Abrasive article, system, and method of use

Abstract

The polishing article evaluation system includes a detection unit that detects a polishing wear queue. The system also includes a validity indication generation unit that generates an indication of wear of the polishing article based on the polishing wear queue. The system also includes a command generation unit that generates a command based on the generated indication of wear.

Description

Background Art

[0001] Coated abrasive articles containing shaped abrasive grains are useful for shaping, finishing, or grinding a variety of materials and surfaces, such as wood, metals (e.g., non-ferrous metals such as aluminum, which tend to clog grinding wheels in particular), and burrs. Subsequently, there is a need to improve the cost, performance, and / or service life of coated abrasive articles.

Summary of the Invention

[0002] An abrasive article evaluation system includes a detection unit that detects an abrasive wear cue. The system also includes a validity indication generation unit that generates an indication of wear of the abrasive article based on the abrasive wear cue. The system also includes a command generation unit that generates a command based on the generated indication of wear.

[0003] A robotic grinding system is presented that includes an abrasive article that includes an abrasive wear cue. The system also includes a backup pad coupled to the abrasive article. The system also includes a robotic arm configured to move the abrasive article to a fixed position relative to a substrate. The system also includes a force control unit that is on the robotic arm and is coupled to the backup pad. The force control unit applies a force to the backup pad. The system also includes a wear indication system that determines the amount of wear of the abrasive article based on the abrasive wear cue and adjusts the operating parameters of the robotic grinding system based on the amount of wear.

[0004] Systems and methods are described herein for detecting when an abrasive article is approaching the end of its service life. Some of the systems and methods herein may improve the effectiveness of use of the abrasive article as the abrasive particles wear. However, the systems and methods herein are not limited to measuring the wear of the abrasive particles. For example, it may also be useful to detect the wear of the resin matrix in non-woven abrasive articles or bonded abrasive articles where the entire article wears during use. Some abrasive articles wear down to the backing layer, providing an opportunity to visually detect changes.

[0005] Some of the systems and methods described herein may be particularly useful in robotic polishing systems where there is no human operator to detect the end of the useful life by noticing changes in polishing effectiveness. Additionally, some of the systems and methods described herein may be useful for a hand-held polishing tool to assist an operator in adjusting the tool's usage parameters during a polishing operation.

[0006] The above summary of the disclosure is not intended to describe each and every embodiment of the disclosed embodiments or all implementations of the disclosure. The following description illustrates exemplary embodiments in more detail. Accordingly, it should be understood that the following description should not be construed as unduly limiting the scope of the disclosure.

Brief Description of the Drawings

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[0008] When reference characters are repeatedly used in the specification and drawings, they are intended to represent the same or similar features or elements of the present disclosure. Those skilled in the art should understand that many other modifications and embodiments can be devised, which are included within the scope and spirit of the principles of the present disclosure. The figures may not be drawn to scale.

Best Mode for Carrying Out the Invention

[0009] Throughout this document, values expressed in a range format should be interpreted flexibly such that they include not only the numerical values explicitly recited as the limits of the range, but also all individual numerical values or sub-ranges included within that range, in the same way as if each numerical value and sub-range were explicitly recited. For example, a range of "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 the individual values (e.g., 1%, 2%, 3%, and 4%) and sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. A description of "about X to Y" has the same meaning as "about X to about Y" unless otherwise indicated. Similarly, a description of "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z" unless otherwise indicated.

[0010] In this document, the terms "a", "an", or "the" are used to include one or more, unless the context clearly dictates otherwise. The term "or" is used to refer to a non-exclusive "or" unless otherwise indicated. A description of "at least one of A and B" has the same meaning as "A, B, or both A and B". Additionally, any expressions or terms not specifically defined herein are for illustrative purposes only and should not be construed as limiting. The use of section headings is intended solely to assist in reading the document and should not be construed as limiting, and information related to a particular section may be located within or outside that particular section.

[0011] In the methods described herein, acts can be performed in any order without departing from the principles of the disclosure, unless the temporal or operational order is explicitly recited. Further, unless the claims explicitly recite that particular acts are performed separately, those acts can be performed simultaneously. For example, the claimed act of doing X and the claimed act of doing Y can be performed simultaneously in a single operation, and the resulting process falls within the literal scope of the claimed process.

[0012] As used herein, the term “about” can tolerate a certain degree of variability of a value or range, e.g., within 10%, within 5%, or within 1% of the recited value or the limits of the recited range, and includes the precisely recited value or range.

[0013] As used herein, the term “substantially” refers to a majority or most or 100%, 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.

[0014] As used herein, the term "formed abrasive particles" means abrasive particles at least a portion of which have a predetermined shape reproduced from a mold cavity used to form pre-formed abrasive particles. Except in the case of abrasive fragments (such as those described in U.S. Patent Application Publication Nos. 2009 / 0169816 and 2009 / 0165394), formed abrasive particles generally have a predetermined geometric shape that substantially reproduces the mold cavity used to form the formed abrasive particles. As used herein, formed abrasive particles do not include abrasive particles obtained by mechanical crushing operations. Suitable examples of geometric shapes having at least one vertex include polygons (including equilateral polygons, equiangular polygons, star polygons, regular polygons, and non-regular polygons), lens shapes, crescent shapes, circular shapes, semi-circular shapes, elliptical shapes, sectors, segments, drop shapes, and hypocycloids (such as super-elliptical shapes).

[0015] For the purposes of the present invention, the geometric shape may also include a regular polygon or a non-regular polygon, or a star, in which one or more edges (the portion around the face) may be arcuate (either inwardly or outwardly, with the former option being preferred). Thus, for the purposes of the present invention, a triangular shape also includes a three-sided polygon in which one or more of the edges (the portion around the face) may be arcuate. The second side may include a second face (preferably the second face). The second face may have a perimeter of a second geometric shape.

[0016] For the purposes of the present invention, formed abrasive particles also include abrasive particles that include surfaces having a plurality of different shapes, for example, on a plurality of different surfaces of the abrasive particle. Some embodiments include formed abrasive particles having opposite sides of different shapes. The different shapes may include, for example, a difference in surface area between two opposite sides, or different polygon shapes on two opposite sides.

[0017] The shaped abrasive particles are typically selected to have an edge length in the range of 0.001 mm to 26 mm, more typically 0.1 mm to 10 mm, and even more typically 0.5 mm to 5 mm, although other lengths may also be used.

[0018] The shaped abrasive particles can have a "sharp portion" as used herein to describe either the sharp tip or the sharp edge of the abrasive article. The sharp portion may be defined using the radius of curvature, which in the present disclosure is understood to be, for a sharp point, the radius of the arc that best approximates the curve at that point. In the case of a sharp edge, the radius of curvature is understood to be the radius of curvature of the edge profile in a plane perpendicular to the tangent direction of the edge. Further, the radius of curvature is the radius of the circle that best fits the perpendicular cross-section or the average of the cross-sections measured 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 No. 62 / 877443, filed July 23, 2019, which is incorporated herein by reference.

[0019] In cases where the abrasive particles are precisely shaped (e.g., into small triangular plates or conical particles), the effect of this orientation can be particularly important, as discussed in U.S. Patent Application Publication No. 2013 / 0344786 (A1) (Keipert), which is incorporated herein by reference. As used herein, the term "alignment" is used to refer to the relative position of the abrasive particles on the backing, while the term "orientation" refers to the rotational position of the abrasive particles in the aligned position. For example, a triangular particle can have an orientation with the "tip up" or the "tip down" with respect to the backing.

[0020] As used herein, the term shaped abrasive particle refers to a monolithic abrasive particle. As shown, the shaped abrasive particle does not include a binder and is not an agglomerate of abrasive particles held together by a binder or other adhesive material.

[0021] Embodiments of the present specification describe abrasive articles that include wear indicators or other polishing effectiveness indicators. Some exemplary embodiments are described in the context of specific abrasive article types, such as bonded abrasive wheels or coated fiber disks. However, at least some of the effectiveness indicators herein are applicable to multiple types of abrasive articles, and it is explicitly contemplated that the figures and examples described herein are not intended to be limiting.

[0022] Furthermore, with respect to coated abrasive articles, many examples in this specification specifically consider abrasive disks. However, it is explicitly contemplated that abrasive belts may also benefit from the effectiveness indicators described herein.

[0023] Furthermore, with respect to bonded abrasive articles, some examples of grinding wheels are described herein. However, it is explicitly contemplated that wear indicators suitable for some grinding articles may also be suitable for other grinding articles. Bonded abrasive articles may use a vitreous, resin, or polymer-based bond matrix. The bonded abrasive structure may include, for example, a concave center grinding wheel, a cutoff wheel, a cut & grind wheel, a precision bonded wheel, a cup wheel, a segment grinding wheel, and the like.

[0024] FIG. 1 and FIG. 2 show an exemplary coated abrasive disk 100 according to the present disclosure, where the shaped abrasive particles 130 are fixed in the correct location and in a Z-axis rotational orientation with respect to the backing 110. In one embodiment, the shaped abrasive particles 130 are prismatic particles that appear rectangular when viewed from above.

[0025] Generally, the coated abrasive article 100 includes a plurality of abrasive particles that are at least partially embedded in a make coat that fixes the particles to the backing. The backing may be formed from, for example, any known flexible coated abrasive backing. Suitable materials for the backing include polymer films, metal foils, woven fabrics, knitted fabrics, paper, non-woven materials, foams, screens, laminates, combinations thereof, and treated versions thereof.

[0026] The abrasive particles 130 may be embedded in the abrasive layer, and the abrasive layer may include a multilayer structure having a make layer 120 and a size layer 140. The coated abrasive article according to the present disclosure may include an additional layer such as any supersize layer superimposed on the abrasive layer, or may include a backing antistatic treatment layer as desired. Exemplary suitable binders can be prepared from thermosetting resins, radiation curable resins, and combinations thereof.

[0027] The make layer 120 can be formed by coating a curable make layer precursor on the main surface of the backing 110. The make layer precursor may include, for example, an adhesive, a phenolic resin, an aminoplast resin, a urea-formaldehyde resin, a melamine-formaldehyde resin, a urethane resin, a free radical polymerizable polyfunctional (meth)acrylate (e.g., an aminoplast resin having pendant α,β-unsaturated groups, acrylated urethane, acrylated epoxy, acrylated isocyanurate), an epoxy resin (including bis-maleimide and fluorene-modified epoxy resins), an isocyanurate resin, and mixtures thereof. Among these, a phenolic resin is preferred.

[0028] Phenolic resins are generally formed by the condensation of phenol and formaldehyde and are usually classified as resol resins or novolak phenolic resins. Novolak-type phenolic resins are acid-catalyzed and have a molar ratio of formaldehyde to phenol of less than 1:1. Resol-type phenolic resins can be catalyzed by an alkaline catalyst, and the molar ratio of formaldehyde to phenol is 1 or more, typically 1.0 to 3.0, presenting pendant methylol groups. Suitable alkaline catalysts for catalyzing the reaction of the aldehyde and phenol components of resol-type phenolic resins include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, and sodium carbonate, all as solutions of the catalyst dissolved in water.

[0029] Resole phenolic resins are typically coated as a solution with water and / or an organic solvent (e.g., alcohol). Typically, this solution contains from about 70 weight percent to about 85 weight percent solids, although other concentrations may be used. If the solids content is extremely low, more energy is required to remove the water and / or solvent. If the solids content is extremely high, the resulting viscosity of the phenolic resin will typically be overly high, which will typically cause processing problems.

[0030] Phenolic resins are well known and readily available from commercial suppliers. Examples of commercially available resole phenolic resins useful 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. (Seoul, South Korea).

[0031] The make layer precursor can be applied by any known coating method for applying a make layer to a backing, such as roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

[0032] The basis weight of the make coat to be used can depend, for example, on the intended use, the type of abrasive particles, and the properties of the coated abrasive article to be prepared, but typically ranges from 1, 2, 5, 10, or 15 grams per square meter (gsm) to 20, 25, 100, 200, 300, 400, and even 600 gsm. The make coat can be applied by any known coating method for applying a make coat (e.g., a make coat) to a backing, including, for example, roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

[0033] Once the make coat precursor is coated on the backing, triangular abrasive particles are added to and at least partially embedded in the make coat precursor. The triangular abrasive particles are nominally added onto the make coat precursor according to a predetermined pattern and Z-axis rotational orientation. To improve the performance of the particles, it is possible to orient the abrasive particles with respect to the backing using known orientation methods such as electrostatic orientation or magnetic orientation.

[0034] Although FIGS. 1-2 show coated abrasive articles, it is expressly contemplated that the systems and methods herein may also be suitable for understanding the use and wear of other abrasive articles such as bonded abrasive articles having a resinous or vitreous bond matrix, non-woven abrasive articles, brushes, or other abrasive articles.

[0035] A polishing article can be used in many contexts. This specification describes the context of robotic repair (Figure 3) and the context of handheld tools (Figure 4). Various usage scenarios of the polishing article present various problems with respect to the use of the article over time. For example, a skilled human operator can often "feel" when the polishing article is losing cutting effectiveness over time and can adjust accordingly, either by applying more force or by adjusting the angle. A robotic system may not have insight into the wear or loading that occurs on the polishing article and thus may not make the necessary adjustments or may not replace the polishing article when needed. The systems and methods herein may be similarly useful in other contexts.

[0036] Figure 3 is a schematic diagram of a robotic arm that can benefit from the embodiments disclosed in this specification. The robotic repair unit 200 has a base portion 210 that may be stationary in some embodiments. In other embodiments, the base portion 210 can move in six degrees of freedom, i.e., translation, or rotation about the x-axis, y-axis, and / or z-axis. For example, the robot 200 may have a base portion 210 that is fixed to a rail system configured to move with the moving substrate being repaired. Depending on the particular task, the robot 200 may need to approach or move away from the substrate, or may need to move higher or lower than the polishing area. Thus, a movable base portion 200 can enhance functionality.

[0037] The robotic arm unit 200 has one or more tools 240 that can interact with the surface to be machined. The tool 240 may include a backup pad 250 in one embodiment, or may include another suitable polishing tool. During the polishing operation, the tool 240 may have a polishing disk or other suitable polishing article attached using an adhesive, hook and loop, clip system, vacuum, or other suitable attachment system. However, since the polishing article moves with the attached backup pad 250, the polishing article is not necessarily considered to add additional degrees of freedom to the movement of the robotic repair unit 200. Since the tool 240 is attached to the robotic repair unit 200, it has the ability to be positioned within the degrees of freedom provided by the robotic repair unit 200 (most often, six degrees of freedom), as well as within the range of any other degrees of freedom (e.g., compliant force control 230 unit).

[0038] The backup pad 250 is connected to a tool 240 that has a trajectory providing some additional degrees of freedom. (In most tools, one degree of freedom is provided by a rotating shaft with or without some offset. The tool 240 is connected to the output of the force control 230 unit. The force-controlled flange 230 results in a flexible (i.e., not stiffened) displacement curve. (In most force control units, one degree of freedom is provided along the active axis by a sliding (linear) joint. The force control section 230 is connected to the flange 220. The movement of components 210, 220, 230, 240, and 250 can all be controlled using a robot controller (e.g., robot controller 270).

[0039] In addition to moving components 210 to 250 based on the parameters of the polishing operation, the robot controller 270 may adjust the parameters based on the information received from the polished article usage evaluation 260. For example, if the evaluation system 260 indicates that the polished article has reached the end of its service life, the controller 270 may instruct the system 200 to stop the polishing operation, replace the old polished article with a new one, and then continue the polishing operation. Further, for example, the controller 270 may provide new parameters for polishing based on the feedback from the system 260. For example, when the polished article is loaded, the controller 270 may increase the coolant flow to wash away the accumulated chips. When the polished article is capped, the controller 270 may start a dressing process to reduce the detected capping. If the polished article is worn but not at the end of its service life, the controller may increase the force applied by the force control unit 230 or adjust the angle of the tool 240 relative to the substrate. Such adjustments will be described in more detail with reference to later figures.

[0040] Figure 4 shows a hand tool 300 that can be used by a human operator during the polishing operation. The tool 300 includes a polished article 310 connected to a backup pad 312. The tool is operable by a human operator such that the angle of the polished article 310 is adjustable. The applied force may also be adjustable, for example, by the human operator leaning into the operation.

[0041] While a skilled human operator may be able to adjust the operating conditions based on the "feel" of the polishing operation, at least some operators may benefit from the evaluation system 320. The polishing article evaluation system 320 may detect the usage state of the polishing article 310, and the evaluation communication unit 330 may communicate the wear state or the operating state of the polishing article to a human operator. For example, the tool 300 may include a display that provides instructions to a human operator, and based on, for example, an internal gyroscope or accelerometer, the tool may guide the user to adjust the angle of the tool with respect to the surface. In other embodiments, the communication unit 330 may display results, instructions, or suggestions on a display associated with a human operator, such as a display on a protective device worn by the user (e.g., a head-up display or an augmented reality overlay provided on safety glasses) or a display within that area. The communication unit 330 may also communicate the results in another manner, such as audibly, or simply by indicating whether the polishing article is allowed to continue use or not.

[0042] A system and method for evaluating a polishing article are described herein. The polishing article may be associated with a robotic polishing system as shown in FIG. 3, or may be a human-operated tool as shown in FIG. 4. Evaluating a polishing article is used broadly to refer to evaluating parameters related to the polishing effectiveness of the polishing article. The polishing efficacy may be affected by wear, and as the article is used and the particles are worn down, the cutting rate decreases. However, the polishing efficacy may also be affected by other factors that may be detectable using the systems and methods of this specification. For example, capping or loading may occur, where the tip of the polishing particle is covered and becomes unavailable for polishing. Other efficacy factors may also be detectable.

[0043] FIG. 5 shows a polishing article evaluation system according to an embodiment of the present specification. The polishing article evaluation system 500 is preferably accessible to the polishing article 502. For example, a robotic arm can move the polishing article 502 within the range of the detection unit 502 having the queue capture device 522. In some embodiments of the present specification, the queue capture device 522 is a camera or other image capture component that images the polishing article 502. In other embodiments, the queue capture device 522 is a sensor that captures another signal such as the sound, vibration, weight, thickness, or another parameter of the polishing article 502 as described in the embodiments of the present specification. In an embodiment where the queue capture device 522 is a camera, the detection unit 520 may also have a light source 524. The light source may provide illumination in the visible spectrum, ultraviolet spectrum, infrared spectrum, or another wavelength suitable for detecting the queue 510.

[0044] As described herein, the polishing article 502 includes a queue 510 that can be detected by the sensor 522. The queue may be incorporated into the particles 512 within the polishing article 502, the backing 514 or resin structure, or another component 516 of the polishing article. The detectable queue 510 may be a visual indication 504, an auditory indication 506, or another queue 508. For example, the queue 510 may be a detectable weight loss or shrinkage of the polishing article 502 that can be detected by a scale or caliper.

[0045] The detection unit 520 may be stationary such that a robotic arm or a human operator carries the polishing article 502 within the range of the queue capture device 522. In other embodiments, the detection unit 520 is movable and has a movement controller 525 that can move the queue capture device 522, the light source 524, or other components 529 to a fixed position to detect the queue 510. The detection unit 520 may communicate a signal generated by the queue capture device 522 using the detection instruction communication unit 528. However, although the detection unit 520 is shown as separate from the controller 540 that completes the evaluation in FIG. 5, it is explicitly contemplated that in some embodiments it may be a single component.

[0046] The controller 540 receives a detection instruction from the detection unit 520 using the detection unit indicator capture unit 558. The detection unit indicator capture unit 558 may request an instruction from the detection unit 520 in response to the detection unit start unit 556, and the detection unit start unit may send a command to the detection unit 520 to operate the queue capture device 522. In some embodiments, a trigger 554 may activate the detection unit start unit 556. For example, the motion detection unit 554 may detect that the polishing article 502 has moved to a fixed position. The trigger 554 may also be time-based or position-based.

[0047] The instruction processor 562 processes the received signal from the detection unit 520. As described herein, this may include comparing the received signal to a threshold, considering it in light of the historical signal value fetched from the data store by the history value capture unit 544, or otherwise processing the signal to determine whether the polishing efficacy of the article 502 has reached an undesirably low value.

[0048] The instruction process 562 may use a threshold set by a manufacturer, customer, operator, shift supervisor, etc. For example, one customer may set the minimum acceptable thickness of a polishing disk to T, and a second customer may set the threshold to 2T.

[0049] In some embodiments, the controller 540 may determine that even if the polishing efficacy has dropped below a threshold, it may be possible to improve it by changing one or more operating parameters. The parameter capture unit 542 may capture the current set of operating parameters, such as the force applied from the force control unit and the polishing angle from the accelerometer. The command generation unit 546 may generate a command, for example, to the robot arm controller, to adjust the applied force or angle, which is then communicated to the robot arm controller using the command communication unit 548. The command generation unit 546 may also generate a command to replace the polishing article 502 with a new one, or a command to redress the polishing article 502 to remove loading or capping. In some embodiments, the command generation unit 546 and the command communication unit 548 may operate automatically such that the robot controller continuously adjusts the parameters to improve the polishing efficacy.

[0050] The efficacy indication generation unit 564 generates an indication of the polishing efficacy of the polishing article 502. This indication may be displayed, for example, on the display component 590. The indication may be provided, for example, in words such as "60% used" or "capping detected", or may be provided as simply "good" or "bad". The indication may be auditory, for example, an alarm or signal indicating that an action is required to improve the polishing efficacy or to replace the polishing article 502. The indication may be provided to the graphical user interface generation unit 552, which may generate an interface for the display component 590. The controller 540 may also have other components 566.

[0051] In some embodiments, the display component 590 may be incorporated into the hand tool so that the effectiveness indication 592 is visible to the user of the hand tool. In other embodiments, the display component 590 is separate from the tool. For example, in the context of robotic polishing, the display component 590 may be separated from the robotic arm but may still be 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. Then, the GUI generation unit 552 may send an instruction to the application running on the device to update the effectiveness indication 592.

[0052] The display component 590 may also present parameter changes 594 such as adjustment of the tool angle, increase or decrease of the applied force, etc. A change in use 596 may also be indicated. For example, a coated abrasive article that has undergone significant wear may no longer be suitable for the initial bulk grinding removal process of the process but may be suitable for a later minor grinding removal process. The display component 590 may also provide other information 598 received from the controller 540, the detection unit 520, or other locations. For example, the number of completed parts, the average polishing time, or other relevant information can also be displayed.

[0053] Although the system 500 is shown as separate from the display component 590 in FIG. 5, it is expressly 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, although the detection unit 520 and the controller 540 are shown as part of a single unit, it is expressly contemplated that at least some components may be part of separate devices. For example, the controller 540 may be part of a separate computing device remote from the robotic arm controller, the detection unit 520, and the display component 590.

[0054] FIG. 6 shows a method for evaluating a polishing article. In some embodiments, the evaluation may be automatically completed using method 600. For example, a robotic arm or a human operator may move the polishing article within the range of the detection unit or through the detection unit, and the detection unit may capture a signal indicating the polishing efficacy of the polishing article.

[0055] In block 610, attach the polishing article to the tool. For example, the polishing article may be coupled to a backup pad of a hand-held polishing tool or to the tool of a robotic polishing unit. The polishing article may be a polishing article suitable for a given polishing operation, such as a coated polishing article, an agglomerated polishing article, a hair brush, or another suitable polishing article.

[0056] In block 620, the polishing article engages the workpiece and a polishing operation is performed. As the workpiece is polished, the abrasive particles of the polishing article wear down. They may also undergo capping, loading, or other degradation.

[0057] In block 630, evaluate the polishing article. The polishing efficacy of the polishing article is determined. In some embodiments, visual cue 632 may be analyzed to detect wear, capping, or loading. Auditory cue 634 may be analyzed to detect wear, capping, or loading. In other embodiments, a different detection unit 636 detects cues of polishing efficacy.

[0058] The evaluation of the polishing article may be performed by directly measuring parameters of the polishing article, such as visual cues, sounds, or other cues of the polishing article, during or after the polishing operation. In other embodiments, the evaluation of the polishing article may be performed by evaluating the workpiece, the chips removed from the workpiece, or another component.

[0059] The evaluation in block 630 may be performed automatically as part of the polishing process. For example, a robotic arm connected to the polished article may change position, for example, while a completed workpiece is being exchanged for a new workpiece, such that the article comes within the range of the detection unit. Similarly, while a human operator changes the part being polished or completes another task, the human operator can place the polishing tool connected to the polished article at a position within the range of the detection unit.

[0060] In block 642, if the polishing efficacy of the polished article is maintained at an acceptable level, it can be continued to be used for another polishing operation. In some embodiments, new operating parameters are provided based on a decrease in polishing efficacy detected between one evaluation and the next. In a robotic polishing operation, the new parameters may be automatically implemented. In the context of a hand-held tool, the new parameters may be proposed to the operator.

[0061] In block 644, if the polishing efficacy is lower than the acceptable level, as shown in block 650, the polishing efficacy can be treated, for example, by either dressing the polished article to remove capping or cleaning or purging the polished article to remove loading. However, in some embodiments, method 600 returns to block 610.

[0062] Examples and embodiments of the present invention in which the indication of the detected polishing efficacy is essentially visual are described herein with reference to FIGS. 7-12. However, other cues for polishing efficacy are explicitly contemplated and are described in co-pending U.S. Patent Applications Nos. 63 / 366,803 and 63 / 366,805, both filed on June 22, 2022.

[0063] Figures 7A - 7F show fluorescent non - woven fibers that can be used in the embodiments of this specification. Figure 7A shows the fibers as seen under the visible light spectrum, and Figure 7B shows the same non - woven fibers that glow bright blue under a black light. Figures 7C - 7E show different ratios of dyes incorporated into the fibers. Figure 7F shows control fibers without the incorporated dye, indicating that the dyed fibers can be detected while the undyed fibers are not detected or have only a negligible amount of fluorescence. The non - woven fibers have fluorescent dyes incorporated during the fiber manufacturing process. This fiber can then be incorporated into a non - woven abrasive backing, which can be coated with a resin and abrasive particles. When applied by spray - coat application or dip / roll - coat application, the resin covers most of the fibers. As the abrasive article is used and the resin and abrasive particles degrade, the fibers are exposed again. Over time, as the slurry spray layer wears away, more and more fluorescence is detected.

[0064] Although Figures 7A - 7F relate to fluorescent non - woven fibers, the use of fluorescence can also be useful in other applications. For example, the backing of a coated abrasive article may similarly have incorporated fluorescent dyes.

[0065] Figure 8 shows the use of a fluorescent lamp to detect the degradation of an abrasive article according to an embodiment of this specification. Figure 8 shows an abrasive belt (specifically, a 784F 36 + Cubitron (trademark) II belt made by 3M Company) with a fluorescent dye incorporated into the polyester backing and held in front of a fluorescent lamp. In areas where the abrasive particles and resin matrix have worn away and the backing is exposed, the fluorescent lamp shines through.

[0066] By incorporating a UV fluorescent indicator into the coated abrasive backing or resin / mineral layer, the abrasive article can be easily evaluated on-site and serves as an indicator of the end of its useful life. This can enable both robot cell operators and human operators to know when to replace a used coated abrasive belt or coated abrasive disk. When the coated abrasive is used and erosion of the resin / mineral layer occurs, the backing is exposed and the UV fluorescent indicator is detected. A suitable detector may be a UV spectrophotometer device mounted on a robot arm or otherwise placed near the human operator. The detection of the erosion depth of the coated abrasive may vary depending on the placement of the UV fluorescent indicator. For example, it can be placed in the backing, make resin layer, or size resin layer. The UV fluorescent indicator is typically a dye that fluoresces under UV light. As shown in FIG. 8, a portion of 784F 36+ was eroded down to the backing and was easily detected with UV light. The UV fluorescence-based system for detecting the end of useful life is a very effective way to determine the end of useful life of the coated abrasive for manual operation or for automated robotic grinding and finishing operations.

[0067] Although fluorescence has been described in detail, there are other options that can be easily detectable for visual cues. In other embodiments, a state change material or a reactive material is encapsulated and enclosed within the abrasive article. When the encapsulated portion is worn or heated due to the friction of the abrasive operation, the state of the material changes. The material can melt, burn, or sublime to produce a detectable visual cue. Similarly, a reaction such as the generation of smoke or fumes can occur. The reactive material can be, for example, sodium that reacts when exposed to air. Materials that react with air (dry sanding) or water (wet sanding) can be used to provide a detectable indication at the end of the useful life. Wax and polymer can be used to encapsulate dyes, fragrances, or fuming materials. In some embodiments, as the temperature rises due to the increased friction of the worn abrasive material against the surface, the capsule material melts and the encapsulated material is released and becomes detectable. In some embodiments, the capsule material wears rather than melts.

[0068] The material can also change the color of the abrasive disk or the generated chips. For example, the encapsulated wax can also change the red abrasive disk to appear purple. The color change can be detectable by a human operator or by a spectrometer.

[0069] In some embodiments, the material has an odor detectable by a human nose or an odor meter when released.

[0070] Furthermore, in some embodiments, a spark shower is generated when the material interacts with the workpiece. For example, both titanium and cast iron have identifiable spark showers. Titanium or other particles disposed in the backfill layer provide different colored spark showers. Flint or other materials can be used to increase the spark shower. The spark generating material can also be incorporated as a wire or strand in the backing.

[0071] FIG. 9 is a diagram showing an overview of a polishing article according to an embodiment of the present specification. The polishing article 900 has a backing 910, polishing particles 920 having a first color, and a material 930 having a second color. The material 930 may also be polishing particles having a color different from the first color in some embodiments. The second polishing particles 930 may be arranged in a pattern as described in, for example, U.S. Patent Application Publication No. 2022 / 0040814 published on February 10, 2022.

[0072] The material 930 may be a different type of polishing particle from the particles 920, such as backfill or other crushed polishing particles. The material 930 may also be a dye, ink, or print on one of the layers of the article 900, such as a backing, make coat, size coat, or another layer. FIG. 9 shows an embodiment in which the material 930 spells the word "STOP", but it is explicitly contemplated that other visual cues, such as a brand, shape, or another suitable visual indication, may appear.

[0073] FIG. 10 shows a method of making a polishing article having a detectable cue according to an embodiment of the present specification. The method 1000 can be used to make a polishing article that can be used by a robotic polishing system or a human operator and can be used to provide an indication of polishing efficacy. The indication may be an indication of the end of the service life, an indication that new operating parameters are required to improve polishing efficacy, or an indication that the polishing article is no longer suitable for the current operation but may be suitable for downstream polishing operations.

[0074] In block 1010, an indicator material is obtained. The indicator material may be a coloring dye, a fragrance, a spark generating material, a smoke or haze generating material, a material that reacts with air or water, or another material that generates a detectable indication of polishing efficacy.

[0075] In block 1020, an indicator material, such as a dye 1012 that imparts color 1014, may be incorporated into the abrasive particles. The indicator may be encapsulated 1014 and incorporated into a binder layer. For example, a colored wax may be incorporated into the abrasive article by encapsulation, or may be a material that produces a detectable odor or fumes. The indicator may also be a spark generating material 1016, such as titanium, iron, or copper.

[0076] The indicator material may be part of a resin or binder layer, backing, or scrim layer. For example, the abrasive article backing 1018 may have an indicator such as a fluorescent dye or a printed indication. The indicator may also be part of the scrim layer 1022, such as a fluorescent dye or print. The indicator may be incorporated into the resin layer 1024 or alternatively into another component 1026 of the abrasive article.

[0077] In block 1030, an abrasive article is formed. For example, dyed fibers are incorporated into the backing, an encapsulated colored wax is used as part of a resin that cures to form the abrasive article, and the colored abrasive particles are suitably disposed.

[0078] The properties of the uncured or partially cured resin composition are not limited. For example, the uncured or partially cured resin composition may include any suitable material that can be cured to form a make coat. Suitable materials for forming the polishing layer include phenolic resins (e.g., PREFERE 80 5077A manufactured by Arclin (Mississauga, Ontario, Canada)). Suitable phenolic resins are generally formed by the condensation of phenol or alkylated phenol (e.g., cresol) and formaldehyde and are usually classified as resol-type phenolic resins or novolak-type phenolic resins. Novolak-type phenolic resins are acid-catalyzed and have a molar ratio of formaldehyde to phenol of less than 1:1. Resol-type phenolic resins can be catalyzed by an alkaline catalyst and present pendant methylol groups by having a molar ratio of formaldehyde to phenol of 1 or more, typically 1.0 to 3.0. Suitable alkaline catalysts for catalyzing the reaction of aldehyde and phenol components of resol-type phenolic resins include sodium hydroxide, barium hydroxide, potassium hydroxide, calcium hydroxide, organic amines, and sodium carbonate, all of which are in the form of a solution of the catalyst dissolved in water.

[0079] Resol-type phenolic resins are typically coated as a solution with water and / or an organic solvent (e.g., alcohol). Typically, this solution contains from about 70 weight percent to about 85 weight percent solids, although other concentrations may be used. If the solids content is extremely low, more energy is required to remove water and / or the solvent. If the solids content is extremely high, the resulting viscosity of the phenolic resin will typically be too high, resulting in processing problems.

[0080] Phenolic resins are well-known and readily available from commercial suppliers. Examples of commercially available resol-type phenolic resins useful 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. (Seoul, South Korea).

[0081] The uncured or partially cured resin composition that is converted to a cured resin composition may include additional components, including polyurethane dispersions, such as aliphatic and / or aromatic polyurethane dispersions. For example, the polyurethane dispersion may include a polycarbonate polyurethane, a polyester polyurethane, or a polyether polyurethane. The polyurethane may include a homopolymer or a copolymer.

[0082] The abrasive article may be a coated abrasive article having abrasive particles embedded in a resin layer on a suitable backing such as cloth, non-woven fiber, paper, film, foam, etc. The abrasive article may be a bonded abrasive article having abrasive particles embedded in a bond matrix such as a resinous or vitreous bond matrix.

[0083] In block 1040, when the abrasive efficacy of the abrasive article drops below a suitable threshold, an indicator is detected. For example, the abrasive particles may preferably wear such that the encapsulated material is exposed and reacts, causing a spark or changing the color of the surface of the abrasive article. The abrasive article may deteriorate such that an indicator on or within the backing is exposed. The indicator may be detectable using a spectrometer 1042, an odometer 1044, or another suitable sensor such as an ionization chamber or a photoelectric sensor for detecting smoke.

[0084] Figures 11A and 11B show images of swarf from a polishing article according to an embodiment of the present specification. By inspecting other components of the polishing operation, it may be possible to obtain an indication of the polishing efficacy. Figures 11A and 11B show how the swarf generated from the polishing operation changes from an early cycle (Figure 11A) to a cycle near the end of the useful life of the polishing article (Figure 11B). As shown, during the early use of a polishing article with a metal substrate, the swarf is thin and fibrous like shavings, but at the end of the useful life of the polishing article, the swarf agglomerates and forms a spherical shape like powder. This may be due to the fact that as the polishing efficacy decreases, the heat generated increases, which may cause the metal to melt and form spherical droplets. The swarf formed at the end of the polishing effective period may also be different in color from the swarf formed early in the useful life of the polishing article and may often be darker in color.

[0085] In the case of a robotic polishing operation, a camera located at the mounting position of the arm end may be able to image the swarf as the polishing operation progresses. The camera may be any suitable camera capable of capturing an image of the swarf, which may include fine particles on the order of microns. The robotic arm may also include a light source if necessary. In one embodiment, a swarf collection device, such as a conveyor belt, funnel, or other suitable conveying mechanism, collects the swarf generated from the polishing operation and moves the swarf to a sensor.

[0086] Imaging of the swarf may be more suitable for estimating the polishing efficacy of a grinding wheel on a metal substrate. However, it may also be suitable for the polishing efficacy on a hard substrate such as wood where the flake pattern may change or discolor due to combustion.

[0087] Techniques for visually detecting changes in a polishing article, waste, or other attributes of a polishing operation are described herein. However, another indicator of abrasive particle degradation is a temperature change in the polishing operation. As the surface area of the abrasive particles contacting the surface increases (e.g., as precision shaped abrasive particles wear from the tip to the particle base), friction increases, causing the temperature of the polishing operation to rise. An infrared detection sensor, such as a camera or thermometer, may detect the increase in temperature. Based on known attributes of the polishing article (e.g., particle density, resin composition, particle composition, etc.) and known attributes of the polishing operation (e.g., substrate, speed, applied force, etc.), a temperature threshold and corresponding infrared spectrum may be set.

[0088] In some embodiments, a sensor does not detect the infrared spectrum but detects different parameters related to the operating temperature. As shown in FIGS. 12A and 12B, as the polishing article is used and worn, in addition to a decrease in the material removal rate, the substrate temperature rises. Measuring the temperature over time enables detection of this temperature rise and correlating it to the wear of the polishing article and / or the need to adjust operating parameters for the next polishing operation.

[0089] Furthermore, thermally activated components within the resin layer or on the substrate itself may indicate temperature or temperature change to provide an indication of wear. For example, a thermally activated dye or wax may be present in the make coat. As the make coat is heated, the dye is released or the wax melts to produce a visual indication that can be detected by an operator or sensor.

[0090] In some embodiments, the thermally activated dye or wax changes color at a temperature threshold indicating the end of the useful life, or within a time frame of the expected end of the useful life. For example, when the remaining period is 50%, or when the remaining particle height is 25%.

[0091] Similarly, the indicator may be retained within the encapsulated wax, and the indicator is released when the wax melts and is pulled to the outside of the polishing disk due to centripetal force and is thus detectable.

[0092] The abrasive particles may also have a layer of wax applied thereon, which may release a coloring dye or other indicator when a temperature threshold is released.

[0093] In some embodiments, the polishing disk is carried near a sensor such as a camera or thermometer during the polishing operation cycle so that the temperature can be detected. In some embodiments, a thermometer or sensor continuously monitors the polished article. For example, a thermocouple may be incorporated into a backup pad of a polishing belt or a contact wheel, or into a camera set up so that the polishing operation is within the field of view and an image is captured over time during the polishing operation.

[0094] The polishing disk also physically changes during the polishing operation. When the abrasive particles engage the substrate, they are crushed or ground in other ways and lose mass. The bonded wheel decreases in thickness over time as the abrasive particles are depleted or fall off due to shelling. The change in thickness can be measured, for example, using calipers. Similarly, a bonded abrasive wheel, a non-woven polishing article, or a coated polishing article also undergoes a weight change as the abrasive particles are ground or removed. This change in weight can be measured using the force control unit of a robotic polishing unit or by placing the polished article on a scale for measurement. In some embodiments, the polished article may be rapidly rotated without first contacting the substrate to remove entrained water, polish, or debris. In some embodiments, the entrained material is corrected by a correction factor calculated based on a database of polishing operation data for each polishing operation, and this database takes into account machine learning for predicting the weight of the entrained material.

[0095] In some embodiments, only the weight change is monitored rather than the absolute weight of the polishing article. This can eliminate some concerns about contaminating materials. As the polishing article approaches the end of its useful life, the loss of abrasive grains due to shearing increases, resulting in a detectable change in weight. The change in weight may be detectable by a sufficiently sensitive force control unit or by using a scale.

[0096] FIG. 13 is a networked architecture for a polishing article usage evaluation system 1310. Architecture 900 shows one implementation of the implementation of system 1310, but other implementations are also possible. In various embodiments, the remote server can deliver services via a wide area network such as the Internet using an appropriate protocol. For example, the remote server can deliver applications via a wide area network and access them through a web browser or any other computing component.

[0097] Software or components, and the corresponding data, can be stored on a server at a remote location. Computing resources in a remote server environment can be aggregated at the location of a remote data center or can be distributed. The remote server infrastructure can deliver services through a shared data center, which appears as a single access point to the user. Therefore, the components and functions described herein can be provided from a remote server at a remote location using a remote server architecture. Alternatively, they can be provided by a conventional server, installed directly on a client device, or provided in other ways.

[0098] As described herein, based on instructions from the polishing article usage evaluation system 1310, the robotic polishing unit 1304B may adjust the force or speed associated with the polishing operation, or another parameter, in response to a command received via a wired or wireless network (e.g., fetched from the command data store 1340).

[0099] Knowing when a polishing article is approaching the end of its useful life can, in addition to improving the effectiveness benefits to the polishing operation, make it possible to improve the environmental health and safety of the operator in the immediate vicinity. For example, it is known that finer dust is generated towards the end of the useful life of a polishing article than at the beginning. Knowing whether the polishing article(s) in use is approaching the end of its useful life can, for example, trigger a command sent to the ventilation system 1304A to increase ventilation in response to increased dust generation. Similarly, when the polishing article is relatively close to the start of its useful life, the settings of the ventilation system 1304A may be reduced. The trigger for changing the ventilation settings may be generated using any of the methods for detecting the end of the useful life described herein, including detecting visual cues, detecting temperature changes, detecting physical changes, or inspecting swarf.

[0100] Similarly, knowing how a polishing article is being used can be useful for downstream repair rather than for replacement. Generally, the polishing operation starts with the coarsest grade and works towards finer grades to polish the substrate surface. For example, first a 60 grit disk, then an 80 grit disk, and finally a 120 grit disk. However, if it is known that the 60 grit disk is approaching the end of its useful life, it may not leave such deep scratches, so the 80 grit polishing step can be completely skipped and proceed directly to the 120 grit disk. Such a determination may be made by a skilled operator, but similar guidance may assist a novice operator and also increase the effectiveness of the robotic polishing system.

[0101] FIG. 13 specifically shows that the system 1310 can be placed at the remote server location 1302. Accordingly, the computing devices 1320 access those systems through the remote server location 1302. The operator 1350 can also access the user interface 1322 using the computing device 1320. For example, the user interface 1322 may provide instructions on how the polished article is worn, changes made to any of the networked systems 904, or suggestions for changes to the operations by the operator (such as an increase in force, an increase in RPM, etc.).

[0102] FIG. 13 shows that it is also contemplated that some elements of the systems described herein may be placed at the remote server location 1302 while other elements may not be. By way of example, the storage areas 1330, 1340, or 1360, or the robotic system 1370, can be placed at a location separate from the location 1302 and accessed via the remote server at the location 1302. Regardless of where they are located, they can be accessed directly by the computing device 1320 via a network (either a wide area network or a local area network), hosted at a remote site by a service, provided as a service, or accessed by a connection service existing at a remote location. Also, the data can be stored substantially anywhere and accessed intermittently by interested parties or transferred to interested parties. For example, a physical carrier can be used instead of or in addition to an electromagnetic wave carrier.

[0103] Note also that the elements of the systems described herein, or portions thereof, can be placed on a wide variety of different devices. Some of those devices include servers, desktop computers, laptop computers, embedded computers, industrial controllers, tablet computers, or other mobile devices such as palmtop computers, cellular phones, smartphones, multimedia players, personal digital assistants, and the like.

[0104] FIGS. 14-16 show examples of computing devices that can be used in the embodiments shown in the preceding figures.

[0105] FIG. 14 is a simplified block diagram of an exemplary example of a handheld computing device or mobile computing device that can be used as a user or client handheld device 16 (such as, for example, computing device 1320 of FIG. 13) on which the present system (or a portion thereof) can be deployed. For example, a mobile device can be deployed within the operator compartment of computing device 1320 for use in generating, processing, or displaying data. FIG. 14 is another example of a handheld device or mobile device.

[0106] FIG. 114 is an overall block diagram of the components of client device 1016 that can execute some of the components illustrated and described herein. Client device 1416 interacts with them, or executes some and interacts with some. Device 1416 is provided with a communication link 1413 that enables other computing devices and handheld devices to communicate, and in some embodiments provides a channel for automatically receiving information, such as by scanning. Examples of communication link 1413 include enabling communication via one or more communication protocols, such as wireless services used to provide cellular access to a network, and protocols that provide a local wireless connection to a network.

[0107] In other examples, an application can be received on a suitable removable memory card (such as a Secure Digital (SD) card, CF card, micro SD, or portable hard drive) connected to interface 1415. Interface 1015 and communication link 1413 communicate with processor 1417 (which can also embody a processor) along bus 1419, which is also connected to memory 1421 and input / output (I / O) components 923, as well as clock 1425 and position information system 1427.

[0108] I / O components 1423 are provided in one embodiment to facilitate input and output operations, and device 1416 can 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 can be used similarly.

[0109] Clock 1425 illustratively includes a real-time clock component that outputs time and date. It can also provide a timing function to processor 1417.

[0110] Exemplarily, the location information system 1427 includes components that output the current geographical location of the device 1416. This can include, for example, a global positioning system (GPS) receiver, a LORAN system, a dead reckoning system, a cellular triangulation system, or other positioning systems. Also, for example, mapping software or navigation software that generates desired maps, navigation routes, and other geographical functions can also be included.

[0111] The memory 1421 stores an operating system 1429, network settings 1431, applications 1433, application configuration settings 1435, a data store 1437, a communication driver 1439, and communication configuration settings 1441. The memory 1421 can include all types of tangible volatile computer-readable memory devices and non-volatile computer-readable memory devices. Also, computer storage media (described below) can also be included. The memory 1421 stores computer-readable instructions that, when executed by the processor 1417, cause the processor to perform steps or functions implemented by the computer according to the instructions. The processor 1017 can similarly be activated by other components to facilitate their functions.

[0112] FIG. 15 shows that the device can be a smartphone 1501. The smartphone 1571 has a touch-sensitive display 1573 that displays icons or tiles or other user input mechanisms 1575. The mechanism 1575 can be used by the user to execute applications, make phone calls, perform data transfer operations, etc. Generally, the smartphone 1571 is built on a mobile operating system and provides more advanced computing capabilities and connectivity than a feature phone.

[0113] Note that other forms of device 1516 are possible.

[0114] FIG. 16 is a block diagram of a computing environment that can be used in the embodiments shown in the preceding figures.

[0115] FIG. 16 is an example of a computing environment in which elements of the systems and methods described herein, or (for example) portions thereof, can be deployed. Referring to FIG. 16, an example system for implementing some embodiments includes a general-purpose computing device in the form of a computer 1610. The components of computer 1610 can 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 that system memory to the processing unit 1620. System bus 1621 can 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 memory and programs described herein with respect to the systems and methods can be deployed to the corresponding portions of FIG. 16.

[0116] Computer 1610 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by computer 1610 and includes both volatile / non-volatile media and removable / non-removable media. By way of example and not limitation, computer-readable media may include computer storage media and communication media. Computer storage media is different from and does not include modulated data signals or carrier waves. Computer storage media includes hardware storage media implemented in any method or technology for storing information such as computer-readable instructions, data structures, program modules, or other data, including both volatile / non-volatile removable / non-removable media. Computer storage media includes, without limitation, RAM, ROM, EEPROM, flash memory, or other memory technology, CD-ROM, digital versatile disk (DVD), or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage, or other magnetic storage devices, or any other media that can be used to store desired information and can be accessed by computer 1210. Communication media can embody computer-readable instructions, data structures, program modules, or other data in a transfer 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.

[0117] The system memory 1630 includes computer storage media in the form of volatile and / or non-volatile memory, such as a read only memory (ROM) 1631 and a random access memory (RAM) 1632. A basic input / output system 1633 (BIOS), including basic routines that help transfer information between elements within the computer 1610 during startup and the like, is typically stored in the ROM 1631. The RAM 1632 typically includes data modules and / or program modules that are immediately accessible by and / or currently being operated on by the processing unit 1620. By way of example and not limitation, FIG. 16 shows an operating system 1634, an application program 1635, other program modules 1636, and program data 1637.

[0118] The computer 1610 may also include other removable / non-removable volatile / non-volatile computer storage media. By way of mere example, FIG. 16 shows a hard disk drive 1641 that reads from and writes to non-removable, non-volatile magnetic media, a non-volatile magnetic disk 1652, an optical disk drive 1655, and a non-volatile optical disk 1656. The hard disk drive 1641 is typically connected to the system bus 1621 via a non-removable memory interface, such as interface 1640, and the optical disk drive 1655 is typically connected to the system bus 1621 by a non-removable memory interface, such as interface 1650.

[0119] Alternatively, or in addition, the functions described herein can be performed, at least in part, by one or more hardware logic components. By way of example, and not limitation, exemplary 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), system-on-a-chip systems (SOCs), complex programmable logic devices (CPLDs), and the like.

[0120] The drives discussed above and shown in FIG. 16, and their associated computer storage media, provide storage space for computer-readable instructions, data structures, program modules, and other data for computer 1610. In FIG. 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.

[0121] The user can input commands and information into the computer 1610 via input devices such as the keyboard 1662, the microphone 1663, and a pointing device 1661 such as a mouse, trackball, or touchpad. Other input devices (not shown) can include a joystick, game pad, satellite receiver, scanner, and the like. These input devices and other input devices are often connected to the processing unit 1620 via a user input interface 1660 connected to the system bus, but can also be connected by other interfaces 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 can also include other peripheral output devices such as a speaker 1697 and a printer 1696 that can be connected via an output peripheral interface 1695.

[0122] The computer 1610 operates in a networked environment using a logical connection such as a Local Area Network (LAN) or a Wide Area Network (WAN) to one or more remote computers such as the remote computer 1680.

[0123] When used in a LAN network environment, the computer 1610 is connected to the LAN 1671 via a network interface or adapter 1670. When used in a WAN network environment, the computer 1610 typically includes a modem 1672 or other means for establishing communication via a WAN 1673 such as the Internet. In a networked environment, program modules can be stored in a remote memory storage device. FIG. 16 shows, for example, that a remote application program 1685 can exist on the remote computer 1680.

[0124] The objectives and advantages of the present disclosure are further illustrated by the following non-limiting examples, but the specific materials described in these examples and their amounts, as well as other conditions and details, should not be construed as unduly limiting the present disclosure.

[0125] A polishing article evaluation system includes a detection unit that detects a polishing wear cue. The system also includes a validity indication generation unit that generates an indication of wear of the polishing article based on the polishing wear cue. The system also includes a command generation unit that generates a command based on the generated indication of wear.

[0126] The system may also be implemented to include a parameter capture unit that captures the current operating parameters of a tool associated with the polishing article. The command generation unit generates a command to adjust the operating parameters from a first value to a second value different from the first value.

[0127] The system may be implemented such that the operating parameter is the applied force, the tool is a robotic polishing unit, and the second value is an applied force higher than the first applied force.

[0128] The system may be implemented such that the operating parameter is speed. The second speed is higher than the first speed.

[0129] The system may be implemented such that the operating parameter is an angle. The second angle is different from the first angle.

[0130] The system may be implemented such that the command is a replacement command and the robotic polishing unit associated with the polishing article automatically initiates a polishing article replacement sequence based on that command.

[0131] The system may be implemented such that the command is a downstream operation command that adjusts downstream polishing operation parameters based on the indication of wear.

[0132] The system may be implemented such that the downstream polishing operation parameter is speed, force, or residence time.

[0133] The system may be implemented such that the downstream polishing operation parameter is a second polishing operation using a second polishing article.

[0134] The system may be implemented such that the history value acquisition unit acquires the history value of the operation parameter.

[0135] The system may be implemented such that the detection unit detects the queue in response to a detection start unit that generates a trigger for operating the detection unit.

[0136] The system may be implemented such that the detection start unit periodically generates a trigger.

[0137] The system may be implemented such that the detection start unit generates a trigger in response to a manual input.

[0138] The system may be implemented such that the detection start unit generates a trigger before the polishing operation starts.

[0139] The system may be implemented such that the detection start unit generates a trigger at the end of the polishing operation.

[0140] The system may be implemented such that the command is a graphical user interface update command and the command is communicated to a device having a display. The command causes the updated graphical user interface to be presented on the display.

[0141] The system may be implemented to include a command communication unit that communicates the command to a second device.

[0142] The system may be implemented such that the second device is a robotic polishing unit.

[0143] The system may be implemented such that the second device is a ventilation system.

[0144] The system may be implemented such that the second device is a dust collection system.

[0145] The system may be implemented such that the detector includes a queue capture device.

[0146] The system may be implemented such that the queue capture device is a camera.

[0147] The system may be implemented such that the queue capture device is a temperature measurement device.

[0148] The system may be implemented such that the temperature measurement device includes a thermocouple incorporated in the backup pad.

[0149] The system may be implemented such that the temperature measurement device includes an infrared camera.

[0150] This system may be implemented such that the queue capture device is a scale. The queue is the weight of the polished article.

[0151] The system may be implemented such that the queue capture device is a caliper. The queue is the thickness of the polished article.

[0152] The system may be implemented such that the detection unit includes a moving mechanism and a movement controller that moves the detection unit to a fixed position.

[0153] The system may be implemented such that the detection unit includes a light source.

[0154] The system may be implemented such that the wear queue is a spark and the queue capture device captures an increase or change in the spark.

[0155] The system may be implemented such that the command is a dressing command for redressing the polishing article.

[0156] The system may be implemented such that the command is a processing command for processing the polishing article to remove the loaded material.

[0157] A robotic polishing system is presented that includes a polishing article including a wear queue. The system also includes a backup pad coupled to the polishing article. The system also includes a robotic arm configured to move the polishing article to a fixed position relative to a substrate. The system also includes a force control unit that is on the robotic arm and is coupled to the backup pad. The force control unit applies a force to the backup pad. The system also includes a wear indication system that determines the amount of wear of the polishing article based on the wear queue and adjusts the operating parameters of the robotic polishing system based on the amount of wear.

[0158] The robotic polishing system may be implemented such that a detection unit detects the wear queue, a validity indication generation unit generates the polishing validity of the polishing article, and a command generation unit generates a command for adjusting the operating parameters.

[0159] The robotic polishing system may be implemented such that the detection unit includes an ultraviolet light source, the wear queue is a fluorescent material on the polishing article, and the generated polishing validity is based on the detection area of the fluorescent material.

[0160] The robotic polishing system may be implemented such that the wear queue is a thermally activated material that changes color at a temperature threshold. The detection unit includes a camera.

[0161] The robotic polishing system may be implemented such that the wear queue is the operating temperature. The detection unit includes a temperature sensor.

[0162] The robotic polishing system may be implemented such that the temperature sensor includes a thermocouple within the backup pad.

[0163] The robotic grinding system may be implemented such that the temperature sensor includes an infrared camera.

[0164] The robotic grinding system may be implemented such that the temperature sensor includes a thermometer.

[0165] The robotic grinding system may be implemented such that the detection unit includes a scale. The robotic arm provides the grinding article to the scale between the grinding operation and the next grinding operation.

[0166] The robotic grinding system may be implemented such that the detection unit includes a force control unit. The force control unit detects a change in the weight of the grinding article.

[0167] The robotic grinding system may be implemented such that the detection unit includes a caliper. The robotic arm provides the grinding article to the caliper between the grinding operation and the next grinding operation.

[0168] The robotic grinding system may be implemented such that the detection unit includes a camera that images the grinding article.

[0169] The robotic grinding system may be implemented such that the camera images the surface of the grinding article.

[0170] The robotic grinding system may be implemented such that an image from the camera is analyzed by a validity indication generation unit to detect a visual indication of wear.

[0171] The robotic grinding system may be implemented such that the visual indication is a change in color, a message, thin smoke, or smoke.

[0172] The robotic grinding system may be implemented such that the detection unit includes a camera that images the chips generated during the grinding operation.

[0173] The robotic polishing system may be implemented such that the detection unit identifies spherical or circular shapes within the generated chips.

[0174] The robotic polishing system may be implemented such that the operating parameters are an automatic shutdown.

[0175] The robotic polishing system may be implemented such that the automatic shutdown is based on a temperature threshold.

[0176] The robotic polishing system may be implemented such that the operating parameters are the force applied by the force control unit, the rotational speed of the polishing article, or the residence time of the polishing article on the substrate.

[0177] The robotic polishing system may be implemented such that the operating parameters are parameters for future polishing operations on the substrate.

[0178] The robotic polishing system may be implemented such that the operating parameters are parameters for future polishing operations using the polishing article.

[0179] The robotic polishing system may be implemented such that the detection unit is mounted on the robotic arm.

[0180] The robotic polishing system may be implemented to include a moving mechanism that moves the detection unit relative to the robotic arm. The detection unit is independent of the robotic arm.

[0181] The robotic polishing system may be implemented such that the detection unit activates a detection sequence in response to a start command from the controller.

[0182] The robotic polishing system may be implemented such that the controller periodically transmits a detection start command.

[0183] The robot polishing system may be implemented such that the controller transmits a detection start command at the start or end of the polishing operation.

[0184] The robot polishing system may be implemented such that the controller generates a command for adjusting the operating parameters.

[0185] The robot polishing system may be implemented such that the wear indication system includes a history value capturing unit that captures the history value of the wear queue, and a wear processor that determines the amount of wear based on the wear queue and the captured history value.

[0186] The robot polishing system may be implemented such that the history value is the last captured wear queue.

[0187] The robot polishing system may be implemented such that the history value is the initial wear queue.

[0188] The robot polishing system may be implemented such that the system includes a light source connected to the robot arm.

[0189] A wear detection unit for the polished article is presented, including a queue capture device arranged close to the polished article such that a wear queue associated with the polished article is detected. The detection unit also includes an effectiveness indication generation unit that receives the detected wear queue and provides a wear indication based on the detected wear queue. The detection unit also includes a wear communication unit that communicates the detected wear queue to a second device.

[0190] The detection unit may be implemented such that the movement mechanism moves the queue capture device to a fixed position in response to a movement control command.

[0191] The detection unit may be implemented such that the movement control command is received from a second device.

[0192] The detection unit may be implemented to include a history value capture unit that captures a wear history instruction of the polished article.

[0193] The detection unit may be implemented to include a threshold capture unit that captures a threshold value of the efficacy generation unit.

[0194] The detection unit may be implemented to include a parameter capture unit that captures a set of operation parameters of the polished article. The threshold value is captured based on the set of operation parameters.

[0195] The detection unit may be implemented such that the second device includes a data store that receives and stores a wear instruction.

[0196] The detection unit may be implemented such that the wear communication unit generates a wear alarm and the second device generates an alarm based on the received detected wear queue.

[0197] The detection unit may be implemented such that the queue capture device includes a camera.

[0198] The detection unit may be implemented to include an ultraviolet light source.

[0199] The detection unit may be implemented such that the camera is an infrared camera.

[0200] The detection unit may be implemented such that the camera images the surface of the polished article.

[0201] The detection unit may be implemented such that the camera images the chips generated by the polishing operation.

[0202] The detection unit may be implemented such that the queue capture device includes a temperature sensor.

[0203] The detection unit may be implemented such that the temperature sensor includes a thermocouple incorporated in the backup pad.

[0204] The detection unit may be implemented such that the queue capture device includes a scale for measuring the weight of the polished article.

[0205] The detection unit may be implemented such that the queue capture device includes a caliper for measuring the thickness of the polished article.

[0206] The detection unit may be implemented such that the efficacy indication generation unit analyzes an image for color changes.

[0207] The detection unit may be implemented such that the efficacy indication generation unit analyzes an image for fluorescence.

[0208] The detection unit may be implemented such that the efficacy indication generation unit analyzes the shape of the generated swarf.

[0209] A polished article having a wear queue including a bond matrix and a plurality of shaped abrasive grains within the bond matrix. The polished article also includes a detectable wear indicator that becomes detectable after a portion of the useful life of the polished article has passed.

[0210] The polished article may be implemented such that the polished article is a bonded polished article. The bond matrix is a resin, polymer, or vitreous bond.

[0211] The polished article may be implemented such that the wear queue is a fluorescent material. When the polished article wears, the fluorescent material appears.

[0212] The polished article may be implemented such that the fluorescent material is incorporated into the bond matrix.

[0213] The polished article may be implemented such that the wear queue is a thermally activated composition.

[0214] The polished article may be implemented such that the wear queue melts at a temperature threshold.

[0215] The abrasive article may be implemented such that the wear cue changes color at a temperature threshold.

[0216] The abrasive article may be implemented such that the thermally activated composition is a colored wax.

[0217] The abrasive article may be implemented such that the wax encapsulates a wear indicator.

[0218] The abrasive article may be implemented such that the wear cue is a dye.

[0219] The abrasive article may be implemented such that the wear cue produces thin smoke or smoke during operation.

[0220] The abrasive article may be implemented such that the wear cue produces an odor during operation.

[0221] The abrasive article may be implemented such that the wear cue is an encapsulated material.

[0222] The abrasive article may be implemented such that the abrasive article includes a backing. The abrasive grains are connected to the backing by a bond matrix.

[0223] The abrasive article may be implemented such that the wear cue is a fluorescent material. When the abrasive article wears, the fluorescent material appears.

[0224] The abrasive article may be implemented such that the fluorescent material is incorporated into the bond matrix.

[0225] The abrasive article may be implemented such that the backing is a non-woven backing.

[0226] A method of evaluating an abrasive article includes polishing a substrate using the abrasive article, capturing an indication of the abrasive article with a detection unit proximate to the abrasive article, evaluating the indication in light of a wear threshold using an effectiveness evaluation unit, and providing a wear indication when the indication is greater than the wear threshold.

[0227] The method may also be implemented to include capturing an initial instruction before a first polishing operation using a polishing article.

[0228] The method may be implemented such that the detection unit includes a camera.

[0229] The method may be implemented such that the detection unit includes a thermometer.

[0230] The method may be implemented such that the wear threshold is selected based on the polishing article.

[0231] The method may be implemented such that the wear threshold is selected based on a set of operating parameters for the polishing operation.

[0232] The method may be implemented such that no wear indication is provided if the indication is lower than the wear threshold.

[0233] The method may be implemented such that an indication of the remaining useful life is provided if the indication is lower than the wear threshold.

[0234] The method may be implemented to include estimating the remaining useful life based on the indication.

[0235] The method may be implemented such that the indication of the remaining useful life is estimated based on the historical wear trend of the polishing article.

[0236] The method may be implemented such that the indication of the remaining useful life is estimated based on the current operating parameters.

[0237] The method may be implemented such that the indication of the remaining useful life is based on predicted operating parameters.

[0238] The method may be implemented such that if the indication is higher than the threshold, an indication is generated that the polishing article should be processed before the next operation.

[0239] The method may be implemented to generate a command for a robotic polishing unit to process a polishing article before the next operation when the indication is higher than a threshold value.

[0240] A method of forming a polishing article is presented that includes providing a plurality of abrasive particles, a bond matrix precursor, and a backing material. The method also includes incorporating a wear indicator into any of the abrasive particles, the bond matrix precursor, or the backing. The method also includes embedding the abrasive particles in the bond matrix precursor. The method also includes curing the bond matrix precursor to form the polishing article. The wear indicator becomes detectable as the polishing article is used in a polishing operation.

[0241] The method may be implemented such that the wear indicator is not detectable before a first polishing operation in which the polishing article is used.

[0242] The method may be implemented such that the polishing article is an abrasive bonded article. The backing material is a scrim layer.

[0243] The method may be implemented such that the backing material is a non-woven material.

[0244] The method may be implemented such that the bond matrix precursor is a resin bond precursor, a vitrified bond precursor, or a polymer bond precursor.

[0245] The method may be implemented such that the wear indicator is a fluorescent material.

[0246] The method may be implemented such that the wear indicator is a first subset of the abrasive particles. The subset of abrasive particles is a first color that is different from a second subset of the abrasive particles.

[0247] The method may be implemented such that the wear indicator is an encapsulated material.

[0248] The method may be carried out such that the encapsulated material contains a dye.

[0249] The method may be carried out such that the encapsulated material contains a smoke or aerosol generating material.

[0250] The method may be carried out such that the wear indicator is a material that generates sparks.

Examples

[0251] The following materials were used in the examples of this specification.

[0252] AX55362 - polyester backing AX55362 is a polyester backing manufactured by 3M ASD in Alexandria, MN, and its preparation is described in U.S. Patent No. 6,843,815. A polyester backing containing a fluorescent dye purchased from Milliken and then treated with K2A size (epoxy / acrylate / novolak resin) and calcium carbonate filled phenolic resin backsize.

[0253] 784F 36 + LH42 coated abrasive belt 784F 36 + is a Cubitron™ II Y weight polyester metalworking belt manufactured by 3M ASD in Alexandria, MN. The 784F 36 + Cubitron™ II belt includes AX55362 backing, phenolic make resin, PSG and aluminum oxide mineral blend, phenolic resin size and epoxy resin supersize.

[0254] UV lamp The UV lamp is an EL series 6 watt hand-held lamp with a 365 nm wavelength output purchased from transluminators.com.

[0255] Example 1: Chip collection A coated abrasive belt measuring 10.16 cm × 91.44 cm (784F grade 36+, Saint Paul, Minnesota, 3M Company) was applied to and polished a 304 stainless steel bar measuring 1.9 cm × 1.9 cm × 61 cm with a surface to be polished of 1.9 cm × 1.9 cm. A 70 durometer rubber contact wheel with a diameter of 20.3 cm, a 1:1 land / groove ratio, and serrations was used. The belt was run at 2750 rpm. The workpiece was applied to the center of the belt with a normal force of 5.5 kg for 15 seconds. After each cycle, the workpiece was cooled and dried by immersing it 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. Those images are shown in FIGS. 11A and 11B.

[0256] Example 2: Fluorescent backing material Using the following materials, fibers chemically crosslinked with a photochromic dye or a thermochromic dye were prepared. It should be noted that this is an example of making fibers. For specific applications, many other materials may replace this or even be more suitable. This set of materials was selected because this manufacturing method can be easily carried out within 3M and is easily accessible for feasibility testing. A detailed description of the materials used in the present invention is summarized in Table 1.

[0257] [Table 1]

[0258] Fiber spinning method In this study, a single-hole blunt needle was used to obtain a large fiber diameter. In the case of polishing application, novel fibers having a fiber diameter of about 40 micrometers or more were expected, and with a certain blunt needle, fiber diameters ranging from dozens of micrometers to hundreds of micrometers could be produced. The resin was filled in a 20 mL stainless steel metal syringe and placed on a syringe pump having a Luer lock adapter for connecting an 18-gauge stainless steel blunt needle. By using a metal syringe, it was prevented that the resin in the barrel was unintentionally initiated by the laboratory fluorescent lamp. The resin dropped vertically into the collection part at the bottom of the device. In the current fiber spinning setting, up to two light sources can be installed on an 8020 frame that can move in the x-direction, y-direction, z-direction, and various angles. The syringe flow rate was set to 5 mL / min to obtain a continuous stream without breakage of the fiber strand.

[0259] Two UV LED light sources having peak wavelengths at 365 nm and 405 nm were purchased from Phoseon. Their spectra are shown in Table 2 below. The light intensity was controlled using a controller provided by the manufacturer. For consistency, the highest light intensity of 100% was used throughout the experiment. To thin the fibers, UV LED light was irradiated just above the collection part, and the 8020 mounting frame for the light source was 30.25 inches below the 8020 mounting frame for the syringe pump. Unless otherwise specified, a 405 nm UV LED was used for fiber spinning.

[0260] [Table 2]

[0261] Comparative Example 2A A control sample was prepared by mixing 100 parts by weight of IOA / AA with 1 phr of Irg651, 1 phr of Irg819, and 10 phr of TMPTA. All materials were poured into a black plastic jar and mixed using a speed mixer. The mixed resin was used 12 hours later to allow sufficient time to remove the bubbles generated during the mixing process. The fibers were optically transparent.

[0262] Comparative Example 2B To the same composition as described in Comparative Example 2A, 0.1 phr of FD was added. The materials were treated similarly. According to the product data sheet, FD absorbs UVA light and emits visible light as shown on the left side of Figure 18. To examine the effect of the dye, after turning off the light of the optical microscope, the sample was irradiated with UVA dim light. As can be seen from Figure 18, the control fibers reflect very little UVA light when irradiated. However, the fibers containing even a small amount of FD emitted a bright blue glow in the dim light.

[0263] Example 3 The coated abrasive belt 784F 36+Cubitron™ II, commercially available from 3M in St. Paul, MN, was polished with a stainless steel metal bar (0.635 mm×0.635 mm×152 mm) to expose the backing. Next, the polished area of the belt was illuminated with a UV hand-held lamp, an EL series 6-watt hand-held lamp with a 365 nm wavelength output, commercially available from transluminators.com in Atkinson, NH. As shown in Figure 8, the polished area fluoresced, indicating the end of the useful life of the coated abrasive belt.

[0264] Example 4 To investigate the relationship between the workpiece stock removal rate and the workpiece temperature, a grinding test was conducted on a 10.16 cm × 91.44 cm belt converted from a coated abrasive sample. A 70 durometer rubber contact wheel with a diameter of 20.3 cm, a 1:1 land / groove ratio, and serrations was used. The belt was run at 2750 rpm. The workpiece was a 304 stainless steel bar with dimensions of 1.9 cm × 1.9 cm × 60.96 cm, and the surface to be polished was 1.9 cm × 1.9 cm. The weight of the workpiece was recorded in grams and then pushed into the central part of the belt. The test was conducted at 11.34 kg (25 lb). Each cycle of the test was 6 seconds of grinding. At the end of each 6-second grinding cycle, the end of the workpiece in contact with the polishing belt was moved to an IR thermometer make and model Omega OS552-MA-6 to record the workpiece temperature. Next, the workpiece was cooled by quenching the polished end 1.3 cm in water at 15.5 °C for 8 seconds, followed by a 10-second continuous jet of pressurized air to dry the workpiece. Next, the workpiece was weighed to determine the amount of material removed in grams and the cycle was completed. The final workpiece weight obtained from the previous cycle was used as the initial workpiece weight for the next cycle. If the final mass of the workpiece after polishing was less than 275 grams, a new 304 stainless steel bar with dimensions of 1.9 cm × 1.9 cm × 60.96 cm was weighed and used for the next cycle. The test was completed after 120 cycles. Analyzing the workpiece removal amount in grams per cycle (Figure 12A) and the workpiece temperature in °F per cycle (Figure 12B), as the abrasive wore and the cutting effectiveness decreased, as a result, the temperature accumulation in the workpiece increased.

[0265] Example 5 The 984F Cubitron™ II belt was subjected to 60 grinding cycles with a force of 180 N equal to 0.45 N / mm2 to remove 15 mm of a stainless steel bar. After each cycle, all parameters were measured, in particular the time required to grind the substrate and the temperature after grinding. In addition, photographs of the same abrasive piece were taken every 5 cycles to visually show the state of the belt, in particular the amount of "blue" material generated by the exposure of the PSG grains.

[0266]

Table 3

[0267] The experiments carried out clearly showed that the progression of the grinding cycles resulted in an increase in temperature and an increase in the amount of "blue" PSG grains visible on the surface of the belt.

[0268] An image of the grinder interface is shown in Figure 17. In the grinder interface of 3M Neuss lab, the range of process operating parameters can be modified to adjust the amount of material removed or the rate of material removal.

[0269] In this user interface, the process operating conditions can be modified and in this case can be maintained to show the wear of the abrasive over a series of fixed operating conditions. In this case, the belt type, contact force, belt speed, and amount of material removed were fixed. The automatic grinder performed 60 material removal cycles on individual metal bars and after each cycle measured the material removal rate (time), substrate temperature (°C), and delta belt thickness (mm) and correlated them with the appearance of the abrasive grains.

[0270] The increase in cycle time required to remove 15 mm of material indicates wear of the abrasive and correspondingly the increase in temperature indicates a decrease in the effectiveness of the cutting rate as the mineral chips begin to wear. In all cases, the thickness of the belt changed from cycle to cycle, indicating the loss of mineral chips over time and the change in the height of the belt geometry when subjected to metal cutting cycles.

[0271]

Table 4

Claims

1. A polishing article evaluation system, comprising: a detection unit configured to detect a polishing wear queue; a validity instruction generation unit configured to generate an instruction for wear of the polishing article based on the polishing wear queue; a command generation unit configured to generate a command based on the generated instruction for wear; The system comprising the above components.

2. The system further comprises a parameter acquisition unit configured to acquire current operation parameters of a tool associated with the polishing article, wherein the command generation unit generates a command for adjusting the operation parameters from a first value to a second value different from the first value. The system according to claim 1.

3. The system according to claim 2, wherein the operation parameter is the applied force, the tool is a robot polishing unit, and the second value is an applied force higher than the first applied force.

4. The system according to claim 2, wherein the operation parameter is speed, and the second speed is higher than the first speed.

5. The system according to claim 1, wherein the operation parameter is an angle, and the second angle is different from the first angle.

6. The system according to any one of claims 1 to 5, wherein the command is a downstream operation command for adjusting downstream polishing operation parameters based on the instruction for wear.

7. The system according to any one of claims 1 to 6, wherein the command is a graphical user interface update command, the command is communicated to a device having a display, and the command causes the updated graphical user interface to be presented on the display.

8. The system according to any one of claims 1 to 7, wherein the detection unit comprises a queue capture device.

9. The system according to claim 8, wherein the queue capture device is a camera.

10. The system according to claim 8, wherein the queue capture device is a temperature measurement device.

11. The system according to claim 10, wherein the temperature measurement device comprises a thermocouple incorporated in a backup pad.

12. The system according to claim 10, wherein the temperature measurement device comprises an infrared camera.

13. The system according to claim 8, wherein the queue capture device is a scale, and the queue is the weight of the polishing article.

14. The system according to claim 8, wherein the queue capture device is a caliper and the queue is the thickness of the polished article.

15. The system according to claim 8, wherein the detection unit includes a moving mechanism and a movement controller that moves the detection unit to a fixed position.

16. The system according to claim 8, wherein the detection unit includes a light source.

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

18. A robotic polishing system comprising: a polished article including a wear queue; a backup pad coupled to the polished article; a robotic arm configured to move the polished article to a fixed position relative to a substrate; a force control unit on the robotic arm and coupled to the backup pad, the force control unit applying a force to the backup pad; a wear indication system that determines an amount of wear of the polished article based on the wear queue and adjusts an operating parameter of the robotic polishing system based on the amount of wear. A robotic polishing system comprising the above components.

19. The wear indication system includes: a detection unit that detects the wear queue; an effectiveness indication generation unit that generates a polishing effectiveness of the polished article; a command generation unit that generates a command to adjust the operating parameter. The robotic polishing system according to claim 18, comprising the above components.

20. The robotic polishing system according to claim 19, wherein the detection unit includes an ultraviolet light source, the wear queue is a fluorescent material on the polished article, and the generated polishing effectiveness is based on a detection area of the fluorescent material.

21. The robotic polishing system according to claim 19, wherein the wear queue is a thermally activated material that changes color at a temperature threshold, and the detection unit includes a camera.

22. The robotic polishing system according to claim 19, wherein the wear queue is an operating temperature and the detection unit includes a temperature sensor.

23. The robotic polishing system according to claim 22, wherein the detection unit includes a scale, and the robotic arm provides the polished article to the scale between a polishing operation and a next polishing operation.

24. The robotic polishing system according to claim 22, wherein the detection unit includes the force control unit, and the force control unit detects a change in weight of the polished article.

25. The robot polishing system according to claim 22, wherein the detection unit includes a caliper, and the robot arm provides the polishing article to the caliper between a polishing operation and a next polishing operation.

26. The robot polishing system according to claim 22, wherein the detection unit includes a camera that images the polishing article.

27. The robot polishing system according to claim 26, wherein the camera images the surface of the polishing article.

28. The robot polishing system according to claim 26, wherein an image from the camera is analyzed by the validity indication generation unit to detect a visual indication of wear.

29. The robot polishing system according to claim 28, wherein the visual indication is a change in color, a message, thin smoke, or smoke.

30. The robot polishing system according to claim 19, wherein the detection unit includes a camera that images swarf generated during the polishing operation.

31. The robot polishing system according to claim 18, wherein the operation parameter is an automatic shutdown.

32. The robot polishing system according to claim 18, wherein the operation parameter is a force applied by the force control unit, a rotation speed of the polishing article, or a residence time of the polishing article on the substrate.

33. A method for evaluating a polishing article, comprising: polishing a substrate using the polishing article; capturing an indication of the polishing article with a detection unit proximate to the polishing article; evaluating the indication using an effectiveness evaluation unit in light of a wear threshold; and providing a wear indication when the indication is greater than the wear threshold. Method.

34. The method according to claim 33, further comprising capturing an initial indication before a first polishing operation using the polishing article. The method according to claim 33.

35. The method according to claim 33, wherein the detection unit includes a camera.

36. The method according to claim 33, wherein the detection unit includes a thermometer.

37. The method according to claim 33, wherein the wear threshold is selected based on the polishing article.

38. The method according to claim 33, wherein the wear threshold is selected based on a set of operation parameters for the polishing operation.

39. The method according to claim 33, wherein when the indication is lower than the wear threshold, an indication of the remaining useful life is provided.

40. The method according to claim 39, further comprising estimating the remaining useful life based on the indication. The method according to claim 39. ​

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