Abrasive article, system, and method of use

Abstract

A polishing article evaluation system is presented that includes a detection unit that detects a non-visual polishing wear queue, and a validity indication generation unit that generates an indication of wear of the polishing article based on the polishing wear queue. The system also includes a command generation unit that generates a command based on the generated indication of wear.

Description

Background Art

[0001] Coated abrasive articles containing shaped abrasive grains are useful for shaping, finishing, or grinding a wide 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] A polishing article evaluation system is presented that includes a detection unit that detects non-visual polishing wear cues and a validity indication generation unit that generates an indication of wear of the polishing article based on the polishing wear cues. The system also includes a command generation unit that generates a command based on the generated indication of wear.

[0003] A robotic polishing system is presented that includes a polishing article that includes wear cues detectable by a sensor, the polishing article being configured to contact a substrate. The system also includes a robotic arm configured to contact the polishing article with the substrate. The system also includes a force control unit on the robotic arm. The force control unit contacts the polishing article with the substrate. The system also includes a wear indication system that determines the amount of wear of the polishing article based on the wear cues and adjusts the operating parameters of the robotic polishing system based on the amount of wear.

[0004] A polishing article having wear cues is presented that includes a bond matrix and a plurality of abrasive grains within the bond matrix. The article also includes a detectable wear indicator that changes after a portion of the service life of the polishing article has elapsed.

[0005] This specification describes systems and methods for detecting when a polishing article is approaching the end of its useful life. Some of the systems and methods of this specification may improve the effectiveness of the use of the polishing article as the polishing particles wear. However, the systems and methods of this specification are not limited to measuring the wear of the polishing particles. For example, it may also be useful to detect the wear of the resin matrix in a non-woven polishing article or a bonded polishing article where the entire article wears during use. Some polishing articles are worn down to the backing layer, providing an opportunity to visually detect changes.

[0006] Some of the systems and methods of this specification may be particularly useful in robotic polishing systems where there is no human operator to detect the end of the useful life by noticing a change in polishing effectiveness. Additionally, some of the systems and methods of this specification may be useful for a hand-held polishing tool to assist an operator in adjusting the tool's usage parameters during a polishing operation.

[0007] The above summary of the disclosure is not intended to describe each and every embodiment of the disclosed embodiments or all implementations of the disclosure. The following description illustrates exemplary embodiments in more detail. Accordingly, it should be understood that the following description should not be construed as unduly limiting the scope of the disclosure.

Brief Description of the Drawings

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[0009] 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 figures may not be drawn to scale.

Modes for Carrying Out the Invention

[0010] Throughout this document, values expressed in a range format are to be interpreted flexibly such that they include not only the numerical values explicitly recited as the limits of the range, but also all individual numerical values or sub-ranges included within that range, 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%" is to be interpreted as including not only about 0.1% to about 5%, but also the individual values (e.g., 1%, 2%, 3%, and 4%) and sub-ranges (e.g., 0.1% to 0.5%, 1.1% to 2.2%, 3.3% to 4.4%) within the indicated range. A description of "about X to Y" has the same meaning as "about X to about Y" unless otherwise indicated. Similarly, a description of "about X, Y, or about Z" has the same meaning as "about X, about Y, or about Z" unless otherwise indicated.

[0011] In this document, the terms "a", "an", or "the" are used to include one or more, unless the context clearly dictates otherwise. The term "or" is used to refer to a non-exclusive "or" unless otherwise indicated. A description of "at least one of A and B" has the same meaning as "A, B, or A and B". Additionally, any expressions or terms used herein that are not specifically defined are to be understood as being for illustrative purposes only and not for purposes of limitation. The use of section headings is intended to assist in reading the document and is not to be construed as limiting, and information related to a particular section may be located within or outside of that particular section.

[0012] In the methods described herein, the 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, the acts can be performed simultaneously, unless explicitly recited in the claims 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 falls within the literal scope of the claimed process.

[0013] 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 recited value or of the limits of the recited range, and includes the recited exact value or range.

[0014] As used herein, the term "substantially" refers to 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, etc., of the majority or almost all or 100%.

[0015] 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 (e.g., as 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, drop shapes, and hypocycloids (e.g., super-elliptical shapes).

[0016] 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 surrounding the face) may be arcuate (either inwardly or outwardly, with the former option being preferred). Thus, for the purposes of the present invention, the triangular shape also includes a three-sided polygon in which one or more of the edges (the portion surrounding 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.

[0017] 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 particle. 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 polygonal shapes on two opposite sides.

[0018] 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.

[0019] 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 Jul. 23, 2019, which is incorporated herein by reference.

[0020] In cases where the abrasive particles are precisely shaped (e.g., into small triangular plates or conical particles), the effect of this orientation can be particularly important, as discussed in U.S. Patent Application Publication No. 2013 / 0344786 (A1) (Keipert), which is incorporated herein by reference. As used herein, the term "alignment" is used to refer to the relative position of the abrasive particles on the backing, while the term "orientation" refers to the rotational position of the abrasive particles in the aligned position. For example, a triangular particle can have an "apex-up" orientation or an "apex-down" orientation with respect to the backing.

[0021] 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.

[0022] 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.

[0023] Furthermore, with respect to coated abrasive articles, many 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.

[0024] 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.

[0025] FIG. 1 and FIG. 2 show an exemplary coated abrasive disc 100 according to the present disclosure, in which the shaped abrasive particles 130 are fixed in an exact 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.

[0026] 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.

[0027] 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.

[0028] 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.

[0029] 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 of which are in the form of a solution of the catalyst dissolved in water.

[0030] 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.

[0031] Phenolic resins are well known and readily available from commercial suppliers. Examples of commercially available resole phenolic resins useful in the practice of this 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).

[0032] 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.

[0033] The basis weight of the make coat to be used can depend on, for example, 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 the backing, including, for example, roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

[0034] Once the make coat precursor is coated on the backing, triangular abrasive particles are added to and embedded in the make coat precursor. The triangular abrasive particles are nominally added on 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 a known orientation method such as electrostatic orientation or magnetic orientation.

[0035] Although FIGS. 1-2 show coated abrasive articles, it is expressly contemplated that the systems and methods herein may also be suitable for understanding the use and wear of other abrasive articles such as bonded abrasive articles having a resinous or vitreous bond matrix, non-woven abrasive articles, brushes, or other abrasive articles.

[0036] A polishing article can be used in many contexts. This specification describes the context of robotic repair (Figure 3) and the context of handheld tools (Figure 4). Various usage scenarios of polishing articles present various problems with respect to the use of the article over time. For example, a skilled human operator can often "feel" when a polishing article is losing its cutting efficacy over time and can adjust accordingly, either by applying more force or by adjusting the angle. Similarly, a polishing article may maintain an acceptable polishing efficacy but may need to be replaced because it is too close to the end of its useful life. A robotic system may not have insight into the wear or loading occurring on the polishing article and thus may not make the necessary adjustments or may not replace the polishing article when needed. The systems and methods herein may be similarly useful in other contexts.

[0037] Figure 3 is a schematic view of a robotic arm that can benefit from the embodiments disclosed herein. The robotic repair unit 200 has a base 210 that may be stationary in some embodiments. In other embodiments, the base 210 can move in six degrees of freedom, i.e., translation, or rotation about the x-axis, y-axis, and / or z-axis. For example, the robot 200 may have a base 210 that is fixed to a rail system configured to move with the moving substrate being repaired. Depending on the particular task, the robot 200 may need to approach or move away from the substrate, or may need to move higher or lower than the polishing area. Thus, a movable base 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 trajectory that provides 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 unit 230. 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 all of the components 210, 220, 230, 240, and 250 can 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 flush away the accumulated chips. When the polished article is capped, the controller 270 may start a dressing process to reduce the detected 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 a polishing operation. The tool 300 includes a polished article 310 coupled 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 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 relative to the surface. In other embodiments, the communication unit 330 may display results, instructions, or suggestions on a display associated with a human operator, such as a display on a protective device worn by the user (e.g., a 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 acceptable for continued use or not acceptable 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 are worn down, the cutting rate decreases. However, the polishing efficacy may also be affected by other factors that may be detectable using the systems and methods of this specification. For example, capping or loading may occur, and the tips of the polishing particles may be covered and rendered 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 may include 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] In some embodiments of the present specification, the cue is detectable by an operator holding a tool connected to the polishing article, and a tactile change 507 is detected as the polishing article approaches the end of its useful life. In the context of a robot, the tactile change 507 may be detectable by a force control unit or an accelerometer.

[0047] The detection unit 520 may be fixed so that a robot arm or a human operator can carry 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 the 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 expressly contemplated that in some embodiments it may be a single component.

[0048] 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 activate the queue capture device 522. In some embodiments, a trigger 554 may activate the detection unit start unit 556. For example, the motion detection unit 554 may detect that the polishing article 502 has moved to a fixed position. The trigger 554 may also be time-based or position-based.

[0049] The instruction processor 562 processes the received signal from the detection unit 520. As described herein, this may include comparing the received signal to a threshold, reviewing it in light of the historical signal value fetched from the data store by the history value capture unit 544, or otherwise processing the signal to determine whether the polishing efficacy of the article 502 has reached an undesirably low value or whether the polishing article 502 is approaching the end of its useful life and needs to be changed soon.

[0050] The indication process 562 may use threshold values set by a manufacturer, customer, operator, shift manager, etc. For example, a certain customer may set the minimum acceptable thickness of the polishing disk as T, and a second customer may set the threshold value to 2T.

[0051] In some embodiments, the controller 540 may determine that even if the polishing efficacy has decreased below the threshold value, it may be possible to improve it by changing one or more operating parameters. The parameter capturing unit 542 may capture the current set of operating parameters such as the force applied from the force control unit and the polishing angle from the accelerometer. The command generation unit 546 may generate a command for 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 for replacing the polishing article 502 with a new polishing article, or for redressing the polishing article 502, to remove loading or metal capping. 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 sharpened again by themselves, but the metal capping prevents such crushing. 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.

[0052] The effectiveness indication generation unit 564 generates an indication of the polishing effectiveness of the polishing article 502. This indication can be displayed, for example, on the display component 590. The indication may be provided in words such as "60% used" or "capping detected", or may be provided simply as "good" or "bad". The indication may be auditory, for example, an alarm or signal indicating that an action is required to improve the polishing effectiveness or to replace the polishing article 502. The indication may be provided to the graphical user interface generation unit 552, and that generation unit may generate an interface for the display component 590. The controller 540 may also have other components 566.

[0053] 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. The GUI generation unit 552 may then send an instruction to the application running on the device to update the effectiveness indication 592.

[0054] 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 of use 596 may also be indicated. For example, a coated polishing article that has suffered significant wear may no longer be suitable for the initial large-scale polishing removal process of the process, but may be suitable for a later small-scale polishing 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.

[0055] Although system 500 is shown as being separate from display component 590 in FIG. 5, it is expressly contemplated that a single computing unit may include display component 590 and some or all of the components of system 500. For example, although detection unit 520 and controller 540 are shown as part of a single unit, it is expressly contemplated that at least some components may be part of separate devices. For example, controller 540 may be part of a separate computing device remote from the robotic arm controller, detection unit 520, and display component 590.

[0056] FIG. 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 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 indicative of the polishing efficacy of the polishing article.

[0057] In block 610, the polishing article is attached to a tool. For example, the polishing article may be coupled to a backup pad of a hand-held polishing tool or to the tool of a robotic polishing unit. The polishing article may be a polishing article suitable for a given polishing operation, such as a coated polishing article, an agglomerated polishing article, a hair brush, a non-woven polishing article, or another suitable polishing article.

[0058] In block 620, the polishing article engages the workpiece and a polishing operation is performed. As the workpiece is polished, the abrasive particles of the polishing article wear away. They may also undergo capping, loading, or other degradation.

[0059] At block 630, the polished article is evaluated. The polishing efficacy of the polished article is determined. In some embodiments, visual cues 632 may be analyzed to detect wear, capping, or loading. Auditory cues 634 may be analyzed to detect wear, capping, or loading. In other embodiments, different detectors 636 detect cues of polishing efficacy.

[0060] The evaluation of the polished article may be performed by directly measuring parameters of the polished article, such as visual signs, sounds, or other signs of the polished article, during or after the polishing operation. In other embodiments, the evaluation of the polished article may be performed by evaluating the workpiece, the chips removed from the workpiece, or another component.

[0061] The evaluation at block 630 may be automatically performed as part of the polishing process. For example, a robotic arm connected to the polished article may change position, for example, while a completed workpiece is being exchanged for a new workpiece, such that the article comes within the range of the detector. Similarly, while a human operator changes the part being polished or completes another task, the human operator may place the polishing tool connected to the polished article at a position within the range of the detector.

[0062] If the polishing efficacy of the polished article is maintained at an acceptable level at block 642, 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.

[0063] In block 644, when the polishing efficacy is lower than the acceptable level, as shown in block 650, the polishing efficacy can be treated, for example, by either dressing the polishing article to remove capping or cleaning or purifying the polishing article to remove loading. However, in some embodiments, method 600 returns to block 610.

[0064] Examples and embodiments of the present invention in which the indication of the detected polishing efficacy is essentially visual are described herein with reference to FIGS. 7-12. However, it is explicitly contemplated that other cues of polishing efficacy are possible and are described in co-pending U.S. Patent Application Nos. 63 / 366,803 and 63 / 366,802, both filed on June 22, 2022.

[0065] FIGS. 7A and 7B show a polishing article according to an embodiment of the present specification. FIG. 7A shows a top view of a polishing disk, and FIG. 7B shows a cross-sectional view of the same polishing disk. However, although the polishing disk is illustrated, it is explicitly contemplated that the embodiments of the present specification can be similarly incorporated into non-woven polishing articles or bonded polishing articles.

[0066] The polishing disk 700 includes abrasive particles 730 embedded in a resin layer 720 on a backing 710. A second resin layer 740 covers the abrasive particles 730. As shown, a number of low electrical resistance paths 702 extend through the polishing article. In one embodiment, the paths extend across the polishing article such that when the edge or center of the surface of the article 700 is significantly worn, the paths are exposed and / or broken. The low electrical resistance paths may be, for example, wires or lines of metal paste printed or applied on the disk. The metal paste can also be copper, aluminum or another preferably conductive material. Additionally, in some embodiments, an anti-seizing material (e.g., a material used to prevent galling of the substrate) may be used. In some embodiments, the wire may extend beyond the edge of the polishing article so that continuity can be easily verified. As shown in FIG. 7B, depending on the polishing operation, several arrangement options may be suitable. For example, within the make coat 712, at the interface 714 between the backing and the make coat, or within the backing 710 as illustrated by the position 716. However, in some embodiments, it is explicitly contemplated that the low conductivity path is disposed at only one of the positions 712, 714, 716. Other positions within the polishing article may also be suitable. The low conductivity paths 702 are illustrated in FIG. 7A as being parallel and equally spaced across the surface of the polishing article. However, it is explicitly contemplated that other arrangements are possible. In some polishing operations, it may be preferred to have one or more low conductivity paths 702 extending through the center of the polishing article. The wire may preferably have a length that winds through the article in, for example, a zigzag or curved pattern. The low conductivity paths may preferably be arranged concentrically so that feedback is available about where discontinuities occur. This can be useful for estimating the available contact area and providing feedback for the next operation. For example, if a broken wire is detected in the middle region of the polishing disk, a recommendation may be made to the operator to change the contact angle to utilize the edge region of the disk instead, or a command may be sent to a robotic operating system.This can be useful to ensure that the polishing article is fully utilized before being discarded. However, it is also desirable to be able to easily confirm the conductivity. Thus, in some embodiments, a wire or other low-conductivity path extends beyond the edge of the polishing article or protrudes through the backing of the polishing article so that the continuity can be easily confirmed.

[0067] In embodiments where the backing 710 is multilayered, the low-conductivity path may be embedded within the backing as part of the construction process. In some embodiments, it may also be preferable to have wires embedded in multiple different layers of the polishing article to provide several different wear indications when different wires are exposed and broken.

[0068] Although coated polishing articles have been discussed, it is also expressly contemplated that low-conductivity paths may be used to detect wear of other polishing articles. For example, embedding low-conductivity paths at different radial depths of a bonded polishing article can be useful for maintaining a constant polishing rate. For example, grinding wheels are often operated at a constant rpm, so the surface area of a new grinding wheel with a long radius moves at a faster rate than a worn grinding wheel with a shorter radius. The radius of the grinding wheel can be inferred when different low-conductivity paths are exposed and broken, and the rotational speed can be increased to maintain a constant speed of surface area contact between the grinding wheel and the substrate. Similar techniques may be used for other polishing articles with varying radii, such as polishing brushes or non-woven convolute wheels.

[0069] The low conductivity path 702 may have a voltage applied to it during the polishing operation or between successive polishing operations, and the voltage travels from a voltage source to a receiver. The received voltage is measured over time such that discontinuities are detected. In some embodiments, the voltage is continuously measured while the polishing article is in contact with the substrate. When a discontinuity is detected, in some embodiments, an alarm may sound to indicate to the operator that the wear threshold has been reached. The low conductivity path 702 may be made of any suitable, preferably conductive material such as aluminum, silver, gold, zinc, brass, nickel, etc. The conductivity may be measured using a power receiving device, and in some embodiments, the device is in contact with a portion of the path 702 that extends to or beyond the edge of the polishing article, as more clearly shown in, for example, FIG. 7C.

[0070] FIG. 7C shows a polishing article 750 through which a low conductivity path 754 extends. The spindle 752 may connect the polishing article 750 to a hand-held polishing tool or a robotic polishing unit. The polishing article 750 can be brought close to a current generating or voltage generating device 760, which produces results at a conductivity reading section when the conductive path 754 is intact.

[0071] In the context of a hand-held polishing tool, the user may place the grinding tool in a pedestal incorporating the electrode 756 such that the electrode 756 is connected to the low conductivity path end 754. The user may lower the grinding tool during the polishing operation, for example, to wipe away accumulated debris, polish material, fluid, etc.

[0072] In the context of a robotic polishing system, the electrode 756 may be disposed on the robot unit such that at some point during the polishing operation cycle, the polishing article 750 comes to a position where the path end 754 contacts the electrode 756. For example, a two-head tool design such as that described in U.S. Patent Application No. 17 / 779,218, filed Nov. 24, 2020, may have an electrode 756 arranged such that the polishing article 750 contacts the lead wire when the second tool is in use. The polishing article 750 may also contact the electrode 756 when entering or exiting the use position while rotating.

[0073] It is also contemplated that the robot arm may maintain the active position of the polishing article 750 (e.g., the orientation in contact with the workpiece) and at some point during the polishing operation cycle, move the polishing article 750 such that the path end 754 contacts the electrode 756. For example, the robot arm 750 may move the polishing article 750 to a fixed position while the wiping operation is in progress so that no additional cycle time is added to determine whether the path 754 remains intact. However, it is also contemplated that the conductivity or voltage may be measured during the polishing operation cycle.

[0074] The wire may be of any suitable, preferably conductive material, and the voltage may be an amount suitable to produce a detectable resistance without risk of damage to the polishing article. For example, a copper wire, which is a soft metal, can preferably be bent without breaking during use. When the wire is unbroken, the resistance results in a very low conductivity, and when the wire breaks, the resistance rapidly increases, thereby triggering an alarm.

[0075] Although coated abrasive disks are illustrated in FIGS. 7A-7C, it is expressly contemplated that the wire may be inserted into non-woven abrasive articles or bonded abrasive articles, as well as abrasive belts, as long as a voltage or current can flow through the wire in a detectable state. Further, some metals, such as copper, may preferably be malleable so that they can be used in non-woven abrasive articles without breaking.

[0076] In some embodiments, instead of voltage, dissimilar metals are used and a current is passed across the disk to measure the temperature of the polishing disk. An alarm may be triggered if the temperature exceeds a threshold temperature. The temperature of the polishing article increases as the abrasive particles wear away, increasing the area of contact with the substrate of the polishing article and causing more friction.

[0077] FIG. 8 shows a cross-section of a polishing article according to an embodiment of the present specification. The illustrated cross-section is that of a polishing wheel 800 having a central hole 802, which may receive, for example, a tool spindle. The wheel 800 also includes a forming core 810. The forming core 810 may have threads along the edge of the central hole for receiving a tool spindle. The wheel 800 is a convolute polishing wheel formed of a non-woven polishing article wound around the core a plurality of times. The wheel 800 may be suitable for polishing finishes or deburring.

[0078] As shown in FIG. 8, the core 810 includes a feature 812 that results in a non-uniform outer surface of the core and a difference in the thickness of the polishing layer 830 from a minimum thickness 832 to a maximum thickness 834. Since the non-woven material is compressible, as a result, there is a difference in density near the core at the minimum thickness (low density) and the maximum thickness (high density). This density difference causes vibrations, which may become detectable as the wheel 800 wears, or the intensity may increase.

[0079] However, it is contemplated that the bonded abrasive article may also benefit from an irregular core shape. For example, when using core 810 in a bonded abrasive article, the core 810 has a different composition and density than the bond matrix, and as a result, detectable vibrations or sounds occur when it is exposed and contacts the substrate. Core 810 may have another feature 812, such as a longer extending protrusion that spreads radially from the core, so that when the core 810 is used in a bonded abrasive article, feature 812 is visible when wear occurs beyond a certain point. Core 810 may have a feature 812 colored a different color than the bond matrix so that it is visually detectable. Feature 812 is shown as extending uniformly along the length of core 810, but it is expressly contemplated that feature 812 may extend only partially along the length of core 810. This may be useful for ensuring that integrity is maintained when feature 812 is exposed for a bonded abrasive article.

[0080] Vibrations provide an indication that the end of the useful life is approaching. The difference between thickness 832 and thickness 834 can be adjusted according to the degree of warning required for a given operation by selecting a grinding wheel 800 having different desired thicknesses.

[0081] Feature 812 is shown as a triangular protrusion extending from a ring-shaped core. However, it is expressly contemplated that feature 812 may be of any suitable shape, such as semi-circular, square, rectangular, sinusoidal, etc. Similarly, any suitable number of features 812 may be present. Particularly in the context of robotic grinding, it may be suitable to have only one feature 812 since the sensor can be fine enough to detect changes in the rhythm of the grinding contact.

[0082] For a human operator, when the curing feature portion 812 is exposed, it shifts the grinding process from a smooth feel to a bumpy feel. Similarly, if the lower layer of the bonded abrasive article has different particle densities or smaller patterned particles, specificities may be detectable. When chattering occurs, different sounds, feels, or signals are generated during the polishing operation.

[0083] Adding features to the core 810 may provide additional advantages such as an increase in the adhesive force between the core and the polishing layer.

[0084] Although the core 810 is illustrated, it is explicitly contemplated that a scrim layer having suitable embossed features may provide a similar indication.

[0085] As the feel of the polishing tool changes as the end of use approaches, a similar concept can be applied to non-woven abrasive articles or coated abrasive articles by having an embossing on the backing surface.

[0086] As described with respect to FIG. 8, as the abrasive article is used, the sound may change detectably. For example, the particle arrangement can affect the sound profile of the polishing operation. Thus, it may be possible to train an acoustic sensor to measure the usage amount based on the audible sound. For example, a polishing disk or belt having a backfill between shaped abrasive grains may make different sounds when the raised abrasive grains are ground down to the level of the backfill particles and the backfill particles engage the substrate surface.

[0087] Backfill, i.e., filler particles, may be selected to change in a manner detectable for the pitch or tone of the polishing operation. In some embodiments, this change is detectable by the human ear as a change in tone. However, in other embodiments, this change is either not large enough to be detected by humans or is outside the range of human hearing. Therefore, an auditory sensor may be placed in the vicinity of the polishing operation to detect changes in sound. When detected, the sensor may trigger an alarm or alert regarding the amount of remaining useful life. Chinese Patent Gazette No. 105345663 describes one suitable acoustic emission sensor, but other suitable options are also conceivable.

[0088] Other options for changing the sound are also conceivable. For example, a material that generates a squeaking sound when contacting a specific substrate may be inserted. For example, steel ball bearings may be added to the make layer of the coated abrasive. When the steel particles contact the metal workpiece, the sound changes from the normal tone of the polishing and grinding to a substantially different pitch or tone that is detectable. When the steel particles contact the metal workpiece, the sound changes from the normal tone of the polishing and grinding to a substantially different pitch or tone that is detectable.

[0089] Similarly, within the polishing wheel article, an auditory warning tab is placed at a specified diameter such that when the wheel wears down to that diameter, the warning tab contacts the metal substrate and emits a substantially different audible pitch or tone that is detectable.

[0090] FIG. 9 shows a method of polishing a substrate according to an embodiment of the present specification. Method 900 may be used to determine the amount of wear during the useful life of the polishing article.

[0091] At block 910, attach the polishing article to the tool. The tool may be a manual tool or a robotic polishing unit. In some embodiments, the polishing article may be a bonded polishing article having a resin, vitreous, or polymer-based bond matrix. In other embodiments, the polishing article is a disk, belt, or pad containing abrasive particles. The polishing article also includes in its structure a wear indicator that provides a cue of wear detectable at some point during the useful life of the polishing article. The wear cue may indicate that the polishing article has been used up, is approaching the end of its useful life, or another point in time. For example, the wear cue may indicate that 25% of the abrasive particles have been used and additional force must be applied to maintain the polishing efficacy.

[0092] At block 920, polish the workpiece using the polishing article. As the polishing article polishes the surface, the abrasive particles are abraded or fractured.

[0093] At block 930, after a specific amount of wear, a sensor detects the wear cue. In embodiments where the wear cue is sound 932, the sensor is an auditory emission detector. For example, as the article wears, the decibel level of the sound may increase or decrease, or the pitch or tone may increase or decrease. A discontinuity 934 may be detected using a voltmeter or current detector when a wire extending through a portion of the polishing article breaks. The wire extends through a layer of the polishing article, becomes exposed, and may ultimately break or wear in response to the amount of use. The wear cue may also be an increase in vibration 936 detectable by a change in the polishing rhythm of the polishing article with respect to the substrate, a human operator, an accelerometer, a force control unit, or another suitable sensor. Other wear cues 938, or combinations of wear cues, may exist.

[0094] At block 940, the detected wear queue is used to determine the polishing efficacy of the polishing article. The detected wear queue may be an alarm indicating that the polishing article is worn out and needs to be replaced. In such a case, as shown at block 970, the polishing article is considered unacceptable and a new polishing article is attached.

[0095] However, in some embodiments, there may be several wear queues within the polishing article, or a single wear queue may change over time, such as the sound generated by the polishing particles when the polishing particles are further ground or when other particles are exposed. As shown at block 950, even if the first detected wear queue indicates that the polishing article is still usable, the operating parameters may be modified to increase the polishing efficacy, as shown at block 960. For example, the outer region of the polishing article may be worn out, and the wear indicator may trigger a change in the angle of attack of the polishing article with respect to the substrate.

[0096] A system and method for detecting wear of a polishing article are described herein. The polishing article may be a grinding wheel having a vitreous, resin, or polymer-based bond matrix, as described herein. For example, the grinding wheel may be a concave center grinding wheel, a cutoff wheel, etc. The polishing article may also be a coated polishing article such as a fiber-backed disk or a woven fabric-backed belt having polishing particles attached through a resin layer. The polishing article may include a non-woven layer as a backing or impregnated with polishing particles.

[0097] FIG. 10 is a networked architecture for a polishing article use evaluation system 1010. Architecture 1000 shows one implementation form of the implementation of system 1010, 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 applications via a wide area network and access them through a web browser or any other computing component.

[0098] Software or components, and corresponding data can be stored on a server at a remote location. Computing resources in a remote server environment can be aggregated at the location of a remote data center or can be distributed. The remote server infrastructure can deliver services through a shared data center, 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.

[0099] As described herein, based on instructions from the polishing article use evaluation system 1010, the robotic polishing unit 1004B may adjust the force or speed related to the polishing operation, or another parameter, in response to commands received via a wired or wireless network (e.g., fetched from the command data store 1040).

[0100] 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 the end of the useful life of a polishing article approaches, 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 1004A 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 1004A 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.

[0101] 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 to 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, since it will not leave such deep scratches, 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.

[0102] Figure 10 specifically shows that the system 1010 can be placed at the remote server location 1002. Therefore, the computing devices 1020 access those systems through the remote server location 1002. The operator 1050 can also access the user interface 1022 using the computing device 1020. For example, the user interface 1022 may provide instructions on how the polished article is worn, changes made to any of the networked systems 1004, or suggestions for changes to the operations by the operator (such as an increase in force, an increase in RPM, etc.).

[0103] Figure 10 shows that it is also contemplated that some elements of the systems described herein may be placed at the remote server location 1002 while other elements are not. As an example, the storage areas 1030, 1040, or 1060, or the robotic system 1070 can be placed at a location separate from the location 1002 and accessed via the remote server at the location 1002. Regardless of the location where they are located, they can be directly accessed by the computing device 1020 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 at substantially any location 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.

[0104] Also, note that the elements of the systems described herein, or portions thereof, can be arranged 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.

[0105] Figures 11-13 show examples of computing devices that can be used in the embodiments shown in the preceding figures.

[0106] Figure 11 is a simplified block diagram of an exemplary example of a handheld computing or mobile computing device that can be used as a user or client handheld device 1116 (such as, for example, the computing device 1020 of FIG. 10) on which the present system (or a portion thereof) can be deployed. For example, a mobile device can be deployed within the operator compartment of the computing device 1020 for use in generating, processing, or displaying data. FIG. 12 is another example of a handheld or mobile device.

[0107] FIG. 11 provides an overall block diagram of the components of client device 1116 that can execute some of the components illustrated and described herein. Client device 1116 interacts with them, or executes some and interacts with some. Device 1116 is provided with a communication link 1113 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 communication link 1113 include enabling communication via one or more communication protocols, such as wireless services used to provide cellular access to a network, and protocols that provide a local wireless connection to a network.

[0108] In other examples, an application can be received on a suitable removable memory card (such as a Secure Digital (SD) card, CF card, micro SD, or portable hard drive) connected to interface 1415. Interface 1115 and communication link 1113 communicate with processor 1117 (which can also embody a processor) along bus 1119 that is also connected to memory 1121 and input / output (I / O) components 1123 and clock 1125 and location information system 1127.

[0109] I / O components 1123 are provided, in one embodiment, to facilitate input and output operations, and device 1116 can include input components such as buttons, touch sensors, optical sensors, microphones, touch screens, proximity sensors, accelerometers, orientation sensors, and output components such as display devices, speakers, and / or printer ports. Other I / O components 1123 can be used as well.

[0110] Clock 1125 illustratively includes a real-time clock component that outputs time and date. It can also provide a timing function to processor 1117.

[0111] By way of example, the location information system 1127 includes components that output the current geographical location of the device 1116. 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 a desired map, navigation route, and other geographical functions can also be included.

[0112] The memory 1121 stores an operating system 1129, network settings 1131, applications 1133, application configuration settings 1135, a data store 1137, a communication driver 1139, and communication configuration settings 1141. The memory 1121 can include all types of tangible volatile computer-readable memory devices and non-volatile computer-readable memory devices. Also, a computer storage medium (described below) can also be included. The memory 1121 stores computer-readable instructions that, when executed by the processor 1117, cause the processor to perform steps or functions implemented by a computer according to the instructions. The processor 1117 can similarly be activated by other components to facilitate their functions.

[0113] FIG. 12 shows that the device can be a smartphone 1201. The smartphone 1271 has a touch-sensitive display 1273 that displays icons or tiles or other user input mechanisms 1275. The mechanism 1275 can be used by the user to execute applications, make phone calls, perform data transfer operations, etc. Generally, the smartphone 1271 is built on a mobile operating system and provides more advanced computing capabilities and connectivity than a feature phone.

[0114] Note that other forms of device 1216 are possible.

[0115] FIG. 13 is a block diagram of a computing environment that can be used in the embodiments shown in the preceding figures.

[0116] FIG. 13 is an example of a computing environment in which the elements of the systems and methods described herein, or (for example) portions thereof, can be deployed. Referring to FIG. 13, an exemplary system for implementing some embodiments includes a general-purpose computing device in the form of a computer 1310. The components of computer 1310 can include, without limitation, a processing unit 1320 (which may include a processor), a system memory 1330, and a system bus 1321 that couples various system components including that system memory to the processing unit 1320. System bus 1321 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. 13.

[0117] Computer 1310 typically includes a variety of computer-readable media. Computer-readable media can be any available media that can be accessed by computer 1310 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 1310. 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 having one or more of its characteristics set or changed in such a manner as to encode information in the signal.

[0118] The system memory 1330 includes computer storage media in the form of volatile and / or non-volatile memory, such as a read only memory (ROM) 1331 and a random access memory (RAM) 1332. A basic input / output system 1333 (BIOS), including basic routines that help transfer information between elements within the computer 1310 during startup and the like, is typically stored in the ROM 1331. The RAM 1332 typically includes data modules and / or program modules that are directly accessible by and / or currently being operated on by the processing unit 1320. By way of example and not limitation, FIG. 13 shows an operating system 1334, an application program 1335, other program modules 1336, and program data 1337.

[0119] The computer 1310 may also include other removable / non-removable volatile / non-volatile computer storage media. By way of mere example, FIG. 13 shows a hard disk drive 1341 that reads from and writes to non-removable, non-volatile magnetic media, a non-volatile magnetic disk 1352, an optical disk drive 1355, and a non-volatile optical disk 1356. The hard disk drive 1341 is typically connected to the system bus 1321 via a non-removable memory interface, such as interface 1340, and the optical disk drive 1355 is typically connected to the system bus 1321 by a non-removable memory interface, such as interface 1350.

[0120] Alternatively, or in addition, the functions described herein can be performed, at least in part, by one or more hardware logic components. By way of example, and not limitation, exemplary types of hardware logic components that can be used include field-programmable gate arrays (FPGAs), application-specific integrated circuits (e.g., ASICs), application-specific standard products (e.g., ASSPs), system-on-a-chip systems (SOCs), complex programmable logic devices (CPLDs), and the like.

[0121] The drives discussed above and shown in FIG. 13, and their associated computer storage media, provide storage space for computer-readable instructions, data structures, program modules, and other data for a computer 1310. In FIG. 13, for example, hard disk drive 1341 is shown as storing operating system 1344, application programs 1345, other program modules 1346, and program data 1347. Note that these components can be either the same as or different from operating system 1334, application programs 1335, other program modules 1336, and program data 1337.

[0122] The user can input commands and information into the computer 1310 via input devices such as the keyboard 1362, the microphone 1363, and a pointing device 1361 such as a mouse, trackball, or touchpad. Other input devices (not shown) can include a joystick, game pad, satellite receiver, scanner, etc. These input devices and other input devices are often connected to the processing unit 1320 via a user input interface 1360 connected to the system bus, but can also be connected by other interfaces and bus structures. A visual display 1391 or other type of display device is also connected to the system bus 1321 via an interface such as a video interface 1390. In addition to the monitor, the computer can also include other peripheral output devices such as a speaker 1397 and a printer 1396 that can be connected via an output peripheral interface 1395.

[0123] The computer 1310 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 1380.

[0124] When used in a LAN network environment, the computer 1310 is connected to the LAN 1371 via a network interface or adapter 1370. When used in a WAN network environment, the computer 1310 typically includes a modem 1372 or other means for establishing communication via a WAN 1373 such as the Internet. In a networked environment, program modules can be stored in a remote memory storage device. FIG. 13 shows, for example, that a remote application program 1385 can exist on the remote computer 1380.

[0125] The objects and advantages of the present disclosure are further illustrated by the following non-limiting examples, but the specific materials described in these examples and their amounts, as well as other conditions and details, should not be construed as unduly limiting the present disclosure.

[0126] A polishing article evaluation system is presented that includes a detection unit that detects a non-visual polishing wear cue and a validity indication generation unit that generates an indication of wear of the polishing article based on the polishing wear cue. The system also includes a command generation unit that generates a command based on the generated indication of wear.

[0127] 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.

[0128] 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.

[0129] The system may be implemented such that the operating parameter is speed and the second speed is higher than the first speed.

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

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

[0132] The system may be implemented such that the downstream polishing operation parameters are speed, force, or dwell time.

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

[0134] The system may be implemented to include a history value capturing unit that captures a history value of the operation parameters.

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

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

[0137] The system according to claim 10, wherein the detection start unit generates a trigger in response to a manual input.

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

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

[0140] The system may be implemented such that the command is a graphical user interface update command. 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.

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

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

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

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

[0145] The system may be implemented such that the detection unit includes an acoustic emission sensor.

[0146] The system may be implemented such that the detection unit includes a voltmeter or an ammeter.

[0147] The system may be implemented such that the detection unit includes a thermometer.

[0148] The system may be implemented such that the detection unit includes an accelerometer.

[0149] The system may be implemented such that the detection unit includes a force control unit of a robotic polishing system.

[0150] The system may be implemented such that the detection unit detects a wear cue when it is near the polished article.

[0151] The system may be implemented such that the detection unit detects a wear cue when it is in contact with the polished article.

[0152] The system may be implemented such that the detection unit includes an electrode that contacts the lead wire of the polished article.

[0153] A robotic polishing system is presented that includes a polished article containing a wear cue detectable by a sensor, the polished article being configured to contact a substrate. The system also includes a robotic arm configured to contact the polished article with the substrate. The system also includes a force control unit on the robotic arm. The force control unit contacts the polished article with the substrate. The system also includes a wear indication system that determines the wear amount of the polished article based on the wear cue and adjusts the operating parameters of the robotic polishing system based on the wear amount.

[0154] The robotic polishing system may be implemented to further include an effectiveness indication generation unit that generates an effectiveness indication of the polished article based on a signal from a sensor, and a command generation unit that generates a command for adjusting the operation parameters.

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

[0156] The robotic polishing system may be implemented such that the sensor is mounted on the moving mechanism.

[0157] The robotic polishing system may be implemented such that the sensor is a sound emission sensor, and the sensor is configured to detect a change in the sound emitted from the polished article.

[0158] The robotic polishing system may be implemented such that the sensor is a voltmeter or an ammeter. The sensor detects a discontinuity in the conductive path extending across a part of the polished article.

[0159] The robotic polishing system may be implemented such that the sensor is a force control unit mounted on the robotic arm. The force control unit detects a change in the polishing rhythm.

[0160] The robotic polishing system may be implemented such that the sensor is an accelerometer.

[0161] The robotic system may be implemented such that the operation parameter is an automatic shutdown.

[0162] The robotic system may be implemented such that the operation parameter is the force applied by the force control unit, the rotational speed of the polished article, or the residence time of the polished article on the substrate.

[0163] The robotic system may be implemented such that the operation parameter is the position of the polished article relative to the substrate.

[0164] The robot system may be implemented such that the operation parameters are parameters for a future polishing operation on the substrate.

[0165] The robot system may be implemented such that the operation parameters are parameters for a future polishing operation using a polishing article.

[0166] The robot system may be implemented such that the detection unit activates a detection sequence in response to a detection start command from the controller.

[0167] The robot system may be implemented such that the controller periodically transmits a detection start command.

[0168] The robot system may be implemented such that the controller transmits a detection start command at the start or end of a polishing operation.

[0169] The robot system may be implemented such that the controller generates a command for adjusting the operation parameters.

[0170] The robot system may be implemented to include a wear indication system having a history value capture unit that captures history values of a wear queue, and a wear processor that determines a wear amount based on the wear queue and the captured history values.

[0171] The robot polishing system may be implemented such that the history value is the wear queue that was last captured.

[0172] The robot system may be implemented such that the history value is the initial wear queue.

[0173] The system may be implemented such that the polishing article is a polishing disk or a polishing belt.

[0174] The system may be implemented such that the polishing article is a bonded polishing article.

[0175] The system may be implemented such that the polishing article is a polishing wheel.

[0176] The system may be implemented such that the polishing article is a non-woven polishing article.

[0177] A wear detection unit for a polishing article is presented, including a cue capture device that detects changes in the polishing article during or after a polishing operation. The detection unit also includes an efficacy indication generation unit that receives the changes and provides a wear indication based on the detected changes. The detection unit also includes a wear communication unit that communicates the detected wear cue to a second device.

[0178] The wear detection unit may be implemented such that the change is a change in the sound emitted by the polishing article in contact with the substrate.

[0179] The wear detection unit may be implemented such that the change is a change in the vibration of the polishing article with respect to the substrate.

[0180] The wear detection unit may be implemented such that the change is a change in the measured voltage or measured current across a part of the polishing article.

[0181] The detection unit may be implemented to include a motion mechanism that moves the cue capture device to a fixed position in response to a motion control command.

[0182] The detection unit may be implemented such that the motion control command is received from a second device.

[0183] The detection unit may be implemented to include a history value capture unit that captures a history wear indication of the polishing article.

[0184] The detection unit may be implemented to include a threshold capture unit that captures a threshold value for the efficacy generation unit.

[0185] The detection unit may be implemented to include a parameter acquisition unit that acquires a set of operation parameters of the polishing article, and the threshold value is acquired based on the set of operation parameters.

[0186] The detection unit may be implemented such that the second device includes a data store that receives and stores wear instructions.

[0187] The detection unit may be implemented to generate a wear alarm such that the wear communication unit generates an alarm based on the received and detected wear queue for the second device.

[0188] A polishing article having a wear queue including a bond matrix and a plurality of polishing particles within the bond matrix is presented. The article also includes a detectable wear indicator that changes after a portion of the useful life of the polishing article has elapsed.

[0189] The polishing article may be implemented such that the wear indicator is a sound emitted by the polishing article when in contact with the substrate.

[0190] The polishing article may be implemented such that the emitted sound includes the polishing particles contacting the substrate and the emitted sound changes from a first sound to a second sound as the polishing article wears.

[0191] The polishing article may be implemented such that the emitted sound is a first sound emitted by a first set of polishing particles and a second sound is generated after a portion of the useful life has elapsed. The second sound is generated by a second material.

[0192] The polishing article may be implemented such that the second material includes metal particles.

[0193] The polishing article may be implemented such that the second material polishes a metal substrate.

[0194] The polishing article may be implemented such that the second material increases the reflectivity of the workpiece.

[0195] The abrasive article may include a conductive path that extends through a portion of the abrasive article, and the conductive path is severed after a portion of the useful life such that a detectable wear indicator is a discontinuity.

[0196] The abrasive article may be implemented such that the wear indicator includes a rapid change in the measured voltage or current across the wire.

[0197] The abrasive article may be implemented such that the wire is a first wire and the abrasive article includes a second wire that extends through a second portion of the abrasive article.

[0198] The abrasive article may be implemented such that the first wire and the second wire are parallel.

[0199] The abrasive article may be implemented such that the first wire and the second wire do not cross.

[0200] The abrasive article may be implemented such that the first wire and the second wire cross.

[0201] The abrasive article may be implemented such that the abrasive article includes a core and the surface includes features that extend from a cylindrical shape.

[0202] The abrasive article may be implemented such that the features are exposed prior to the cylindrical shape during the abrasive operation.

[0203] The abrasive article may be implemented such that the features impart a density difference to the abrasive article adjacent to the features.

[0204] The abrasive article may be implemented such that the features include a semi-circle, semi-ellipse, sine wave, triangle, square, rectangle, polygon, or arc.

[0205] The abrasive article may be implemented such that the features are a first set of features and the surface includes a plurality of features.

[0206] The lapping article may be implemented such that a plurality of features include an odd number of features.

[0207] The lapping article may be implemented such that a plurality of features include an even number of features.

[0208] The lapping article may be implemented such that a first feature includes a first shape and a second feature includes a second shape different from the first shape.

[0209] The lapping article may be implemented such that the first shape has a first height with respect to a cylindrical shape, the second shape has a second height with respect to the cylindrical shape, and the first height is different from the second height.

[0210] The lapping article may be implemented such that the lapping article includes a scrim layer or a backing layer having raised features.

[0211] The lapping article may be implemented such that the features are embossed.

[0212] The lapping article may be implemented such that the lapping article is a bonded lapping article and the bond matrix is a resin, polymer, or vitreous bond.

[0213] The lapping article may be implemented such that the lapping article includes a backing and abrasive particles are connected to the backing by a bond matrix.

[0214] The lapping article may be implemented such that the backing is a non-woven backing.

[0215] A method for evaluating an abrasive article is presented that includes polishing a substrate using the abrasive article and detecting a change in the output of the abrasive article using a sensor while the abrasive article is in contact with the substrate. The method also includes evaluating a signal from the sensor using a potency evaluation unit and generating a wear indication based on the sensor signal. The method also includes communicating the wear indication to a device. The method also includes comparing the sensor signal to a first sensor signal captured earlier in time than the sensor signal. The method also includes detecting that the sensor signal is significantly different from the first signal. The method also includes generating an alarm.

[0216] The method may be implemented such that the device includes a data store.

[0217] The method may be implemented such that the device includes a display component.

[0218] The method may be implemented to include generating an operating parameter change and communicating the operating parameter change to a robotic polishing unit coupled to the abrasive article.

[0219] The method may be implemented to include estimating a remaining useful life based on the wear indication.

[0220] The method may be implemented such that the indication of the remaining useful life is estimated based on the historical wear trend of the abrasive article.

[0221] The method may be implemented such that the indication of the remaining useful life is estimated based on current operating parameters.

[0222] The method may be implemented such that the indication of the remaining useful life is based on predicted operating parameters.

[0223] The method may be implemented such that the sensor signal is sound and the wear indication is based on a change in the sound signal from an initial sound signal.

[0224] The method may be implemented such that the sensor signal is sound and the wear indication is based on analyzing the sound, i.e., comparing the sound to a sound data store that correlates the sound to known wear amounts of the abrasive article.

[0225] The method may be implemented such that the sensor signal is a voltage or current reading and the wear indication is based on detected discontinuities in a wire extending through a portion of the abrasive article.

[0226] The method may be implemented such that the sensor signal is a change in the polishing rhythm of the abrasive article relative to the substrate.

[0227] A method of forming an abrasive article is presented that includes providing a plurality of abrasive particles, a bond matrix precursor, and a backing material, and incorporating a wear indicator into any of the abrasive particles, the bond matrix precursor, or the backing. The method also includes embedding the abrasive particles within the bond matrix precursor. The method also includes curing the bond matrix precursor to form the abrasive article.

[0228] The method may be implemented such that the wear indicator is not detectable prior to a first polishing operation using the abrasive article.

[0229] The method may be implemented such that the abrasive article is an abrasive bonded article and the backing material is a scrim layer.

[0230] The method may be implemented such that the backing material is a non-woven material.

[0231] The method may be implemented such that the bond matrix precursor is a resin bond precursor, a vitrified bond precursor, or a polymer bond precursor.

[0232] The method may be implemented such that the wear indicator includes a filler material that generates a detectable sound when the filler material contacts the substrate.

[0233] The method may be implemented such that the wear indicator includes a conductive path extending through a portion of the abrasive article.

[0234] The method may be implemented such that the wire extends through a portion of the backing.

[0235] The method may be implemented such that the wire extends through the abrasive article within a layer of the bond matrix.

[0236] The method may be implemented such that the wire extends through the abrasive article at an interface between the backing and the bond matrix precursor.

[0237] The method may be implemented such that the abrasive article also includes a core having a surface that bonds to the bond matrix, and the wear indicator includes features on that surface.

[0238] The method may be implemented such that the feature is a tab extending from the abrasive article when exposed, and the tab emits a detectable sound when it strikes a substrate.

[0239] The method may be implemented such that the feature includes a protrusion from the core.

[0240] The method may be implemented such that the protrusion includes a polygonal shape, a sine wave shape, a curved shape, a semi-circular shape, or a semi-oval shape.

Example

[0241] Example 1: Vibration in a convolute wheel Preparation of the vibration core Two core sleeves each having three protrusions as features were printed in ABS resin using a 3D printer (Fortus 450 (Eden Prairie, Minnesota, Stratasys)) machine. The length of the sleeve was 12 inches (304.8 mm), and the geometric shape (in millimeters) of the cross-section of the core sleeve is shown in FIG. 14.

[0242] The sleeves were aligned and adhered with an epoxy resin (DP100, 3M Company (Saint Paul, Minnesota)) to a standard glass fiber core with an outer diameter of 1.39 inches (35.3 mm), an inner diameter of 1 inch (25.4 mm), and a length of 24 inches (609.6 mm).

[0243] Example 1 A convolute band was prepared according to exactly the same specifications as those used when manufacturing the wheel "GP Plus 8 SF" commercially available from 3M Company in St. Paul, MN, except that the core shown in Figure AA was used. Wheels with thicknesses of 0.5 inches (12.7 mm) and 1 inch (25.4 mm) were used.

[0244] Comparative Example A A wheel having dimensions of 0.5 inches (12.7 mm) and 1 inch (25.4 mm) and commercially available under the product name "GP Plus 8 SF" from 3M Company in St. Paul, MN, was obtained.

[0245] Density measurement Uniform cylindrical slugs with dimensions of 7.7 mm in diameter × 12.7 mm in thickness were punched out from the wheel of Example 1 with a thickness of 0.5 inches (12.7 mm). A total of six slugs were punched out such that the center line of each was at a distance of approximately 28.1 mm from the center. Three of the slugs were collected directly above the protrusions of the sleeve, and three of the slugs were collected directly above the valleys between the protrusions. The slugs were weighed. The average density is listed in Table 1 below.

Table 1

[0246] Vibration test Wheels with a thickness of 1 inch from both Example 1 and Comparative Example A were mounted on an electric buffer (Baldor 412B 1.5 HP electric buffer, ABB Motors and Mechanicals Inc, Fort Smith, Arkansas) and operated at 1750 rpm. An operator pushed a 1-inch × 1-inch steel bar into the surface of the wheel. No difference was observed.

[0247] Wheels with a thickness of 1 inch from both Example 1 and Comparative Example A were dressed up to a diameter of 3 inches to simulate severe wear. Both wheels were mounted on an electric buffer (Baldor 412B 1.5 HP electric buffer, ABB Motors and Mechanicals Inc, Fort Smith, Arkansas) and operated at 1750 rpm. An operator pushed a 1-inch × 1-inch steel bar into the surface of the wheel. It was found that the wheel of Example 1 showed significant vibration when compared with Comparative Example A.

Claims

1. A polishing product evaluation system, A detection unit for detecting non-visual polishing wear cues, An effectiveness instruction generation unit generates an instruction for the wear of the polished article based on the polishing wear cue, A command generation unit that generates commands based on the generated instructions for wear, Equipped with, The system further includes a parameter acquisition unit for acquiring the current operating parameters of the tool associated with the polishing article, A system in which 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.

2. The system according to claim 1, 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.

3. The system according to claim 1, wherein the operating parameter is speed, and the second speed is higher than the first speed.

4. The system according to any one of claims 1 to 3, wherein the command is a replacement command, and a robot polishing unit associated with the polishing article automatically starts a polishing article replacement sequence based on the command.

5. The system according to any one of claims 1 to 3, wherein the command is a downstream operation command that adjusts downstream polishing operation parameters based on the wear instruction, and the downstream polishing operation parameters are speed, force, residence time, or a second polishing operation using a second polishing article.

6. The system according to any one of claims 1 to 3, wherein the detection unit comprises a voltmeter or an ammeter.

7. The system according to any one of claims 1 to 3, wherein the detection unit includes a thermometer.

8. The system according to any one of claims 1 to 3, wherein the detection unit comprises an accelerometer.

9. The system according to any one of claims 1 to 3, wherein the detection unit detects the wear cue when it is in the vicinity of the polishing article.

10. The system according to claim 9, wherein the detection unit detects the wear cue when it is in contact with the polishing article.

11. It is a robotic polishing system, An abrasive article having a wear cue detectable by a sensor, wherein the abrasive article is configured to contact a substrate, A robotic arm configured to bring the polishing article into contact with the substrate, A force control unit on the robot arm, comprising a force control unit that brings the polishing article into contact with the substrate, A wear instruction system determines the amount of wear of the polishing article based on the wear cue, and adjusts the operating parameters of the robot polishing system based on the amount of wear. A robotic polishing system equipped with the following features.

12. The wear indicator system, A performance indicator generation unit that generates the polishing effectiveness of the polished article based on the signal from the sensor, A command generation unit that generates commands for adjusting the aforementioned operating parameters, The robot polishing system according to claim 11, further comprising:

13. The robot polishing system according to claim 11 or 12, wherein the sensor is a force control unit attached to the robot arm, and the force control unit detects changes in the polishing rhythm.

14. The robot system according to claim 11 or 12, wherein the operation parameter is automatic shutdown.

15. The robot system according to claim 11 or 12, wherein 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.

16. A wear detection unit for polished articles, A cue capture device that detects changes in the polished article during or after the polishing operation, A unit that receives the aforementioned change and provides a wear instruction based on the detected change, A wear communication unit that communicates the detected wear queue to a second device, A wear detection unit comprising:

17. The wear detection unit according to claim 16, wherein the change is a change in the vibration of the polishing article relative to the substrate.

18. The wear detection unit according to claim 16, wherein the change is a change in the measured voltage or measured current across a portion of the polished article.

19. The detection unit according to any one of claims 16 to 18, wherein the wear communication unit generates a wear alarm so that the second device generates an alarm based on the received and detected wear queue.

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