Abstract:
A system for enhancing lens preparation which allows for error compensation to provide nearly error-free lens fining and/or polishing. The system employs a flexure to allow three degrees of freedom for a lens being prepared. The system also employs a Hall effect circuit board to monitor movement of the flexure to account for error, provide feedback to a controller so that compensation for such error can be effected and so that proper force may be maintained. The flexure and the sensor feedback subsystem enable nearly error-free lens surfaces.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The invention relates to the field of three dimensional surface finishing. More particularly, the invention relates to a flexure and a position monitoring subsystem of a lens preparation system. 
     2. Prior Art 
     Ophthalmic and other types of lenses are typically produced from lens blanks of glass or plastic having two major surfaces, one of which is typically finished, and the other of which is unfinished. Cutting, fining and polishing, operations are performed on the unfinished surface of the lens blank by a machine responsive to data corresponding to a particular lens prescription. The cutting operations are usually accomplished by employing a ball mill for plastic lenses, or a grinder for glass lenses. These cutting operations generally create a lens surface closely approximating the shape of the finished lens. However, the cut surface of the lens blank is often rough and requires that subsequent fining and polishing operations be performed on the lens blank to achieve the requisite optical clarity. 
     The fining and polishing operations are ordinarily performed by engaging the cut surface of the lens blank with a tool having a shape that closely approximates the desired finished shape of the lens as defined by the lens prescription. This abrasive surface is referred to by those skilled in the pertinent art as a tool or “lap”. During operation, the lens blank moves relative to the abrasive surface of the lap along a conforming contoured semi-spherical path, thereby fining and/or polishing the lens surface. Laps consist of a mandrel, to which a removable abrasive pad is applied. The lens blank is moved relative to the lap during fining and polishing operations. The combined shape of the mandrel and the pad must conform as closely as possible to the prescribed shape of the lens, therefore, different lens prescriptions require different laps to be used. 
     Prior lens fining and polishing machines have used mechanical oscillating machines to move the lap relative to the lens blank. The oscillating motions have been fixed, defined by the mechanical structure of the fining and polishing machine, with differences between the ideal motion for sliding the lap against the lens blank taken up by a biasing mechanism which provides the force between the lap and lens blank and by leaving either the lap or lens blank free to pivot about at least one axis in response to the motion of the fining and polishing machine. 
     SUMMARY OF THE INVENTION 
     The above-identified drawbacks of the prior art are overcome or alleviated by the tactile feedback system of the invention. 
     The tactile feedback system of the invention comprises a flexure having three degrees of freedom and a deflection-sensing subsystem. The subsystem comprises a plurality of movement-sensing arrangements such as a plurality of magnets mounted on a chuck and a Hall effect circuit board in operable communication with said plurality of magnets. The tactile feedback system is configured to supplement an apparatus which is the subject of U.S. patent application Ser. No. 09/073,491 filed May 6, 1998 entitled METHOD AND APPARATUS FOR PERFORMING WORK OPERATIONS ON A SURFACE OF ONE OR MORE LENSES, assigned to the assignee hereof and fully incorporated herein by reference. The flexure portion of the feedback system comprises a configuration which provides predictable stiffness, allows only three degrees of freedom, and exhibits an extended service life. The deflection-sensing subsystem collects information about the deflection of the flexure by measuring magnetic field movement and transmits the information back to a controller to process which allows the controller to maintain a uniform distribution of force at a desired magnitude on the lens surface throughout the programmed movement. It is also important to note that the tactile feedback allows the machine itself to compensate for misalignments in its structure because the structure does not dictate the working parameters but merely supports the various components of the machine. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     Referring now to the drawings wherein like elements are numbered alike in the several Figures: 
     FIG. 1 is a schematic perspective view of the lens machine with which the tactile feedback system of the invention is employed; 
     FIG. 2 is a plan view of a flexure of the invention; 
     FIG. 3 is a perspective exploded view of a portion of the lens machine and the components of the tactile feedback system; 
     FIG. 4 is a perspective view of the tactile feedback system of the invention; and FIG. 5 is a control diagram depicting the operation of the invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     In the following discussion and in the drawing figures referenced herein, a lens-making machine is directly disclosed. It is important to note, however, that the tactile feedback system of the invention is not limited to lens-making machines but rather may be employed for any type of machining where a tactile feedback loop is desirable. The invention provides multiple degrees of freedom and the ability to control forces in all of the degrees of freedom available to it. It should also be pointed out that the portion of the invention controlled by the Controller as described herein may be employed to support and move the lens (work piece) or the lap (work tool) as desired. 
     Referring to FIG. 1, the lens machine  10  with which the invention is to be employed is illustrated schematically. Frame  12  is the basis of the lens machine  10  and provides structural support for all elements thereof. Within frame  12  are mounted six lead screws  14  of which four are visible in the figure. The lead screws  14  are powered rotationally in a clockwise or counterclockwise direction by individual motors  60  depending upon the operation performed and the direction of the controller (not shown). Each lead screw  14  is attached to a follower  16  which is connected to an individual articulated arm  18 . Arms  18  are connected at their respective other ends in an articulated manner to a moving platform  20 . (Moving platform  20  was referred to as a “mounting bracket” in the prior application which this application incorporates by reference. The identifier “moving platform” has been adopted in this application since it is deemed to be more descriptive). A lens chuck and lens (not shown) would be mounted to the moving platform  20  in a location central to moving platform  20  and on a flexure (not shown) and moved by selective movement of the lead screws  14 . Beneath the moving platform  20  is a lap  22  which will retain an abrasive pad (not shown). The lens is prepared by being abraded against the lap  22  in a controlled manner and motion described in the hereinbefore identified patent application. The device, as disclosed in the prior application identified above, provides preferably six degrees of freedom which is advantageous in lens making. It is important to note however that a five degree of freedom assembly is also useable to produce lenses. Such a machine would remove the capability of rotation about the z-axis. 
     Referring to FIG. 2, a flexure  24  of the invention is illustrated. The flexure is preferably constructed of phosphor bronze which is commercially available from McMaster-Carr and is commercially known as alloy 510/spring temper grade A material. A preferred thickness of the material is dictated by the range of forces desired to be employed. In the preferred embodiment described herein the material is in the range of 0.015 to 0.050 with a preferred thickness of 0.032. Exterior planar dimensions of flexure  24  are dictated by lens machine  10  and may be of any geometric shape and size. In a preferred embodiment, flexure  24  is circular and is of a diameter of about 5.5 inches. Preferably the diameter will closely approximate that of the moving platform  20  to which it will be attached. 
     Flexure  24  defines an outer ring  26  which is joined to an inner ring  28  (which is sized to accept a lens chuck (not shown) by a series of dog leg members  30 , each of which is the result of the removal of material from a raw solid disk. In a preferred embodiment, nine dog leg members  30  are created by removal of material from flexure  24  in the pattern illustrated in FIG.  2 . Several fastener holes  32  and  34  are provided for attaching flexure  24  to other components as will be appreciated from the following description. 
     Due to the configuration of flexure  24 , three degrees of freedom are allowed. More specifically, inner ring  28  may be displaced to a plane parallel with the plane of outer ring  26 . Inner ring  28  may also be displaced relative to outer ring  26  at an angle. Perusal of FIG. 2 reveals an x and y axis drawn thereon for reference. The angular movement freedom of ring  28  is referred to as α and β, α being rotation about the x-axis and , being rotation about the y-axis. α and β movements are limited to a maximum of about ±3° total and the stop ring limits movement to about ±2° but it is important to note that software employed with the tactile feedback system of the invention preferably limits movement to about ±0.1°. It will of course be M appreciated that any combination of the movements stated is possible thus, three degrees of freedom. The maximum linear deflection of inner ring  28  is preferably in the range of 0-0.125 inch in a direction normal to x-y plane, (z) direction. 
     Since it is desirable in the art that flexure  24  be capable of enduring a great many cycles, it is advantageous to break all edges of the material and polish the same. The procedure removes small surface imperfections that might otherwise lead to failure of the flexure. It has been determined that the breaking and polishing procedure allow a single flexure to have a service life equaling that of the lens machine  10 . 
     Flexure  24 , by providing the freedom of movement discussed hereinabove, helps to maintain even pressure on a lens blank mounted in the machine  10  for abrasion during the lens preparing operation. By maintaining even pressure, the likelihood that an imperfection such as a flat spot in the lens or unwanted prism would be introduced in the lens is reduced. This is desirable both to the manufacture and to the public. Fewer “defective” lenses and better vision, respectively, is achieved. 
     To render the lens machine  10  even more capable of producing near-error-free lenses, a deflection-sensing subsystem is added to the flexure  24 . The deflection-sensing subsystem measures the amount of deflection of flexure  24  at preferably three points equally spaced at about 120° apart on the circular embodiment illustrated. By measuring such deflection and feeding such information to the controller (not shown) of lens machine  10 , the significant benefits of the invention are realized. More specifically, the tactile feedback system of the invention allows for the maintenance of uniform force of a desired magnitude over the entirety of the workpiece surface whether that surface be a lens or any other product By maintaining uniform force of a desired magnitude over the surface of the workpiece, material removed will be consistent over the entire surface. In the lens-making art, such consistency avoids unwanted prism in the final lens produced by a lens machine employing the tactile feedback system of the invention. While it is a superior benefit to have sufficient control to maintain uniform force of a desired magnitude on the work product, it is also possible, if desired, to intentionally prevent uniformity of force. The controller of the invention is capable of changing forces on certain areas only and therefore building in a wanted prism (lens art) or other nonuniformity of surface structure. The nonuniformity may be a raised portion or a lowered portion of the material of the workpiece depending upon interest and appropriate programming. Another significant benefit of the system of the invention is that it is not dependent upon proper construction of support members of a housing of the device. More particularly, even if the device is assembled incorrectly (missing spacer, uneven frame, etc.) the workpiece is not affected. Adjustments are made by the controller to maintain its uniform or programmed nonuniform pressure and will do so regardless of any misalignment of the frame  12  of the machine. 
     The deflection-sensing subsystem may employ many different kinds of sensors including Eddy current sensors, capacitor sensors (these must be in a protected environment), LVDTs, strain gauges, linear encoders, etc. In the following discussion, however, Hall effect sensors are employed. 
     Referring to FIGS. 3 and 4, the exploded view will provide understanding of the invention while FIG. 4 shows the assembled invention. Beginning from the lowest level on drawing FIG. 3, moving platform  20  is illustrated. It will be recalled that moving platform  20  is a driven member in lens machine  10 . Immediately upwardly adjacent moving platform  20  is flexure  24  which will be fixedly attached to moving platform  20  thorough a clamp  36  using holes  32  of flexure  24  and aligning holes  38  and  40  in clamp  36  and moving platform  20 , respectively. To inner ring  28  is fastened chuck body  42  through holes  44  to holes  34  of flexure  24 . Chuck body  42 , it will be appreciated, is moveable relative to clamp  36  due to deflection of flexure  24 . 
     Chuck body  42  includes magnet arms  46  to receive and position magnet studs  48 . Preferably three magnet studs  48  are provided, each being endowed with a permanent magnet (not shown). Because of the movement of chuck body  42 , magnet studs  48  will change position to a small degree. This movement is sensed by components discussed hereunder. In an alternate configuration, magnets are mounted directly on magnet arms  46  deleting the studs  48 . This configuration is not shown but is clear to one of ordinary skill in the art. 
     Above chuck body  42  is stop ring  50  which is fixedly attached to clamp  36 . Stop ring  50  provides for movement in chuck body  42  by leaving space thereunder (not shown) to the extent movement is desired in chuck body  42 . Movement thereof is also limited by stop ring  50 . Visible at the outside diameter of stop ring  50  are scallops  52  which allow space for magnet studs  48  and their associated magnets (not shown). The space allows movement but also, and importantly, facilitates an unimpeded path for the magnetic field of each magnet to reach a Hall effect circuit board  54  which is attached to an upper surface of stop ring  50 . The Hall effect circuit board employs the moving magnetic fields of the magnets mounted on the chuck body  42  along a stationary field of a ring  56  having three preferably Samarium cobalt magnets mounted therein and aligned with magnet stubs  48  mounted atop thereof to determine the degree of deflection of flexure  24  during operation of lens machine  10 . The deflection is measured at the three locations occupied by magnet arms  46  and studs  48  with their magnets (not shown) by sensing a change in the magnetic field interaction between the moveable magnets and the stationary ring  56 . It is also desirable to include a dampener material (not shown) near each moveable magnet. Preferably the dampener material is about ¼ inch in diameter and about ½ inch long-Isodam® (trademark of E•A•R specialty composites) vinyl urethane material. 
     The Hall effect circuit board  54  is communicatively attached to a controller (not shown) of lens machine  10  and allows for processing within said controller so that adjustments may be made (approximately 2000 times per second) to maintain uniformity of force of a desired magnitude or the specific programmed nonuniformity. The tactile feedback system of the invention allows lens machine  10  to make a nearly perfect lens for each run of the machine. The same is true for any type of machining where measured force and a feedback loop are applicable. 
     Referring to FIG. 5, a control diagram is provided which will provide one of ordinary skill in the art with an enhanced understanding of the control operation of the invention. The control diagram comprises several information loops which together derive the benefits of the invention. Moving platform  20  is schematically shown at the right lower portion of the control diagram. Moving platform  20  is shown to be attached via articulated arm  18  to a lead screw  14  which is driven by a motor  60  (six of these arms and motors are preferred). Motor  60  is connected to an encoder  62  which measures motor movements to provide definitive position information regarding motor  60 . Encoder  62  provides digital information to PID calculation module  64  which then determines desired movement of motor  60  based first upon an overage of the sensors and then on a comparison for equality so that the precise force is known. The desired movement is also dictated by a computational loop discussed below. Communication of PID calculation module  64  proceeds to digital-to-analogue converter  66  which sends the analogue signal to servo amp  68  for driving motor  60 . The loop x described from encoder  62  to motor  60  is dubbed the operational loop  70 . Components of the operational loop are duplicated for each motor which in the preferred embodiment means that six loops are preferred. 
     Assisting in the provision of data to PID calculation module  64  is computational loop  72 . Loop  72  receives input from three lines  74 ,  76 , and  78  in digital format. Each of the lines has its own analogue-to-digital converter  80  (only one shown). Analogue-to-digital converter  80  receives information for the deflection-sensing subsystem of the invention, one sensor of which is illustrated here at  82 . Preferably three sensors are provided, one for each line ( 74 ,  76  and  78 ). The digital input of, for example, line  74  is received in computation module  84  where z, α and β, are calculated, tilt being equal or not to zero and θ being equal or not to zero. This information is also affected by the input of orbit parameters  86  which are preprogrammed. It is additionally affected by the calculated x and y coordinates module  88  for the next expected orbit. The calculation of x and y in module  88  is also provided with the PID calculation module  64  information from the previous command. Subsequent to each of the calculations noted, the calculated information is conveyed to converter  90  which converts desired x, y, z, α, β and θ to motor positions A,B,C,D,E,and F. This information is provided to PID  64  and the process continues. All of these functions and directions are effected, as stated above, approximately 2000 times per second. 
     While preferred embodiments have been shown and described, various modifications and substitutions may be made thereto without departing from the spirit and scope of the invention. Accordingly, it is to be understood that the present invention has been described by way of illustration and not limitation.