheel is brought into contact with the lens, whereby the latter grinds the safety bevel. On completion of this grinding operation, the carrier may then be moved to a position appropriate for grinding a safety bevel on the other edge of the lens, the actuator first being operated to retract the driving shaft and the third and then to extend the same for grinding the second bevel. The third grinding means is then returned to the rest position. In an alternative, and preferred, embodiment the third grinding means is fixedly mounted on a shaft so as to be pivotable therewith, means being provided for releasably and selectively holding the shaft in a first position in which the third grinding means in an inoperative position, and in a second position in which the third grinding means is in an operative position. The first grinding means of the first and second aspects of the invention may be of composite construction in the form of two annular discs releasably contiguously mounted to form in effect a single grinding wheel, the discs being reversible whereby a peripheral trough or groove resulting from wear can be turned into a peripheral peak or ridge and thus prevent the grinding of oversize lenses. It will be appreciated that the two discs can be reversed as many times as necessary, the only constraint being the thickness of the grinding material which normally in the context of a lens edging machine is finite in that it is in the form of band of abrasive material releasably attached to the periphery of a wheel or other mounting member. Typically the abrasive material is in the form of a band of diamond-impregnated material. From the foregoing it will be seen that known lens edging machines basically grind a lens to the required size and shape but in so doing, the edge of the lens often becomes chipped. Although this chipping of the lens is of a relatively fine order, as opposed to coarse, it is still necessary to effect a final and finishing grind to smooth the chipped edges, i.e. the interfaces between the basic rim or periphery of the lens and the front and rear faces of the lens. This lens finishing operation is presently effected by hand and involves offering each of said interfaces to a polishing wheel to provide what is termed a safety level. This necessitates handling of the lens by the operator which is time-consuming and can often result in damage to the lens to an extent such that it has to be scrapped. Lens edging machines and methods of edge grinding a lens in accordance wi th the present invention will now be described in greater detail, by way of example, with reference to the accompanying diagrammatic drawings, in which:- Figure 1 is a front view of the machine with a third grinding means thereof in a rest position, Figure 2 is a plan view of Figure 1, Figure 3 is a view similar to Figure 1 but showing the third grinding means in an operative position, Figure 4 is a plan view of Figure 3, Figure 5 is a block diagram of the control circuitry of the machine, Figures 6 and 7 illustrate alternative forms of grinding means for the machine of Figures 1 to 5, Figure 8 illustrates typical wear of a grinding means, Figure 9 is a front view of an alternative embodiment, Figure 10 is a plan view of Figure 9, and Figures 11 and 12 are side views of Figure 9 showing one component in two different positions. Referring first to Figures 1 to 4, the basic lens edging machine comprises a chuck 1 for a lens 2, the chuck being arranged to hold the lens centrally so as to free the edge of the lens for grinding. The chuck 1 is provided in a housing 3 below which is a further housing 4 for a pair of grinding wheels 5 and 6. This basic machine is of conventional form and normally, the shape of the lens 2 to be ground is determined by a dummy lens of the required shape mounted coaxially with the chuck 1 to one side of the housing 3. Alternatively, the shape of the lens may be written into a digital memory device. Whichever type of datum is used, the grinding wheels 5 and 6 are moved with respect to the lens 2 to grind the required shape and size. The grinding wheel 5 is first employed and this is a cylindrical or "flat" grinding wheel having a diamond-impregnated abrasive surface. The grinding wheel 5 produces the basic size and shape to the lens 2 and then a peripheral ridge is formed on that lens by bringing the V-shaped grinding wheel 6 into operation, the peripheral ridge being required in order that the lens can be located and retained within a spectacle frame as discussed above. The operation of the flat grinding wheel 5 is such as to be likely to give rise to slight chipping at the transitions between the front (convex) and rear (concave) faces of the lens and the peripheral edge. This chipping occurs both with glass and synthetic plastics lenses and is more of a potential danger as regards the rear or concave edge because the concavity of the lens gives rise to a relatively sharp edge which is directed towards the wearer and hence potentially hazardous to the wearer, irrespective of whether chipping has occurred. Accordingly, it is required to put a safety bevel at least on this rear edge but often also on the front edge. This safety bevel has to date been provided manually which involves handling of the lens and one aspect of the present invention obviates this by providing a third grinding wheel 7 mounted at the output shaft of a motor 8 attached by a bracket 9 to the piston 11 of an actuator 12. The actuator 12 is pivotally mounted at 10 on a carriage 13 which in turn is mounted for sliding movement on a superstructure 14 mounted on the housing 3. More specifically, the carriage 13 is mounted on a shuttle or slide comprising a stationary body 15 and a slide member 16 mounted on one side of the body. A connecting rod 17 attaches the carriage 13 to the slide 16. The carriage 13 is movable along a track 18 forming part of the superstructure 14, via a pair of rollers 19. The motor 8, actuator 12 and slide 15, 16 are all pneumatic devices although this is not essential. As seen in Figures 1 and 2, the bevelling grinding wheel 7 is disposed in a home or rest position when not required for use in which the actual grinding wheel is received in a recess in the housing 3. When a safety bevel is to be ground on the lens 2 once the latter has been ground to the required size and shape and formed with a peripheral ridge using the grinding wheels 5 and 6 as described above, the bevelling sequence of operation is initiated and the carriage 13 is first moved from the home position along the track 18 and if the carriage were to move completely along the track, then it would be seen that the bevelling wheel 7 would not contact the lens 2. In order that contact can be made between the bevelling wheel 7 and the lens 2, the actuator 12 is extended and carries with it the motor 8. The motor 8 is actuated so that the bevelling wheel 7 is rotated and as the carriage 13 moves further along the track 18, the bevelling wheel 7 contacts the rear edge of the lens 2 as illustrated in Figures 3 and 4. It will be seen from these Figures that the carriage is in fact moved to an extent such that the pivot point 10 of the actuator 12 on the carriage 13 is generally above the lens 2 so that the actuator 12 and the motor 8 are pivoted out of the vertical, whereby the contact between the bevelling wheel 7 and the lens 2 is by way of gravity. This arrangement has been found to be satisfactory when grinding a safety bevel on a lens of synthetic plastics material using a motor speed for the bevelling wheel 7 of 200-300 rpm. This arrangement of contact between the bevelling wheel 7 and the lens 2 enables the former to follow the contour of the latter and not be forced into contact which might otherwise effect over-grinding in certain places. With glass lenses, it may be desirable to arrange for the actuator 8 to pivot from the vertical to the operative position against the action of a light spring, for example, in order to prevent bounce of the bevelling wheel 7. The bevelling wheel 7 is maintained in the operative position for a predetermined time and when the safety bevel has been completed, the carriage 13 is moved back to the home position, the actuator 12 contracted so as to allow the bevelling wheel 7 once again to sit in the recess in the housing 3. However, if it is desired to grind a safety bevel on the front edge of the lens 2, then the carriage 3 is first moved to the right as seen in Figure 3 of the drawings, the actuator 12 contracted so as to enable the bevelling wheel 7 to clear the lens 2, the carriage then moved to the left to an extent such that the bevelling wheel 7 passes the lens 2, whereupon the actuator 11 is then re-extended and the carriage finally returned slightly to the right in order that the bevelling wheel 7 can contact the front edge of the lens 2 in a manner similar to that shown in Figure 3 with respect to the rear edge. Once a safety bevel has been ground on the front edge of the lens, the actuator 12 is then contacted and the carriage 3 returned to the home position. Figure 5 shows the control circuitry for the machine. The circuit is in two parts, a first circuit controlling the shaping and sizing of a lens in accordance with the conventional machine, and the second controlling the sequence of grinding one or more safety bevels on a lens. This second aspect of the circuit is shown in Figure 5 and a push button 21 initiates the electrical supply for the first circuit via a switch 21′ and sets up an inhibit via a switch 21″ on the second circuit through a solenoid 22 which controls the supply of air from a line 23. A digital memory 30 is set ON when the push button 21 is initially depressed and at the end of the basic grinding of the lens 2, a timer 24 removes the inhibit from the solenoid 22, whereby the slide or shuttle 15, 16 is powered through a control valve 25 from the air line 23. Thus, the carriage 13 is moved from left to right as seen in Figure 3 of the drawings along the track 18 as already described. The same signal resets the memory for the next cycle of operation. As soon as the shuttle or slide 15, 16 moves, the push button supply is removed and when the shuttle or slide line is pressured, a pressure switch 26 operates to activate a relay 27 in the supply line to the motor 8. This pressure switch 26 also commits a second timing sequence through timers 27 and 28. When timer 28 times out, it switches a motor/advance valve 33 to extend the actuator 12 and to energise the motor 8. This enables full adjustment of the speed of the motor 8. A mechanical stop (not shown) provides for adjustment to suit various style and contours of lenses. With the shuttle or slide 15, 16 moving and the motor 8 energised, the bevelling wheel 7 advances along the grinding line until contact is made with the edge of the lens 2 as already described. The timer 28 allows contact between the bevelling wheel 7 and the lens 2 to be made for a preset period before the resetting of the shuttle or slide 15, 16 is initiated. A delay 29 is provided to ensure that the shuttle or slide 15, 16 is retracted clear of the lens 2 before the actuator 12 and motor 8 are retracted. Once the carriage 13 is back in the home or rest position, the circuit is reset for the next cycle of operation. A supply of water 31 is provided in order to provide lubrication for grinding and in order to interlock with the finishing (bevelling) sequence. The water flow system is set into two separate cascades and is controlled by logic circuitry 32. The memory output opens a stop valve through a normally open port of a diverter. When the second or finishing cycle commences, the memory signal is removed and substituted direct onto the diverter. Both the shuttle or slide 15, 16 and the motor 8 are fitted with speed control devices and the air supply for the system is provided through an air service unit with atomised lubrication. A motor speed of 200-300 rpm has been found suitable for synthetic lenses and a speed of up to about 8000 rpm (conventionally 3000 rpm) for glass lenses. Turning now to Figures 6, 7 and 8, these illustrate alternative arrangements of basic grinding wheels which can be substituted for the wheels 5 and 6 which are those conventionally used. Figure 6 shows an arrangement in which two cylindrical or flat wheels 32 and 33 are provided, together with a conventional V-wheel 34. The wheel 32 is of a relatively coarse grade and is used to remove most of the unwanted lens. The lens is then further finished on the finer grade wheel 33 which essentially produces no chips on the edges of the lens. Thus, the V-wheel 34 has to remove much less material to produce a substantially perfect peripheral ridge on the lens. With this arrangement, the wheel 33 retains its flat or cylindrical shape much longer, thus obviating the problems discussed above with the use of the two conventional wheels 5 and 6. Figure 7 illustrates a modification of the grinding arrangement of Figure 6, with basically the same three wheels being employed but with the first wheel 35 being of composite form although the second and third wheels are similar to the wheels 33 and 34 of Figure 6 and have been accorded like reference numerals. The composite wheel 35 comprises two contiguous and regular annular discs and when wear eventually takes place so as to produce a peripheral groove around that wheel, which groove is illustrated at 36 in Figure 8 of the drawings, the two discs can be separated, reversed and rejoined in order that the generally central groove is transformed into a central peripheral peak or ridge around the wheel which is then used for grinding purposes. When this peak or ridge is eventually worn down and in due course another groove such as illustrated in Figure 8 produced, the discs can again be reversed. The reversing procedure can take place until such time as all of the abrasive material has been used. This arrangement dramatically increases the life of the coarse grinding wheel 35. The two discs are convention and are merely bolted together on the grinding wheel shaft so that no special construction for the discs is required. All of the grinding wheels involved in the overall apparatus are of the type using a diamond-impregnated abrasive surface which is provided in strip form, the strips being attached to a cylindrical wheel or the carrier, or a contoured wheel in the case of the V-shaped grinding wheels 6 and 34. Figures 9 - 12 illustrate an alternative, and preferred, embodiment to that shown in Figures 1-8. In this preferred embodiment, like components have been allocated reference numerals similar to those of the embodiment of Figures 1-8. The machine comprises an overall casing 40 to top portion of which is provided with an opening 41 closable by a hinged lid 42 (shown open in Figure 12), the lens 2 being loaded into the machine through the opening 1. The basic arrangement of chuck 1 for holding the lens 2 and the provision of two grinding wheels 5 and 6 is similar to that of the embodiment of Figures 1-8. Once a lens 2 has been loaded into the machine for grinding, with the appropriate dummy lens fitted as with the first embodiment, the lid 41 can be closed (Figure 11) either manually or by some drive arrangement. The lid 41 carries on its upper surface a shaft 43 rotatably mounted at each end in a bearing block 44 and having attached thereto towards one end a depending abutment 45 and attached towards the other end a mounting block 46 for a shaft 47 the lower end of which carries a diamond wheel similar to that designated 7 in the embodiment of Figures 1 - 8. The shaft 47 is driven via a flexible drive from a motor not shown. An air cylinder 48 is provided, the piston 49 of which is in contact with the abutment 45 attached to the shaft 43. When the piston 49 is extended, the shaft is pivoted to a position in which the bevel grinding wheel 7 is in an inoperative position, and when the piston 49 is retracted, the shaft 43 pivots under the weight of the grinding wheel 7 so that the latter pivots until it is in contact with the lens 2. The control of the embodiment of Figures 9 - 12 is basically similar to that described in connection with the embodiment of Figures 1 - 8, the grinding wheels 5 and 6 being rotated once the lid 42 has been closed (either manually or drivingly), whereby the lens 2 is first ground to its basic shape as dictated by the dummy lens. When the lid 42 is closed, the air cylinder 48 has the piston thereof extended so that the grinding wheel 7 is in its inoperative position in relation to the lens 2. When the lens 2 has been ground to the correct size and shape by the grinding wheel 5 and then provided with the peripheral ridge by the grinding wheel 6, the grinding wheels 5 and 6 are arrested and a timer is then activated which retracts the air cylinder 48 so that the shaft 47 is allowed to pivot under weight of the grinding wheel 7 until the latter contacts the lens 2 and is thus placed in the operative position. At the same time, the timer energises the motor which drives the grinding wheel 7 and also triggers rotation of the lens 2. The grinding wheel 7 is rotated at at least 250 RPM, but the rotational speed may be higher, whereas the lens 2 is rotated relatively slowly the safety bevel typically taking about one minute to grind. Once the grinding wheel 7 is in contact with the lens 2, then a safety bevel is ground on the latter, as with the embodiment of Figure 1 - 8, and when the timer times out, the air cylinder 48 is extended, whereupon the piston 49 thereof pivots the shaft 47 in the operative direction and hence pivots the grinding wheel 7 away from the lens 2 to its inoperative position. The lid 42 is now opened (again either manually or drivingly), and the ground lens removed and replaced by a new lens to be ground and the sequence of operation described above repeated. The alternative arrangement of basic grinding wheels illustrated in Figures 6, 7 and 8 may be used in the preferred embodiment in Figures 9 - 12. It will be seen that the preferred embodiment is simpler and more compact than the embodiment of Figures 1 - 8. The pivotal movement of the shaft 47 is of the order of 25 - 30° and it will be appreciated that means other than an air cylinder can be used in order to hold the grinding wheel 7 in the inoperative position. Furthermore, the means used to control the pivotal movement of the shaft 47 can be such as to drive the shaft in both directions or just in one direction as described with reference to Figures 9 - 12. It will be seen that the present invention provides a significant advance in the art in that the time consuming operation of providing a safety bevel is obviated and brings with it the attendant advantage of not having to handle the lens to produce that safety bevel and providing a regular safety bevel as opposed to an irregular bevel resulting from a stop-start bevelling action due to the lens having to be rotated by hand.

Claims: A method of edge grinding a lens (2) comprising the steps of:- a. grinding the periphery of a lens (2) to the required basic size and shape using first grinding means (5), and b. producing an outwardly-extending peripheral ridge or an inwardly-extending peripheral groove on the lens (2) using second grinding means (6) the grinding face of which is suitably contoured to provide said ridge or groove, characterised in that it comprises the further steps of c. automatically providing a safety bevel on the lens using pivotally mounted third grinding means (7) by moving the third grinding means from an inoperative to an operative position and in so doing allow the third grinding means to pivot into contact with the lens. A method according to claim 1, characterised in that steps b and c are reversed when a peripheral groove is formed for rimless spectacles. A lens edging machine comprising first grinding means (5) operable to grind a lens to a required basic size and shape, second grinding means (6) operable to grind an outwardly-extending peripheral ridge or an inwardly-extending peripheral groove on the lens, and control means operable to control automatically the operation of the first and second grinding means, characterised in that it further comprises third pivotally mounted grinding means (7) operable to grind a safety bevel on the lens, the third grinding means being controlled automatically by the control means and being movable from an inoperative position to an operative position in which the third grinding means pivots into contact with the lens. A machine according to claim 3, characterised in that the third grinding means (7) contacts the lens (2) under gravity. A machine according to claim 3, characterised in that the third grinding means (7) is biased by resilient means into contact with the lens (2). A machine according to any of claims 3 to 5, characterised in that the third grinding means (7) is movable in one direction from a rest position to a region of operation in which it is clear of the lens (2), and then movable in another direction to an operative position in contact with the lens. A machine according to claim 6, characterised in that the third grinding means (7) is mounted on the output shaft of a motor (8) which is mounted on a piston (11) of an actuator (12) which in turn is pivotally mounted on a carriage (13), the carriage effecting movement of the third grinding means (7) in said one direction and the actuator effecting movement in said another direction. A machine according to claim 7, characterised in that the carriage (13) is mounted on a track (18) via rollers (19) and is movable by a slide mechanism. A machine according to any of claims 3 to 5, characterised in that the third grinding means (7) is mounted on a shaft (43) for pivotal movement between operative and inoperative positions, means (48) being provided for pivoting the shaft in at least one direction. A machine according to claim 9, characterised in that the means for pivoting the shaft is in the form of an actuator (48) engageable with an abutment (45) attached to the shaft (43). A machine according to claim 9 or 10, characterised in that the third grinding means (7) and the shaft (43) on which the third grinding means is mounted are mounted on a lid (41) of casing (40) forming part of the machine. A machine according to any of claims 3 to 11, characterised in that the first grinding means (5) is of composite construction in the form of two annular discs (35) releasably contiguously mounted to form in effect a singe grinding wheel, the discs being reversible whereby a peripheral trough or groove resulting from wear can be turned into a peripheral peak or ridge and thus prevent the grinding of oversize lenses. A machine according to any of claims 3 to 12, wherein the rotational speed of the third grinding means (7) is 200-300 rpm when the lens is of a synthetic plastics material. A machine according to any of claims 3 to 12, wherein the rotational speed of the third grinding means (7) is up to 8000 rpm when the lens is of glass.

Inventors: CURCHER DENNIS VICTOR, CURCHER, DENNIS VICTOR
Applicants: BERKSHIRE OPHTHALMIC LAB LTD, BERKSHIRE OPHTHALMIC LABORATORIES LIMITED
Application year: 1989
Main classification: B24B9
IPC codes: B24B9