Abrasive articles, systems, and methods of use

Abstract

An abrasive article evaluation system includes a detector that detects an abrasive wear prompt. The system also includes an efficiency indicator generator that generates a wear indication of the abrasive article based on the abrasive wear cue. The system also includes a command generator that generates a command based on the generated wear 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, metals (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 article evaluation system includes a detector for detecting an indication of abrasive wear. The system also includes an efficiency indicator generator for generating an indication of wear of the abrasive article based on the indication of abrasive wear. The system also includes a command generator for generating a command based on the generated indication of wear.

[0003] A robotic grinding system is presented, comprising an abrasive article including a wear indicator. The system also includes a back-up pad coupled to the abrasive article. The system also includes a robotic arm configured to move the abrasive article into position relative to a substrate. The system also includes a force control unit on the robotic arm and coupled to the back-up pad. The force control unit applies a force to the back-up pad. The system also includes a wear indication system that determines an amount of wear of the abrasive article based on the wear indicator and adjusts operating parameters of the robotic grinding system based on the wear amount.

[0004] This article describes systems and methods for detecting when an abrasive article is nearing the end of its useful life. Some systems and methods herein can improve the effectiveness 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 the resin matrix can also be useful, such as in nonwoven or bonded abrasive articles, where the entire article wears away during use. Some abrasive articles experience wear of the particles and resin down to the backing layer, which provides an opportunity to visually detect changes.

[0005] Some of the systems and methods herein may be particularly useful for robotic grinding systems where a human operator may not be able to detect end-of-life by noticing changes in grinding efficiency. Additionally, some of the systems and methods herein may be used with handheld abrasive tools to assist an operator in adjusting tool 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 1is 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 Methods of abrading abrasive articles according to embodiments herein are shown.

[0013] 7A to 7F Nonwoven fibers that may be used in embodiments herein are shown.

[0014] Figure 8 An abrasive belt according to embodiments herein is shown.

[0015] Figure 9 An abrasive article according to embodiments herein is shown.

[0016] Figure 10 A method of detecting wear indicators in an abrasive article according to embodiments herein is shown.

[0017] Figures 11A to 11B Chips produced according to embodiments herein are shown.

[0018] FIG. 12A to FIG. 12B The material removal rate and temperature during the cycle are shown.

[0019] Figure 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 An exemplary interface of a grinder that may be used in embodiments herein 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 spirit of the principles of the present disclosure. The accompanying 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, the various actions may be performed in any order without departing from the principles of the present disclosure. Furthermore, specified actions may be performed simultaneously unless explicit claim language implies that they should be performed separately. For example, performing a claimed action of X and performing a claimed action of Y may be performed simultaneously in a single operation, and the resulting process would fall within the literal scope of the claimed process.

[0026] As used herein, the term "about" can allow for a 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 specifically recited 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, term " shaped abrasive grain " means that wherein at least a portion of abrasive grain has the abrasive grain of predetermined shape, and this predetermined shape is obtained by being copied by the die cavity for forming shaped precursor abrasive grain.Except in the case of abrasive fragments (for example, as described in U.S. Patent Application Publication 2009 / 0169816 and 2009 / 0165394), shaped abrasive grain will generally have the predetermined geometry that has roughly copied the die cavity for forming shaped abrasive grain.As used herein, shaped abrasive grain does not include the abrasive grain obtained by mechanical crushing operation.The suitable example of the geometric shape with at least one top comprises polygon (comprising equilateral, equiangular, star-shaped, regular and irregular polygon), lens shape, half-moon shape, circular shape, semicircular shape, elliptical shape, circular sector, circular segment, drop shape and hypocycloid (for example superelliptical).

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

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

[0031] The shaped abrasive particles are typically selected to have side lengths 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 can be used.

[0032] The shaped abrasive particles may have a "sharp portion", which is used herein to describe a sharp point or sharp edge of an abrasive article. The sharp portion can be defined using a radius of curvature, which in the present disclosure is understood to be the radius of the arc of the curve that most closely approximates the point at which the sharp point is formed. 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 having 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 that are 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 the abrasive particles at the aligned position. For example, a triangular particle can have an orientation that is "tilted upward" or an orientation that is "tilted 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 grains are binder-free and are not agglomerates of abrasive grains held together by a binder or other adhesive material.

[0035] Described herein are abrasive articles that include wear indicators or other abrasive efficiency indicators. Some exemplary embodiments are described in the context of specific abrasive article types, such as bonded grinding wheels or coated fiber discs. However, it is expressly contemplated that at least some of the efficiency indicators described herein are applicable to a variety of abrasive article types, 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] Furthermore, 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 utilize a vitreous, resinous, or polymer-based bond matrix. Bonded abrasive structures may include depressed center grinding wheels, cut-off 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] Typically, the coated abrasive article 100 includes a plurality of abrasive particles at least partially embedded in a primer that secures 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 treated 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 applying a curable primer layer precursor to the main surface of the backing 110. The primer layer precursor can include, for example, glue, phenolic resin, aminoplast resin, urea-formaldehyde resin, melamine-formaldehyde resin, urethane resin, multifunctional (meth)acrylate that can be polymerized in a free radical manner (e.g., aminoplast resin with pendant α, β-unsaturated groups, acrylated urethane, acrylated epoxy resin, acrylated isocyanurate), epoxy resin (including bis-maleimide and fluorene-modified epoxy resin), isocyanurate resin, and mixtures thereof. Among these, phenolic resin is 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 formaldehyde to phenol molar ratio of less than 1:1. Resole / resol phenolic resins can be catalyzed with a basic catalyst and have a formaldehyde to phenol molar ratio greater than or equal to one, typically between 1.0 and 3.0, resulting in the presence of pendant hydroxymethyl groups. Suitable basic catalysts 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 of which are provided 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 can 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 often 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 in the practice of the present disclosure include those sold under the trade name VARCUM (e.g., 29217, 29306, 29318, 29338, 29353) by Durez Corporation; those sold under the trade name AEROFENE (e.g., AEROFENE 295) by Ashland Chemical Co., Bartow, Florida; and those sold under the trade name PHENOLITE (e.g., PHENOLITE TD-2207) by Kangnam Chemical Company Ltd. of Seoul, South Korea.

[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 layer used can depend on, for example, the intended use, the type of abrasive grain, and the properties 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 layer can be applied by any known coating method for applying a make layer (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 applied to the backing, triangular abrasive particles are applied to the make coat precursor and at least partially embedded therein. The triangular abrasive particles are nominally applied to the make coat precursor according to a predetermined pattern and Z-axis rotational orientation. The abrasive particles can be oriented relative to the backing using known orientation methods, such as electrostatic or magnetic orientation, to improve the performance of the particles.

[0048] However, although Figures 1 to 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 4Over time, different usage scenarios for abrasive articles can present different issues with the article's use. For example, an experienced human operator can often "feel" that an abrasive article is losing its cutting effectiveness over time and adjust accordingly by applying more force or adjusting the angle. A robotic system may not be able to perceive the wear or load occurring on the abrasive article and may not be able to make the necessary adjustments or replace the abrasive article when needed. The systems and methods herein are also useful in other contexts.

[0050] 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 be movable in any of six dimensions, translation, or rotation, about the x-axis, y-axis, and / or 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 further 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.

[0051] 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 (in most cases, 6 degrees of freedom) as well as any other degrees of freedom (e.g., the compliance control 230 unit).

[0052] Support pads 250 are coupled to tool 240, which has rails 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 the 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 the active axis. Force control 230 is coupled to flange 220. The movement of components 210, 220, 230, 240, and 250 can all be controlled using a robotic controller (e.g., robotic controller 270).

[0053] In addition to moving components 210-250 based on the parameters of the grinding operation, the robotic controller 270 can also adjust parameters based on information received from the abrasive article usage 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 accumulated chips. If the abrasive article is blocked, the controller 270 can initiate a dressing process to reduce the detected blockage. 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 adjust the angle of the tool 240 relative to the substrate. Such adjustments are described in more detail with reference to later figures.

[0054] 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 the human operator so that the angle of the abrasive article 310 is adjustable. The applied force can also be adjustable, for example, by tilting the tool by the human operator.

[0055] 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 can detect the condition of use of the abrasive article 310, and the evaluation communicator 330 can 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 can guide the user to adjust the angle of the tool relative to the surface. In other embodiments, the communicator 330 can 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., a head-up display or an augmented reality overlay provided on safety glasses) or a display in the area. The communicator 330 can 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.

[0056] This article describes systems and methods for evaluating abrasive articles. Abrasive articles can be associated with a robotic grinding system, such as Figure 3 As shown, or it can be a manually operated tool, such as Figure 4As shown. Evaluating an abrasive article broadly refers to evaluating parameters related to the abrasive efficiency of an abrasive article. Wear can affect abrasive efficiency—as the article is used and the particles gradually wear away, the cut rate decreases. However, abrasive efficiency can also be affected by other factors that can be detected using the systems and methods herein. For example, capping or loading can occur, causing the abrasive particle tips to become covered and unable to abrade. Other efficiency factors can also be detected.

[0057] Figure 5 An abrasive article evaluation system according to embodiments herein is shown. The abrasive article evaluation system 500 is adapted for an abrasive article 502. For example, a robotic arm can move the abrasive article 502 within the range of the detector 502 using a cue capture device 522. In some embodiments herein, the cue capture device 522 is a camera or other image capture component that images the abrasive article 502. In other embodiments, the cue 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 herein. In embodiments where the cue capture device 522 is a camera, the detector 520 can 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 cue 510.

[0058] As described herein, the abrasive article 502 includes a cue 510 that can be detected by a sensor 522. The cue can be incorporated into particles 512 within the abrasive article 502, the backing 514, or 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.

[0059] The detector 520 may be stationary, such that a robotic arm or a human operator brings the abrasive article 502 into range of the cue capture device 522. In other embodiments, the detector 520 is mobile, having a motion 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 stationary, it may be mobile. Figure 5 5. It is shown as separate from the controller 540 that performs the evaluation, but in some embodiments it may be a single component.

[0060] The controller 540 receives a detection indication from the detector 520 using a detector indicator acquirer 558. The detection indicator acquirer 558 can request an indication from the detector 520 in response to a detector actuator 556, which can send a command to the detector 520 to activate the cue capture device 522. In some embodiments, a trigger 554 can cause the detector actuator 556 to activate. For example, the motion detector 554 can detect that the abrasive article 502 has been moved into position. The trigger 554 can also be based on time or position.

[0061] The processor 562 is instructed to process the received signal from the detector 520. As described herein, this may include comparing the received signal to a threshold value, referencing it against historical signal values ​​retrieved from a data store by the historical value retriever 544, or otherwise processing the signal to determine whether the abrasive efficacy of the article 502 has reached an undesirably low value.

[0062] The instruction process 562 may use thresholds set by the manufacturer, customer, operator, shift supervisor, etc. For example, one customer may set the minimum acceptable thickness of an abrasive disc to T, while another customer sets the threshold to 2T.

[0063] In some embodiments, the controller 540 may determine that, although the abrasive efficacy has fallen below a threshold, it is possible to improve it by changing one or more operating parameters. The parameter acquirer 542 may acquire 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, for example, to the robot arm controller to adjust the applied force or angle, and then transmit the command to the robot arm controller using the command communicator 548. 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 end cap. 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.

[0064] The performance indicator generator 564 generates an indication of the abrasive performance of the abrasive article 502. This indication can be displayed, for example, on the display member 590. The indication can be provided in text, such as "60% used" or "Capping detected," or can be simply provided as "good" or "bad." The indication can be audible, such as an alarm or signal, indicating that action is needed to improve abrasive performance or replace the abrasive article 502. The indication can be provided to the graphical user interface generator 552, which can generate an interface for the display member 590. The controller 540 can also have other functions 566.

[0065] In some embodiments, the display component 590 may be incorporated into the hand tool, making the performance indicator 592 visible to the user of the hand tool. In other embodiments, the display component 590 is separate from the tool. For example, in the context of robotic grinding, 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 the operator's mobile phone or tablet. The GUI generator 552 may then send instructions to an application running on the device, causing the performance indicator 592 to be updated.

[0066] The display component 590 may also present parameter changes 594, such as adjustments to the tool angle, increases or decreases in applied force, and the like. 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 abrasive removal step of a process, but may be suitable for subsequent, low-volume abrasive 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.

[0067] System 500 Figure 5 590, however, it is clearly contemplated that a single computing unit may include the display component 590 and some or all of the components of the system 500. For example, the detector 520 and the controller 540 are shown as part of a single unit, but it is clearly contemplated that at least some of the components may be part of separate devices. For example, the controller 540 may be part of a robotic arm controller and be a separate computing device remote from the detector 520 and the display component 590.

[0068] Figure 6 A method for 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 abrasive efficacy.

[0069] In block 610, an abrasive article is mounted on a tool. For example, the abrasive article can be coupled to a back-up pad on a handheld abrasive tool, or to a tool of a robotic grinding unit. The abrasive article can 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.

[0070] In block 620, the abrasive article engages the workpiece and performs a grinding operation. As the workpiece is ground, the abrasive particles of the abrasive article experience wear. They may also experience end capping, loading, or other degradation.

[0071] In block 630, the abrasive article is evaluated. The abrasive article's abrasive efficacy is determined. In some embodiments, visual cues 632 may be analyzed to detect wear, end capping, or loading. Auditory cues 634 may be analyzed to detect wear, end capping, or loading. In other embodiments, a different detector 636 detects cues of abrasive efficacy.

[0072] Evaluation of the abrasive article can be accomplished by directly measuring a parameter of the abrasive article during or after the abrasive operation, such as a visual marker, sound, or other marker of the abrasive article. In other embodiments, evaluation of the abrasive article can be accomplished by evaluating the workpiece, swarf removed from the workpiece, or another component.

[0073] The evaluation in block 630 can be performed 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 with a new workpiece, so that the abrasive article is within the range of the detector. Similarly, when a human operator changes the part to be ground or completes another task, the human operator can position the abrasive tool coupled to the abrasive article within the range of the detector.

[0074] In block 642, if the abrasive article's abrasive efficacy is still at an acceptable level, it can be used for another abrasive operation. In some embodiments, new operating parameters are provided based on the decrease in abrasive efficacy detected between evaluations. In robotic abrading operations, the new parameters can be automatically implemented. In the context of a handheld tool, the new parameters can be suggested to the operator.

[0075] In block 644 , if the abrasive efficacy is below an acceptable level, it may be treated as indicated in block 650 , such as by conditioning the abrasive article to remove capping, washing or cleaning the abrasive article to remove loading. However, in some embodiments, the method 600 returns to block 610 .

[0076] Described herein in Figures 7 to 12 are examples and embodiments of the present invention in which the detected indication of abrasive efficacy is actually visible. However, it is clearly contemplated that other abrasive efficacy cues are possible, and are described in both co-pending applications 63 / 366,803 and 63 / 366,805, filed on June 22, 2022.

[0077] 7A to 7F Shown are fluorescent nonwoven fibers that may be used in embodiments herein. Figure 7A shows the fiber as seen under the visible light spectrum, and Figure 7B The same nonwoven fiber is shown glowing bright blue under a black light. Figures 7C to 7E Different proportions of dye incorporated into the fibers are shown. Figure 7FA control fiber without dye incorporated is shown, indicating that dyed fibers can be detected, while undyed fibers may not be detected or may have only a negligible amount of fluorescence. Nonwoven fibers have fluorescent dye incorporated into them during fiber manufacturing. The fibers can then be incorporated into a nonwoven abrasive backing, which can be coated with a resin and abrasive particles. If applied in a spray application or dip / roller application, the resin will cover most of the fibers. As the abrasive article is used and the resin and abrasive particles deteriorate, the fibers will be exposed again. Over time, as the slurry spray coating is worn away, more and more fluorescence will be detected.

[0078] Although 7A to 7F Reference is made to fluorescent nonwoven fibers, but the use of fluorescent lamps can also be used in other applications. For example, the backing of a coated abrasive article can similarly incorporate a fluorescent dye.

[0079] Figure 8 The use of fluorescent lighting to detect degradation of an abrasive article according to embodiments herein is shown. Figure 8 An abrasive belt (particularly 784F 36+Cubitron from 3M) is shown. TM II abrasive belts) in which fluorescent dye is incorporated into the polyester backing are held in front of a fluorescent lamp. In areas where the abrasive grains and resin matrix have been worn away to expose the backing, the fluorescence shines through.

[0080] The incorporation of a UV fluorescent indicator into the coated abrasive backing or resin / mineral layer allows for convenient in situ evaluation of the abrasive article as an end of life indicator. This allows both robotic and human operators to know when to replace a used coated abrasive belt or disc. As the coated abrasive is used and corrosion of the resin / mineral layer occurs, the backing will be exposed and the UV fluorescent indicator will be detected. A suitable detector could be a UV spectrophotometer device attached to a robotic arm or placed near the human operator. The depth of corrosion detection of the coated abrasive can vary depending on the location of the UV fluorescent indicator. For example, it could be located in the backing layer, the base resin layer, or the top resin layer. The UV fluorescent indicator is typically a dye that fluoresces under UV light. As Figure 8 As shown, a portion of the 784F 36+ has eroded through to the backing and is easily detected using UV light. The UV fluorescent end-of-life detection system is a very effective method for determining the end of life of coated abrasives in manually operated or automated robotic grinding and finishing operations.

[0081] Although fluorescence has been described in detail, there are other options for visual cues that can be easily detected. In other embodiments, a state-changing material or reactive material is encapsulated and enclosed in the abrasive article. When the encapsulation is worn away or heated due to the friction of the abrasive operation, the material changes state. The material can melt, burn or sublime to produce a detectable visual cue. Similarly, a reaction may occur, thereby producing smoke or mist. For example, the reactive material can be sodium that reacts when exposed to air. Materials that react with air (dry scrubbing) or water (wet scrubbing) can be used to provide a detectable end-of-life indication. Waxes and polymers can be used to encapsulate dyes, spices or smoky materials. In some embodiments, as the temperature increases due to the friction of the worn abrasive on the surface, the encapsulating material melts, and the encapsulating material is released and can be detected. In some embodiments, the encapsulating material is worn away rather than melted.

[0082] The material can also change the color of the abrasive disc or swarf produced. For example, encapsulated wax can turn a red abrasive disc purple. The color change can be detected by a human operator or a spectrometer.

[0083] In some embodiments, the material has an odor upon release that is detectable by the human nose or an odor meter.

[0084] Additionally, in some embodiments, spark showers are generated when the material interacts with the workpiece. For example, titanium and cast iron both have recognizable spark showers. Titanium or other particles placed in the backfill will produce spark showers of different colors. Flint or other materials can be used to increase the spark shower. Spark-generating materials can also be incorporated into the backing as wires or strands.

[0085] Figure 9 A schematic diagram of an abrasive article according to embodiments herein is shown. Abrasive article 900 has a backing 910, abrasive particles 920 having a first color, and a material 930 having a second color. In some embodiments, material 930 may also be abrasive particles having a color different from the first color. Second abrasive particles 930 may be arranged in a pattern, for example, as described in U.S. Patent No. 2022 / 0040814, published on February 10, 2022.

[0086] Material 930 can be a separate type of abrasive grain than grain 920, such as backfill or other crushed abrasive grains. Material 930 can also be a dye, ink, or print on one of the layers of article 900, such as on a backing, primer, undercoat, or another layer. Figure 9 An embodiment is shown in which material 930 spells out the word "STOP," however, it is clearly contemplated that another visual cue may be apparent, such as branding, shape, or another suitable visual indication.

[0087] Figure 10 A method for manufacturing an abrasive article having a detectable cue according to embodiments herein is shown. Method 1000 can be used to manufacture an abrasive article that can be used by a robotic grinding system or a human operator and provides an indication of grinding efficacy. The indication can be an end-of-life indication, an indication that new operating parameters are needed to improve abrasive efficacy, or an indication that the abrasive article is no longer suitable for the current operation but may be suitable for a downstream grinding operation.

[0088] In block 1010, an indicator material is obtained. The indicator material may be a colored dye, an odor, a spark-producing material, a material that produces smoke or mist, a material that reacts with air or water, or another material that produces a detectable indication of the effectiveness of the abrasive.

[0089] At block 1020, an indicator material may be incorporated into the abrasive grains, such as a dye that imparts color 1012. The indicator may be encapsulated 1014 and incorporated into the adhesive layer. For example, a colored wax or a material that produces smoke or a detectable odor may be incorporated into the abrasive article by encapsulation. The indicator may also be a spark-generating material 1016, such as titanium, iron, or copper.

[0090] The indicator material can be part of the resin or adhesive layer, the backing, or the scrim layer. For example, the abrasive article backing 1018 can have an indicator, such as a fluorescent dye, or printed indication. The indicator can also be part of the scrim layer 1022, such as a fluorescent dye or printed indication. The indicator can be incorporated into the resin layer 1024 or incorporated into another component 1026 of the abrasive article.

[0091] The abrasive article is formed in block 1030. For example, dyed fibers are incorporated into a backing, an encapsulated colored wax is used as part of a resin that cures to form the abrasive article, and colored abrasive particles are appropriately arranged.

[0092] The property of uncured or partially cured resin composition is non-restrictive. For example, uncured or partially cured resin composition can include any suitable material that can be cured to form a primer. Suitable materials for forming the abrasive layer include phenolic resin (for example, deriving from PREFERE 805077A of Arclin, Mississauga, Ontario, Canada). Suitable phenolic resin is usually formed by the condensation of phenol or alkylated phenol (for example, cresol) and formaldehyde, and is usually classified as resol or linear phenolic resin. Novolac phenolic resin is acid catalyzed and the mol ratio of formaldehyde to phenol is less than 1:1. Resol (resole / resol) phenolic resin can be catalyzed with an alkaline catalyst, and the mol ratio of formaldehyde to phenol is greater than or equal to one, usually between 1.0 and 3.0, so there is a hydroxymethyl side group. Suitable basic catalysts for catalyzing the reaction between the aldehyde and phenol components of the resol resin include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, and sodium carbonate, all as catalyst solutions dissolved in water.

[0093] 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 can 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 often leads to processing problems.

[0094] Phenolic resins are well known and readily available from commercial sources. Examples of commercially available resol phenolic resins that can be used in the practice of the present disclosure include those sold under the trade name VARCUM (e.g., 29217, 29306, 29318, 29338, 29353) by Durez Corporation; those sold under the trade name AEROFENE (e.g., AEROFENE 295) by Ashland Chemical Co., Bartow, Florida; and those sold under the trade name PHENOLITE (e.g., PHENOLITE TD-2207) by Kangnam Chemical Company Ltd. of Seoul, South Korea.

[0095] The uncured or partially cured resin composition converted into the cured resin composition may comprise additional components, including polyurethane dispersions, such as aliphatic and / or aromatic polyurethane dispersions. For example, the polyurethane dispersion may comprise polycarbonate polyurethane, polyester polyurethane or polyether polyurethane. The polyurethane may comprise a homopolymer or a copolymer.

[0096] The abrasive article can be a coated abrasive article having abrasive particles embedded in a resin layer on a suitable backing, which can be cloth, nonwoven fabric, paper, film, foam, etc. The abrasive article can be a bonded abrasive article having abrasive particles embedded in a bonding matrix, such as a resin or vitreous bonding matrix.

[0097] In block 1040, an indicator is detected when the abrasive efficacy of the abrasive article decreases below a suitable threshold. For example, the abrasive particles may be worn away enough to expose the encapsulating material and react, producing sparks or changing the color of the abrasive article surface. The abrasive article may degrade sufficiently to expose an indicator on or in the backing. The indicator may be detected using a spectrometer 1042, an odometer 1044, or other suitable sensor, such as an ionization chamber or a photoelectric sensor for detecting smoke.

[0098] Figures 11A to 11B An image of swarf from an abrasive article according to embodiments herein is shown.By examining other components of the abrasive operation, it is possible to gain an indication of the efficacy of the abrasive. Figures 11A to 11B shows how the chips generated by the grinding operation are removed from the first cycle ( Figure 11A ) changes to the cycle at the end of the abrasive product life ( Figure 11B As shown in the figure, during the early use of a metal-based abrasive article, the chips are thin and fibrous, like wood shavings, while at the end of the abrasive article's life, the chips become agglomerated and spherical, like powder. This is likely due to the increased heat generated as the abrasive loses its effectiveness, causing the metal to melt and form spherical droplets. The chips formed at the end of an abrasive's life may also differ in color, typically being darker than those formed earlier in the abrasive article's life.

[0099] In the case of a robotic grinding operation, a camera mounted at the end of the arm can image the chips as the grinding operation proceeds. The camera can be any suitable camera capable of capturing images of the chips, which can include micron-sized particles. The robotic arm can also include a light source if desired. In one embodiment, a chip collection device (such as a conveyor belt, funnel, or other suitable transport mechanism) collects the chips generated by the grinding operation and moves the chips to a sensor.

[0100] Chip imaging may be more suitable for evaluating the grinding power of a grinding wheel on metal substrates. However, it can also be applied to grinding efficacy on hard substrates such as wood, where the chip pattern may be altered or discolored by burning.

[0101] This article describes a technique for visually detecting changes in the properties of abrasive articles, waste products, or abrasive operations. However, another indicator of abrasive grain degradation is the temperature change of the abrasive operation. As the surface area of ​​the abrasive grain contact surface increases (e.g., as the precisely shaped abrasive grain wears from the top to the bottom of the abrasive grain), the temperature of the abrasive operation increases due to increased friction. An infrared detection sensor (such as a camera or a thermometer) may be able to detect a rise in temperature. Based on the known properties of the abrasive article (e.g., particle density, resin composition, particle composition, etc.) and the abrasive operation (e.g., substrate, speed, applied force, etc.), a temperature threshold and a corresponding infrared spectrum may be set.

[0102] In some embodiments, rather than detecting infrared light, the sensor detects a different parameter related to operating temperature. FIG. 12A to FIG. 12B As shown, as the abrasive article is used and worn, in addition to a decrease in the material removal rate, the substrate temperature also increases. Measuring the temperature over time can allow this temperature increase to be detected and correlated with the wear of the abrasive article and / or the need to adjust the operating parameters of the next abrasive operation.

[0103] Additionally, heat-activated components in the resin layer or on the substrate itself can indicate temperature or temperature changes and provide an indication of wear. For example, a heat-activated dye or wax can be present in the primer. When the primer is heated, the dye is released or the wax melts, creating a visual indication that can be detected by an operator or sensor.

[0104] In some embodiments, the heat activated dye or wax changes color at a temperature threshold indicating end of life or within an expected end of life timeframe, such as 50% of the time remaining or 25% of the particle height remaining.

[0105] Similarly, the indicator may be held in encapsulated wax, which when melted releases the indicator and is drawn to the outside of the abrasive disc due to centripetal force and is thus detectable.

[0106] The abrasive particles may also be coated with a wax that releases a colored dye or other indicator when a temperature threshold is exceeded.

[0107] In some embodiments, between cycles of abrasive operation, the abrasive disc is brought into proximity with a sensor (such as a camera or thermometer) so that the temperature can be detected. In some embodiments, the thermometer or sensor continuously monitors the abrasive article. For example, a thermocouple can be built into the back-up pad or contact wheel of the abrasive belt, or a camera can be positioned so that the abrasive operation is within the field of view and images are captured over time during the abrasive operation.

[0108] During abrasive operation, the abrasive disc also undergoes physical changes. As the abrasive particles engage the substrate, the abrasive particles break or are ground away, losing mass. As the abrasive particles become exhausted or fall off due to shelling, the thickness of the bonded wheel gradually decreases. The change in thickness is measurable, for example using a caliper. Similarly, the weight of the bonded grinding wheel, nonwoven or coated abrasive article also changes as the abrasive particles are ground or removed. This weight change can be measured using the force control unit of a robotic abrasive unit or by placing the abrasive article on a scale for measurement. In some embodiments, the abrasive article can first be spun rapidly without contacting the substrate to remove entrained water, polishing agent or debris. In some embodiments, entrained material is corrected by a correction factor calculated for each abrasive operation based on a database of abrasive operation data, which allows machine learning to predict the weight of the entrained material.

[0109] In some embodiments, only the weight change is monitored, rather than the absolute weight of the abrasive article. This can eliminate some concerns about entrained material. As the abrasive article nears the end of its useful life, the loss of abrasive grains due to shelling increases, making the weight change detectable. The weight change can be detected by a sufficiently sensitive force control unit or using a scale.

[0110] Figure 13 13 is a networked architecture for the abrasive product usage assessment system 1310. Architecture 900 illustrates one embodiment of a specific implementation of the system 1310, however, other embodiments are possible. In various embodiments, a remote server can deliver these services over a wide area network (such as the Internet) using appropriate protocols. For example, a remote server can deliver applications over a wide area network, and they can be accessed through a web browser or any other computing component.

[0111] 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 to be a single access point for users. Thus, the components and functionality 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.

[0112] As described herein, based on indications 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 the command database 1340).

[0113] 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 for workers in the immediate environment. For example, it is well known that the dust generated by an abrasive article nearing the end of its life is finer than at the beginning. For example, knowing whether an abrasive article in use is nearing 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 nearing 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 ventilation settings, including detecting visual cues, detecting temperature changes, detecting physical changes, or by inspecting cuttings.

[0114] Similarly, it's useful to understand the usage of abrasive products—not for replacement, but for downstream repair. Generally speaking, abrasive operations begin with the coarsest grade and work down to finer grades to polish the substrate surface. For example, a 60-grit disc might be used first, followed by an 80-grit disc, and finally a 120-grit disc. However, if a 60-grit disc is known to be nearing the end of its life, it won't leave such deep scratches, and the 80-grit grinding step can be skipped entirely, moving directly to a 120-grit disc. While such decisions can be made by experienced operators, similar guidance can be helpful to newer operators and improve the efficiency of robotic grinding systems.

[0115] Figure 13 Specifically shown is 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 904, or suggested changes to the operation by the operator—such as increasing force, increasing RPM, etc.

[0116] Figure 13It is also contemplated that some elements of the system described herein are located at a remote server location 1302, while other elements are not located at the remote server location. By way of example, storage devices 1330, 1340, or 1360 or robotic system 1370 may be located at a location separate from location 1302 and accessed at location 1302 via a remote server. Regardless of where they are located, they can be accessed directly by computing device 1320 via a network (wide area network or local area network), hosted at a remote site by a service, 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 or forwarded to interested parties. For example, a physical carrier can be used instead of or in addition to an electromagnetic wave carrier.

[0117] It should also be noted that the elements of the system described herein or portions thereof can be provided on a variety of different devices, some of which 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, and the like.

[0118] Figures 14 to 16 An example of a computing device that may be used in the embodiments shown in the previous figures is shown.

[0119] Figure 14 is a handheld device 16 (e.g., Figure 13 1320) in which the system of the present invention (or portions thereof) 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. Figure 14 is another example of a handheld or mobile device.

[0120] Figure 114 provides a general block diagram of the components of the client device 1016 that can run some of the components shown and described herein. 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 the communication link 1413 include allowing communication via 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.

[0121] In other examples, the application program may be received on a suitable removable memory card, such as a Secure Digital (SD) card, a CF card, a microSD card, or a portable hard drive, connected to the interface 1415. The interface 1015 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 923, as well as the clock 1425 and the positioning system 1427.

[0122] 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.

[0123] Clock 1425 illustratively includes a real-time clock component that outputs time and date. It can also provide a timing function for processor 1417.

[0124] 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 systems. It may also include, for example, mapping software or navigation software that generates desired maps, navigation routes, and other geographic functions.

[0125] Memory 1421 stores an operating system 1429, network settings 1431, applications 1433, application configuration settings 1435, a data repository 1437, communication drivers 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 according to these instructions. Processor 1417 may also be activated by other components to facilitate its functions.

[0126] Figure 15 The device shown may be a smartphone 1501. Smartphone 1501 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 calls, perform data transfer operations, etc. Generally speaking, smartphones 1501 are built on mobile operating systems and provide more advanced computing capabilities and connectivity than non-smartphones.

[0127] Note that other forms of device 1516 are possible.

[0128] Figure 16 is a block diagram of a computing environment that can be used in the embodiments shown in the previous figures.

[0129] Figure 16 is an example of a computing environment in which elements or, for example, portions thereof, of the systems and methods described herein may be deployed. Figure 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 Figure 16 in the corresponding part.

[0130] Computer 1610 typically includes a variety of computer-readable media. Computer-readable media can be any available media accessible by computer 1610 and includes both volatile / non-volatile media and removable / non-removable media. By way of example and not limitation, computer-readable media can include computer storage media and communication media. Computer storage media is distinct from, and does not include, modulated data signals or carrier waves. Computer storage media includes hardware storage media, including 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 includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technologies, CD-ROM, Digital Versatile Disks (DVDs) or other optical disk storage devices, magnetic cassettes, magnetic tape, magnetic disk storage devices or other magnetic storage devices, or any other media that can be used to store the desired information and that can be accessed by computer 1210. Communication media can embody computer-readable instructions, data structures, program modules, or other data in a transport mechanism and includes 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.

[0131] 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, Figure 16 Operating system 1634 , application programs 1635 , other program modules 1636 , and program data 1637 are shown.

[0132] The computer 1610 may also include other removable / non-removable and volatile / non-volatile computer storage media. For example only, Figure 16 Shown is a hard drive 1641 that reads from and writes to a non-removable, nonvolatile magnetic medium, a nonvolatile magnetic disk 1652, an optical drive 1655, and a nonvolatile optical disk 1656. The hard drive 1641 is typically connected to the system bus 1621 through a non-removable storage interface, such as interface 1640, and the optical drive 1655 is typically connected to the system bus 1621 through a removable storage interface, such as interface 1650.

[0133] Alternatively or additionally, the functionality 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), and the like.

[0134] discussed above and in Figure 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. Figure 16 , for example, hard disk drive 1641 is shown as storing operating system 1644, application programs 1645, other program modules 1646, and program data 1647. Note that these components can be the same as or different from operating system 1634, application programs 1635, other program modules 1636, and program data 1637.

[0135] A user can 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, and 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 through 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.

[0136] Computer 1610 operates in a networked environment with one or more remote computers, such as remote computer 1680 , using logical connections, such as a local area network (LAN) or a wide area network (WAN).

[0137] 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, Figure 16 Remote application programs 1685 are shown as residing on remote computer 1680 .

[0138] 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.

[0139] An abrasive article evaluation system includes a detector for detecting an indication of abrasive wear. The system also includes an efficiency indicator generator for generating an indication of wear of the abrasive article based on the indication of abrasive wear. The system also includes a command generator for generating a command based on the generated indication of wear.

[0140] The system may be implemented such that it includes a parameter acquirer that acquires 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.

[0141] 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.

[0142] The system may be implemented such that the operating parameter is speed. The second speed is higher than the first speed.

[0143] The system may be implemented such that the operating parameter is an angle. The second angle is different from the first angle.

[0144] The system may be implemented such that the command is a replacement command, and the robotic grinding unit associated with the abrasive article automatically initiates an abrasive article replacement sequence based on the command.

[0145] 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.

[0146] The system can be implemented so that the downstream grinding operation parameter is speed, force or residence time.

[0147] The system may be implemented such that the downstream lapping operation parameter is a second abrasive article operation using a second abrasive article.

[0148] The system may be implemented such that the history value acquirer acquires the history value of the operation parameter.

[0149] The system may be implemented such that the detector detects the cue in response to a detection actuator that generates a trigger to actuate the detector.

[0150] The system may be implemented such that the detection initiator generates a trigger periodically.

[0151] The system may be implemented such that the detection initiator generates a trigger in response to a manual input.

[0152] The system may be implemented such that the detection initiator generates a trigger before the grinding operation begins.

[0153] The system may be implemented such that the detection initiator generates a trigger at the end of the grinding operation.

[0154] 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.

[0155] The system may be implemented such that it includes a command communicator that transmits the command to the second device.

[0156] The system may be implemented such that the second device is a robotic grinding unit.

[0157] The system may be implemented such that the second device is a ventilation system.

[0158] The system may be implemented such that the second device is a dust collection system.

[0159] The system may be implemented such that the detector comprises a cue capturing device.

[0160] The system may be implemented such that the cue capture device is a camera.

[0161] The system may be implemented such that the prompt capturing device is a temperature measuring device.

[0162] The system may be implemented such that the temperature measuring device comprises a thermocouple incorporated into the support mat.

[0163] The system may be implemented such that the temperature measuring device comprises an infrared camera.

[0164] The system may be implemented such that the cue capturing device is a scale.The cue is the weight of the abrasive article.

[0165] The system can be implemented such that the cue capturing device is a caliper.The cue is the thickness of the abrasive article.

[0166] The system may be implemented such that the detector includes a movement mechanism and a movement controller that moves the detector into position.

[0167] The system may be implemented such that the detector comprises the light source.

[0168] The system may be implemented such that the cue of wear is sparking, and the cue capture device captures increases or changes in sparking.

[0169] The system may be implemented such that the command is a re-dressing command to re-dress the abrasive article.

[0170] The system can be implemented such that the command is a treatment command to treat the abrasive article to remove burden material.

[0171] A robotic grinding system is presented, comprising an abrasive article including a wear indicator. The system also includes a back-up pad coupled to the abrasive article. The system also includes a robotic arm configured to move the abrasive article into position relative to a substrate. The system also includes a force control unit on the robotic arm and coupled to the back-up pad. The force control unit applies a force to the back-up pad. The system also includes a wear indication system that determines an amount of wear of the abrasive article based on the wear indicator and adjusts operating parameters of the robotic grinding system based on the wear amount.

[0172] The robotic grinding system may be implemented such that a detector detects wear indications, an efficiency generator generates an indication of abrasive efficiency for the abrasive article, and a command generator generates commands to adjust operating parameters.

[0173] The robotic grinding system may be implemented such that the detector includes an ultraviolet light source, the wear cue is a fluorescent material on the abrasive article, and the generated abrasive efficiency is based on a detected area of ​​the fluorescent material.

[0174] The robotic grinding system may be implemented such that the wear cue is a heat activated material that changes color at a temperature threshold.The detector includes a camera.

[0175] The robotic grinding system may be implemented such that the wear cue is the operating temperature. The detector comprises a temperature sensor.

[0176] The robotic milling system can be implemented such that the temperature sensor comprises a thermocouple within the support pad.

[0177] The robotic grinding system may be implemented such that the temperature sensor comprises an infrared camera.

[0178] The robotic grinding system may be implemented such that the temperature sensor comprises a thermometer.

[0179] The robotic grinding system may be implemented such that the detector comprises a scale.The robotic arm provides the abrasive article to the scale between grinding operations.

[0180] The robotic grinding system may be implemented such that the detector includes a force control unit. The force control unit detects a weight change of the abrasive article.

[0181] The robotic grinding system can be implemented such that the detector comprises a caliper. The robotic arm provides the abrasive article to the caliper between grinding operations.

[0182] The robotic grinding system can be implemented such that the detector includes a camera that images the abrasive article.

[0183] The robotic grinding system can be implemented such that the camera images the surface of the abrasive article.

[0184] The robotic grinding system may be implemented such that images from the camera are analyzed by the efficiency indicator generator and visual wear indications are detected.

[0185] The robotic grinding system may be implemented so that the visual indication is a color change, a message, mist, or smoke.

[0186] The robotic grinding system may be implemented such that the detector includes a camera that images swarf generated during abrasive operation.

[0187] The robotic grinding system may be implemented such that the detector recognizes a spherical shape or a round shape in the generated chips.

[0188] The robotic grinding system may be implemented such that an operating parameter is an automatic shutdown.

[0189] The robotic grinding system can be implemented so that automatic shutdown is based on a temperature threshold.

[0190] The robotic grinding system may be implemented such that the operating parameter is the applied force of the force control unit, the rotational speed of the abrasive article, or the dwell time of the abrasive article on the substrate.

[0191] The robotic grinding system can be implemented such that the operating parameter is a parameter of a future abrasive operation on the substrate.

[0192] The robotic grinding system can be implemented such that the operating parameter is a parameter of a future abrasive operation using the abrasive article.

[0193] The robotic grinding system may be implemented such that the detector is mounted on a robotic arm.

[0194] The robotic grinding system may be implemented such that it includes a moving mechanism that moves the detector relative to the robotic arm. The detector is independent of the robotic arm.

[0195] The robotic grinding system may be implemented such that the detector activates an inspection sequence in response to an inspection start command from the controller.

[0196] The robotic grinding system may be implemented such that the controller periodically sends a detection start command.

[0197] The robotic grinding system may be implemented such that the controller sends a detection initiation command at the beginning or end of a grinding operation.

[0198] The robotic grinding system may be implemented such that the controller generates the command to adjust the operating parameter.

[0199] The robotic grinding system may be implemented such that the wear indication system includes a history value acquirer that acquires history values ​​of the wear prompt, and a wear processor that determines the wear amount based on the wear prompt and the acquired history values.

[0200] The robotic grinding system may be implemented such that the historical value is the last captured wear cue.

[0201] The robotic grinding system may be implemented such that the historical values ​​are initial wear indicators.

[0202] The robotic milling system may be implemented such that it includes a light source coupled to a robotic arm.

[0203] A wear detector for an abrasive article is presented. The wear detector includes a cue capture device positioned near the abrasive article to detect wear cues associated with the abrasive article. The detector also includes an efficacy indicator generator that receives the detected wear cues and provides a wear indication based on the detected wear cues. The detector also includes a wear communicator that transmits the detected wear cues to a second device.

[0204] The detector may be implemented so that the motion mechanism moves the cue capture device into position in response to the motion control command.

[0205] The detector may be implemented such that a motion control command is received from the second device.

[0206] The detector may be implemented such that it includes a historical value acquirer that acquires historical wear indications of the abrasive article.

[0207] The detector may be implemented such that it includes a threshold value acquirer that acquires a threshold value of the efficacy generator.

[0208] The detector may be implemented such that it includes a parameter acquirer that acquires a set of operating parameters of the abrasive article and acquires a threshold value based on the set of operating parameters.

[0209] The detector may be implemented such that the second device comprises a data store for receiving and storing the indication of wear.

[0210] The detector may be implemented to cause the wear communicator to generate a wear alert, causing the second device to generate an alert based on the received detected wear cue.

[0211] The detector may be implemented such that the cue capturing device comprises a camera.

[0212] The detector may be implemented such that it comprises a UV light source.

[0213] The detector may be implemented such that it comprises a camera, which is an infrared camera.

[0214] The detector may be implemented such that a camera images the surface of the abrasive article.

[0215] The detector may be implemented such that the camera images the swarf produced by the abrasive operation.

[0216] The detector may be implemented such that the cue capturing device comprises a temperature sensor.

[0217] The detector may be implemented such that the temperature sensor comprises a thermocouple integrated into the support mat.

[0218] The detector may be implemented such that the cue capturing device includes a scale for measuring the weight of the abrasive article.

[0219] The detector may be implemented such that the cue capture device includes a caliper that measures the thickness of the abrasive article.

[0220] The detector may be implemented such that the efficacy indicator generator analyses colour changes of the image.

[0221] The detector may be implemented such that the efficacy indicator generator analyzes the fluorescence of the image.

[0222] The detector may be implemented such that the efficacy indicator generator analyses the shape of the generated chips.

[0223] An abrasive article having a wear indicator includes a bonded matrix and a plurality of shaped abrasive particles within the bonded matrix. The abrasive article also includes a detectable wear indicator that becomes detectable after a portion of the useful life of the abrasive article has expired.

[0224] The abrasive article may be implemented such that the abrasive article is a bonded abrasive article. The bond matrix is ​​a resin, polymer, or vitreous bond.

[0225] The abrasive article can be implemented so that the wear indication is a fluorescent material.As the abrasive article wears, the fluorescent material becomes visible.

[0226] The abrasive article can be implemented such that the fluorescent material is incorporated into the bonding matrix.

[0227] The abrasive article can be implemented such that the wear cue is a heat-activated component.

[0228] The abrasive article may be implemented such that the wear tips melt at a temperature threshold.

[0229] The abrasive article may be implemented such that the wear indicator changes color at a temperature threshold.

[0230] The abrasive article can be implemented so that the heat-activatable component is a colored wax.

[0231] The abrasive article may be implemented such that the wax encapsulates the wear indicator.

[0232] The abrasive article can be implemented so that the wear cue is a dye.

[0233] The abrasive article may be implemented such that the wear cue produces mist or smoke when activated.

[0234] The abrasive article may be implemented such that the wear cue produces an odor when activated.

[0235] The abrasive article may be implemented such that the wear cue is an encapsulated material.

[0236] The abrasive article can be implemented such that the abrasive article includes a backing abrasive. The particles are coupled to the backing via a bonding matrix.

[0237] The abrasive article can be implemented so that the wear indication is a fluorescent material.As the abrasive article wears, the fluorescent material becomes visible.

[0238] The abrasive article can be implemented such that the fluorescent material is incorporated into the bonding matrix.

[0239] The abrasive article can be implemented such that the backing is a nonwoven backing.

[0240] A method of evaluating an abrasive article includes abrading a substrate with the abrasive article, capturing an indication of the abrasive article with a detector proximate the abrasive article, evaluating the indication against a wear threshold using an efficacy evaluator, and providing a wear indication if the indication is greater than the wear threshold.

[0241] The method may be implemented such that it further comprises capturing an initial indication prior to performing a first abrasive operation using the abrasive article.

[0242] The method may be implemented such that the detector comprises a camera.

[0243] The method may be implemented such that the detector comprises a thermometer.

[0244] The method may be implemented such that the wear threshold is selected based on the abrasive article.

[0245] The method may be implemented such that the wear threshold is selected based on a set of operating parameters of the abrasive operation.

[0246] The method may be implemented such that no wear indication is provided if the indication is below a wear threshold.

[0247] The method may be implemented such that if the indication is below a wear threshold, a remaining useful life indication is provided.

[0248] The method may be implemented such that it comprises estimating a remaining useful life based on the indication.

[0249] The method may be implemented such that the remaining useful life indication is estimated based on historical wear trends of the abrasive article.

[0250] The method may be implemented such that the remaining useful life indication is estimated based on current operating parameters.

[0251] The method may be implemented such that the remaining useful life indication is based on planned operating parameters.

[0252] The method may be implemented such that if the indication is above a threshold, an indication is generated that the abrasive article should be treated before the next operation.

[0253] The method may be implemented such that if the indication is above a threshold value, a command is generated for the robotic grinding unit to process the abrasive article before the next operation.

[0254] A method for forming an abrasive article is presented, comprising providing a plurality of abrasive grains, a bonding matrix precursor, and a backing material. The method further comprises incorporating a wear indicator into any of the abrasive grains, the bonding matrix precursor, or the backing. The method further comprises embedding the abrasive grains into the bonding matrix precursor. The method further comprises curing the bonding matrix precursor to form the abrasive article. The wear indicator becomes detectable when the abrasive article is used in an abrasive operation.

[0255] The method may be implemented such that the wear indicator is not detectable prior to performing a first abrasive operation using the abrasive article.

[0256] The method can be implemented such that the abrasive article is a bonded abrasive article.The backing material is a scrim layer.

[0257] The method may be implemented such that the backing material is a nonwoven material.

[0258] The method may be implemented such that the bonding matrix precursor is a resin bonding precursor, a glassy bonding precursor, or a polymer bonding precursor.

[0259] The method may be implemented such that the wear indicator is a fluorescent material.

[0260] The method can be implemented such that the wear indicator is a first subset of abrasive particles.The subset of abrasive particles has a first color that is different from a second subset of abrasive particles.

[0261] The method may be implemented such that the wear indicator is an encapsulating material.

[0262] The method may be implemented such that the encapsulating material comprises a dye.

[0263] The method may be implemented such that the encapsulating material comprises a smoke or haze generating material.

[0264] The method may be implemented such that the wear indicator is a spark-generating material.

[0265] Example

[0266] The following materials were used in the embodiments herein.

[0267] AX55362-Polyester backing

[0268] AX55362 is a polyester backing manufactured by 3M ASD, Alexandria, Minn., and its preparation is described in U.S. Patent 6,843,815. A polyester backing containing fluorescent dye was purchased from Milliken and then treated with K2A presize (epoxy / acrylate / novolac) and a calcium carbonate-filled phenolic backsize.

[0269] 784F 36+LH42 coated abrasive belt

[0270] 784F 36+ is a Cubitron manufactured by 3M ASD in Alexandria, Minnesota TM II Y-type polyester metal processing belt. 784F 36+Cubitron TM II tape includes AX55362 backing, phenolic resin, PSG and alumina mineral blend, phenolic resin size, and epoxy resin supersize.

[0271] UV lamp

[0272] The UV lamp was an EL series 6-watt handheld lamp purchased from transluminators.com with an output wavelength of 365 nm.

[0273] Example 1: Chip Collection

[0274] A coated abrasive belt (784F Grade 36+, obtained from 3M Company, Saint Paul, Minnesota) measuring 10.16 cm x 91.44 cm was abraded against a 304 stainless steel bar measuring 1.9 cm x 1.9 cm x 61 cm, with the surface to be abraded measuring 1.9 cm x 1.9 cm. A serrated contact wheel with a diameter of 20.3 cm, a hardness of 70, and a land to groove ratio of 1:1 was used. The belt was run at 2750 rpm. A normal force of 5.5 kg was applied to the center portion of the belt for 15 seconds. After each cycle, the workpiece was cooled and dried by immersion in water. The test was run for 50 cycles. Chips were collected during cycle 1 and imaged under a microscope. Chips were also collected during cycle 50 and imaged under a microscope. Images are as follows: Figure 11A and Figure 11B shown.

[0275] Example 2: Fluorescent backing material

[0276] The following materials were used to prepare chemically cross-linked fibers with photochromic or thermochromic dyes. It is worth noting that this is an example of fiber fabrication. Many other materials could be substituted or even more suitable for specific applications. This material set was chosen because the formula is easily implemented within the 3M range and feasibility testing is readily available. A detailed description of the materials used in this invention is summarized in Table 1.

[0277] Table 1. Materials used in Examples 2, 2A, and 2B.

[0278]

[0279] Fiber spinning method

[0280] The study used a single-hole blunt needle to obtain large fiber diameters. Abrasive applications are looking for new fibers with fiber diameters of about 40 microns or larger, and the blunt needle is capable of producing fiber diameters ranging from tens to hundreds of microns. A 20mL stainless steel metal syringe was filled with resin and placed on a syringe pump with a Luer lock adapter that connected to an 18-gauge stainless steel blunt needle. The use of a metal syringe prevented the fluorescent lights in the laboratory from inadvertently activating the resin inside the barrel. The resin fell vertically into a collector at the bottom of the apparatus. The current fiber spinning setup can mount up to two light sources on an 8020 frame that can move at various angles in the x, y, and z directions. The syringe flow rate was set to 5mL / min to obtain a continuous fiber beam stream without breakage.

[0281] Two UVLED light sources with peak wavelengths of 365 nm and 405 nm were purchased from Phoseon; their specifications are listed in Table 2 below. Light intensity was controlled using a manufacturer-supplied controller. For consistency, 100% maximum light intensity was used throughout the experiments. To thin the fibers, the UVLED lamp was positioned directly above the collector, where the light source's 8020 mounting frame was 30.25 inches below the syringe pump's 8020 mounting frame. Unless otherwise noted, a 405 nm UVLED was used for fiber spinning.

[0282] Table 2. Specifications of the UVLED light sources used in this study .

[0283] model Peak wavelength Peak irradiance Launch size FJ240 150X40AC 365-8W 365nm <![CDATA[8W / cm 2 ]]> 150mm×40mm FJ240 150X40AC405-12W 405nm <![CDATA[12W / cm 2 ]]> 150mm×40mm

[0284] Comparative Example 2A

[0285] A control sample was prepared by mixing 100 parts of 10A / AA with 1 phr of Irg 651, 1 phr of Irg 819, and 10 phr of TMPTA. All materials were poured into a black plastic jar and mixed with a speed mixer. The mixed resin was used after 12 hours to allow sufficient time to remove any bubbles that were generated during the mixing process. The fiber was optically clear.

[0286] Comparative Example 2B

[0287] 0.1 phr of FD was added to the same components described in Comparative Example 2A. The materials were processed identically. According to the product datasheet, FD absorbs UVA light and emits visible light, as shown on the left side of Figure 18. To verify the effectiveness of the dye, the light of the optical microscope was turned off, and then a dark UVA light was shone onto the sample. As can be seen in Figure 18, when illuminated, the control fiber only reflected UVA light. However, the fiber containing only a small amount of FD emitted a bright blue color under dark light.

[0288] Example 3

[0289] Stainless steel metal rods (0.635 mm x 0.635 mm x 152 mm) were used to measure the surface of 784F 36+Cubitron purchased from 3M Company in St. Paul, Minnesota. TM A Type II coated abrasive belt was abraded to expose the backing. Next, the abraded area of ​​the belt was irradiated with a UV handheld lamp, an EL series 6-watt handheld lamp with a wavelength output of 365 nm, commercially available from trasluminators.com in Atkinson, New Hampshire. Figure 8 As shown, the abrasive area fluoresces, indicating the end of life of the coated abrasive belt.

[0290] Example 4

[0291] To investigate the relationship between workpiece material removal rate and workpiece temperature, grinding tests were conducted on a 10.16 cm x 91.44 cm abrasive belt converted from a coated abrasive sample. A 20.3 cm diameter 70 durometer rubber (1:1 land to groove ratio) serrated contact wheel was used. The belt was operated at 2750 rpm. The workpiece was a 304 stainless steel bar measuring 1.9 cm x 1.9 cm x 60.96 cm, with the surface to be ground measuring 1.9 cm x 1.9 cm. The workpiece weight was recorded in grams, and the workpiece was then pressed into the center portion of the belt. The tests were conducted under a weight of 11.34 kg (25 lbs). Each test cycle consisted of 6 seconds of grinding. At the end of the 6-second grinding cycle, the end of the workpiece contacting the abrasive belt was moved to an IR thermometer, brand and model Omega OS552-MA-6, to record the workpiece temperature. The workpiece is then cooled by quenching 1.3 cm of the grinding end in 15.5°C water for 8 seconds, followed by a continuous jet of pressurized air for 10 seconds to dry the workpiece. The workpiece is then weighed to determine the amount of material removed in grams, thereby ending the cycle. The final workpiece weight from the previous cycle is used as the initial workpiece weight for the subsequent cycle. If the final mass of the workpiece after wear weighs less than 275 grams, a new 304 stainless steel bar with dimensions of 1.9 cm x 1.9 cm x 60.96 cm is weighed and used for the subsequent cycle. The test is terminated after 120 cycles. The amount of workpiece removed (in grams / cycle) is calculated. Figure 12A ) and workpiece temperature in °F / cycle ( Figure 12B ) were analyzed and the results showed that when abrasive wear and cutting efficiency decrease, the workpiece temperature will increase.

[0292] Example 5

[0293] 60 grinding cycles were performed on a 984F Cubitron™ II belt to remove a 15 mm stainless steel rod at a force of 180 N (equivalent to 0.45 N / mm2). After each cycle, all parameters were measured, but in particular the time taken to grind the substrate and the temperature after grinding. In addition, after every 5 cycles, the same abrasive sheet was photographed to visually illustrate the condition of the belt, and in particular the amount of "blue" material produced by the exposure of the PSG abrasive grains.

[0294] Table 3: Experimental input:

[0295]

[0296]

[0297] The experiments performed showed very clearly that as the grinding cycle progressed, the temperature increased and the number of “blue” PSG particles visible on the belt surface increased.

[0298] Figure 17 An image of the mill interface is shown. The mill interface in the 3M Neuss lab allows modification of a range of process operating parameters to adjust the amount of material removed or the rate of material removal.

[0299] The user interface allows the process operating conditions to be modified, or in this case, maintained to display the abrasive attenuation under a range of fixed operating conditions. In this case, the belt type, contact force, belt speed, and material removal volume were fixed. The automated grinding machine performed over 60 material removal cycles on a single metal rod, where after each cycle, the material removal rate (time), substrate temperature (°C), and belt thickness increase (mm) were measured and correlated with the appearance of the abrasive grains.

[0300] The increase in cycle time required to remove 15mm of material shows the attenuation of the abrasive, and the corresponding increase in temperature shows that the cut rate is less effective as the mineral tip begins to wear. In all cases, the thickness of the strip changed with each cycle, indicating that loss of the mineral tip and changes in the strip's topography occur over time when subjected to metal grinding cycles.

[0301] Table 4: Temperature and cutting rate

[0302]

Claims

1. An abrasive product evaluation system, the abrasive product evaluation system comprising: a detector that detects abrasive wear indication; an efficiency indicator generator that generates a wear indication of the abrasive article based on the abrasive wear cue; and A command generator generates commands based on the generated wear indication.

2. The system according to claim 1, further comprising: a parameter acquirer that acquires 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 1, wherein the operating parameter is an angle, and wherein the second angle is different from the first angle.

6. The system of any one of claims 1 to 5, wherein the command is a downstream operation command that adjusts a downstream grinding operation parameter based on the wear indication.

7. The system of any one of claims 1 to 6, 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.

8. The system of any one of claims 1 to 7, wherein the detector comprises a cue capture device.

9. The system of claim 8, wherein the cue capturing device is a camera.

10. The system of claim 8, wherein the prompt capturing device is a temperature measuring device.

11. The system of claim 10, wherein the temperature measurement device comprises a thermocouple incorporated into the support pad.

12. The system of claim 10, wherein the temperature measuring device comprises an infrared camera.

13. The system of claim 8, wherein the cue capturing device is a scale, and wherein the abrasive wear cue is the weight of the abrasive article.

14. The system of claim 8, wherein the cue capturing device is a caliper, and wherein the abrasive wear cue is a thickness of the abrasive article.

15. The system of claim 8, wherein the detector comprises a movement mechanism and a movement controller, the movement controller moving the detector into position.

16. The system of claim 8, wherein the detector comprises a light source.

17. The system of any one of claims 1 to 16, wherein the abrasive wear cue is a spark, and wherein the cue capture device captures an increase or change in the spark.

18. A robotic grinding system, the robotic grinding system comprising: an abrasive article comprising a wear indication; a back-up pad coupled to the abrasive article; a robotic arm configured to move the abrasive article into position relative to a substrate; a force control unit located on the robot arm and coupled to the support pad, wherein the force control unit applies a force to the support pad; and A wear indication system determines an amount of wear of the abrasive article based on the wear indication and adjusts an operating parameter of the robotic grinding system based on the amount of wear.

19. The robotic grinding system of claim 18, wherein the wear indication system comprises: a detector, the detector detecting the wear indication; an efficiency indicator generator, the efficiency indicator generator generating an abrasive efficiency of the abrasive article; and A command generator generates commands to adjust the operating parameters.

20. The robotic grinding system of claim 19, wherein the detector comprises an ultraviolet light source, the wear cue is a fluorescent material on the abrasive article, and the generated abrasive efficiency is based on a detected area of ​​the fluorescent material.

21. The robotic grinding system of claim 19, wherein the wear cue is a heat activated material that changes color at a temperature threshold, and wherein the detector comprises a camera.

22. The robotic grinding system of claim 19, wherein the wear cue is an operating temperature, and wherein the detector comprises a temperature sensor.

23. The robotic grinding system of claim 22, wherein the detector comprises a scale, and wherein the robotic arm provides the abrasive article to the scale between abrasive operations.

24. The robotic grinding system of claim 22, wherein the detector comprises the force control unit, and wherein the force control unit detects a change in weight of the abrasive article.

25. The robotic grinding system of claim 22, wherein the detector comprises a caliper, and wherein the robotic arm provides the abrasive article to the caliper between abrasive operations.

26. The robotic grinding system of claim 22, wherein the detector comprises a camera that images the abrasive article.

27. The robotic grinding system of claim 26, wherein the camera images a surface of the abrasive article.

28. The robotic grinding system of claim 26, wherein images from the camera are analyzed by the efficiency indication generator and visual wear indications are detected.

29. The robotic grinding system of claim 28, wherein the visual indication is a color change, a message, mist, or smoke.

30. The robotic grinding system of claim 19, wherein the detector comprises a camera that images swarf generated during the abrasive operation.

31. The robotic grinding system of claim 18, wherein the operating parameter is an automatic shutdown.

32. The robotic grinding system of claim 18, wherein the operating parameter is a force applied by the force control unit, a rotation speed of the abrasive article, or a residence time of the abrasive article on the substrate.

33. A method of evaluating an abrasive article, the method comprising: abrading a substrate using the abrasive article; capturing an indication of the abrasive article with a detector proximate the abrasive article; evaluating the indication against a wear threshold using an efficacy evaluator; as well as If the indication is greater than the wear threshold, a wear indication is provided.

34. The method of claim 33, further comprising: An initial indication is captured prior to performing a first abrasive operation with the abrasive article.

35. The method of claim 33, wherein the detector comprises a camera.

36. The method of claim 33, wherein the detector comprises a thermometer.

37. The method of claim 33, wherein the wear threshold is selected based on the abrasive article.

38. The method of claim 33, wherein the wear threshold is selected based on a set of operating parameters of an abrasive operation.

39. The method of claim 33 wherein if the indication is below the wear threshold, providing a remaining useful life indication.

40. The method of claim 39, further comprising: A remaining useful life is estimated based on the indication.

Images