These machines inspect large batches of intraocular lenses as part of the lens manufacturer's certification process. The lenses replace the human eye's natural lenses in cataract surgery.

      I was in charge of the mechanical design for this entire project. I was given an optical layout with lenses, objectives, windows, water, apertures, targets, a mirror, filters, a lamp, and a CCD camera. There were motion requirements for speed, flatness, and repeatability, and the customer had several concerns for ease of use.

      I did the entire mechanical design except the enclosure. That included CAD layouts, a unique low cost approach to very flat open frame X-Y motion, multiple optical components moved with a stage, or air cylinders , a step by step procedure for aligning the optics, mechanical drawings, and electrical schematics.


      View a typical drawing of an optical part.


      A screen capture of the user interface shows a test pattern and how much motion control is possible.

Details:
-1000 x 1000 pixel camera with 1024 gray levels
-Inspects 60 lenses in 30 minutes
-Microscope supported by welded powder coated steel box structure
-Step motors and lead screws combined for unique telescoping mechanisms.
-Air bearings on granite for 5 micron flatness over large X-Y motion
-Numerous off the shelf electronic and pneumatic components
-2 bit binary motion mechanism for optical target selection.,
-Dell computer inside, keyboard, mouse and monitors on small table

Result:
One prototype and five production machines were built. The production machines at the customer's plant run 3 shifts, and have been running for 4 years with occasional replacement of bulbs, rheostats and CCD cameras.