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Critical Design Review 05/12/2006

Design a system reducing bubbles on lenses. Achieve 75% bubble reduction, integrate with production line later, comply with requirements.

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Critical Design Review 05/12/2006

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  1. Automated Bubble Elimination System#P06219 Critical Design Review05/12/2006 Team Members: Andrew Shabashevich, Greg Penoyer, Jessica Pierce, Tony Kukla, Bill Dugan, Gaurav Sanghi, Piyush Aggarwala Team Mentor: Dr. Edward Hensel Kate Gleason College of Engineering Rochester Institute of Technology

  2. Mission Statement • Design and build a stand-alone system to reduce the number of bubbles on a contact lens and in the water cell • 75% Bubble Reduction • Design the system with potential to be integrated into the automated production line (freedial) machine at a later date • Keep the same dimensional constraints • Keep the same power/operating sources • Operate within current cycle time • Comply with Wet Vision Inspection requirements

  3. Senior Design I Milestones • Conducted background research • Brainstormed for concepts • 10 initial concepts tested qualitatively • Chose 3 for quantitative tests in SD II • Ultrasound, Rotary Motion, Recirculation • Test with and without degassed water • Designed Test fixture

  4. Objectives for Senior Design II • Assemble/Install Test Fixture • Assess the 3 concepts in more detail: • DOE • Settling time/Time study • Cost Benefit Analysis • Quantitatively prove concept feasibility • Propose final solution to B&L

  5. Test Fixture Set-up Sliding Stage Water Cell

  6. Design Test Fixture • Test fixture used with Bausch & Lomb one-up vision inspection system stand • Fixture is modular to quantitatively test all final concepts • Fixture is easy to adjust and modify during testing

  7. Testing Procedure • Create bubbles on a contact lens • Take a before picture of the lens • Apply Test • Take an after picture of the lens • Run the images through wet vision inspection algorithm • Record bubble count and bubble area

  8. Rotary Motion Module Teflon Head Parameters Varied Water Cell

  9. Rotary Motion Testing Results Before Non degassed, De-ionized Water After Degassed, De-ionized Water

  10. Ultrasonic Module Ultrasonic Tip Parameters Varied Water Cell

  11. Ultrasound Testing Results Before Non degassed, De-ionized water Degassed, De-ionized water After Live Run with Degassed, De-ionized water

  12. Recirculation Module Inlet/Outlet Tubes Parameters Varied Water Cell

  13. Recirculation Testing Results Before Degassed, De-ionized water After

  14. Results – Percent Bubble Reduction

  15. Results – Bubbles Remaining on Lens

  16. Recirculation Rotary Motion Cost Benefit Analysis Ultrasound

  17. 15 Power (W) Time (s) 1 1.5 2 Recommendation • Ultrasound • Consistent bubble reduction: < 1 average bubbles per lens • Settling time < 1 sec • Less moving parts • Operating Conditions • Frequency – 20 kHz • Max. Power – 15 W • Tip Diameter – 14 mm • Concentric to the water cell • 0.25” below water line

  18. Deliverables • Method for eliminating over 99% of bubbles on a contact lens • Technical package • Background Research • Vender Research • CD package • Complete test data • Test fixture design package • Detailed feasibility test reports

  19. Questions? Acknowledgements: Matt Place – Bausch & Lomb Sponsor Kevin Beebe – Bausch & Lomb Sr. Process Engineer Travis Fisher – Bausch & Lomb Mechanical Engineer Tom Natalie – Bausch & Lomb Advanced Engineering Manager Prof. Edward Hensel– Mentor Prof. Satish Kandlikar– RIT Professor

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