Abrasive article, system, and method of use

Abstract

A polishing article evaluation system including a camera for imaging a polishing article is presented. The system includes a validity indication generation unit that generates an indication of the polishing efficacy of the polishing article based on the image. The system also includes a command generation unit that generates a command based on the generated polishing efficacy indication.

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 is presented that includes a camera for imaging an abrasive article. The system includes a validity indicator generation unit that generates an indication of the abrasive efficacy of the abrasive article based on the image. The system also includes a command generation unit that generates a command based on the generated abrasive efficacy indication.

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

[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 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 in particle and resin wear.

[0005] Some of the systems and methods herein may be particularly useful for robotic polishing systems that detect the end of the useful life by noticing changes in polishing effectiveness without a human operator. Additionally, some of the systems and methods 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

[0007]

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[0008] When reference characters in the specification and drawings are repeatedly used, 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, and they are included within the scope and spirit of the principles of the present disclosure. The diagrams may not be drawn to scale.

Mode for Carrying Out the Invention

[0009] Throughout this document, values expressed in a range format should be interpreted flexibly to 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, 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. The description "about X to Y" has the same meaning as "about X to about Y" unless otherwise indicated. Similarly, the description "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. The description "at least one of A and B" has the same meaning as "A, B, or both A and B". Additionally, any expressions or terms used herein that are not specifically defined 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 found within or outside of that specific section.

[0011] In the methods described herein, acts can be performed in any order without departing from the principles of the disclosure, unless the order in time or of performance is explicitly recited. Further, acts can be performed simultaneously unless the claims explicitly recite that the particular acts are to be performed separately. 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 will fall within the literal scope of the claimed process.

[0012] As used herein, the term "about" can tolerate a degree of variability of a value or range, e.g., within 10%, 5%, or 1% of the limits of the recited value or 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 "shaped abrasive particles" means abrasive particles having a predetermined shape at least a portion of which is reproduced from a mold cavity used to form the shaped precursor abrasive particles. Except for the case of abrasive fragments (such as those described in U.S. Patent Application Publication Nos. 2009 / 0169816 and 2009 / 0165394), shaped abrasive particles generally have a predetermined geometric shape that substantially reproduces the mold cavity used to form the shaped abrasive particles. As used herein, shaped 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, bows, droplet 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 inward or outward, 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, shaped 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 particles. Some embodiments include shaped 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 an abrasive article. The sharp portion may be defined using a 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 vertical 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 on July 23, 2019, which is incorporated herein by reference.

[0019] In cases where the abrasive particles are precisely shaped (e.g., 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 / 0344786A1 (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 "apex-up" orientation or an "apex-down" orientation 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 discs. However, at least some of the effectiveness indicators herein are applicable to multiple types of abrasive articles, and it is expressly contemplated that the figures and examples described herein are not intended to be limiting.

[0022] Furthermore, with respect to coated abrasive articles, many of the examples in this specification specifically consider abrasive discs. However, it is expressly 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 expressly 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] Figures 1 and 2 show an exemplary coated abrasive disc 100 according to the present disclosure, in which 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 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, resulting in 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 the 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 utilized can depend, for example, on the intended use, the type of abrasive particles, and the nature 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 onto the backing, triangular abrasive particles are added to and embedded within 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 illustrate coated abrasive articles, it is expressly contemplated that the systems and methods of the present specification 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] The abrasive article can be used in many contexts. The context of robotic repair (FIG. 3) and the context of a handheld tool (FIG. 4) are described herein. The various use scenarios of the abrasive 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 abrasive article is losing cutting efficacy over time and can adjust accordingly, either by applying more force or by adjusting the angle. The systems and methods of the present specification can enable a human operator to know how close the abrasive article is to the end of its useful life.

[0036] A robotic system may lack insight into wear or loading occurring on a polishing article, and thus may not make necessary adjustments or may not replace the polishing article without intervention when needed. For example, known polishing wear rates can be used to modify process parameters to maintain polishing efficacy throughout the useful life of the polishing article. The systems and methods herein may be similarly useful in other contexts.

[0037] FIG. 3 is a schematic diagram of a robotic arm that may benefit from the embodiments disclosed herein. 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 dimensions, 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 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.

[0038] 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 range of 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).

[0039] The backup pad 250 is connected to a tool 240 that has a track 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 rigid) 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).

[0040] 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 initiate a dressing process to reduce the detected metal capping. When 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.

[0041] 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 force applied may also be adjustable, for example, by the human operator leaning into the operation.

[0042] 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 protective gear worn by the user (e.g., a heads-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 for continued use or not allowed for continued use.

[0043] 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 wear 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, metal capping or loading may occur, covering the tip of the polishing particles and making them unavailable for polishing. Other efficacy factors may also be detectable.

[0044] 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 cue capture device 522. In some embodiments of the present specification, the cue capture device 522 is a camera or other image capture component that images the polishing article 502. In other embodiments, the cue 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 embodiments where the cue 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 cue 510.

[0045] As described herein, the polishing article 502 includes a cue 510 that can be detected by the sensor 522. The cue 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 cue 510 may be a visual indication 504, an auditory indication 506, or another cue 508. For example, the cue 510 may be a detectable weight loss or shrinkage of the polishing article 502 that can be detected by a scale or caliper.

[0046] The detection unit 520 may be fixed so that the 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. 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.

[0047] 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, the 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.

[0048] The indication processor 562 processes the received signal from the detection unit 520. As described herein, this may include comparing the received signal with a threshold value, considering it in light of the historical signal values fetched from the data store by the history value fetching unit 544, or otherwise processing the signal to determine whether the polishing efficacy of the article 502 has reached an undesirably low value. As described in more detail herein, the indication processor 562 may perform processing steps such as applying machine learning to the detected queue. For example, the indication processor 562 may process the captured image of the polishing article 502 to evaluate the amount of metal capping accumulated on the surface of the polishing article or the amount of contact area available for the next polishing operation, or may determine the wear of the patterned abrasive by applying pattern recognition techniques. Metal capping occurs, for example, when metal adheres to the abrasive grains due to excessive heat and / or insufficient pressure. When the abrasive particles are crushed, they can be self-sharpened, but the metal capping prevents such crushing.

[0049] The indication processor 562 may perform the evaluation in light of threshold values set by a manufacturer, a customer, an operator, a shift supervisor, etc. For example, one customer may set the minimum acceptable efficacy of a polishing disk as E, and a second customer may set the threshold value as ET.

[0050] 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, the polishing angle from the accelerometer, etc. The command generation unit 546 may generate a command for adjusting the applied force or angle, for example, to the robot arm controller, 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 metal 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.

[0051] 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 "metal capping detected", or alternatively as a simple "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.

[0052] 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 still 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.

[0053] 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 shown. For example, a coated abrasive article that has undergone significant wear may no longer be suitable for the initial large-scale abrasive removal process of the process but may be suitable for a later small-scale abrasive 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.

[0054] Although the system 500 is shown as separate from the display component 590 in FIG. 5, it is explicitly 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 explicitly 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.

[0055] Figure 6 shows a method of 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.

[0056] At 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 a 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.

[0057] At 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. They may also undergo metal capping, loading or other degradation.

[0058] At 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, metal capping or loading. Auditory cue 634 may be analyzed to detect wear, metal capping or loading. In other embodiments, a different detection unit 636 detects cues of polishing efficacy.

[0059] The evaluation of the polishing article may be performed by directly measuring parameters of the polishing article, such as visual signs, sounds, or other signs 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. Evaluating may also include processing a captured image of the surface of the polishing article to determine loading, metal capping, available contact area, wear, or another parameter that affects polishing efficacy.

[0060] 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 finished workpiece is being exchanged for a new workpiece, so 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.

[0061] In block 642, if the polishing efficacy of the polished article is maintained at an acceptable level, it can be used continuously 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.

[0062] In block 644, if the polishing efficacy is below the acceptable level, the polishing efficacy can be treated, as shown in block 650, for example, by dressing the polished article to remove metal capping or by cleaning or purging the polished article to remove loading. However, in some embodiments, method 600 returns to block 610.

[0063] Examples and embodiments of the present invention are described herein with reference to FIGS. 7-12, where the indication of the detected polishing efficacy is essentially visual. However, other cues for polishing efficacy are explicitly contemplated and are described in co-pending U.S. Patent Applications Nos. 63 / 366,805 and 63 / 366,802, both filed on June 22, 2022.

[0064] Figures 7A and 7B are diagrams showing metal capping quantification according to embodiments of the present specification. Figure 7A shows a captured image 700 of the surface of a polishing article, and abrasive grains with their tips exposed through a resin layer can be seen. Metal capping 710 can be seen on some of the tips. Metal capping is a common phenomenon that occurs due to the deposition of metal on the abrasive grains during operations such as stainless steel polishing. Since metal capping covers the sharp tips of the abrasive grains, it reduces the polishing efficacy. Metal capping can be removed or reduced by redressing the polishing article to remove the metal capping. Additionally, the metal capping can be reduced in future operations by adjusting parameters such that, for example, the robot polishing system increases the force applied to promote the crushing of the abrasive grains.

[0065] Figure 7B shows a processed image 720 obtained from the image 700. Metal capping 730 causes reflection. Regions showing high reflectivity in a photograph of the polishing article are good indicators of the metal capping regions. When the image is converted to binary, the metal capping is shown more clearly. When converted to binary, the capped particles 730 appear black against a white background. Then, the percentage of the polished article capped with metal can be calculated by comparing the amount of black in the image with the total area of the image. The amount of metal capping may increase over time, and when the polishing article reaches a deterioration threshold, a warning may be generated to replace the polishing article, redress the polishing article, or adjust the operating parameters to increase the polishing efficacy of the polishing article.

[0066] The initial image 700 may be captured using any suitable camera. In some embodiments, an additional light source is provided to increase the reflectivity of the capped particles. In some embodiments, the image is underexposed. In some embodiments, the exposure and contrast are adjusted to make the binary conversion accurate and to avoid incorrect data points.

[0067] In an embodiment where the grinding operation is a robotic grinding operation, the camera is mounted on the robotic arm so that it can image the grinding article between the grinding operation and the next grinding operation. However, it is explicitly contemplated that the camera may be placed in other locations such as a separate robotic system, a mobile detection system, or a stationary detection unit. For example, a stationary camera can image a rotating belt and compare it with a still image so that correlation can be made and the dynamic characterization of the belt can be enabled.

[0068] Metal capping detection is also useful for hand-held grinding operations. The operator may take an image of the grinding article between grinding operations, for example, by using a mobile computing device (such as a smartphone, tablet, etc.) or passing the grinding article in front of a camera located near the grinding operation area. Other suitable image capture systems and techniques are also envisioned.

[0069] The grinding article may also be modified to improve metal capping detection. For example, a size resin or supersize resin colored black or other dark colors increases the contrast between the capped particles and the uncapped grinding article. Currently, many manufacturers use coloring in the resin layer to easily distinguish the brand, and in some cases the grade, of the grinding particles in the grinding article. Further, additives may be included in the grinding article to increase the reflectivity. For example, glass beads or other reflective materials may be included in the make coat or size coat of the coated grinding article so that as the grinding article is ground, the reflective material is exposed and the reflectivity increases. The reflected material may be provided as a backfill in some embodiments or may be embedded in the backing if suitable.

[0070] FIG. 8 shows a method for evaluating metal capping according to an embodiment of the present specification. As described above, metal capping reduces the polishing efficacy. However, metal capping can be removed by redressing the polished article. Therefore, identifying when metal capping occurs is important in order to remove it and enable the polished article to be used over its potential useful life. Method 800 may be implemented, for example, to automatically evaluate the polished article between a polishing operation and the next polishing operation. In particular, in the robotic polishing industry, it would be particularly useful if method 800 could be performed without increasing the total cycle time of the polishing operation. However, method 800 is useful for the handheld tool industry as well, if an evaluation can be performed without interrupting the operator's process.

[0071] In block 810, attach the polished article to the tool. The tool may be a handheld tool to which the polished article is attached by an operator. However, it may also be a polished article attached on a robotic polishing machine. The polished article may be automatically attached, for example, in response to an indication that the polished article has reached the end of its useful life or that re-dressing is required at a different station.

[0072] In block 820, use the polished article to polish the workpiece. The polished article contacts the substrate with the applied force, rotational speed, and dwell time selected for the polishing operation. In the context of a robot, the applied force, speed, and dwell time may be selected or adjusted, for example, based on the known amount of wear of the polished article or metal capping, as described herein.

[0073] In block 830, image the polished article. The imaging step may be performed, for example, while the tool is being moved from a first substrate polishing location to a second polishing location between a polishing operation and the next polishing operation.

[0074] At block 840, the image is processed to quantify the reflectivity. Although this specification describes one method of processing as conversion to binary, it is explicitly contemplated that any suitable processing that increases the contrast and enables quantification of the reflectivity is appropriate.

[0075] This specification describes a method of converting an image to binary. However, it is also contemplated that other methods may be possible, such as image processing that removes pixels above a threshold of RGB values using an RGB filter. For example, in a polishing article having blue polishing particles and red sizing resin, if there is a portion of the image that results in pure white, that portion is likely to indicate metal capping. Thus, the metal capping can be estimated as the percentage of the white area to the total area.

[0076] At block 850, the polishing efficacy is quantified. The polishing efficacy can be affected not only by metal capping or loading, but also by overall wear. In the above binary example, quantifying the metal capping involves estimating the ratio of the area showing "black" to the total area expected to include the tips of the polishing particles. To determine the end of the service life or the need for re-dressing of the article, it may be sufficient to compare the amount of the "black" (capped) area to the total area.

[0077] At block 860, the polishing article is evaluated. This may include evaluating the quantified metal capping against a threshold to determine whether re-dressing is appropriate or whether the polishing efficacy needs to be improved. Evaluating may also include more comprehensively evaluating the wear of the polishing disk to determine whether the disk has worn beyond a threshold where the efficacy is improved to a valuable extent by re-dressing.

[0078] At block 870, if the metal capping is sufficiently low, the polishing article can be used for the next polishing operation. Evaluating at block 860 may also include estimating wear or metal capping to provide a new set of operating parameters to improve the effectiveness of the polishing article. For example, as shown at block 890, the polishing article may have no metal capping to the extent that it is deemed appropriate to send it to a re-dressing station, but may have wear such that polishing effectiveness would be improved using a stronger force, a faster speed, or a different angle. In some embodiments, at block 860, metal capping and wear can be evaluated in the same step. Wear can be evaluated using the same image captured to evaluate metal capping, or by using another method as described in U.S. Patent Application No. 63 / 366805 or 63 / 366802 filed herewith.

[0079] At block 880, if the metal capping reaches the re-dressing threshold, send the metal capping to a re-dressing station for a re-dressing operation. Re-dressing may include grinding the polishing article against a re-dressing substrate to remove the metal capping. However, as indicated by the arrows in FIG. 8, it may be necessary to replace the polishing article with a new one. For example, if re-dressing causes the polishing effectiveness to drop below a suitable threshold due to wear, the polishing article should be replaced.

[0080] Figures 9A to 9C show the calculation of the contact area. Figure 9A shows the contact area and cutting rate of the polishing article over the service life of the polishing disk, measured by multiple polishings on a certain substrate. Figure 9B shows a chart of the projected contact area versus the cutting rate per pass. Figure 9C is a table showing how the thickness of the disk changes as the disk is used. The change in thickness is significant but not easily measurable by the human eye. An ultrasonic caliper was used to obtain the measured values in Figure 9C. Depending on the application example, when the polishing article reaches the end of its service life can also be determined by different final thicknesses.

[0081] However, it may also be possible to measure the contact area, that is, the contact projection area parallel to the surface being polished, by analyzing the measured values of the surface height of the polishing disk over a specific area. The image may be acquired using a structured light microscope where the structured light helps to reduce the shadows in the image. However, it may also be possible to determine the contact area using 3D surface shape measurement, for example, using a structured light microscope.

[0082] First, capture a 3D surface shape measurement scan of a part of the polishing disk surface using, for example, a structured light microscope. Next, the contact area at a specific cutting depth (20 microns is used in Figure 9) is calculated by integrating the xy area on the scan occupied by a z-direction height that is 20 microns lower than the highest z-direction height. The highest z-direction height is determined by taking the median of the top five median heights to minimize the influence of outliers. To determine the contact area over the service life of the disk, this process is repeated for the same part of the polishing disk after passing the abrasive over the substrate several times.

[0083] Since a portion of the disk (including abrasive particles) is exposed, contacts the surface, and is crushed / worn, the contact area varies during the polishing operation. As the surface changes, the contact area changes. FIGS. 10A - 10B show images that can be collected during the evaluation process and / or presented to the operator. FIGS. 10A - 10B show an embodiment where the user interacts with the images via a graphical user interface on a smartphone display. However, it is explicitly contemplated that the images may be viewed on a laptop, desktop, tablet, or other display. Additionally, although FIGS. 10A - 10B show images, it is explicitly contemplated that text information may be displayed instead of the images. The images may be analyzed, and the calculation of the metal capping / contact area may be performed without any indication to the operator until treatment is required to redress or replace the polishing article.

[0084] FIGS. 10A - 1, 10A - 2, and 10A - 3 capture a first point in time of the polishing article, and FIGS. 10B - 1, 10B - 2, and 10B - 3 capture a second point in time of the same polishing article. A first image of the polishing article is captured. It may be possible to provide a zoomed view so that individual abrasive particles are visible to the operator and so that metal capping or wear, as shown in the second image, is visible. However, such a view is not necessary for the analysis. A third view presents a binary view and an estimated value of the metal capping or wear currently detected.

[0085] FIGS. 10A - 10B show a coated polishing article that wears over time. Abrasive articles with bonds need to be measured differently because when the first layer of the polishing article wears, new particles are exposed in the underlying layer.

[0086] In addition, FIGS. 10A-10B show a method of determining wear by measuring the exposed particle area, but it is explicitly contemplated that another trigger may indicate the end of the useful life. For example, precision formed abrasive grains can be designed to break down at a predictable rate, and the breakdown generates new sharp tips that can effectively polish the surface. The area of the exposed particles is an indication of wear, but does not necessarily perfectly correlate with the end of the useful life. It may be possible to look for other cues through image analysis, such as if a make coat, filler particles, or backing is visible. For example, pigments of various colors may be present in the make resin of the coated abrasive article or during the presizing cross process. In a bonded abrasive article, a scrim may become visible or detectable.

[0087] The level of wear can be determined by counting the number of pixels predicted to be PSG. As the abrasive is used, it can be seen that more PSG is exposed from under the resin coating layer. The surface area of the PSG changes significantly as particle breakdown occurs.

[0088] This process of detecting and estimating the area of the exposed particles can be fully automated. There are three classes of methods that can be used to solve this problem, namely, conventional machine learning-based, convolutional neural network-based, or older rule-based computer vision algorithms. The decision of which algorithm to use is based on the amount of data available for processing and the accuracy required to provide value to the user.

[0089] A machine learning-based classification unit (e.g., either a conventional neural network or a convolutional neural network) can automatically identify exposed abrasive particles in the captured image. For example, a conventional machine learning algorithm can be trained to extract features from the image and characterize each pixel based on FIGS. 10A-2 and 10B-2. Since the abrasive grains are often colored differently from the resin covering them, one parameter of interest is color. Other features such as shape, structure, and texture are also likely to be beneficial. In the case of a conventional machine learning approach, SVM or random forest can also be trained to make such a determination (other options may also be suitable). When appropriately trained on a characteristic combination, the classification unit may be able to capture the availability of the remaining sharp tips while quantifying the wear of the particles.

[0090] The images used to evaluate wear can be obtained, for example, from a mobile phone assigned to an operator or from any suitable imaging device. Although the variability of the images may change between cameras, an algorithm can be developed to compensate for the variability.

[0091] In a handheld context, the lighting conditions are likely to change when different images are captured. For example, it may be recommended to image the abrasive article in a consistent lighting environment, such as using a mobile phone within a hood or other controlled environment. In a robotic context, the abrasive article may preferably be imaged in a consistent setting, such as when the robot is in the same orientation with respect to the lighting.

[0092] The camera should be calibrated to take accurate images. In the situation of using a smartphone, it may be useful to calibrate the evaluation algorithm using a calibration card having a sample of the abrasive on one side and resin on the other side, which can improve the accuracy.

[0093] Figures 11A and 11B show the results of a computer vision algorithm applied to images of a polished article over time, showing how this segmentation algorithm can extract polishing particles within the photograph. As can be seen, as the cycle index increases, more exposed abrasive grains become detectable. Figure 11B shows a plot of the exposed polishing particles within each of the captured images, showing how more polishing particles are exposed over time.

[0094] For the calculation of the contact area, it may be beneficial to use structured light to fully capture the 3D aspect of the surface of the polished article.

[0095] Figures 12A and 12B show images of the surface of a polished article. The surface is a 363FC sanding belt, with no TRIZACT™ abrasive used on the surface in Figure 12A and 25% used in Figure 12B. As wear occurs, the microreplication pattern degrades. A computer vision algorithm can be used for both detection of degradation and prediction of the rate of degradation. As shown in Figure 12A, the hexagonal pattern has a distinct contrast around each of the raised hexagonal structures. In Figure 12B, after significant use, the contrast is less distinct. Texture analysis may also be performed using machine learning to determine the polishing effectiveness. Analysis of the contact area may also be useful for measuring wear of high-definition patterns such as those illustrated in Figures 12A and 12B.

[0096] Using the systems and methods described herein, it is possible to image a polished article and generate an indication of polishing efficacy based on the image. The polishing efficacy may be reported in terms of remaining useful life, amount of metal capping, available contact area, number of future polishing operations (assuming the parameters of the next polishing operation are known), need to redress the polishing application, or recommended changes to the parameters.

[0097] When information about the next polishing operation is known, the systems and methods of this specification can provide an indication of whether the current polishing article is sufficient for the next operation, or whether a new polishing article should be used, an existing polishing article should be redressed, or parameters can be changed to increase effectiveness. Downstream changes may also be made. For example, the dwell time required for future polishing operations on the same substrate may be longer or shorter based on the wear of the polishing article in the current operation. For example, the more wear on the polishing article, the fewer scratches left, and it may be possible to completely skip intermediate polishing operations. However, a worn polishing article may also not remove as much material as desired, which may result in a longer dwell time for subsequent steps.

[0098] If multiple partially used disks are available, the systems and methods of this specification may also be able to propose which polishing article is most suitable for a given job. For example, if only 5 minutes of polishing is required, a nearly used-up polishing disk can be used, reducing waste.

[0099] In addition to knowing when to replace the polishing article, the systems and methods of this specification may propose or automatically change parameter settings. For example, increase the force applied from 10 pounds to 15 pounds at X wear.

[0100] Furthermore, the systems and methods of this specification may track parameter settings and the resulting wear over time to provide better recommendations about service life. For example, it can be seen that applying a force of 10 pounds can grind 10 gates per disk, while applying a force of 15 pounds can grind 30 gates before replacement. In the context of a robot, it may be possible to collect data on polishing operations and wear, determine parameter values, and increase the effectiveness of future polishing operations with the same requirements.

[0101] FIG. 13 is a networked architecture for a polishing article use evaluation system 1310. Architecture 1300 shows one implementation form of the implementation of system 1310, but other implementation forms 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 an application via a wide area network and access it through a web browser or any other computing component.

[0102] 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 dispersed. The remote server infrastructure can deliver services through a shared data center, and those shared data centers appear as a single access point to the user. Therefore, the components and functions described in this specification 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.

[0103] As described herein, based on an instruction from the polishing article use evaluation system 1310, the robotic polishing unit 1304B may adjust a force or speed related to 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).

[0104] Knowing when a polishing article is approaching the end of its useful life can, in addition to improving the effectiveness benefits of 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 as a polishing article approaches the end of its useful life, more dust is generated 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 beginning 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.

[0105] Similarly, knowing how a polishing article is being used can be useful not for replacement but for downstream repair. 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 help a novice operator and may also increase the effectiveness of a robotic polishing system.

[0106] Figure 13 specifically shows that the system 1310 can be placed at the remote server location 1302. Thus, the computing devices 1320 access those systems through the remote server location 1302. The operator 1350 can also use the computing device 1320 to access the user interface 1322. For example, the user interface 1322 may provide instructions on how the polished article is worn, changes made to any of the networked systems 1304, or suggestions for changes to the operations by the operator (such as an increase in force, an increase in RPM, etc.).

[0107] Figure 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 are not. 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 directly accessed 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.

[0108] It should also be noted 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.

[0109] Figures 14 - 16 show examples of computing devices that can be used in the embodiments shown in the preceding figures.

[0110] Figure 14 is a simplified block diagram of an exemplary example of a handheld computing device or a mobile computing device that can be used as a user or client handheld device 1416 (such as the computing device 1320 of FIG. 13) capable of deploying the present system (or a portion thereof). For example, a mobile device can be deployed within the operator compartment of the computing device 1320 for use in generating, processing, or displaying data. Figure 15 is another example of a handheld device or a mobile device.

[0111] Figure 14 is an overall block diagram of the components of client device 1416 that can execute some of the components illustrated and described herein. Client device 1416 interacts with them, or executes some and interacts with some. The device 1416 is provided with a communication link 1413 that enables other computing devices and handheld devices to communicate, and under some embodiments, provides a channel for automatically receiving information, such as by scanning. Examples of the communication link 1413 include 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.

[0112] 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 the interface 1415. The interface 1415 and the communication link 1413 communicate with a processor 1417 (which can also embody a processor) along a bus 1419 that is also connected to the memory 1421, the input / output (I / O) components 1423, the clock 1425, and the position information system 1427.

[0113] The I / O components 1423 are provided in one embodiment to facilitate input and output operations, and the device 1416 can include input components such as buttons, touch sensors, optical sensors, microphones, touch screens, proximity sensors, accelerometers, azimuth sensors, and output components such as display devices, speakers, and / or printer ports. Other I / O components 1423 can be used as well.

[0114] The clock 1425 illustratively includes a real-time clock component that outputs time and date. It can also provide a timing function to the processor 1417.

[0115] 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.

[0116] 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.

[0117] FIG. 15 shows that the device can be a smartphone 1500. 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.

[0118] Note that other forms of devices 1400 and 1500 are possible.

[0119] FIG. 16 is a block diagram of a computing environment that can be used in the embodiments shown in the preceding figures.

[0120] 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. The 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 with respect to the systems and methods herein can be deployed to the corresponding portions of FIG. 16.

[0121] 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 1610. Communication media can embody computer-readable instructions, data structures, program modules, or other data in a transmission 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.

[0122] 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, 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.

[0123] The computer 1610 may also include other removable / non-removable volatile / non-volatile computer storage media. By way of mere example and not limitation, 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.

[0124] 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, but are not limited to, Field-programmable Gate Array (FPGA), Application-specific Integrated Circuit (ASIC), Application-specific Standard Product (ASSP), System-on-a-chip system (SOC), Complex Programmable Logic Device (CPLD), and the like.

[0125] 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 either the same as, or different from, operating system 1634, application programs 1635, other program modules 1636, and program data 1637.

[0126] 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.

[0127] The computer 1610 operates in a networked environment using logical connections 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.

[0128] 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.

[0129] The objects and advantages of the present disclosure are further illustrated by the following non-limiting examples, but the specific materials and their amounts described in these examples, as well as other conditions and details, should not be construed as unduly limiting the present disclosure.

[0130] A polishing article evaluation system including a camera for imaging a polishing article is presented. The system includes an effectiveness indication generation unit that generates an indication of the polishing effectiveness of the polishing article based on the image. The system also includes a command generation unit that generates a command based on the generated polishing effectiveness indication.

[0131] The system may also be implemented to include a parameter capture unit that captures current operating parameters of a tool associated with the polishing article. The command generation unit generates a command to adjust the operating parameter from a first value to a second value different from the first value.

[0132] 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.

[0133] The system may be implemented such that the operating parameter is the speed and the second speed is higher than the first speed.

[0134] The system may be implemented such that the operating parameter is the polishing angle and the second polishing angle is different from the first polishing angle.

[0135] 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 the command.

[0136] The system may be implemented such that the command is a re-dressing command and the robotic polishing unit moves the polishing article to a re-dressing station based on the command.

[0137] The system may be implemented such that the command is a downstream operation command that adjusts downstream polishing operation parameters based on wear instructions.

[0138] The system may be implemented such that the downstream polishing operation parameters are speed, force, or dwell time.

[0139] The system may be implemented such that the downstream polishing operation parameters are a second polishing operation using a second polishing article.

[0140] The system may be implemented to include a history value capturing unit that captures history values of operation parameters.

[0141] The system may be implemented such that the camera captures an image in response to a potency evaluation start unit that generates a trigger to activate the camera.

[0142] The system may be implemented such that the potency evaluation start unit generates the trigger periodically.

[0143] The system may be implemented such that the potency evaluation start unit generates the trigger in response to a manual input.

[0144] The system may be implemented such that the potency evaluation start unit generates the trigger before the polishing operation starts.

[0145] The system may be implemented such that the potency evaluation start unit generates the trigger at the end of the polishing operation.

[0146] The system may be implemented such that 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.

[0147] The system may be implemented to include a command communication unit that communicates commands to a second device.

[0148] The system may be implemented such that the second device is a robotic polishing unit.

[0149] The system may be implemented such that the second device is a ventilation system.

[0150] The system may be implemented such that the second device is a dust collection system.

[0151] The system may be implemented such that the polishing efficacy indication is a metal capping measurement.

[0152] The system may be implemented such that the polishing efficacy indication is a wear estimate.

[0153] The system may be implemented such that the polishing efficacy indication is an estimate of the remaining useful life.

[0154] The system may be implemented such that the camera is incorporated into a portable computing device.

[0155] The system may be implemented such that the camera is mounted on a robotic polishing system.

[0156] The system may be implemented to include a structured light source.

[0157] The system may be implemented to include a mount that maintains the position of the camera.

[0158] A robotic polishing system is presented that includes a polishing article containing abrasive particles within a bond matrix. The system also includes a robotic arm configured to move one of the polishing article and the substrate to a fixed position such that the polishing article contacts the substrate. The system also includes a force control unit on the robotic arm. The force control unit applies a force to the polishing article or the substrate. The system also includes an article evaluation system that images the polishing article, evaluates the polishing article, and generates updated operating parameters for the robotic polishing system based on the evaluation.

[0159] The robotic polishing system may be implemented such that the article evaluation system includes a wear estimator that estimates the amount of wear of the polishing article.

[0160] The robotic polishing system may be implemented such that the article evaluation system includes a metal capping detector that detects the amount of metal capping on the polishing article.

[0161] The robotic polishing system may be implemented such that the captured image is segmented by the metal capping detector.

[0162] The robotic polishing system may be implemented such that the captured image is converted to binary by the metal capping detector.

[0163] The robotic polishing system may be implemented such that the metal capping detector quantifies regions that are reflective of the polishing article.

[0164] The robotic polishing system may be implemented such that the article evaluation system includes an ultrasonic caliper.

[0165] The robotic polishing system may be implemented such that the updated operating parameters re-dress the polishing article prior to the next operation.

[0166] The robotic polishing system may be implemented such that the polishing article evaluation system includes a camera that images the polishing article.

[0167] The robotic polishing system may be implemented to include a structured light source.

[0168] The robotic polishing system may be implemented such that a camera is mounted on the robotic arm.

[0169] The robotic polishing system may be implemented such that the camera is separated from the robotic arm.

[0170] The robotic polishing system may be implemented such that the camera, the substrate, or the polishing article is connected to a moving mechanism.

[0171] The robotic polishing system may be implemented such that the camera images the surface of the polishing article.

[0172] The robotic polishing system may be implemented such that the camera images the profile of the polishing article.

[0173] The robotic polishing system may be implemented such that the operating parameter is the replacement of the polishing article.

[0174] The robotic polishing system may be implemented such that the operating parameter is 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.

[0175] The robotic polishing system may be implemented such that the operating parameter is a parameter for a future polishing operation on the substrate.

[0176] The robotic polishing system may be implemented such that the operating parameter is a parameter for a future polishing operation using the polishing article.

[0177] The robotic polishing system may be implemented such that the article evaluation system operates in response to a start command from the controller.

[0178] The robot polishing system may be implemented such that the controller periodically transmits a start command.

[0179] The robot polishing system may be implemented such that the controller transmits a start command at the start or end of the polishing operation.

[0180] The robot polishing system may be implemented such that the controller generates a command for adjusting the operation parameters.

[0181] The robot polishing system may be implemented such that the article evaluation system compares the amount of metal capping with a metal capping threshold value, and when the amount of metal capping exceeds the metal capping threshold value, a redressing command or a replacement command for polishing the article is generated.

[0182] The robot polishing system may be implemented such that the metal capping threshold value is based on the operation parameters of the polishing operation.

[0183] The robot polishing system may be implemented such that the metal capping threshold value is based on the operation parameters of a future polishing operation.

[0184] The robot polishing system may be implemented such that the article evaluation system compares the wear amount with a wear threshold value, and when the wear amount exceeds the wear threshold value, a replacement command for polishing the article is generated.

[0185] The robot polishing system may be implemented such that the wear threshold value is based on the operation parameters of a future polishing operation.

[0186] The robot polishing system may be implemented such that the polishing article includes a backing, and the bond matrix includes a make coat layer that binds the abrasive particles to the backing.

[0187] The robot polishing system may be implemented such that the polishing article includes a polishing disk or a polishing belt.

[0188] The robotic polishing system may be implemented such that the polishing article is a bonded polishing article and the bond matrix is a vitreous, resin, polymer or metal bond matrix.

[0189] The robotic polishing system may be implemented such that the polishing article is a non-woven polishing article including a plurality of non-woven fibers and the bond matrix binds abrasive particles to the plurality of non-woven fibers.

[0190] A system for evaluating the effectiveness of a polishing article includes a tool coupled to the polishing article having abrasive particles on a polishing surface. The system also includes a surface shape measuring device configured to capture an indication of the polishing surface. The system also includes an evaluation unit that receives the captured indication, processes the captured indication, and generates a polishing effectiveness indication.

[0191] The system may be implemented such that the surface shape measuring device includes a camera and the captured indication is an image.

[0192] The system may be implemented such that the surface shape measuring device is a 3D profilometer and the captured indication is a surface profile indication.

[0193] The system may be implemented to include a structured light source.

[0194] The system may be implemented such that the evaluation unit also communicates the polishing effectiveness indication to a receiving device.

[0195] The system may be implemented such that the receiving device is a display component and communicating the polishing effectiveness indication includes communicating an update to a graphical user interface of the display component.

[0196] The system is a robot polishing system in which a receiving device is connected to a tool, and the system may be implemented to include a polishing parameter update unit that generates an updated set of parameters for the robot polishing system based on a polishing efficacy instruction. The updated parameters change one of the applied force, rotational speed, or dwell time.

[0197] The system may be implemented such that the polishing efficacy instruction includes a wear instruction.

[0198] The system may be implemented such that the polishing efficacy instruction includes a metal capping instruction.

[0199] The system may be implemented such that the polishing efficacy instruction includes an estimated remaining useful life.

[0200] The system may be implemented such that the estimated remaining useful life includes several remaining future polishing operations.

[0201] The system may be implemented such that a display component is associated with the tool.

[0202] The system may be implemented such that the display component is within an area of the work site near the tool.

[0203] The system may be implemented such that the display component is part of a device associated with the operator of the tool.

[0204] The system may be implemented such that the device is personal protective equipment worn by the operator.

[0205] The system may be implemented such that the polished article includes a polishing disk or a polishing belt.

[0206] The system may be implemented such that the polished article is a bonded polished article.

[0207] The system may be implemented such that the polishing article is a non-woven polishing article.

[0208] A method of polishing a substrate is disclosed, the method comprising contacting a substrate surface with a polishing article having a surface, capturing a surface indication of the surface using a surface indication capture device, and processing the surface indication using a polishing effectiveness evaluation unit to generate a polishing effectiveness indication. Based on the polishing effectiveness indication, the next polishing operation of the polishing article is modified.

[0209] The method may be implemented such that modifying comprises adding a re-dressing step of the polishing article prior to the next polishing operation.

[0210] The method may be implemented such that modifying comprises adjusting the force, speed, or dwell time applied.

[0211] The method may be implemented such that modifying comprises replacing the polishing article with a new polishing article prior to the next polishing operation.

[0212] The method may be implemented such that the polishing article is coupled to a robotic polishing system. Modifying comprises generating a command based on polishing effectiveness knowledge and communicating the command to the robotic polishing system.

[0213] The method may be implemented such that the polishing article is coupled to a hand-held power tool. Modifying comprises providing the polishing effectiveness indication on a display associated with the hand-held power tool or associated with an operator of the hand-held power tool.

[0214] The method may be implemented such that the polishing article is coupled to a hand-held power tool and modifying comprises providing a modification command to the operator.

[0215] The method may be implemented such that the correction instruction is provided using a personal protection device worn by an operator.

[0216] The method may be implemented such that the correction instruction is provided via a speaker of an auditory protection unit.

[0217] The method may be implemented such that the correction instruction is provided on a head-up display.

[0218] The method may be implemented such that the correction instruction is provided to a portable computing device associated with the operator.

[0219] The method may be implemented to include communicating a polishing efficacy indication to a data store.

[0220] The method may be implemented such that the polishing efficacy indication is communicated along with an indication of a set of current operating parameters of the polishing article.

[0221] The method may be implemented such that the polishing efficacy indication includes a wear indication or a metal capping indication.

[0222] The method may be implemented such that the surface indication is an image of the surface.

[0223] The method of processing an image may be implemented to include segmenting the image.

[0224] The method of processing an image may be implemented to include converting the image to binary.

[0225] The method of processing an image may be implemented to include applying machine learning to detect exposed polishing particles or capped polishing particles.

[0226] The method of processing an image may be implemented to include measuring a reflectivity from the polishing article.

[0227] The method may be implemented such that the surface indication includes a surface profile indication.

[0228] The method may be implemented such that the surface indication capture device includes a structured light microscope.

[0229] The method may be implemented such that the surface indication capture device includes a 3D profilometer.

Example

[0230] Example 1 An algorithm was described to analyze the disk and identify PSG abrasive grains. This algorithm uses the information provided by the illumination / shadow angle and the observation of the coverage range of the red layer of the abrasive. The computer vision algorithm selects a specific color of the abrasive grains in the image to illustrate how the segmentation algorithm extracts the PSG in the photo. It was found that as the image progresses, more blue of the PSG is exposed, which indicates a strong correlation with the wear of the abrasive.

[0231] Next, the PSG abrasive grains are evaluated for wear. In the images of FIGS. 17A - 17B, the worn areas are colored with a first color and the non - worn areas are represented as a second color. Some of the PSG abrasive grains are partly of the first color and partly of the second color, indicating that they are partly worn.

[0232] Next, statistics can be used to calculate the wear state of the disk.

[0233] 1) G = the number of pixels of the first color (worn PSD); P = the number of pixels of the second color (non - worn PSG). W = % of disk wear W = G / (G + P) W can also be displayed to the user as a color scale indicating the % of disk wear.

[0234] 2) The evaluation of disk wear by region can also be calculated in the same way as described above. These regions can also be concentric circles. This has added value because the maximum wear appears to occur in the central annulus of the disk. In this region, the user may experience wear percentages to a fairly large extent. Weighting can also be learned, which represents the user experience when reporting the wear percentage statistics to the user.

[0235] 3) The value of W may be correlated with the remaining time of disk use. This is achieved by asking the operator to use the abrasive disk over a varying period and observing W. Initially, regression will be used to predict the remaining time. If insufficient R^2 values / p-values are achieved, additional parameters may be integrated for more advanced investigations such as multiple linear regression or non-linear regression.

[0236] 4) These scores may be further personalized for each individual operator using machine learning. For the sake of brevity of the IS purpose, this detail is not described here but is possible upon request. This would be a feature implemented at horizon 2 or 3 of the feature roadmap.

[0237] Technical Methodology From a technical perspective, this was achieved by training a machine learning classifier (specifically, random forest) to predict the state of each pixel in the image based on the numerical value of that pixel and the numerical values of adjacent pixels. Feature calculation was used to achieve this, and the features calculated include the first and second derivatives of the region, along with the Gaussian pyramid.

[0238] There are other ways to achieve this, but this serves as an example.

[0239] Figure 17A shows a new disk. Figure 17B shows the output image, with annotation colors assigned based on whether abrasive grains were used. Green means it was used, and purple means it was not used.

[0240] All red pixels in the right image prediction are predicted not to be abrasive grains and are excluded from the calculation.

[0241] Example 2 Previously, a machine learning algorithm was created to assist manufacturing by diagnosing manufacturing issues using an optical microscope. Figure 18A shows the acquired microscope image of the polished article.

[0242] As shown in Figure 18B, a human inputs training data for the machine learning algorithm. The corresponding colors in the lower image are as follows. ● Red: Manually labeled as the background area ● Blue: Manually labeled PSG ● Green: Areas not labeled, and the machine learning algorithm predicts their class

[0243] Example 3 A random forest was created to predict the class of the green areas as PSG or "background". To assist the classification section, a series of intermediate images were generated, for example, as shown in Figures 19A and 19B.

[0244] The probability map shown in Figure 19C indicates areas with a high probability of being PSG. The thresholded image shown in Figure 19D provides a binary image representing where PSG can be located.

[0245] The results can be overlaid on the original image to select PSG (schematically shown in Figure 19E).

[0246] Example 4 Figure 20 shows multiple images of the same polished surface when subjected to fixed grinding conditions. In each grinding cycle, there is an increase in the visible abrasive grains related to the crushing mechanism of the ceramic mineral. The abrasive grains, in this case "precision formed abrasive grains", wear down and remove less material to be ground, while at the same time the grinding experienced becomes hotter. The PSG abrasive grains are blue and can thus be easily selected against the red background of the abrasive. Using the area of the visible blue abrasive grains, the area of the abrasive against the red background can be calculated, providing a strong indication of the abrasive service life.

Claims

1. A polishing product evaluation system, A camera for imaging the polished object, Based on the aforementioned image, an effectiveness indicator generation unit generates an indication of the polishing effectiveness of the polishing article, A command generation unit that generates a command based on the generated polishing effectiveness instruction, Equipped with, The command is a downstream operation command that adjusts the downstream polishing operation parameters based on the wear indication. system.

2. The system further includes a parameter acquisition unit for acquiring the current operating parameters of the tool associated with the polishing article, The command generation unit generates a command to adjust the operation parameter 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 operating parameter is an applied force, the tool is a robot polishing unit, and the second value is an applied force that is higher than the first applied force.

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

5. The system according to claim 2, wherein the operating parameter is a polishing angle, and the second polishing angle is different from the first polishing angle.

6. The system according to any one of claims 1 to 5, wherein the command is a redressing command, and the robot polishing unit moves the polishing article to a redressing station based on the command.

7. The system according to any one of claims 1 to 5, wherein the polishing effectiveness indicator is a metal capping measurement value.

8. The system according to any one of claims 1 to 5, further comprising a structured light source.

9. The system according to any one of claims 1 to 5, further comprising a mount for maintaining the position of the camera.

10. It is a robotic polishing system, A polishing article containing abrasive particles within a bond matrix, A robotic arm configured to move one of the polishing articles and the substrate to a fixed position such that the polishing article contacts the substrate, A force control unit on the robot arm, which applies force to the polishing article or the base material, A product evaluation system, The polished article is imaged, The polished article is evaluated, An article evaluation system that generates updated operating parameters for the robot polishing system based on the evaluation, Equipped with, Robot polishing system.

11. The aforementioned item evaluation system The system includes a wear estimation unit for estimating the amount of wear on the polished article. The robot polishing system according to claim 10.

12. The aforementioned item evaluation system The system includes a metal capping detection unit for detecting the amount of metal capping on the polished article. The robot polishing system according to claim 10 or 11.

13. The robot polishing system according to claim 12, wherein the metal capping detection unit segments the captured image.

14. The robotic polishing system according to claim 10 or 11, wherein the article evaluation system is equipped with an ultrasonic caliper.

15. The robotic polishing system according to claim 10 or 11, further comprising a structured light source, wherein the polishing article evaluation system comprises a camera for imaging the polished article.

16. The robot system according to claim 15, wherein the camera, the substrate, or the polishing article is connected to a moving mechanism.

17. The robotic system according to claim 10, wherein the article evaluation system compares the amount of metal capping with a metal capping threshold, and if the amount of metal capping exceeds the metal capping threshold, a redressing command or replacement command for the polished article is generated.

18. The robotic system according to claim 10, wherein the article evaluation system compares the amount of wear with a wear threshold, and if the amount of wear exceeds the wear threshold, a replacement command for the polished article is generated.

19. The robot system according to claim 18, wherein the wear threshold is based on the operating parameters of a future polishing operation.

Images