Abstract:
This invention discloses a handheld apparatus for measuring surface power or radius of prescription ophthalmic spectacle lenses, optical lenses or molds blocked with or without chuck during Rx production, and after comparing measurement results with designed data, providing correction data to the processing machines via wireless connection for correction processing if needed. The handheld apparatus integrates an optical measurement head into a monolithic optical system.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a Continuation-in-part Application of PCT application No. PCT/CN2013/087640 filed on Nov. 21, 2013, which claims the benefit of Chinese Patent Application No. 201310471241.X filed on Oct. 11, 2013. All the above are hereby incorporated by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention includes an apparatus based monolithic optical system, including imaging sensor that measures surface power, cylinder, axis and other optical characteristics of the polished surface of prescription ophthalmic spectacle lenses or molds with or without chuck during Rx production. 
       BACKGROUND OF THE INVENTION 
       [0003]    During the prior arts ophthalmic spectacle lens Rx production, the lens production and measurement are irrelevant and cannot form a closed loop; the semi-finished lens should be first blocked with chuck, which will then be clamped on the generation machine for surface generating and grinding, and later moved to the polishing machine for surface polishing. After polishing, the polished lens will be engraved on the surface. Then the engraved lens should be de-blocked from the chuck, and its optical power and other optical characteristics will be measured on measuring machines, such as conventional Foci meter. If the power measured is out of tolerance, this lens should be rejected and discarded because it is impossible to reprocess the lens. Any lens that has been de-blocked from the chuck cannot be kept at the same position as before. Even a very tiny difference will cause the surface deform and make reprocess to fail. As a result, the rejected and discarded lens may lead to too much waste during Rx production and a large time delay for quality control. 
         [0004]    A number of prior arts measuring apparatus exist that measures the power, cylinder, axis and other characteristics of ophthalmic lenses by transmission light and those lenses have to be removed from the blockers. Because of the transmission light structure, commercial instruments available for performing this job can only measure the lens transmission power and some characteristics, but not the surface power and other characteristics of surface. However, during the Rx production processing, it is more important to guarantee the surface power than other characteristics to be the same as the designed data. With compared results, the surface optical measurement apparatus will be better than lens meter. It is directly measuring the surface processed and getting direct results of the surface. 
         [0005]    The prior arts measuring apparatus cannot calculate the power, cylinder, axis and other characteristics for ophthalmic lens or mold surface by reflect light or send feedback of correction data obtained from results comparison to the machines for correction processing. Commercial instruments available for performing this job such as Belgium Automatic and Robotics&#39; Focovision SR2 and Dual Lens Mapper can only provide the result of surface power, cylinder, axis and other characteristic and display the optical difference between measuring results and design data. Checking lens power with chuck is even impossible for Focovision SR2. For de-blocked lenses, although whether the processing surface is qualified can be decided from the results, how to correct the fault surface cannot be provided to the machines. 
         [0006]    The prior arts measuring apparatus has the disadvantage and drawback of bulkiness and immovability while measuring the power, cylinder, axis and other optical characteristics for ophthalmic lens or mold surface by reflect light. Commercial instruments available for performing this job such as Automatic and Robotics&#39; Focovision SR2 and Dual Lens Mapper normally consists of separated optical components and industrial computer in the measuring system. The measuring system is normally a desktop device which consists of optical illumination source, optical path system, lens holder and detecting component, with all components not bonded with each other, so the measuring system is bulky and immovable for stable running. Industrial computer is used for data acquisition, analysis and display. 
         [0007]    The prior arts measuring apparatus measuring the optical power, cylinder, axis and other optical characteristics for ophthalmic lens or mold surface can calculate the feedback correction data after comparing with designed data as a three coordinate machine which includes a measurement pin, encodes, at least three axis slideway, motors, and a movement control system. The optical power, cylinder, axis and other optical characteristics are calculated from the surface coordinate. However this measuring method is very time consuming and measuring one lens may take about 10 minutes. And also another disadvantage is that this apparatus is very huge and immovable. 
       SUMMARY OF THE INVENTION 
       [0008]    The present invention seeks to provide an apparatus to evaluate surface of ophthalmic lenses or molds blocked on the chuck during Rx production. 
         [0009]    The present invention also seeks to provide an apparatus for in-situ quality control of ophthalmic lens production, which overcomes the disadvantage and drawbacks of existing production method that does not have in-situ quality control and cannot do correction if lens surface power is out of tolerance. 
         [0010]    The present invention also seeks to provide an improved lens surface measurement apparatus, which overcomes the disadvantage and drawbacks of existing measurement instruments that are not handheld and cannot be used anytime or anywhere. 
         [0011]    A handheld measurement apparatus based on the present invention comprises a main control body and a monolithic optical measurement head which is integrated into the main control body. The main control body comprises at least a microprocessor data processing board such as DSP, smart phone, and a display screen. The monolithic optical measurement head comprises at least a light source, a ring-shaped aperture, an image sensor. During measurement, the surface of the ophthalmic lens or mold blocked with or without chuck is placed against the lens support. The light source projects a light beam onto the surface to be measured. The reflected light beam goes through the ring-shaped aperture and forms an image on the image sensor, wherein the formed image is subject to the surface power of the surface to be measured. The microprocessor processes the image data and displays the calculated surface power on the display screen. 
         [0012]    In a preferred embodiment of the present invention, the main control body is a present smart mobile phone, which includes a microprocessor, a display screen, an LED light, and a CMOS chip. The LED light is utilized as the light source and the CMOS chip is utilized as the image sensor. 
         [0013]    In another preferred embodiment of the present invention, the optical measurement head comprises a compact monolithic optical system in which all optical components are connected to each other by optical contact bonding or glue cement, and image sensor can be bonded to monolithic optical measurement head as complete monolithic measurement head system, or mounted separately. The alignment of the optical components is done during the bonding process and no further alignment is necessary during assembling or operation, which reduces the complexity and improves the stability and reliability of the apparatus. Thanks to complete monolithic optical system, the volume of the optical measurement head can be minimized so that the apparatus is easy to handle with one hand. 
         [0014]    In another preferred embodiment of the present invention, the main control body includes barcode or QR code reader via camera and a wireless communication module through which the designed surface shape can be achieved from the Rx server. The microprocessor of the main control body calculates the theoretical surface power according to the designed surface shape and determines if the measured ophthalmic lens or mold is ok or not. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0015]    The present invention will be understood and appreciated more from the following detailed description, along with the supplemental drawings in which: 
           [0016]      FIG. 1   a  and  FIG. 1   b  illustrate an external view of a handheld apparatus according to the preferred embodiment of the present invention; 
           [0017]      FIG. 2  shows the principle of the surface power measurement apparatus; 
           [0018]      FIG. 3  illustrates a monolithic optical system according to a preferred embodiment of the present invention. 
       
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
       [0019]      FIG. 1   a  and  FIG. 1   b  show a handheld measurement apparatus according to one embodiment of the present invention, and is respectively a front view and a left-side view of the measurement apparatus in working status. As shown in  FIG. 1   a  and  FIG. 1   b,  the handheld measurement apparatus includes a data processing unit (here we call it a smartphone) such as smart mobile phone  1  as the main control body and an optical measurement head  3  which is fixed on the back side of the smart mobile phone  1 . During Rx production, an ophthalmic lens blank or mold  5  is blocked on a chuck  7  via alloy or wax  6 . The surface generating machine and polishing machine clamp the chuck  7  on their work piece spindle and process the top surface of the lens blank or mold  5 . After polishing, the lens or mold  5  blocked on the chuck  7  is placed against the lens support  4  of the measurement head  3  and the local optical surface power, e.g., spherical power, cylinder power and cylinder axis, of the small surface area where the lens or mold  5  contacts the lens support  4  can be measured and displayed on the display screen  2  of the smart mobile phone  1 . The small surface area to be measured can be the center of a single vision lens or mold or the far-view and near-view reference points of a progressive lens or mold or any other point on the surface. 
         [0020]      FIG. 2  shows the optical principle of the surface power measurement apparatus. As shown in  FIG. 2 , an incident light beam  9  converges at a point A on the optical axis  13 . The surface to be measured is placed against a fixed lens support which intersects with the optical axis  13  at a point O. A ring-shaped aperture  11  with a fixed radius r and an image sensor  12  are fixed on the same side as the incident beam  9  and intersect with the optical axis  13  at points S and C. The incident beam  9  reaches the surface and is reflected. The reflected light beam  10  goes through the ring-shaped aperture  11  and forms an image on the image sensor  12 . 
         [0021]    First assume that the surface  8  is a spherical surface with a radius of curvature R, then the reflected light beam  10  will also converge at a point A′ on the optical axis  13 , and the image formed on the sensor  12  will be a round ring with a radius c. In this illustrated optical system, an object at point A forms an image at point A′ by the reflective surface  8 . According to  FIG. 2 , the object distance I and image distance I′ can be described by the following equations: 
         [0000]      I=  OA   (1)
 
         [0000]        I ′=−(   OS +  SC +  CA′   )   (2)
 
         [0000]    where  OA ,  OS  and  SC  are already known. 
         [0022]    According to homothetic triangle theory, there is: 
         [0000]    
       
         
           
             
               
                 
                   
                     
                       
                         CA 
                         ′ 
                       
                       _ 
                     
                     
                       SC 
                       _ 
                     
                   
                   = 
                   
                     c 
                     
                       r 
                       - 
                       c 
                     
                   
                 
               
               
                 
                   ( 
                   3 
                   ) 
                 
               
             
           
         
       
     
         [0023]    Thus equation (2) can be rewritten as: 
         [0000]    
       
         
           
             
               
                 
                   
                     l 
                     ′ 
                   
                   = 
                   
                     
                       - 
                       
                         ( 
                         
                           
                             OS 
                             _ 
                           
                           + 
                           
                             SC 
                             _ 
                           
                           + 
                           
                             
                               c 
                               
                                 r 
                                 - 
                                 c 
                               
                             
                              
                             
                               SC 
                               _ 
                             
                           
                         
                         ) 
                       
                     
                     = 
                     
                       - 
                       
                         ( 
                         
                           
                             OS 
                             _ 
                           
                           + 
                           
                             
                               r 
                               
                                 r 
                                 - 
                                 c 
                               
                             
                              
                             
                               SC 
                               _ 
                             
                           
                         
                         ) 
                       
                     
                   
                 
               
               
                 
                   ( 
                   4 
                   ) 
                 
               
             
           
         
       
     
         [0024]    According to the imaging formula of a reflective sphere, there is: 
         [0000]    
       
         
           
             
               
                 
                   
                     
                       1 
                       l 
                     
                     + 
                     
                       1 
                       
                         l 
                         ′ 
                       
                     
                   
                   = 
                   
                     2 
                     R 
                   
                 
               
               
                 
                   ( 
                   5 
                   ) 
                 
               
             
           
         
       
     
         [0025]    Hence, the radius of curvature R of surface  8  is: 
         [0000]    
       
         
           
             
               
                 
                   R 
                   = 
                   
                     
                       2 
                       
                         
                           1 
                           l 
                         
                         + 
                         
                           1 
                           
                             l 
                             ′ 
                           
                         
                       
                     
                     = 
                     
                       2 
                       
                         
                           1 
                           
                             AO 
                             _ 
                           
                         
                         - 
                         
                           1 
                           
                             
                               OS 
                               _ 
                             
                             + 
                             
                               
                                 r 
                                 
                                   r 
                                   - 
                                   c 
                                 
                               
                                
                               
                                 SC 
                                 _ 
                               
                             
                           
                         
                       
                     
                   
                 
               
               
                 
                   ( 
                   6 
                   ) 
                 
               
             
           
         
       
     
         [0026]    The spherical power S of surface  8  can thus be calculated by: 
         [0000]    
       
         
           
             
               
                 
                   S 
                   = 
                   
                     
                       
                         
                           n 
                           - 
                           1 
                         
                         R 
                       
                       × 
                       1000 
                     
                     = 
                     
                       500 
                        
                       
                         ( 
                         
                           n 
                           - 
                           1 
                         
                         ) 
                       
                        
                       
                         ( 
                         
                           
                             1 
                             
                               AO 
                               _ 
                             
                           
                           - 
                           
                             1 
                             
                               
                                 OS 
                                 _ 
                               
                               + 
                               
                                 
                                   r 
                                   
                                     r 
                                     - 
                                     c 
                                   
                                 
                                  
                                 
                                   SC 
                                   _ 
                                 
                               
                             
                           
                         
                         ) 
                       
                     
                   
                 
               
               
                 
                   ( 
                   7 
                   ) 
                 
               
             
           
         
       
     
         [0000]    where n is the refractive index of the lens or mold  5 . 
         [0027]    When the surface  8  is a cylinder surface with two radii of curvature R 1  and R 2  on its two orthogonal principal meridians, the image formed on the sensor  12  will be an elliptic ring with a major radius c 1  and a minor radius c 2 . The two spherical power S 1  and S 2  on the two orthogonal principal meridians of the cylinder surface can be calculated by: 
         [0000]    
       
         
           
             
               
                 
                   
                     S 
                     1 
                   
                   = 
                   
                     
                       
                         
                           n 
                           - 
                           1 
                         
                         
                           R 
                           1 
                         
                       
                       × 
                       1000 
                     
                     = 
                     
                       500 
                        
                       
                         ( 
                         
                           n 
                           - 
                           1 
                         
                         ) 
                       
                        
                       
                         ( 
                         
                           
                             1 
                             
                               AO 
                               _ 
                             
                           
                           - 
                           
                             1 
                             
                               
                                 OS 
                                 _ 
                               
                               + 
                               
                                 
                                   r 
                                   
                                     r 
                                     - 
                                     
                                       c 
                                       1 
                                     
                                   
                                 
                                  
                                 
                                   SC 
                                   _ 
                                 
                               
                             
                           
                         
                         ) 
                       
                     
                   
                 
               
               
                 
                   ( 
                   
                     8 
                      
                     a 
                   
                   ) 
                 
               
             
             
               
                 
                   
                     S 
                     2 
                   
                   = 
                   
                     
                       
                         
                           n 
                           - 
                           1 
                         
                         
                           R 
                           2 
                         
                       
                       × 
                       1000 
                     
                     = 
                     
                       500 
                        
                       
                         ( 
                         
                           n 
                           - 
                           1 
                         
                         ) 
                       
                        
                       
                         ( 
                         
                           
                             1 
                             
                               AO 
                               _ 
                             
                           
                           - 
                           
                             1 
                             
                               
                                 OS 
                                 _ 
                               
                               + 
                               
                                 
                                   r 
                                   
                                     r 
                                     - 
                                     
                                       c 
                                       2 
                                     
                                   
                                 
                                  
                                 
                                   SC 
                                   _ 
                                 
                               
                             
                           
                         
                         ) 
                       
                     
                   
                 
               
               
                 
                   ( 
                   
                     8 
                      
                     b 
                   
                   ) 
                 
               
             
           
         
       
     
         [0028]    The cylinder power C can be calculated by: 
         [0000]        C=|S   1   −S   2 |  (9)
 
         [0029]    And the cylinder axis is the orientation of the major axis of the elliptic ring image on the sensor  12 . 
         [0030]      FIG. 3  illustrates a monolithic optical system according to the preferred embodiment of the present invention with the aid of which the above-described principle can be carried out. The smart mobile phone includes an LED flash light  14  and a CMOS image sensor  15 . The monolithic optical system comprises optical components including reflective prisms  16 ,  17 ,  18  and  19 , support prisms  20 ,  21  and  22 , a converging lens  23 , a ring-shaped aperture  24 , and a beam splitter  25  and CMOS image sensor  15 . All the optical components and CMOS image sensor are fixed with each other by optical contact bonding or glue cement. 
         [0031]    During measurement, the LED flash light  14  or additional separated LED works as the light source of the optical measurement head. The light beam emitted from the LED flash light  14  is redirected by the reflective prisms  16 ,  17  and  18 , and goes along the optical axis  27  inside the monolithic optical system. A converging lens  23  converts the light beam from the light source into the desired beam which is reflected by a beam splitter  25  and is projected onto surface  26  of the lens or mold to be measured. The light beam reflected from surface  26  goes through the beam splitter  25 , a ring-shaped aperture  24 , and is then reflected by a reflective prism  19  to be projected onto the CMOS sensor  15  to form an image. The image is analyzed by the smart mobile phone and the surface power of the local surface where the lens support contacts is calculated and displayed on the display screen of the smart mobile phone. 
         [0032]    In one embodiment of the present invention, the lens support includes a polished ruby, stainless steel or sapphire ring to contact the lens surface in order not to damage the surface to be measured. 
         [0033]    In a further preferred embodiment of the present invention, the smart mobile phone includes a wireless communication module, e.g., GSM, GPRS, 3G, LTE, Bluetooth or WiFi or WLAN. When measuring a lens or mold, the smart mobile phone communicates with the Rx server via the wireless communication module and gets the designed surface data. The smart mobile phone calculates the theoretical local surface power and compares it with the measured result and tells if the lens or mold is ok or not.