Abrasive articles, systems, and methods of use

Abstract

An abrasive article evaluation system is presented that includes a camera that images an abrasive article. The system includes an efficiency indication generator that generates an indication of abrasive efficacy of the abrasive article based on the image. The system also includes a command generator that generates a command based on the generated abrasive efficacy indication.

Description

Background Art

[0001] Coated abrasive articles containing shaped abrasive grains can be used to shape, finish or grind a variety of materials and surfaces, such as wood, metal (e.g., particularly non-ferrous metals such as aluminum that tend to clog grinding wheels), and burrs. There is a constant need to improve the cost, performance and / or life of coated abrasive articles. Summary of the invention

[0002] An abrasive product evaluation system is presented, the abrasive product evaluation system including a camera for imaging an abrasive product. The system includes an efficiency indication generator that generates an indication of abrasive efficacy of the abrasive product based on the image. The system also includes a command generator that generates a command based on the generated abrasive efficacy indication.

[0003] A robotic grinding system is presented, the robotic grinding system including an abrasive article including abrasive particles in a bonding matrix. The system also includes a robotic arm configured to move one of the abrasive article and a substrate into position so that the abrasive article contacts the substrate. The system also includes a force control unit on the robotic arm. The force control unit applies a force to the abrasive article or the substrate. The system also includes an article evaluation system that images the abrasive article, evaluates the abrasive article, and based on the evaluation, generates updated operating parameters for the robotic grinding system.

[0004] Systems and methods for detecting when an abrasive article is nearing the end of its useful life are described herein. Some systems and methods herein can improve the use efficiency of an abrasive article as the abrasive particles wear away. However, the systems and methods herein are not limited to measuring the wear of abrasive particles. Detecting the wear of a resin matrix can also be useful, such as in nonwovens or bonded abrasive articles, where the entire article wears away during use. Some abrasive articles experience particle and resin wear down to the backing layer, which provides an opportunity for visual detection of changes.

[0005] Some systems and methods herein may be particularly useful for robotic grinding systems where a human operator cannot detect end of life by noticing changes in grinding efficiency. Additionally, some systems and methods herein may be used with handheld abrasive tools to help operators adjust tool usage parameters during grinding operations.

[0006] The above summary of the present disclosure is not intended to describe each disclosed embodiment or each implementation of the present disclosure. The following description more specifically illustrates exemplary embodiments. Therefore, it should be understood that the following description should not be construed as an undue limitation on the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Figure 1 is a schematic top view of an exemplary coated abrasive article.

[0008] Figure 2 is a schematic cross-sectional view of an exemplary coated abrasive article.

[0009] Figure 3 A robotic grinding system that may benefit from embodiments herein is shown.

[0010] Figure 4 A handheld grinding system that may benefit from embodiments herein is shown.

[0011] Figure 5 An abrasive article evaluation system according to embodiments herein is shown.

[0012] Figure 6 A method of evaluating the efficacy of an abrasive article according to embodiments herein is shown.

[0013] FIG. 7A to FIG. 7B Metal termination quantification according to embodiments herein is shown.

[0014] Figure 8 A method of evaluating metal termination according to embodiments herein is shown.

[0015] 9A to 9C A bearing area calculation according to embodiments herein is shown.

[0016] 10A-10B illustrate presenting bearing area calculations to an operator according to embodiments herein.

[0017] FIG. 11A to FIG. 11B The results of a computer vision algorithm applied to an image of an abrasive article are shown.

[0018] FIG. 12A to FIG. 12B The patterned abrasive article is shown before and after use.

[0019] Fig.13 It is the defect inspection system architecture.

[0020] Figures 14 to 16 An example of a computing device that may be used in the embodiments shown in the previous figures is shown.

[0021] Figure 17 to Fig. 20 An example of detecting and quantifying the efficacy of an abrasive article is shown.

[0022] Reference symbols used repeatedly in the specification and drawings are intended to represent the same or similar features or elements of the present disclosure. It should be understood that those skilled in the art can design many other modifications and embodiments that fall within the scope and essence of the principles of the present disclosure. The drawings may not be drawn to scale. DETAILED DESCRIPTION

[0023] Throughout this document, values ​​expressed in a range format should be interpreted in a flexible manner to include not only the values ​​explicitly listed as the limits of the range but also all individual values ​​or subranges encompassed within the range, as if each value and subrange were explicitly listed. For example, the range "about 0.1% to about 5%" or "about 0.1% to 5%" should be interpreted to include not only about 0.1% to about 5%, but also individual values ​​(e.g., 1%, 2%, 3% and 4%) and subranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. Unless otherwise indicated, the expression "about X to Y" has the same meaning as "about X to about Y". Similarly, unless otherwise indicated, the expression "about X, Y or about Z" has the same meaning as "about X, about Y or about Z".

[0024] In this document, unless the context clearly indicates otherwise, the terms "a", "an", or "the" are used to include one or more than one. Unless otherwise indicated, the term "or" is used to refer to a non-exclusive "or". The expression "at least one of A and B" has the same meaning as "A, B, or A and B". In addition, it should be understood that the words or terms used herein and not otherwise defined are for illustrative purposes only and are not limiting. Any use of section headings is intended to facilitate understanding of the document and should not be construed as limiting; information related to a section heading may appear within or outside that particular section.

[0025] In the methods described herein, except where a time or sequence of operations is explicitly enumerated, various actions may be performed in any order without departing from the principles of the present disclosure. In addition, specified actions may be performed simultaneously unless explicit claim language implies that they are performed separately. For example, a claimed action of performing X and a claimed action of performing Y may be performed simultaneously in a single operation, and the resulting process will fall within the literal scope of the claimed process.

[0026] As used herein, the term "about" can allow, for example, a certain degree of variability in a value or range, such as within 10%, within 5%, or within 1% of the stated value or limit of the stated range, and includes the exactly stated value or range.

[0027] As used herein, the term "substantially" refers to a majority or majority, such as at least about 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, 99%, 99.5%, 99.9%, 99.99%, or at least about 99.999% or more, or 100%.

[0028] As used herein, the term "shaped abrasive grains" means that at least a portion of the abrasive grains has a predetermined shape, and the predetermined shape is replicated by the mold cavity for forming the shaped precursor abrasive grains. Except in the case of abrasive fragments (e.g., as described in U.S. Patent Application Publications 2009 / 0169816 and 2009 / 0165394), the shaped abrasive grains will generally have a predetermined geometry that roughly replicates the mold cavity for forming the shaped abrasive grains. As used herein, the shaped abrasive grains do not include the abrasive grains obtained by mechanical crushing operations. Suitable examples of the geometry with at least one top include polygons (including equilateral, equiangular, star-shaped, regular and irregular polygons), lens shapes, half-moon shapes, circular shapes, semicircular shapes, elliptical shapes, circular sectors, circular arcs, drop shapes, and hypocycloids (e.g., superelliptical).

[0029] For the purposes of the present invention, geometric shapes are also intended to include regular or irregular polygons or stars, wherein one or more sides (peripheral portions of the faces) may be arcuate (either towards the inside or towards the outside, wherein the first alternative is preferred). Thus, for the purposes of the present invention, triangular shapes also include three-sided polygons wherein one or more sides (peripheral portions of the faces) may be arcuate. The second side may include (and preferably is) a second face. The second face may have an edge of a second geometric shape.

[0030] For purposes of the present invention, shaped abrasive grains also include abrasive grains with faces of different shapes, for example, on different faces of abrasive grains. Some embodiments include shaped abrasive grains with opposite sides of different shapes. Different shapes can include the difference of the surface area of ​​two opposite sides, for example, or the different polygonal shapes of two opposite sides.

[0031] The shaped abrasive particles are typically selected to have an edge length in the range of 0.001 mm to 26 mm, more typically 0.1 mm to 10 mm, and more typically 0.5 mm to 5 mm, although other lengths may be used.

[0032] The shaped abrasive particles may have a "sharp portion", which is used herein to describe a sharp tip or sharp edge of an abrasive article. The sharp portion can be defined using a radius of curvature, and in the present disclosure, for a sharp point, the radius of curvature is understood to be the radius of the arc of the curve that is closest to the point. For a sharp edge, the radius of curvature is understood to be the radius of curvature of the profile of the edge on a plane perpendicular to the tangent direction of the edge. In addition, the radius of curvature is the radius of the circle that best fits the average value of the normal section or measured section along the length of the sharp edge. The smaller the radius of curvature, the sharper the sharp portion of the abrasive particle. Shaped abrasive particles with a sharp portion are defined in U.S. Provisional Patent Application Serial No. 62 / 877,443, filed on July 23, 2019, which is hereby incorporated by reference.

[0033] In the case of abrasive particles being precisely shaped (e.g., precisely shaped into triangular flakes or pyramidal particles), this orientation effect may be particularly important, as described in U.S. Patent Application Publication No. 2013 / 0344786A1 (Keipert), which is incorporated herein by reference. As used herein, the term "alignment" is used to refer to the relative position of abrasive particles on a backing, while the term "orientation" refers to the rotational position of abrasive particles at the aligned position. For example, a triangular particle may have an orientation of "tilting upward" or an orientation of "tilting downward" relative to the backing.

[0034] As used herein, the term shaped abrasive grain refers to a monolithic abrasive grain. As shown, the shaped abrasive grain contains no binder and is not an agglomerate of abrasive grains held together by a binder or other adhesive material.

[0035] Described in this embodiment are abrasive articles that include wear indicators or other abrasive efficiency indicators. Some exemplary embodiments are described in the context of a particular abrasive article type, such as a bonded grinding wheel or a coated fiber disc. However, it is expressly contemplated that at least some of the efficiency indicators herein are applicable to a variety of types of abrasive articles, and the figures and examples described herein are not intended to be limiting.

[0036] Additionally, with respect to coated abrasive articles, many of the examples herein specifically discuss abrasive discs. However, it is expressly contemplated that abrasive belts may also benefit from the efficacy indicators described herein.

[0037] In addition, with respect to bonded abrasive articles, some examples of grinding wheels are described herein. However, it is clearly contemplated that wear indicators applicable to some abrasive articles may be applicable to other abrasive articles. Bonded abrasive articles may use a vitreous, resinous, or polymer-based bonding matrix. Bonded abrasive structures may include depressed center grinding wheels, cut-off grinding wheels, cut-off grinding wheels, precision bonded grinding wheels, cup wheels, segmented grinding wheels, and the like.

[0038] Figure 1 and Figure 2 An exemplary coated abrasive disc 100 according to the present disclosure is shown with shaped abrasive particles 130 secured to a backing 110 in a precise position and Z-axis rotational orientation. In one embodiment, the shaped abrasive particles 130 are triangular prism-shaped particles that appear rectangular when viewed from above.

[0039] Generally speaking, the coated abrasive article 100 includes a plurality of abrasive particles embedded in a make coat, the make coat securing the particles to a backing. For example, the backing can be formed from any known flexible coated abrasive backing. Suitable materials for the backing include polymer films, metal foils, woven fabrics, knitted fabrics, paper, nonwovens, foams, screens, laminates, combinations thereof, and processed versions thereof.

[0040] Abrasive particles 130 may be embedded in an abrasive layer, which may include a multilayer construction having a make layer 120 and a size layer 140. If desired, a coated abrasive article according to the present disclosure may include additional layers, such as, for example, an optional top size layer superimposed on the abrasive layer, or a backing antistatic treatment layer if desired. Exemplary suitable binders may be made from heat curable resins, radiation curable resins, and combinations thereof.

[0041] The primer layer 120 can be formed by coating a curable primer layer precursor onto the main surface of the backing 110. The primer layer precursor may include, for example, glue, phenolic resin, aminoplast resin, urea-formaldehyde resin, melamine-formaldehyde resin, urethane resin, multifunctional (meth) acrylates that can be polymerized in a free radical manner (e.g., aminoplast resins with pendant α, β-unsaturated groups, acrylated urethanes, acrylated epoxy resins, acrylated isocyanurates), epoxy resins (including bis-maleimide and fluorene-modified epoxy resins), isocyanurate resins, and mixtures thereof. Among these, phenolic resins are preferred.

[0042] Generally speaking, phenolic resins are formed by the condensation of phenol and formaldehyde, and are generally classified as resol or novolac phenolic resins. Novolac phenolic resins are acid catalyzed and have a molar ratio of formaldehyde to phenol of less than 1:1. Resole / resol phenolic resins may be catalyzed with an alkaline catalyst and have a molar ratio of formaldehyde to phenol of greater than or equal to one, typically between 1.0 and 3.0, so that hydroxymethyl side groups are present. Alkaline catalysts suitable for catalyzing the reaction between the aldehyde and phenol components of resol phenolic resins include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, and sodium carbonate, all as catalyst solutions dissolved in water.

[0043] Resols are typically applied as solutions with water and / or organic solvents (e.g., alcohols). Typically, the solution contains about 70% to about 85% solids by weight, but other concentrations may be used. If the solids content is very low, more energy is required to remove the water and / or solvent. If the solids content is very high, the viscosity of the resulting phenolic resin is too high, which typically leads to processing problems.

[0044] Phenolic resins are well known and readily available from commercial sources. Examples of commercially available resol phenolic resins that can be used to practice the present disclosure include those sold by Durez Corporation under the trade name VARCUM (e.g., 29217, 29306, 29318, 29338, 29353); those sold by Ashland Chemical Co., Bartow, Florida, under the trade name AEROFENE (e.g., AEROFENE 295); and those sold by Kangnam Chemical Company Ltd. of Seoul, South Korea under the trade name PHENOLITE (e.g., PHENOLITE TD-2207).

[0045] The make layer precursor may be applied by any known coating method for applying a make layer to a backing including methods such as, for example, roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

[0046] The basis weight of the make coat used may depend, for example, on the intended use, the type of abrasive grains, and the nature of the coated abrasive article being prepared, but will typically range from 1, 2, 5, 10, or 15 grams per square meter (gsm) to 20, 25, 100, 200, 300, 400, or even 600 gsm. The make coat may be applied by any known coating method for applying a make coat (e.g., a make coat) to a backing, including, for example, roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

[0047] Once the make coat precursor is coated on the backing, the triangular abrasive particles are applied to the make coat precursor and embedded therein. The triangular abrasive particles are nominally applied to the make coat precursor according to a predetermined pattern and Z-axis rotational orientation. Using known orientation methods, such as electrostatic or magnetic orientation, the abrasive particles can be oriented relative to the backing to improve the performance of the particles.

[0048] However, although Figure 1 to Figure 2 Coated abrasive articles are shown, but it is expressly contemplated that the systems and methods herein may also be applicable to understanding the use and wear of other abrasive articles, such as bonded abrasive articles having a resinous or vitreous bond matrix, nonwoven abrasive articles, brushes, or other abrasive articles.

[0049] Abrasive articles can be used in many contexts. This article describes the robotic repair context ( Figure 3 ) and hand tool background ( Figure 4). Over time, different use scenarios for abrasive articles can present different issues with the use of the article. For example, an experienced human operator can often "feel" that an abrasive article is losing cutting effectiveness over time and adjust accordingly by applying more force or adjusting the angle. The systems and methods herein can allow a human operator to understand how close an abrasive article is to the end of its useful life.

[0050] The robotic system may not have insight into the wear or load occurring on the abrasive article and may not be able to make necessary adjustments, or replace the abrasive article without intervention when necessary. For example, using a known abrasive wear rate, process parameters may be modified to maintain abrasive efficacy throughout the useful life of the abrasive article. The systems and methods herein are also useful in other contexts.

[0051] Figure 3 is a schematic diagram of a robotic arm that may benefit from the embodiments disclosed herein. In some embodiments, the robotic repair unit 200 has a base 210, which may be fixed. In other embodiments, the base 210 may move in any of six dimensions, translation, or rotation around an x-axis, a y-axis, and / or a z-axis. For example, the robot 200 may have a base 210 fixed to a track system that is configured to travel with a moving substrate being repaired. Depending on the particular operation, the robot 200 may need to move closer to or farther away from the substrate, or may need to move higher or lower relative to the grinding area. Thus, a movable base 200 may increase functionality.

[0052] The robotic arm unit 200 has one or more tools 240 that can interact with the work surface. In one embodiment, the tool 240 may include a support pad 250, or another suitable abrasive tool. During abrasive operation, the tool 240 may have an abrasive disc or other suitable abrasive article that is attached using an adhesive, hook and loop, clamp system, vacuum or other suitable attachment system. However, when the abrasive article moves in conjunction with the support pad 250 to which it is attached, the abrasive article is not necessarily considered to add additional degrees of freedom to the movement of the robotic repair unit 200. When mounted to the robotic repair unit 200, the tool 240 has the ability to be positioned within the degrees of freedom provided by the robotic repair unit 200 (6 degrees of freedom in most cases) as well as any other degrees of freedom (e.g., compliance control 230 unit).

[0053] Support pads 250 are coupled to tool 240 which has tracks that provide some additional degrees of freedom. In most tools, a single degree of freedom is provided by a rotational axis with or without some offset. Tool 240 is coupled to force control 230 unit output. Force control flange 230 provides a soft (i.e., non-rigid) displacement curve. In most force control units, a single degree of freedom is provided by a sliding (prismatic) joint along an axis of motion. Force control 230 is coupled to flange 220. Movement of components 210, 220, 230, 240, and 250 can all be controlled using a robotic controller (e.g., robotic controller 270).

[0054] In addition to moving the components 210-250 based on the parameters of the grinding operation, the robot controller 270 can also adjust the parameters based on the information received from the abrasive article use evaluation 260. For example, if the evaluation system 260 indicates that the abrasive article has reached the end of its life, the controller 270 can instruct the system 200 to stop the grinding operation, replace the old abrasive article with a new abrasive article, and then continue the grinding operation. In addition, for example, the controller 270 can provide new grinding parameters based on feedback from the system 260. For example, if the abrasive article is loaded, the controller 270 can increase the coolant flow to flush the accumulated chips. If the abrasive article is blocked, the controller 270 can start a dressing process to reduce the detected metal blocking. If the abrasive article is worn, but not at the end of its life, the controller can increase the force applied by the force control unit 230, or can adjust the angle of the tool 240 relative to the substrate. Such adjustments are described in more detail with reference to later figures.

[0055] Figure 4 A hand tool 300 is shown that can be used by a human operator during a grinding operation. The tool 300 includes an abrasive article 310 coupled to a support pad 312. The tool can be manipulated by a human operator so that the angle of the abrasive article 310 is adjustable. The applied force can also be adjustable, such as by tilting the human operator.

[0056] While an experienced human operator may be able to adjust operating conditions based on the "feel" of the grinding operation, at least some operators may benefit from the evaluation system 320. The abrasive article evaluation system 320 may detect the use condition of the abrasive article 310, and the evaluation communicator 330 may communicate the wear condition or operating condition of the abrasive article to the human operator. For example, the tool 300 may include a display that provides instructions to the human operator—for example, based on an internal gyroscope or accelerometer, the tool may guide the user to adjust the angle of the tool relative to the surface. In other embodiments, the communicator 330 may display the results, instructions, or suggestions on a display associated with the human operator—such as a display on protective equipment worn by the user (e.g., an augmented reality overlay provided on a head-up display or safety glasses) or a display in the area. The communicator 330 may also communicate the results in another manner, such as by auditory means, or simply by indicating that the abrasive article is acceptable for continued use or unacceptable for continued use.

[0057] Systems and methods for evaluating abrasive articles are described herein. Abrasive articles may be associated with a robotic grinding system, such as Figure 3 As shown, or it can be a manually operated tool, such as Figure 4 As shown. Evaluating an abrasive article is broadly used to refer to evaluating parameters related to the abrasive efficiency of an abrasive article. Wear can affect abrasive efficacy - as the article is used and the particles gradually wear out, the cut rate will decrease. However, abrasive efficacy may also be affected by other factors that can be detected using the systems and methods herein. For example, metal capping or loading may occur, causing the abrasive particle tips to be covered and unable to grind. Other efficacy factors may also be detected.

[0058] Figure 5 An abrasive article evaluation system according to an embodiment of the present invention is shown. The abrasive article evaluation system 500 is suitable for an abrasive article 502. For example, a robotic arm can move the abrasive article 502 within the range of the detector 502 with a prompt capture device 522. In some embodiments of the present invention, the prompt capture device 522 is a camera or other image capture component that images the abrasive article 502. In other embodiments, the prompt capture device 522 is a sensor that captures another signal, such as sound, vibration, weight, thickness, or another parameter of the abrasive article 502 as described in the embodiments of the present invention. In the embodiment where the prompt capture device 522 is a camera, the detector 520 may also have a light source 524. The light source can provide illumination in the visual spectrum, ultraviolet spectrum, infrared spectrum, or another wavelength suitable for detecting the prompt 510.

[0059] As described herein, the abrasive article 502 includes a cue 510 that can be detectable by a sensor 522. The cue can be incorporated into the abrasive article 502, the backing 514, or particles 512 within a resin structure or another component 516 of the abrasive article. The detectable cue 510 can be a visual indication 504, an audible indication 506, or another cue 508. For example, the cue 510 can be a detectable weight loss or shrinkage of the abrasive article 502 that can be detected by a scale or caliper.

[0060] The detector 520 may be stationary, such that a robotic arm or human operator brings the abrasive article 502 into range of the cue capture device 522. In other embodiments, the detector 520 is mobile, with a mobile controller 525 that can move the cue capture device 522, light source 524, or other component 529 to a position to detect the cue 510. The detector 520 may use a detection indication communicator 528 to transmit the signal generated by the cue capture device 522. However, it is expressly contemplated that while the detector 520 may be Figure 5 5 is shown as being separate from the controller 540 that performs the evaluation, but in some embodiments it may be a single component.

[0061] The controller 540 receives detection indications from the detector 520 using the detector indicator retriever 558. The detection indicator retriever 558 may request indications from the detector 520 in response to the detector actuator 556, which may send a command to the detector 520 to actuate the cue capture device 522. In some embodiments, the trigger 554 may cause the detector actuator 556 to actuate. For example, the motion detector 554 may detect that the abrasive article 502 has been moved into position. The trigger 554 may also be based on time or position.

[0062] The instruction processor 562 processes the received signal from the detector 520. As described herein, this may include comparing the received signal to a threshold value, retrieving it against a historical signal value retrieved from a data storage device by a historical value retriever 544, or otherwise processing the signal to determine whether the abrasive efficacy of the product 502 has reached an undesirable low value. As described in more detail herein, the instruction processor 562 may also perform processing steps, such as applying machine learning to the detected prompts. For example, the instruction processor 562 may process a captured image of the abrasive product 502 to assess the amount of metal capping that has accumulated on the surface of the abrasive product or the amount of bearing area available for the next abrasive operation, or apply pattern recognition technology to determine the wear of the patterned abrasive. When metal adheres to abrasive grains, for example due to overheating and / or insufficient pressure, metal capping occurs. Metal capping prevents the abrasive particles from breaking, which allows the abrasive particles to sharpen themselves again.

[0063] The indication processor 562 may be evaluated against a threshold set by the manufacturer, customer, operator, shift supervisor, etc. For example, one customer may set the minimum acceptable efficacy of the abrasive disc to E, while another customer sets the threshold to ET.

[0064] In some embodiments, the controller 540 may determine that, although the abrasive efficacy has dropped below the threshold, it is possible to improve by changing one or more operating parameters. The parameter retriever 542 may retrieve a current set of operating parameters-such as the applied force from the force control unit, the grinding angle from the accelerometer, etc. The command generator 546 may generate a command, such as to the robot arm controller to adjust the applied force or angle, and then use the command communicator 548 to transmit the command to the robot arm controller. The command generator 546 may also generate a command to replace the abrasive article 502 with a new abrasive article, or to re-dress the abrasive article 502 to remove the load or metal end. In some embodiments, the command generator 546 and the command communicator 548 may operate automatically so that the robot controller continuously adjusts the parameters to improve the grinding efficacy.

[0065] The efficacy indication generator 564 generates an indication of the grinding efficacy of the abrasive article 502. The indication may be displayed, for example, on a display member 590. The indication may be provided in words, such as "60% used" or "Metal capping detected," or may be provided simply as "good" or "bad." The indication may be audible, such as an alarm or signal, indicating that action is needed to improve grinding efficacy or replace the abrasive article 502. The indication may be provided to a graphical user interface generator 552, which may generate an interface for the display member 590. The controller 540 may also have other functions 566.

[0066] In some embodiments, the display component 590 may be incorporated into the hand tool so that the efficacy indication 592 is visible to the user of the hand tool. In other embodiments, the display component 590 is separate from the tool. For example, in a robotic grinding context, the display component 590 may be separate from the robot arm, but visible to the operator. In some embodiments, the display component 590 is part of a mobile computing device, such as an operator's mobile phone or tablet. The GUI generator 552 may then send an indication to an application running on the device so that the efficacy indication 592 may be updated.

[0067] The display component 590 may also present parameter changes 594, such as adjustments to the tool angle, increases or decreases in applied force, etc. A change in usage 596 may also be indicated. For example, a coated abrasive article that has experienced significant wear may no longer be suitable for the initial high-volume grinding removal step of a process, but may be suitable for subsequent low-volume grinding removal steps. The display component 590 may also provide other information 598 received from the controller 540, the detector 520, or elsewhere. For example, a unit count of completed parts, average grinding time, or other relevant information may be displayed.

[0068] System 500 Figure 5 590, however, it is expressly contemplated that a single computing unit may include some or all of the components of the display component 590 and the system 500. For example, the detector 520 and the controller 540 are shown as part of a single unit, however, it is expressly contemplated that at least some of the components may be part of separate devices. For example, the controller 540 may be part of a robot arm controller and be a separate computing device remote from the detector 520 and the display component 590.

[0069] Figure 6 A method of evaluating an abrasive article is shown. In some embodiments, the evaluation can be automated using method 600. For example, a robotic arm or a human operator can move the abrasive article within or past a detector that can capture a signal indicative of the abrasive article's grinding efficacy.

[0070] In block 610, an abrasive article is mounted on a tool. For example, the abrasive article may be coupled to a support pad on a handheld abrasive tool, or to a tool coupled to a robotic grinding unit. The abrasive article may be any suitable abrasive article for a given grinding operation, such as a coated abrasive article, a bonded abrasive article, a bristle brush, or another suitable abrasive article.

[0071] In block 620, the abrasive article engages the workpiece and performs a grinding operation. As the workpiece is ground, the abrasive grains of the abrasive article experience wear. They may also experience metal termination, loading, or other degradation.

[0072] In block 630, the abrasive article is evaluated. The abrasive efficacy of the abrasive article is determined. In some embodiments, visual cues 632 may be analyzed to detect wear, metal capping, or loading. Auditory cues 634 may be analyzed to detect wear, metal capping, or loading. In other embodiments, different detectors 636 detect cues of abrasive efficacy.

[0073] Evaluation of abrasive articles can be accomplished by directly measuring parameters of the abrasive article during or after the abrasive operation, such as visual markers, sounds, or other markers of the abrasive article. In other embodiments, evaluation of abrasive articles can be accomplished by evaluating a workpiece, a swarf removed from a workpiece, or another component. Evaluation can also include processing an image of the surface of the abrasive article to determine load, metal capping, available bearing area, wear, or another parameter that affects abrasive efficacy.

[0074] The evaluation in block 630 can be done automatically as part of the grinding process. For example, a robotic arm coupled to the abrasive article can change position, such as when a finished workpiece is replaced by a new workpiece, so that the abrasive article is within the range of the detector. Similarly, when a human operator changes a part to be ground or completes another task, the human operator can place the abrasive tool coupled to the abrasive article in a position within the range of the detector.

[0075] In box 642, if the abrasive efficacy of the abrasive article is still at an acceptable level, it can continue to be used for another abrasive operation. In some embodiments, new operating parameters are provided based on the reduction in abrasive efficacy detected between evaluations. In a robotic grinding operation, the new parameters can be automatically implemented. In the context of a handheld tool, new parameters can be suggested to the operator.

[0076] In block 644, if the abrasive efficacy is below an acceptable level, then processing may be performed as indicated in block 650, such as by conditioning the abrasive article to remove metal capping, washing or cleaning the abrasive article to remove loading. However, in some embodiments, method 600 returns to block 610.

[0077] Described herein in Figures 7 to 12 are examples and embodiments of the present invention in which the detected abrasive efficacy indication is actually visible. However, it is clearly contemplated, and described in both co-pending applications 63 / 366,805 and 63 / 366,802 filed on June 22, 2022, that other abrasive efficacy cues are possible.

[0078] FIG. 7A to FIG. 7B Metal termination quantification according to embodiments herein is shown. Fig. 7AAn image 700 of a captured abrasive article surface is shown, in which abrasive particles can be seen, wherein the tips are exposed through the resin layer. Metal caps 710 can be seen on some of the tips. Metal caps are a common phenomenon caused by metal deposition on abrasive grains, such as in stainless steel grinding operations. Metal caps reduce abrasive effectiveness because the sharp tips of the abrasive particles are covered. Metal caps can be removed or reduced by re-dressing the abrasive article to remove the metal caps. In addition, in future operations, metal caps can be reduced by adjusting parameters, for example, causing the robotic grinding system to increase the applied force to promote the breakage of the abrasive particles.

[0079] Figure 7B A processed image 720 obtained from image 700 is shown. Metal capping 730 causes reflectivity. Areas showing high reflectivity in the abrasive article photograph are good indicators of metal capping areas. When the image is converted to binary, the metal capping is more clearly shown. Once converted to binary, the capping particles 730 appear in black relative to the white background. Then, by comparing the amount of black in the image to the total area of ​​the image, the percentage of abrasive articles that are metal capped can be calculated. The amount of metal capping can increase over time, and when the abrasive article reaches a degradation threshold, an alarm can be generated to: replace the abrasive article, recondition the abrasive article, or adjust operating parameters to increase the abrasive efficacy of the abrasive article.

[0080] The initial image 700 can be captured using any suitable camera. In some embodiments, an additional light source is provided to increase the reflectivity of the capped particles. In some embodiments, the image is underexposed. In some embodiments, exposure and contrast are adjusted to make the binary conversion accurate and avoid erroneous data points.

[0081] In embodiments where the grinding operation is a robotic grinding operation, the camera is mounted on a robotic arm so that the abrasive article can be imaged between grinding operations. However, it is expressly contemplated that the camera can also be positioned elsewhere, such as on a separate robotic system, on a mobile detection system, or on a fixed detector. For example, a fixed camera can image a rotating belt and compare it to a static image, thereby allowing correlation and enabling dynamic characterization of the belt.

[0082] Metal cap detection also aids in handheld abrasive operations. An operator may capture images of the abrasive article between abrasive operations, such as using a mobile computing device (e.g., a smartphone, tablet, etc.) or by passing the abrasive article in front of a camera located near the grinding operation area. Other suitable image capture systems and techniques are also contemplated.

[0083] Abrasive articles may also be modified to improve metal termination detection. For example, a black or other dark colored oversizing or topsizing resin will increase the contrast between the terminated particles and the unterminated abrasive article. Currently, many manufacturers use coloring in the resin layer to easily distinguish brands, and in some cases, to distinguish grades of abrasive particles in abrasive articles. In addition, additives may be included in the abrasive article to increase reflectivity. For example, glass beads or other reflective materials may be included in the base or topsizing layer of the coated abrasive article so that when the abrasive article is gradually ground, the reflective material is exposed and the reflectivity increases. In some embodiments, the reflective material may be provided as a backfill or embedded in the backing as appropriate.

[0084] Figure 8 A method for evaluating metal capping according to an embodiment of the present invention is shown. As described above, metal capping reduces grinding efficiency. However, metal capping can be removed by re-dressing the abrasive article. Therefore, it is important to identify when metal capping occurs so that it can be removed and the abrasive article can be used throughout its potential service life. Method 800 can be implemented to automatically evaluate abrasive articles, such as between abrasive operations. In particular, for the robotic abrasive industry, it would be particularly useful if method 800 could be completed without increasing the total cycle time of the abrasive operation. However, method 800 is also useful for the hand tool industry as long as the evaluation can be completed without interrupting the operator's process.

[0085] In block 810, an abrasive article is mounted on a tool. The tool may be a handheld tool, wherein the abrasive article is mounted by an operator. However, it may also be an abrasive article mounted on a robotic grinding machine. The abrasive article may be mounted automatically, for example in response to an indication that the abrasive article has reached the end of its life or needs to be reconditioned at a different station.

[0086] In block 820, the abrasive article is used to abrade a workpiece. The abrasive article is brought into contact with a substrate at a rotational speed under an applied force and for a dwell time selected for the abrasive operation. In the context of robotics, the applied force, speed, and dwell time may be selected or adjusted, for example, based on a known amount of wear or metal capping of the abrasive article, as described herein.

[0087] The abrasive article is imaged in block 830. The imaging step can be accomplished, for example, between grinding operations while the tool is moving from a first substrate grinding position to a second grinding position.

[0088] In block 840, the image is processed to quantify reflectance. Although conversion to binary is described herein as one method of processing, it is expressly contemplated that any suitable processing that increases contrast and enables quantization of reflectance is suitable.

[0089] This article describes a method of converting an image into binary. However, it is contemplated that other methods are possible, such as image processing using an RBG filter to remove pixels above a threshold RBG value. For example, in an abrasive article with blue abrasive particles and red size resin, any portion of the image returning pure white may indicate metal termination. The percentage of white area to total area can then be used to estimate metal termination.

[0090] In block 850, the abrasive efficacy is quantified. General wear and tear as well as metal capping or loading can affect abrasive efficacy. In the binary example provided above, quantifying the metal capping includes estimating the area showing "black" versus the total area expected to contain the abrasive particle tips. To determine end of life, or whether the article needs to be reconditioned, it is sufficient to compare the amount of "black" (capping) area versus the total area.

[0091] In block 860, the abrasive article is evaluated. This may include evaluating the quantified metal capping against a threshold value to determine whether re-dressing is appropriate or would improve grinding efficacy. The evaluation may also include more generally evaluating the wear of the abrasive disc to determine whether the disc is worn beyond a threshold value at which re-dressing would increase efficacy enough to be worthwhile.

[0092] In box 870, if the metal cap is low enough, the abrasive article can be used for the next abrasive operation. In box 860, the evaluation may also include estimating the wear or metal cap so that a new set of operating parameters can be provided to improve the effectiveness of the abrasive article. For example, as shown in box 890, the abrasive article may not have enough metal cap to prove that it is correct to be sent to a re-dressing station, but it may have enough wear so that the grinding effect will increase with higher force, faster speed or different angle. In some embodiments, in box 860, the metal cap and wear can be evaluated in the same step. As described herein, the wear can be evaluated using the same image captured as the image for evaluating the metal cap, or by using another method described in U.S. patent application 63 / 366,805 or 63 / 366,802 filed with this document.

[0093] In block 880, if the metal cap has reached the re-dressing threshold, it is sent to a re-dressing station for a re-dressing operation. Re-dressing may include grinding the abrasive article against the re-dressing substrate to remove the metal cap. Figure 8 As shown by the arrow in , it may also be necessary to replace the abrasive article with a new abrasive article. For example, if re-dressing will cause the grinding effect to drop below a suitable threshold due to wear, the abrasive article should be replaced.

[0094] 9A to 9C The bearing area calculation is shown. Fig. 9AThe bearing area and cut rate of the abrasive article are shown over the life of the abrasive disc, as measured during the abrasive stroke on the substrate. Fig. 9B A graph of projected bearing area versus cutting rate per pass is shown. Fig. 9C A table is shown which shows how the disc thickness changes as the disc is used. The change in thickness is significant but not easily measured by the human eye. An ultrasonic caliper is used to obtain Fig. 9C Depending on the application, different tip thicknesses can determine when an abrasive article has reached the end of its life.

[0095] However, the bearing area can also be measured by analyzing the measurement of the height of the abrasive disc surface over a specified area, or the projected area of ​​contact parallel to the surface being abraded. The images can be obtained using structured light microscopy, where the structured light helps to reduce shadows in the image. However, it is possible to determine the bearing area using 3D profilometry, for example using structured light microscopy.

[0096] First, a 3D profilometry scan of a portion of the abrasive disc surface is captured, for example using a structured light microscope. The bearing area at a specific depth of cut (20 microns is used in FIG. 9 ) is then calculated by integrating the xy area occupied by z heights more than 20 microns below the highest z height on the scan. The highest z height is determined by taking the median of the first 5 median heights to minimize the effect of outliers. To determine the bearing area over the life of the disc, the process is repeated on the same portion of the abrasive disc after several grinding passes on the substrate.

[0097] During abrasive operation, when parts of the disc (including abrasive particles) are exposed, contact the surface, and break / wear off, the bearing area fluctuates. As the surface changes, the bearing area also changes. Figures 10A to 10B show images that can be collected and / or presented to the operator during the evaluation process. Figures 10A to 10B show an embodiment in which a user interacts with the image through a graphical user interface on a smart phone display. However, it is clearly conceivable to view the image on a laptop, desktop, tablet or other display. In addition, although images are shown in Figures 10A to 10B, it is clearly conceivable that text information can be displayed instead of images. The image can be analyzed and the metal end / bearing area can be calculated without any instructions to the operator until action is needed to re-dress or replace the abrasive product.

[0098] Figure 10A-1 , Figure 10A-2 and Figure 10A-3 The first time the abrasive article is captured, Figure 10B-1 , Figure 10B-2 and Figure 10B-3A second time point of the same abrasive article is captured. A first image of the abrasive article is captured. As shown in the second image, a zoomed view may be provided to the operator to see individual abrasive particles so that metal capping or wear may be seen. However, such a view is not necessary for analysis. A third view presents a binary view and an estimate of the currently detected metal capping or wear.

[0099] 10A-10B illustrate a coated abrasive article undergoing wear over time. For bonded abrasive articles, wear needs to be measured differently because as the first layer of the abrasive article wears away, new particles are exposed in the underlying layer.

[0100] In addition, although Figures 10A to 10B show a method of determining wear by measuring the exposed particle area, it is clearly conceivable that another trigger may indicate the end of life. For example, a precisely formed grain may be designed to break at a predictable rate, and the breakage produces a new sharp tip that can effectively grind the surface. Although the area of ​​the exposed particle is an indication of wear, it is not necessarily completely related to the end of life. It is also possible to find other hints through image analysis, such as visible production coatings, filler particles, or backings. For example, when a coated abrasive article is treated with a primer resin or a pre-tape, pigments of different colors may be present. In a bonded abrasive article, a scrim may become visible or detectable.

[0101] The level of wear can be determined by counting the number of pixels predicted to be PSG. It can be seen that as the abrasive is used, more PSG is exposed from beneath the resin coating. When particle breakage occurs, the surface area of ​​the PSG changes significantly.

[0102] The process of detecting and estimating the area of ​​exposed particles can be fully automated. There are three categories of approaches that can be used to solve this problem: traditional machine learning, convolutional neural networks, or more traditional rule-based computer vision algorithms. The decision on which algorithm should be used will be based on the amount of data available for processing and the level of accuracy required to provide value to the user.

[0103] A machine learning based classifier (e.g., a conventional or convolutional neural network) can automatically identify exposed abrasive particles within the captured image. Figure 10A-2 and Figure 10B-2, a traditional machine learning algorithm can be trained to extract features from the image to characterize each pixel. One parameter of interest is color, since the abrasive grains are often a different color than the resin covering them. Other features, such as shape, structure, and texture may also be informative. In the case of traditional machine learning methods, SVMs or random forests can be trained to make such decisions (other options may also be appropriate). When the combination of features is properly trained, the classifier may be able to quantify the wear of the particles while capturing the availability of the remaining sharp tip.

[0104] The images used to assess wear may be obtained from, for example, a mobile phone assigned to an operator or any suitable imaging device. The image variability between different cameras may vary, but algorithms may be developed to compensate for this variability.

[0105] In a handheld context, the lighting conditions may vary from image to image. It is recommended that the abrasive article be imaged in a consistent lighting environment, such as using a mobile phone in a hood or other controlled environment. In a robotic context, it is preferred that the abrasive article be imaged in a consistent setup - such as the robot being in the same orientation relative to the lighting.

[0106] The camera should be calibrated to take accurate images. In the case of using a smartphone, it may be helpful to calibrate the evaluation algorithm using a calibration card with a sample of exposed abrasive on one side and resin on the other side, which may improve accuracy.

[0107] FIG. 11A to FIG. 11B The results of a computer vision algorithm applied to an image of an abrasive article over time are shown, showing how the segmentation algorithm extracts abrasive grains within the photograph. As shown, as the cycle index increases, more exposed grains can be detected. Fig. 11B A graph showing the abrasive grains exposed in each captured image illustrates how more abrasive grains are exposed over time.

[0108] For bearing area calculations, it may be beneficial to use structured light to fully capture the 3D aspects of the abrasive article surface.

[0109] FIG. 12A to FIG. 12B An image of an abrasive article surface is shown. The surface is a 363FC abrasive belt with TRIZACT TM Abrasive, Fig. 12A Not used in and Fig. 12B As wear occurs, the microreplicated pattern degrades. Computer vision algorithms can be used to detect degradation and predict the rate of degradation. Fig. 12A As shown, the hexagonal pattern has clear contrast around each raised hexagonal structure. Fig. 12BIn the example above, after significant use, the contrast is less noticeable. Machine learning can also be used to perform texture analysis to determine abrasive efficiency. Bearing area analysis is useful for measuring e.g. FIG. 12A to FIG. 12B Abrasion of the microreplicated pattern shown is also useful.

[0110] Using the systems and methods described herein, an abrasive article can be imaged and an indication of abrasive efficacy generated based on the image. Abrasive efficacy can be reported based on remaining useful life, amount of metal capping, available bearing area, number of abrasive operations remaining (assuming the parameters for the next abrasive operation are known), the need to re-dress an abrasive application, or a recommended change in parameters.

[0111] If information about the next abrasive operation is known, the systems and methods herein can provide an indication of whether the current abrasive article is adequate for the next operation, or whether a new abrasive article should be used, whether the existing abrasive article should be refurbished, or whether parameters can be changed to improve efficacy. Downstream changes can also be made. For example, based on the wear of the abrasive article in the current operation, future abrasive operations on the same substrate may require longer or shorter dwell times. For example, a more severely worn abrasive article will leave fewer scratches, and an intermediate grinding operation may be skipped entirely. However, a worn abrasive article may also not remove as much material as desired, which may require a later step to obtain a longer dwell time.

[0112] If there are multiple partially used discs available, the systems and methods herein may also be able to suggest which abrasive article is best suited for a particular job. For example, if only 5 minutes of grinding is required, an almost exhausted abrasive disc may be used, thereby reducing waste.

[0113] In addition to knowing when to replace the abrasive article, the systems and methods herein can also suggest or automatically change parameter settings. For example, increase the applied force from 10 lbs to 15 lbs at X wear.

[0114] Additionally, the systems and methods herein can track parameter settings and resulting wear over time to provide better recommendations regarding service life. For example, it may be found that at 10 lbs of applied force, each disc may grind 10 doors, but at 15 lbs of applied force, 30 doors may be grinded before replacement. In a robotic context, data on abrasive operation, wear, and parameter values ​​may be collected to improve the efficiency of future abrasive operations with the same requirements.

[0115] Fig.131300 is a networked architecture of an abrasive product use assessment system 1310. Architecture 1300 shows one embodiment of a specific implementation of system 1310, but other specific implementations are also possible. In various embodiments, a remote server can deliver these services on a wide area network (such as the Internet) using an appropriate protocol. For example, a remote server can deliver applications on a wide area network, and they can be accessed through a web browser or any other computing component.

[0116] The software or components and corresponding data may be stored on a server at a remote location. The computing resources in a remote server environment may be consolidated at a remote data center location, or they may be dispersed. The remote server infrastructure may deliver services through a shared data center, even though they appear as a single access point for users. Therefore, the components and functions described herein may be provided from a remote server at a remote location using a remote server architecture. Alternatively, they may be provided by a conventional server, installed directly on a client device, or provided in other ways.

[0117] As described herein, based on instructions from the abrasive article usage evaluation system 1310, the robotic grinding unit 1304B can adjust force or speed or other parameters related to the abrasive operation in response to commands received via a wired or wireless network (e.g., commands retrieved from a command database 1340).

[0118] In addition to being beneficial to abrasive operations and improving efficiency, knowing when an abrasive article is nearing the end of its life can also allow for improved environmental health and safety of workers in the immediate environment. For example, it is well known that abrasive articles produce more dust near the end of their life than at the beginning. For example, knowing whether an abrasive article in use is near the end of its life can trigger a command to be sent to the ventilation system 1304A to increase ventilation in response to higher dust generation. Similarly, when an abrasive article is near the beginning of its service life, the setting of the ventilation system 1304A can be reduced. Any end-of-life detection method herein can be used to generate a trigger for changing the ventilation setting, including detecting visual cues, detecting temperature changes, detecting physical changes, or by inspecting cuttings.

[0119] Likewise, it is useful to understand the usage of abrasive articles - not for replacement, but for downstream repair. Generally speaking, abrasive operations start with the coarsest grade and work down to finer grades to polish the substrate surface. For example, a 60 grit disk is used first, then an 80 grit disk, and finally a 120 disk. However, if a 60 grit disk is known to be near the end of its life, it may not leave such deep scratches, and the 80 grit grinding step can be skipped entirely, going directly to a 120 grit disk. While such decisions can be made by experienced operators, similar guidance can be helpful to newer operators and can improve the efficiency of a robotic grinding system.

[0120] Fig.13 It is specifically shown that the system 1310 can be located at a remote server location 1302. Thus, the computing device 1320 accesses those systems through the remote server location 1302. The operator 1350 can also use the computing device 1320 to access a user interface 1322. For example, the user interface 1322 can provide an indication of the degree of wear of the abrasive article, changes made to any networked systems 1304, or a suggested change to the operation by the operator - such as increasing force, increasing RPM, etc.

[0121] Fig.13 It is shown that it is also envisioned that some elements of the system described herein are set at the remote server location 1302, while other elements are not set at the remote server location. By way of example, storage devices 1330, 1340 or 1360 or robotic system 1370 may be set at a location separate from location 1302 and accessed by a remote server at location 1302. Regardless of where they are located, they can be directly accessed by computing device 1320 through a network (wide area network or local area network), hosted by a service at a remote site, provided as a service, or accessed by a connection service residing in a remote location. Moreover, the data can be stored in essentially any location and can be intermittently accessed by interested parties or forwarded to interested parties. For example, physical carriers can be used instead of electromagnetic wave carriers, or in addition to electromagnetic wave carriers, physical carriers can also be used.

[0122] It should also be noted that the elements of the system described herein or their parts can be arranged on a variety of different devices. Some of these devices include servers, desktop computers, laptop computers, embedded computers, industrial controllers, tablet computers or other mobile devices, such as handheld computers, cellular phones, smart phones, multimedia players, personal digital assistants, etc.

[0123] Figures 14 to 16 An example of a computing device that may be used in the embodiments shown in the previous figures is shown.

[0124] Fig.14 is a handheld device 1416 (e.g., Fig.13 1320) in which the system (or portion thereof) of the present invention may be deployed. For example, the mobile device may be deployed in an operator compartment of the computing device 1320 for generating, processing or displaying data. Fig.15 is another example of a handheld or mobile device.

[0125] Fig.14 A general block diagram of the components of a client device 1416 that can run some of the components shown and described herein is provided. The client device 1416 interacts with these components, or runs some components and interacts with some components. In the device 1416, a communication link 1413 is provided, which allows the handheld device to communicate with other computing devices, and in some embodiments provides a channel for automatically receiving information (such as by scanning). Examples of communication links 1413 include allowing communication through one or more communication protocols, such as wireless services for providing cellular access to a network, and protocols for providing local wireless connections to a network.

[0126] In other examples, the application may be received on a suitable removable memory card (such as a secure digital (SD) card, a CF card, a microSD, or a portable hard drive) connected to the interface 1415. The interface 1415 and the communication link 1413 communicate with the processor 1417 (which may also be embodied as a processor) along a bus 1419, which is also connected to the memory 1421 and the input / output (I / O) components 1423, as well as the clock 1425 and the positioning system 1427.

[0127] In one embodiment, I / O components 1423 are provided to facilitate input and output operations, and the device 1416 may include input components such as buttons, touch sensors, optical sensors, microphones, touch screens, proximity sensors, accelerometers, orientation sensors, and output components such as display devices, speakers, and / or printer ports. Other I / O components 1423 may also be used.

[0128] Clock 1425 illustratively includes a real-time clock component that outputs time and date. It can also provide a timing function for processor 1417.

[0129] Illustratively, positioning system 1427 includes components for outputting the current geographic location of device 1416. The positioning system may include, for example, a global positioning system (GPS) receiver, a LORAN system, a dead reckoning system, a cellular triangulation system, or other positioning system. It may also include, for example, mapping software or navigation software that generates desired maps, navigation routes, and other geographic functions.

[0130] Memory 1421 stores operating system 1429, network settings 1431, applications 1433, application configuration settings 1435, data repository 1437, communication driver 1439, and communication configuration settings 1441. Memory 1421 may include all types of tangible volatile and non-volatile computer-readable memory devices. It may also include computer storage media (described below). Memory 1421 stores computer-readable instructions that, when executed by processor 1417, cause the processor to perform computer-implemented steps or functions in accordance with these instructions. Processor 1017 may also be activated by other components to facilitate its functions.

[0131] Fig.15 The device is shown to be a smart phone 1500. Smart phone 1571 has a touch-sensitive display 1573 that displays icons or tiles or other user input mechanisms 1575. Mechanisms 1575 can be used by a user to run applications, make phone calls, perform data transfer operations, etc. In general, smart phones 1571 are built on mobile operating systems and provide more advanced computing capabilities and connectivity than non-smart phones.

[0132] It is noted that other forms of apparatus 1400 , 1500 are possible.

[0133] Fig.16 is a block diagram of a computing environment that can be used in the embodiments shown in the previous figures.

[0134] Fig.16 is an example of a computing environment in which elements or (for example) portions of the systems and methods described herein may be deployed. Fig.16 , an exemplary system for implementing some embodiments includes a general purpose computing device in the form of a computer 1610. Components of the computer 1610 may include, but are not limited to, a processing unit 1620 (which may include a processor), a system memory 1630, and a system bus 1621 that couples various system components including the system memory to the processing unit 1620. The system bus 1621 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. The memories and programs described with respect to the systems and methods described herein may be deployed in Fig.16 in the corresponding part of .

[0135] Computer 1610 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by computer 1610, and includes both volatile / non-volatile media and removable / non-removable media. As an example and not limiting, computer-readable media can include computer storage media and communication media. Computer storage media is different from, and does not include modulated data signals or carrier waves. Computer storage media include hardware storage media, which includes volatile / non-volatile and removable / non-removable media implemented in any method or technology for storing information such as computer-readable instructions, data structures, program modules or other data. Computer storage media include, but are not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disk (DVD) or other optical disk storage, cassettes, tapes, magnetic disk storage or other magnetic storage devices, or any other medium that can be used to store the desired information and can be accessed by computer 1610. Communication media can embody computer-readable instructions, data structures, program modules or other data in a transport mechanism, and include any information delivery media. The term "modulated data signal" means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal.

[0136] System memory 1630 includes computer storage media in the form of volatile and / or nonvolatile memory, such as read-only memory (ROM) 1631 and random access memory (RAM) 1632. A basic input / output system 1633 (BIOS), containing the basic routines that help to transfer information between elements within computer 1610 (such as during startup), is typically stored in ROM 1631. RAM 1632 typically contains data and / or program modules that are immediately accessible to and / or currently being operated on by processing unit 1620. By way of example and not limitation, Fig.16 Operating system 1634 , application programs 1635 , other program modules 1636 , and program data 1637 are shown.

[0137] The computer 1610 may also include other removable / non-removable and volatile / non-volatile computer storage media. For example only, Fig.16 Shown is a hard drive 1641 that reads from or writes to a non-removable, non-volatile magnetic media, a non-volatile magnetic disk 1652, an optical drive 1655, and a non-volatile optical disk 1656. The hard drive 1641 is typically connected to the system bus 1621 through a non-removable memory interface, such as interface 1640, and the optical drive 1655 is typically connected to the system bus 1621 through a removable memory interface, such as interface 1650.

[0138] Alternatively or additionally, the functions described herein can be performed at least in part by one or more hardware logic components. For example, but not limited to, illustrative types of hardware logic components that can be used include field programmable gate arrays (FPGAs), application specific integrated circuits (e.g., ASICs), application specific standard products (e.g., ASSPs), systems on chips (SOCs), complex programmable logic devices (CPLDs), etc.

[0139] Discussed above and in Fig.16 The drives and their associated computer storage media shown in FIG. 1 provide storage of computer readable instructions, data structures, program modules and other data for the computer 1610. Fig.16 1644, application programs 1645, other program modules 1646, and program data 1647. Note that these components may be the same as or different from operating system 1634, application programs 1635, other program modules 1636, and program data 1637.

[0140] A user may enter commands and information into the computer 1610 through input devices such as a keyboard 1662, a microphone 1663, and a pointing device 1661 (such as a mouse, trackball, or touch pad). Other input devices (not shown) may include a joystick, a game pad, a satellite dish, a scanner, or the like. These and other input devices are typically connected to the processing unit 1620 through a user input interface 1660 that is coupled to the system bus, but may be connected by other interface and bus structures. A visual display 1691 or other type of display device is also connected to the system bus 1621 via an interface such as a video interface 1690. In addition to the monitor, the computer may also include other peripheral output devices such as speakers 1697 and a printer 1696, which may be connected through an output peripheral interface 1695.

[0141] The computer 1610 operates in a networking environment with one or more remote computers, such as the remote computer 1680 , using logical connections, such as a local area network (LAN) or a wide area network (WAN).

[0142] When used in a LAN networking environment, the computer 1610 is connected to the LAN 1671 through a network interface or adapter 1670. When used in a WAN networking environment, the computer 1610 typically includes a modem 1672 or other means for establishing communications over the WAN 1673 (such as the Internet). In a networking environment, program modules may be stored in the remote memory storage device. For example, Fig.16 Remote application programs 1685 are shown as being residing on remote computer 1680 .

[0143] Objects and advantages of this disclosure are further illustrated by the following non-limiting examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this disclosure.

[0144] An abrasive product evaluation system is presented, the abrasive product evaluation system including a camera for imaging an abrasive product. The system includes an efficiency indication generator that generates an indication of abrasive efficacy of the abrasive product based on the image. The system also includes a command generator that generates a command based on the generated abrasive efficacy indication.

[0145] The system may be implemented such that it includes a parameter retriever that retrieves a current operating parameter of a tool associated with the abrasive article.The command generator generates a command to adjust the operating parameter from a first value to a second value different from the first value.

[0146] The system may be implemented such that the operating parameter is an applied force, the tool is a robotic grinding unit, and the second value is an applied force that is higher than the first applied force.

[0147] The system may be implemented such that the operating parameter is speed, and the second speed is higher than the first speed.

[0148] The system may be implemented such that the operating parameter is a grind angle, and the second grind angle is different from the first grind angle.

[0149] The system may be implemented such that the command is a replacement command, and a robotic grinding unit associated with the abrasive article automatically initiates an abrasive article replacement sequence based on the command.

[0150] The system may be implemented such that the command is a reconditioning command and the robotic grinding unit moves the abrasive article to the reconditioning station based on the command.

[0151] The system may be implemented such that the command is a downstream operating command that adjusts a downstream grinding operating parameter based on the wear indication.

[0152] The system can be implemented such that the downstream grinding operation parameter is speed, force or residence time.

[0153] The system may be implemented such that the downstream grinding operation parameter is a second abrasive article operation using a second abrasive article.

[0154] The system may be implemented such that it comprises a historical value retriever for retrieving historical values ​​of the operating parameter.

[0155] The system may be implemented such that the camera captures the image in response to an efficacy assessment initiator that generates a trigger to actuate the camera.

[0156] The system may be implemented such that the efficacy evaluation initiator generates the trigger periodically.

[0157] The system may be implemented such that the efficacy assessment initiator generates the trigger in response to a manual input.

[0158] The system may be implemented such that the efficacy evaluation initiator generates the trigger before the grinding operation begins.

[0159] The system may be implemented such that the efficacy evaluation actuator generates the trigger at the end of the grinding operation.

[0160] The system may be implemented such that the command is a graphical user interface update command, and the command is transmitted to a device having a display, and the command causes the display to present an updated graphical user interface.

[0161] The system may be implemented such that it comprises a command communicator that transmits the command to the second device.

[0162] The system may be implemented such that the second device is a robotic grinding unit.

[0163] The system may be implemented such that the second device is a ventilation system.

[0164] The system may be implemented such that the second device is a dust collection system.

[0165] The system may be implemented such that the abrasive efficacy indication is a metal termination measurement.

[0166] The system may be implemented such that the abrasive effectiveness indication is a wear estimate.

[0167] The system may be implemented such that the abrasive effectiveness indication is a remaining useful life estimate.

[0168] The system may be implemented such that the camera is integrated into a portable computing device.

[0169] The system may be implemented such that the camera is mounted on a robotic grinding system.

[0170] The system may be implemented such that it comprises a structured light source.

[0171] The system may be implemented such that it includes a mount that maintains the position of the camera.

[0172] A robotic grinding system is presented, the robotic grinding system including an abrasive article including abrasive particles in a bonding matrix. The system also includes a robotic arm configured to move one of the abrasive article and a substrate into position so that the abrasive article contacts the substrate. The system also includes a force control unit on the robotic arm. The force control unit applies a force to the abrasive article or the substrate. The system also includes an article evaluation system that images the abrasive article, evaluates the abrasive article, and based on the evaluation, generates updated operating parameters for the robotic grinding system.

[0173] The robotic grinding system may be implemented such that the article evaluation system includes a wear estimator that estimates an amount of wear of the abrasive article.

[0174] The robotic grinding system may be implemented such that the article evaluation system includes a metal cap detector that detects an amount of metal cap on the abrasive article.

[0175] The robotic milling system may be implemented such that the metal termination detector segments the captured image.

[0176] The robotic milling system may be implemented such that the metal termination detector converts a captured image into binary.

[0177] The robotic grinding system can be implemented such that the metal cap detector quantifies the reflective area of ​​the abrasive article.

[0178] The robotic grinding system can be implemented such that the article evaluation system includes an ultrasonic caliper.

[0179] The robotic grinding system can be implemented such that the updated operating parameters re-dress the abrasive article prior to a next operation.

[0180] The robotic grinding system may be implemented such that the abrasive article evaluation system includes a camera that images the abrasive article.

[0181] The robotic grinding system may be implemented such that it includes a structured light source.

[0182] The robotic grinding system may be implemented such that the camera is mounted to the robotic arm.

[0183] The robotic grinding system may be implemented such that the camera is separate from the robotic arm.

[0184] The robotic grinding system may be implemented such that the camera, the substrate, or the abrasive article is coupled to a moving mechanism.

[0185] The robotic grinding system can be implemented such that the camera images the surface of the abrasive article.

[0186] The robotic grinding system can be implemented such that the camera images a profile of the abrasive article.

[0187] The robotic grinding system may be implemented such that the operating parameter is abrasive article replacement.

[0188] The robotic grinding system may be implemented such that the operating parameter is the applied force of the force control unit, the rotation speed of the abrasive article, or the residence time of the abrasive article on the substrate.

[0189] The robotic grinding system may be implemented such that the operating parameter is a parameter of a future abrasive operation on the substrate.

[0190] The robotic grinding system may be implemented such that the operating parameter is a parameter of a future abrasive operation using the abrasive article.

[0191] The robotic grinding system may be implemented such that the article evaluation system is actuated in response to an activation command from a controller.

[0192] The robotic grinding system may be implemented such that the controller periodically sends the start command.

[0193] The robotic grinding system may be implemented such that the controller sends the start command at the beginning or end of a grinding operation.

[0194] The robotic grinding system may be implemented such that the controller generates the command to adjust the operating parameter.

[0195] The robotic grinding system may be implemented such that the article evaluation system compares the amount of metal capping to a metal capping threshold and generates a re-dressing command or a replacement command for the abrasive article if the amount of metal capping exceeds the metal capping threshold.

[0196] The robotic grinding system may be implemented such that the metal termination threshold is based on an operating parameter of the abrasive operation.

[0197] The robotic grinding system may be implemented such that the metal termination threshold is based on operating parameters of a future grinding operation.

[0198] The robotic grinding system may be implemented such that the article evaluation system compares the amount of wear to a wear threshold and generates a replacement command for the abrasive article if the amount of wear exceeds the wear threshold.

[0199] The robotic grinding system may be implemented such that the wear threshold is based on operating parameters of future abrasive operations.

[0200] The robotic grinding system can be implemented such that the abrasive article includes a backing, and the bonding matrix includes a make coat that bonds the abrasive particles to the backing.

[0201] The robotic grinding system may be implemented such that the abrasive article comprises an abrasive disc or an abrasive belt.

[0202] The robotic grinding system may be implemented such that the abrasive article is a bonded abrasive article, and the bond matrix is ​​a vitreous, resinous, polymeric, or metallic bond matrix.

[0203] The robotic abrasive system can be implemented such that the abrasive article is a nonwoven abrasive article including a plurality of nonwoven fibers, and the bonding matrix bonds the abrasive particles to the plurality of nonwoven fibers.

[0204] A system for evaluating the effectiveness of an abrasive article includes a tool coupled to the abrasive article, the abrasive article having abrasive particles on an abrading surface. The system also includes a surface profiler configured to capture an indication of the abrading surface. The system also includes an evaluator that receives the captured indication, processes the captured indication, and generates an indication of abrasive effectiveness.

[0205] The system may be implemented such that the surface profiler includes a camera and the captured indication is an image.

[0206] The system may be implemented such that the surface profiler is a 3D profiler and the captured indications are surface profile indications.

[0207] The system may be implemented such that it comprises a structured light source.

[0208] The system may be implemented such that the evaluator also transmits the grinding efficacy indication to a receiving device.

[0209] The system may be implemented such that the receiving device is a display component and transmitting the grinding efficacy indication includes transmitting an update of a graphical user interface of the display component.

[0210] The system can be implemented such that the receiving device is a robotic grinding system coupled to the tool, and the system further includes an abrasive parameter updater that generates a set of updated parameters for the robotic grinding system based on the grinding efficacy indication. The updated parameters change one of the applied force, the rotational speed, or the dwell time.

[0211] The system may be implemented such that the grinding effectiveness indication includes a wear indication.

[0212] The system can be implemented such that the grinding efficacy indication includes a metal capping indication.

[0213] The system may be implemented such that the grinding efficacy indication includes an estimated remaining useful life.

[0214] The system may be implemented such that the estimated remaining useful life includes the number of future abrasive operations remaining.

[0215] The system may be implemented such that the display component is associated with the tool.

[0216] The system may be implemented such that the display component is located in an area of ​​the worksite proximate to the tool.

[0217] The system may be implemented such that the display component is part of a device associated with an operator of the tool.

[0218] The system may be implemented such that the device is personal protective equipment worn by the operator.

[0219] The system may be implemented such that the abrasive article comprises an abrasive disc or an abrasive belt.

[0220] The system can be implemented such that the abrasive article is a bonded abrasive article.

[0221] The system can be implemented such that the abrasive article is a nonwoven abrasive article.

[0222] A method of abrading a substrate is presented, the method comprising contacting a substrate surface with an abrasive article, the abrasive article having a surface, capturing a surface indication of the surface using a surface indication capturing device, and processing the surface indication using an abrasive efficiency evaluator to generate an abrasive efficacy indication. Based on the abrasive efficacy indication, a next abrasive operation of the abrasive article is modified.

[0223] The method may be implemented such that the modification includes adding a reconditioning step to the abrasive article prior to the next abrasive operation.

[0224] The method may be implemented such that the modification includes adjusting the applied force, speed, or dwell time.

[0225] The method may be implemented such that modifying includes replacing the abrasive article with a new abrasive article prior to the next abrasive operation.

[0226] The method may be implemented such that the abrasive article is coupled to a robotic grinding system. The modification includes generating a command based on the abrasive efficacy education and transmitting the command to the robotic grinding system.

[0227] The method may be implemented such that the abrasive article is coupled to a handheld power tool. The modification includes providing the abrasive efficacy indication to a display associated with the handheld power tool or associated with an operator of the handheld power tool.

[0228] The method may be implemented such that the abrasive article is coupled to a handheld power tool, and the modifying includes providing modification instructions to an operator.

[0229] The method may be implemented such that the modification instruction is provided using personal protective equipment worn by the operator.

[0230] The method may be implemented such that the modification instruction is provided via a speaker of the hearing protection unit.

[0231] The method may be implemented such that the modification instruction is provided on a heads-up display.

[0232] The method may be implemented such that the modification instructions are provided to a portable computing device associated with the operator.

[0233] The method may be implemented such that it includes transmitting the abrasive effectiveness indication to a data repository.

[0234] The method may be implemented such that the abrasive efficacy indication is communicated with an indication of a set of current operating parameters of the abrasive article.

[0235] The method may be implemented such that the abrasive efficacy indication comprises a wear indication or a metal cap indication.

[0236] The method may be implemented such that the surface indication is an image of the surface.

[0237] The method may be implemented such that processing the image comprises segmenting the image.

[0238] The method may be implemented such that processing the image comprises converting the image into binary.

[0239] The method may be implemented such that processing the image includes applying machine learning to detect exposed abrasive particles or capped abrasive particles.

[0240] The method may be implemented such that processing the image includes measuring a reflectivity of the abrasive article.

[0241] The method may be implemented such that the surface indication comprises a surface contour indication.

[0242] The method may be implemented such that the surface indication capture device comprises a structured light microscope.

[0243] The method may be implemented such that the surface indication capture device comprises a 3D surface profiler.

[0244] Example

[0245] Example 1

[0246] An algorithm has been written to analyze the disc and identify the PSG grains. The algorithm uses information provided by the angle of lighting / shadow and the coverage of the red layer of the observed abrasive. The computer vision algorithm picks out the specific color of the grains in the image to demonstrate how the segmentation algorithm can extract the PSG in the photo. It can be seen that as the image progresses, the blue color of the PSG becomes more exposed, indicating a strong correlation with abrasive wear.

[0247] The wear of the PSG grains was then evaluated. FIG. 17A to FIG. 17B In the image of FIG. 1 , the worn area is colored with the first color, and the unworn area is represented by the second color. Some PSG grains are partially the first color and partially the second color, indicating that they are partially worn.

[0248] The statistical data can then be used to calculate the wear state of the disc;

[0249] 1) G = number of first color pixels (worn PSD); P = number of second color pixels (unworn PSG). W = percentage of disk wear;

[0250] W=G / (G+P)

[0251] W can be displayed to the user as a color scale to indicate the percentage of disc wear

[0252] 2) Regional assessments of disc wear can be calculated similarly to above. These zones can be concentric circles. This may add value because visually the greatest wear occurs in the center ring of the disc. Users may experience a greater degree of wear in this area. When reporting wear percentage statistics to the user, a weighting representing the user experience can be learned.

[0253] 3) The value of W can be related to the remaining time of disc use. This can be achieved by asking the operator to use the abrasive disc for different time periods and observing W. Regression will initially be used to predict the remaining time. If a poor R^2 value / p value is obtained, additional parameters can be integrated for more complex studies, such as multivariate linear or nonlinear regression.

[0254] 4) These scores can be further personalized to individual operators using machine learning. For the sake of brevity IS, the details of this are not covered here but are available upon request. This will be a feature implemented on horizon 2 or 3 on the feature roadmap.

[0255] Technical Methodology

[0256] From a technical perspective, this is achieved by training a machine learning classifier (specifically a random forest) to predict the state of each pixel in the image based on its value and the values ​​of its neighbors. This is achieved using feature calculations, and the features calculated include the first and second order differentials of the area with a Gaussian pyramid.

[0257] There are other ways to accomplish this, but this is just one example;

[0258] Fig.17A It’s a new disk. Fig. 17B is the output image annotated based on whether a die has been used or not. Green means it has been used, purple means it has not been used.

[0259] All red pixels in the right image prediction are predicted not to be abrasive grains and are excluded from the calculation.

[0260] Example 2

[0261] Previously, a machine learning algorithm has been created to help the manufacturing industry diagnose manufacturing challenges using optical microscopy. Fig.18A The acquired microscopic images of the abrasive article are shown.

[0262] Training data that humans input into machine learning algorithms, such as Fig.18B The corresponding colors in the figure below are:

[0263] ●Red: manually marked as background area

[0264] ●Blue: Manually marked PSG

[0265] ●Green: Unlabeled regions whose class the machine learning algorithm predicted.

[0266] Example 3

[0267] Create a random forest to predict the class of green areas as PSG or "background". Generate a series of intermediate images to help the classifier, such as Fig.19A and Fig.19B shown.

[0268] Fig.19C The probability map shown depicts regions that are likely to be PSGs. Fig.19D ) provides a binary image representing where the PSG may be located.

[0269] The results can be superimposed on the original image to pick out the PSG (in Fig.19E (Overview in ).

[0270] Example 4

[0271] Fig. 20 Multiple images of the same abrasive surface under fixed grinding conditions are shown. There is an increase in visible abrasive grains with each grinding cycle, which is related to the fracture mechanism of the ceramic mineral. The abrasive grains, in this case "precision-shaped grains", will grind less material as they wear, and this will lead to higher grinding temperatures. The PSG particles are blue and are therefore easily recognizable compared to the red background of the abrasive. The area of ​​the visible blue grains can be used to calculate the area of ​​the abrasive relative to the red background, giving a strong indication of the abrasive life.

Claims

1. An abrasive product evaluation system, the abrasive product evaluation system comprising: a camera that images the abrasive article; an efficiency indication generator that generates an indication of abrasive effectiveness of the abrasive article based on the image; and A command generator generates commands based on the generated abrasive efficacy indication.

2. The system according to claim 1, further comprising: a parameter retriever that retrieves current operating parameters of a tool associated with the abrasive article; and The command generator generates a command to adjust the operating parameter from a first value to a second value different from the first value. 3 . The system of claim 2 , wherein the operating parameter is an applied force, the tool is a robotic grinding unit, and the second value is an applied force that is higher than the first applied force.

4. The system of claim 2, wherein the operating parameter is speed, and wherein the second speed is higher than the first speed.

5. The system of claim 2, wherein the operating parameter is a grinding angle, and wherein the second grinding angle is different from the first grinding angle.

6. The system of any one of claims 1 to 5, wherein the command is a re-dressing command, and wherein the robotic grinding unit moves the abrasive article to a re-dressing station based on the command.

7. The system of any one of claims 1 to 6, wherein the command is a downstream operation command that adjusts a downstream grinding operation parameter based on the wear indication.

8. The system of any one of claims 1 to 7, wherein the camera captures the image in response to an efficacy assessment initiator, the efficacy assessment initiator generating a trigger to actuate the camera.

9. The system of any one of claims 1 to 8, wherein the command is a graphical user interface update command, and wherein the command is transmitted to a device having a display, and wherein the command causes the display to present an updated graphical user interface.

10. The system according to any one of claims 1 to 9, and further comprising: A command communicator transmits the command to the second device.

11. The system of any one of claims 1 to 10, and wherein the abrasive efficacy indicator is a metal termination measurement.

12. The system of any one of claims 1 to 11, wherein the abrasive effectiveness indication is a wear estimate.

13. The system of any one of claims 1 to 12, wherein the abrasive efficacy indication is a remaining useful life estimate.

14. The system of any one of claims 1 to 13, and further comprising a structured light source.

15. A system according to any one of claims 1 to 14 and further comprising a mount to maintain the position of the camera.

16. A robotic grinding system, the robotic grinding system comprising: an abrasive article comprising abrasive grains in a bonding matrix; a robotic arm configured to move one of the abrasive article and a substrate into position such that the abrasive article contacts the substrate; a force control unit on the robotic arm, wherein the force control unit applies a force to the abrasive article or the substrate; and A product evaluation system, wherein the product evaluation system: imaging the abrasive article; evaluating the abrasive article, and Based on the evaluation, updated operating parameters are generated for the robotic grinding system.

17. The robotic grinding system of claim 16, wherein the product evaluation system comprises: A wear estimator estimates the amount of wear of the abrasive article.

18. The robotic grinding system according to claim 16 or 17, wherein the product evaluation system comprises: A metal capping detector is provided to detect the amount of metal capping on the abrasive product.

19. The robotic milling system of claim 18, wherein the metal termination detector segments the captured image.

20. The robotic grinding system of claim 16 or 17, wherein the article evaluation system comprises an ultrasonic caliper.

21. The robotic grinding system of any one of claims 16 to 20, wherein the abrasive article evaluation system comprises a camera to image the abrasive article.

22. The robotic grinding system of claim 21 and further comprising a structured light source.

23. The robotic system of claim 16, wherein the camera, the substrate, or the abrasive article is coupled to a movement mechanism.

24. The robotic system according to any one of claims 16 to 23, wherein the operating parameter is an applied force of the force control unit, a rotation speed of the abrasive article, or a residence time of the abrasive article on the substrate.

25. The robotic system of any one of claims 16 to 24, wherein the operating parameters are parameters of a future abrasive operation on the substrate.

26. The robotic system of any one of claims 16 to 25, wherein the operating parameters are parameters of a future abrasive operation using the abrasive article.

27. The robotic system of claim 16, wherein the article evaluation system compares an amount of metal capping to a metal capping threshold and generates a re-dressing command or a replacement command for the abrasive article if the amount of metal capping exceeds the metal capping threshold.

28. The robotic system of claim 16, wherein the article evaluation system compares the amount of wear to a wear threshold and generates a replacement command for the abrasive article if the amount of wear exceeds the wear threshold.

29. The robotic system of claim 28, wherein the wear threshold is based on operating parameters of future abrasive operations.

30. A method of grinding a substrate, the method comprising: contacting a substrate surface with an abrasive article having a surface; capturing a surface indication of the surface using a surface indication capture device; processing the surface indication using an abrasive efficiency evaluator to generate an abrasive efficacy indication; as well as A next abrasive operation of the abrasive article is modified based on the abrasive efficacy indication.

31. The method of claim 30, wherein modifying comprises adding a reconditioning step to the abrasive article prior to the next abrasive operation.

32. The method of claim 30, wherein modifying comprises adjusting applied force, speed, or dwell time.

33. The method of claim 30, wherein the abrasive article is coupled to a robotic grinding system, and wherein modifying comprises: Generates commands based on abrasive efficacy education, and The command is transmitted to the robotic grinding system.

34. The method of claim 30, wherein the abrasive article is coupled to a handheld power tool, and wherein modifying comprises providing the abrasive efficacy indication to a display associated with the handheld power tool or associated with an operator of the handheld power tool.

35. The method of claim 30, further comprising: The abrasive effectiveness indication is communicated to a data repository.

36. The method of claim 30, wherein the surface indication is an image of the surface.

37. The method of claim 36, wherein processing the image comprises segmenting the image.

38. The method of claim 36, wherein processing the image comprises converting the image to binary.

39. The method of claim 36, wherein processing the image comprises measuring a reflectivity of the abrasive article.

40. The method of claim 30, wherein the surface indication comprises a surface contour indication.

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