Abrasive article sensors, systems and methods of use thereof

Abstract

A loading detection system is presented includes an inductive sensor that senses an induction value for an abrasive article when in proximity to it, an abrasive article evaluator that receives the sensed induction value, identifies a loaded material on the abrasive article, and quantifies an amount of the loaded material based on the induction value, and a communication component that communicates an indication of the amount of loaded material.

Description

ABRASIVE ARTICLE SENSORS, SYSTEMS AND METHODS OF USE THEREOFBACKGROUND

[0001] Abrasive articles are useful for shaping, finishing, or grinding a wide variety of materials and surfaces such as wood, metals (e.g., especially non-ferrous metals such as aluminum that tend to clog grinding wheels), and flash. However, when material clogs the surface of an abrasive article, the cut rate and / or life is affected. There continues to be a need for improving the cost, performance, and / or life of Abrasive articles.SUMMARY

[0002] A loading detection system includes an inductive sensor that senses an induction value for an abrasive article when in proximity to it, an abrasive article evaluator that receives the sensed induction value, identifies a loaded material on the abrasive article, and quantifies an amount of the loaded material based on the induction value, and a communication component that communicates an indication of the amount of loaded material.

[0003] The above summary of the present disclosure is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The description that follows more particularly exemplifies illustrative embodiments. It is to be understood, therefore, that the following description should not be read in a manner that would unduly limit the scope of this disclosure.BRIEF DESCRIPTION OF THE DRAWINGS

[0004] FIGS. 1 A-1B illustrate a top-down schematic and a cross-sectional view, respectively, of an exemplary coated abrasive article.

[0005] FIGS. 2A-2B illustrate loading on a coated abrasive article which may be detected and quantified using sensing systems in accordance with embodiments herein.

[0006] FIG. 3 illustrates a schematic view of an abrasive article evaluation system in accordance with an embodiment herein.

[0007] FIG. 4 illustrates an abrasive article evaluation system in accordance with embodiments herein.

[0008] FIG. 5 illustrates a method of evaluating an abrasive article in accordance with embodiments herein.

[0009] FIG. 6 illustrates a robotic abrading system architecture.

[0010] FIGS. 7-8 show examples of computing devices that can be used in accordance with embodiments herein.

[0011] FIG. 9 illustrates an inductive sensor in accordance with an embodiment herein.

[0012] Repeated use of reference characters in the specification and drawings is intended to represent the same or analogous features or elements of the disclosure. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale.DETAILED DESCRIPTION

[0013] In this document, the terms “a,” “an,” or “the” are used to include one or more than one unless the context clearly dictates otherwise. The term “or” is used to refer to a nonexclusive “or” unless otherwise indicated. The statement “at least one of A and B” has the same meaning as “A, B, or A and B.” In addition, it is to be understood that the phraseology or terminology employed herein, and not otherwise defined, is for the purpose of description only and not of limitation. Any use of section headings is intended to aid reading of the document and is not to be interpreted as limiting; information that is relevant to a section heading may occur within or outside of that particular section.

[0014] In the methods described herein, the acts can be carried out in any order without departing from the principles of the disclosure, except when a temporal or operational sequence is explicitly recited. Furthermore, specified acts can be carried out concurrently unless explicit claim language recites that they be carried out separately. For example, a claimed act of doing X and a claimed act of doing Y can be conducted simultaneously within a single operation, and the resulting process will fall within the literal scope of the claimed process.

[0015] As used herein, the term "shaped abrasive particle," means an abrasive particle with at least a portion of the abrasive particle having a predetermined shape that is replicated from a mold cavity used to form the shaped precursor abrasive particle. However, while FIGS. 1A-1B illustrate an exemplary abrasive article that includes shaped abrasive particles with a particular shape and orientation, it is expressly contemplated that sensors, systems, and methods herein may be useful for a larger variety of abrasive articles, having a number of backing materials and a wide variety of abrasive particles having a number of shapes and compositions. For example, abrasive particles may be shaped abrasive particles, crushed abrasive particles or both. Additionally, while abrasive particles of FIGS. 1A-1B are illustrated as having a specific alignment and Z-axis rotational orientation, it is expressly contemplated that systems and methods herein may apply to abrasive articles having abrasive particles in any, or no, alignment or orientation.

[0016] FIGS. 1 A and IB show an exemplary coated abrasive disc 100 according to the present disclosure, having shaped abrasive particles 130 are secured at precise locations and Z-axis rotational orientations to a backing 110. In the illustrated example, shaped abrasive particles 130 are triangular prism shaped particles that appear rectangular when viewed from above.

[0017] Generally, a coated abrasive article 100 includes a plurality of abrasive particles embedded within a make coat that secures the particles to a backing. The backing may be formed from any known flexible coated abrasive backing, for example. Suitable materials for the backing include polymeric films, metal foils, woven fabrics, knitted fabrics, paper, nonwovens, foams, screens, laminates, combinations thereof, and treated versions thereof.

[0018] Additionally, while abrasive articles having a backing material are discussed in detail with respect to FIG. 1, it is expressly contemplated that other abrasive articles, such as those having a resin bond system, may also benefit from systems and methods described herein.

[0019] The abrasive particles 130 may be embedded within an abrasive layer, which can include multilayer construction having make 120 and size layers 140. Coated abrasive articles may also include additional layers such as, for example, an optional supersize layer that is superimposed on the abrasive layer, or a backing antistatic treatment layer may also be included, if desired. Exemplary suitable binders can be prepared from thermally curable resins, radiation-curable resins, and combinations thereof.

[0020] Make layer 120 can be formed by coating a curable make layer precursor onto a major surface of backing 110. The make layer precursor may include, for example, glue, phenolic resin, aminoplast resin, urea-formaldehyde resin, melamine-formaldehyde resin, urethane resin, free-radically polymerizable polyfunctional (meth)acrylate (e.g., aminoplast resin having pendant a,[3-unsaturated groups, acrylated urethane, acrylated epoxy, acrylated isocyanurate), epoxy resin (including bis-maleimide and fluorene- modified epoxy resins), isocyanurate resin, and mixtures thereof. However, other suitable compositions may be appropriate for some applications.

[0021] The make layer precursor may be applied by any known coating method for applying a make layer to a backing such as, for example, including roll coating, extrusion die coating, curtain coating, knife coating, gravure coating, and spray coating.

[0022] Once the make layer precursor is coated on the backing, the abrasive particles are applied to and embedded in the make layer precursor. Using known orientation methods, such as electrostatic or magnetic orientation, it is possible to orient the abrasive particles with respect to the backing in order to improve performance of the particles, if so desired.

[0023] Examples of suitable abrasive particles include: fused aluminum oxide; heat-treated aluminum oxide; white fused aluminum oxide; ceramic aluminum oxide materials such as those commercially available under the trade designation 3M CERAMIC ABRASIVE GRAIN from 3M Company, St. Paul, MN; brown aluminum oxide; blue aluminum oxide; silicon carbide (including green silicon carbide); titanium diboride; boron carbide; tungsten carbide; garnet; titanium carbide; diamond; cubic boron nitride; garnet; fused alumina zirconia; iron oxide; chromia; zirconia; titania; tin oxide; quartz; feldspar; flint; emery; sol-gel-derived abrasive particles; and combinations thereof. Of these, molded sol-gel derived alpha alumina abrasive particles are preferred in many embodiments. Abrasive material that cannot be processed by a sol-gel route may be molded with a temporary or permanent binder to form shaped precursor particles which are then sintered to form shaped abrasive particles, for example, as described in U. S. Pat. Appln. Publ. No.2016 / 0068729 Al (Erickson et al.). However, other abrasive article compositions may be appropriate for some applications.

[0024] Further details concerning the construction of coated abrasive articles comprising an abrasive layer secured to a backing, wherein the abrasive layer includes abrasive particles and make, size, and optional supersize layers are well known, and may be found, for example, in U. S. Pat. Nos. 4,734,104 (Broberg); 4,737,163 (Larkey); 5,203,884 (Buchanan et al.); 5,152,917 (Pieper et al.); 5,378,251 (Culler et al.); 5,417,726 (Stout et al.); 5,436,063 (Follett et al.); 5,496,386 (Broberg et al.); 5,609,706 (Benedict et al.); 5,520,711(Helmin); 5,954,844 (Law et al.); 5,961,674 (Gagliardi et al.); 4,751,138 (Bange et al.); 5,766,277 (DeVoe et al.); 6,077,601 (DeVoe et al.); 6,228,133 (Thurber et al.); and No. 5,975,988 (Christianson).

[0025] Examples of workpiece materials which may have material removed using abrasive articles may include metal, metal alloys, steel, steel alloys, aluminum, exotic metal alloys, ceramics, glass, wood, woodlike materials, composites, painted surfaces, plastics, reinforced plastics, stone, and / or combinations thereof. The workpiece may be flat or have a shape or contour associated with it. Exemplary workpieces include metal components, plastic components, particleboard, camshafts, crankshafts, furniture, and turbine blades.

[0026] FIGS. 2A-2B illustrate loading on a coated abrasive article which may be detected and quantified using sensing systems in accordance with embodiments herein.

[0027] Depending on the composition of a particular workpiece, material loading can be a problem. Soft or sticky materials, such as stainless steel and / or aluminum, may cause material to chip from the workpiece and cover the surface of the abrasive article. Capping, one type of material loading, occurs when loaded material covers the abrasive particle tips, significantly reducing the sharpness of abrasive tips on the abrasive article surface and, consequently, significantly decreasing a cut rate of the abrasive article.

[0028] FIGS. 2A-2B illustrate loading on different abrasive surfaces. A nonwoven structure 200 is illustrated in FIG. 2A with loading 210 accumulating within the nonwoven web. FIG. 2B illustrates a coated abrasive article 250 experiencing capping 260.

[0029] Depending on loading severity, a user may discard the abrasive article before a functional use life, effectively reducing the total cut achieved by the abrasive article and the length of the useful life. In some cases, the abrasive article may be able to undergo a “redressing” process to remove the loaded material.

[0030] A system is desired that allows for detection and quantification of material loading on an abrasive article. While loading may be estimated by detecting a reduction in cut rate or by visible loading on the abrasive article, a system is desired to detect and quantify loading on an abrasive article in-situ.

[0031] Embodiments herein include a sensor configured to detect and quantify loading on an abrasive article. Systems herein may allow for in situ measurement of loading on an abrasive article for at least some applications. Systems herein may provide a user of an abrasive article with more information about how an abrasive article is loading during use, whether a surface of the abrasive article can be redressed, or whether the article has reached a loading level where it should be discarded.

[0032] Systems and methods herein utilize inductive sensing to detect loading. An inductive sensor can detect loading quantitatively. An inductance of a printed circuit board coil changes as conductive and / or magnetic materials are brought within proximity of the coil. The sensed value is dependent on the distance between the PCB coil and the external material, the amount of external material, and the type of the external material. However, while a PCB coil is described in the Examples as one embodiment of an induction-based loading sensor, it is expressly contemplated that other suitable constructions may be used in other applications. For example, a number of laminated structures of alternating conductive and insulating material layers may be suitable.

[0033] Induction-based sensing systems and methods herein provide a contact-less method that can detect not only surface loading but loading throughout a depth of an abrasive article, making it a particularly useful sensing method for either coated, nonwoven or bonded abrasive articles. Sensors described herein are also physically smaller than conventional methods for detecting loading, allowing for loading to be more easily detected during an abrasive process while taking less time to detect and quantify. More efficient detecting and quantification of loading can increase efficiency of industrial abrading operations as the abrasive article can be redressed efficiently.

[0034] FIG. 3 illustrates a schematic view of an abrasive article evaluation system in accordance with an embodiment herein. FIG. 3 illustrates one embodiment where an inductive sensor 320 is incorporated into a robotic abrading system 300. However, while a robotic abrading system 300 is illustrated in FIG. 3, it is expressly contemplated that similar configurations may be useful for users of powered hand-tools. In the illustrated embodiment, a sensor 320 is stationary within system 300. However, it is expressly contemplated that sensor 320 may be mobile with respect to robotic abrading unit 310 in some embodiments. Further, in some embodiments, sensor 320 may be mobile and an abrasive article may remain stationary during a sensing operation.

[0035] As used herein, the term “robotic abrading unit” refers to a robotic system that interacts with a surface to remove material. The robotic abrading unit may be a stationary unit, that operates on a stationary surface, in some embodiments. In other embodiments, the robotic abrading unit is a mobile unit that can move along a rail, track, or other mechanism such that it can abrade a moving surface. Additionally, it is also possible that the repair unit is stationary and the worksurface to be abraded moves. The robotic abrading unit may have one or more end effectors with one or more tools, such as those described in U.S. Provisional Patent Applications with Serial Nos. 62 / 940950 and 62 / 940960, both filed November 2, 2019, both herein incorporated by reference. However, other robotic unit configurations are also expressly contemplated.

[0036] Robotic abrading system includes a force control unit that can be aligned with an end-effector 302. While only one tool is shown, end effector 302 may include two tools, which may be arranged, in one embodiment, as further described such as those described in U.S. Provisional Patent Applications with Serial Nos. 62 / 940950 and 62 / 940960, both filed November 2, 2019. However, other arrangements are also expressly contemplated.

[0037] Abrasive material removal is a pressure-driven process while many industrial manipulators, in general, operate natively in the position tracking / control regime and are optimized with positional precision in mind. The result is extremely precise systems with extremely stiff error response curves (i.e., small positional displacements result in very large corrective forces) that are inherently bad at effort control (i.e., joint torque and / or Cartesian force)). Closed-loop force control approaches have been used (with limited utility) to address the latter along with more recent (and more successful) force-controlled flanges that provide a soft (i.e., not stiff) displacement curve much more amenable to sensitive force / pressure-driven processing. Robotic abrading systems may particularly benefit from systems and methods described herein as the robotic abrading unit can consistently achieve a specified position with respect to a loading sensor 320.

[0038] Robotic abrading systems may use fluids to accelerate or otherwise aid the abrasive removal process. For example, fluid may assist in swarf removal, reduce abrasive clogging, and extend the life of the abrasive article while improving the consistency of cut during use. For example, some sanding operations are wet sanding operations, requiring water, or another fluid, to be dispersed on the repair area prior to, or during, an abrading operation. Additionally, polishing often requires polish to be dispensed before, or during, the polishing operation. Water, or another removal solvent, may be dispensed to remove debris after an abrading operation.

[0039] The robotic abrading system 300 of FIG. 3 includes a base 310, which may be stationary, in some embodiments. In other embodiments, base 310 can move in any of six dimensions, translations or rotations about an x-axis, y-axis and / or z-axis. For example, robotic abrading system 300 may have a base 310 fixed to a rail system configured to travel along with a vehicle being repaired. Depending on an abrading location of a particular worksurface, robot 300 may need to move closer, or further away from a vehicle, or may need to move higher or lower with respect to the vehicle. A moveable base 310 may make repairing difficult-to-reach defects easier. However, it is expressly contemplated that systems described herein may be useful with robotic abrading systems having fewer degrees of freedom of movement as well.

[0040] Robotic abrading system 300, as illustrated has one or more abrading unis 304 that can interact with a worksurface. Abrading units may include a backup pad, in some embodiments, or another suitable abrasive tool that couples to an abrasive article. The abrasive tool may couple to an abrasive disc, abrasive pad or other suitable abrasive article, for example using adhesive, hook and loop, a clip system, a vacuum or other suitable attachment system. As mounted to the robotic unit 300, tool 304 has the ability to be positioned within the provided degrees of freedom by the robotic repair unit 300 (6 degrees of freedom in most cases) and any other degrees of freedom (e.g., a compliant force control 302 unit) with its reference frame.

[0041] A robotic loading sensor 320 may be positioned within the range of movement of robotic abrading system 300. In some embodiments, robotic abrading system 300 may move into position with respect to sensor 320 such that a loading measurement can be taken. However, it is expressly contemplated that, in some embodiments, sensor 320 is brought into position with respect to abrading unit 304. For example, a sensor station 330 is illustrated in FIG. 3, however it is expressly contemplated that a mobile station 330 may be used in some embodiments, the mobile station being separate from a robotic abrading arm. However, it is also expressly contemplated that in some embodiments the loading sensor 320 is fixed to the robotic abrading system 300, e.g. on an end-of-arm abrading unit. Such a configuration may be useful to reduce the amount of movement - for example an end-of-arm abrading unit may only need to rotate in a first direction to bring sensor 320 in range of a surface and then rotate in a second direction to bring an abrasive tool back into position to continue abrading.

[0042] It is also contemplated that the sensor station 330 is a stationary station, such that abrasive articles are moved into and out of proximity when a loading measurement is taken. As noted above, sensed induction values are based on a distance between sensor 320 and abrading unit 304 as well as a quantity and identity of material loaded on an abrasive article. Maintaining a known distance between an abrasive article and sensor320 may be helpful for ensuring consistent measurements. However, it is expressly contemplated that, in some embodiments, sensor 320 may be communicab ly coupled to a distance sensor that can accurately determine a distance between an abrasive article (e.g. on abrading unit 304) and sensor 320.

[0043] Based on a sensed induction signal, sensor processing unit may calculate an amount of material loaded on an abrasive article. In some embodiments, a baseline measurement of an abrasive article prior to any abrading operations is needed. Systems and methods herein may, based on the sensed induction signal, calculate an amount of material loaded on an abrasive article. Systems and methods herein may also, based on the sensed induction signal, identify a material loaded on the abrasive article surface, as different materials will have different induction signal ranges. In some embodiments, based on the sensed induction signal, a sensor processing unit may determine whether the abrasive article should be redressed or replaced.

[0044] The sensor processing unit (not shown in FIG. 3) may be coupled to, or incorporated into a device housing sensor 320, in some embodiments herein. In some embodiments, a sensor processing system is remote from sensor 320. In some embodiments, for a robotic abrading system, the sensor processing system is part of a controller of the robotic unit 300.

[0045] Sensor processing may include generating a graphical user interface for display, on display component 350 for example, that updates with newly sensed induction values, newly sensed loading values, a determined status of an abrasive article - e.g. needs to be redressed or replaced, etc.

[0046] A sensor processing unit may also, based on the sensed induction value, generate a command for a robotic unit 300. A human operator may be able to, based on visual cues of loading, adjust how much force is applied to an abrasive article, or how long the abrasive article is held in contact with a work surface in order to compensate for the reduced cut rate caused by the loaded material. A robotic system 300, however, cannot “see” the loading without the aid of sensor 320. In some embodiments, sensor 320 and / or a robotic controller may adjust one or more parameters of a robotic abrading operation to compensate for the detected loading. Additionally, robotic system 300 may be programmed to automatically replace and / or re-dress an abrasive article after a certain number of abrasive operations.

[0047] In some embodiments, a robotic abrading system 300 may include a display component 350 - e.g. an LCD, LED, OLED or other suitable display component. Display component 350 may be communicably coupled to a robotic system controller (not shown in FIG. 3) and / or to sensor 320, in some embodiments.For example, display component 350 may receive sensor signals and / or outputs from a signal processor using a suitable wired or wireless protocol. Display component 350 may also receive indications of commands generated by, or sent to, a controller of system 300.

[0048] The illustrated embodiment of FIG. 3 shows three distinct devices - a robot 310, a sensor unit 320, 330, and a display component 350. However, it is expressly contemplated that in some embodiments these components are combined. For example, sensor 320 may be built into robot 310. In embodiments where a worksurface moves relative to an abrasive article, sensor 320 may be part of, or coupled to, a mobile unit moving the worksurface.

[0049] FIG. 4 illustrates an abrasive article evaluation system in accordance with embodiments herein. System 400 may be useful for any number of abrasive operations and configurations. For example, tool 440 may be a robotic tool, a powered hand tool or a manual hand tool. Abrasive article 450 may be a coated abrasive article such as a disc or a belt, or may be a nonwoven abrasive article with a plurality of abrasive particles embedded into a nonwoven web.

[0050] Components of system 400 are illustrated in a particular configuration, e.g. abrasive article evaluator 410 is illustrated as separate from inductive sensor 460 and also separate from display component 470. However, it is expressly contemplated that FIG. 4 illustrates a single embodiment. For example, in another embodiment, abrasive article evaluator 410, display component 470 and inductive sensor 460 are all built into a single device, which may be stationary or mobile. Functional blocks illustrated in evaluator 410, display component 470 and inductive sensor 460 may be arranged in other suitable configurations as well. For example, a single computing device may house both display component 470 and include processing components that perform the functions described with respect to abrasive article evaluator 410. Similarly, it is also contemplated that some or all of the functions of abrasive article evaluator 410 may be completed using local processing units, remote processing units, or cloud-networked processing units. Other configurations are also possible.

[0051] Abrasive article 450 may include a backing 456 to which a plurality of abrasive particles 452 are attached. The abrasive particles 452 may be embedded in a make coat 454. The abrasive article 450 may contain other additives, fillers or coatings 459. Over time, abrasive article 450 may experience loading 458. However, while a particular abrasive article 450 is illustrated in FIG. 4, it is expressly contemplated that system 400 may be suitable for detecting and quantifying loading for other abrasive article configurations.

[0052] Abrasive article 450 is coupled to a tool 440, which may be a hand tool, a powered hand-tool a robotic unit or another abrading unit.

[0053] System 400 includes an inductive sensor 460 configured to, when in proximity to abrasive article 450, generate an induction signal. Inductive sensor 460, in some embodiment, includes a PCB coil. However other inductive sensors 460 may be suitable.

[0054] System 400 includes an abrasive article evaluator 410. Evaluator 410 receives a sensor signal relevant to the abrasive article 450 using signal receiver 402. Signal receiver 402 may receive an induction signal from inductive sensor 460. Signal receiver 402 may also receive an indication of a distance between inductive sensor 460 and abrasive article 450.

[0055] Abrasive article evaluator 410 may, based on the induction sensor signal, identify a material causing loading 458, using material identifier 404. Abrasive article evaluator 410 may, based on the induction sensor signal, quantify an amount of loading 458, using material quantifier 406.

[0056] Abrasive article analyzer 408, based on an identity of loaded material 458 and / or a quantification of loaded material 458, may determine whether abrasive article 450 can continue to be used, should undergo a re-dressing operation, or should be replaced.

[0057] In some embodiments, a loading quantity may be calculated by comparing a sensed induction value with previously sensed baseline value, sensed by the same inductive sensor. In some embodiments, a baseline value is retrieved from a data store. The baseline value may be retrieved, in some embodiments from product packaging, e.g. transmitted using RFID, NFC, or another suitable local storage protocol, or it could be retrieved from a remote storage location using a QR code or another suitable remote storage retrieval protocol.

[0058] The loading quantity may be determined based on a comparison of the sensed induction value against the baseline value.

[0059] In embodiments where tool 440 is a robotic tool, abrasive article evaluator 410 may, based on the identity and / or quantity of loading 458, generate a command for the robotic tool 440, using a command generator 412. For example, an abrading parameter such as applied force, speed, angle, etc. may be adjusted to compensate for some loading. The command generator 412 may also generate a command to re-dress or replace abrasive article 450.

[0060] Abrasive article evaluator 410 may include, or be communicably coupled to, a memory 420. Memory 420 may include historic data 422, such as historic inductive sensor signals from the same abrasive article 450 and / or previously used abrasive articles 450. Memory 420 may also include calibration data 428. For example, abrasive article 450 may have an expected base induction value. Memory 420 may also include material identification information 424, such as an expected induction value for a number of different materials. Memory 420 may include other information or datapoints 426.

[0061] Abrasive article evaluator 410 may include a communication component 414 which may communicate, using a suitable wired or wireless protocol, with tool 440, with a display component 470, or with inductive sensor 460. However, it is expressly contemplated that, in some embodiments, a single device may comprise two or more of tool 440, display component 470, abrasive article evaluator 410 or inductive sensor 460.

[0062] Abrasive system 400 may include a display component 470 which may include a graphical user interface generator 474 which generates a graphical user interface 472 which may be updated periodically with data or information received from communication component 414. Graphical user interface 472 may display a graph of inductive sensor signals that is updated as new sensor signals are received. Graphical user interface 472 may also or alternatively display alphanumerical information such as an identity or quantity of loaded material 458.

[0063] Abrasive article evaluator 410 is illustrated in FIG. 4 as separate from display component 470, inductive sensor 460 and tool 440. However, it is expressly contemplated that other configurations are possible. For example, tool 440 may include abrasive article evaluator 410 and / or inductive sensor 460. Other configurations are expressly contemplated.

[0064] FIG. 5 illustrates a method of evaluating an abrasive article in accordance with embodiments herein. Method 500 may be implemented for a robotic abrading system, as described in FIG. 4, in some embodiments. Method 500 may be implemented for a hand-held powered or manual tool, in some embodiments.

[0065] At block 510, a moving abrasive article is stopped. In some embodiments, a sensed induction value is captured while the abrasive article is not rotationally moving. However, it is also expressly contemplated that, in some embodiments, an induction value may be detected while the abrasive article is still in motion.

[0066] At block 520, the sensor is brought into proximity of the abrasive article. In some embodiments, this requires physical movement of the sensor toward the abrasive article. In some embodiments, this requires movement of the abrasive article toward the sensor. Movement may be done manually, using a movement tool, using a robotic tool, etc.

[0067] In some embodiments herein, the inductive sensor is embedded in a backup pad.

[0068] At block 530, a sensed induction value is captured that indicates loading is present. In some embodiments, a sensor senses multiple induction values.

[0069] At block 540, the abrasive article is evaluated based on one or more sensed induction values. Using inductive sensing, it is possible to identify what material is loaded on an abrasive article - for example a metal and a metal oxide of the same metal have different induction values. It may also be possible to quantify an amount of loaded material on an abrasive disc based on the sensed induction value. In some cases, it may be necessary to have a base sensed induction value for the abrasive article, e.g. prior to a first abrading operation.

[0070] It may be possible to determine, based on the sensed induction value, whether or not the abrasive article is fit to use again. For example, if a threshold amount of loading is reached, the abrasive article may need to be re-dressed or replaced, as indicated in block 560. If the amount of loading is below the loading threshold, the abrasive article may be used again, as indicated in block 550.

[0071] Method 500 may be useful for a number of abrasive articles including coated abrasive articles, nonwoven abrasive articles or bonded abrasive articles.

[0072] In some embodiments, at least some functionality described herein is completed using a networked system. Processing functionality described herein may be completed by one or more processors, microprocessors or other suitable processing units, which may be centrally located or distributed.

[0073] FIG. 6 illustrates a robotic abrading system architecture, where a robotic abrading system 670 that interacts with a trajectory generator 610 that generates a trajectory suited for abrading a surface to a desired surface appearance. However, while trajectory generator 610 is illustrated as separate from robotic abrading system 1070, it is expressly contemplated that a controller of robotic abrading system 670 may be incorporated into robotic abrading system 670.

[0074] As an example, surface process system 600 can provide computation, software, data access, and storage services that do not require end-user knowledge of the physical location or configuration of the system that delivers the services. In various embodiments, remote servers can deliver the services over a wide area network, such as the internet, using appropriate protocols. For instance, remote servers can deliver applications over a wide area network and they can be accessed through a web browser or any other computing component.

[0075] Software or components shown or described in FIGS. 1-6 as well as the corresponding data, can be stored on servers at a remote location. The computing resources in a remote server environment can be consolidated at a remote data center location or they can be dispersed. Remote server infrastructures can deliver services through shared data centers, even though they appear as a single point of access for the user. Thus, the components and functions described herein can be provided from a remote server at a remote location using a remote server architecture. Alternatively, they can be provided by a conventional server, installed on client devices directly, or in other ways.

[0076] Notably, FIG. 6 illustrates a computing device 622 that is part of a mobile machine 620. It is expressly contemplated that at least some functionality described herein may be controlled using a mobile computing device, such as a smart phone, for example.

[0077] FIG. 6 specifically shows that a trajectory generator 610 can be located at a remote server location 602. Therefore, computing device 620 accesses those systems through remote server location 602.

[0078] FIG. 6 shows that it is also contemplated that some elements of systems described herein are disposed at remote server location 602 while others are not. By way of example, storage 630, 640 or 660 or robotic systems 670 can be disposed at a location separate from location 602 and accessed through the remote server at location 602. Regardless of where they are located, they can be accessed directly by computing device 620, through 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 that resides in a remote location. Also, the data can be stored in substantially any location and intermittently accessed by, or forwarded to, interested parties. For instance, physical carriers can be used instead of, or in addition to, electromagnetic wave carriers.

[0079] It will also be noted that the elements of systems described herein, or portions of them, can be disposed on a wide variety of different devices. Some of those devices include servers, desktop computers, laptop computers, imbedded computer, industrial controllers, tablet computers, or other mobile devices, such as palm top computers, cell phones, smart phones, multimedia players, personal digital assistants, etc.

[0080] FIGS. 7-8 show examples of computing devices that can be used in embodiments shown in previous Figures.

[0081] FIG. 7 is a simplified block diagram of one illustrative example of a handheld or mobile computing device that can be used as a user's or client's handheld device 716 (e.g., as computing device 620 in FIG. 6), in which the present system (or parts of it) can be deployed. For instance, a mobile device can be deployed in the operator compartment of computing device 720 for use in generating, processing, or displaying the data.

[0082] FIG. 7 provides a general block diagram of the components of a client device 716 that can mn some components shown and described herein. Client device 716 interacts with them, or runs some and interacts with some. In the device 716, a communications link 713 is provided that allows the handheld device to communicate with other computing devices and under some embodiments provides a channel for receiving information automatically, such as by scanning. Examples of communications link 713 include allowingcommunication though one or more communication protocols, such as wireless services used to provide cellular access to a network, as well as protocols that provide local wireless connections to networks.

[0083] In other examples, applications can be received on a removable Secure Digital (SD) card that is connected to an interface 715. Interface 715 and communication links 713 communicate with a processor 717 (which can also embody a processor) along a bus 719 that is also connected to memory 721 and input / output (I / O) components 1023, as well as clock 725 and location system 727.

[0084] I / O components 723, in one embodiment, are provided to facilitate input and output operations and the device 716 can include input components such as buttons, touch sensors, optical sensors, microphones, touch screens, proximity sensors, accelerometers, orientation sensors and output components such as a display device, a speaker, and or a printer port. Other I / O components 723 can be used as well.

[0085] Clock 725 illustratively comprises a real time clock component that outputs a time and date. It can also provide timing functions for processor 717.

[0086] Illustratively, location system 727 includes a component that outputs a current geographical location of device 716. This can include, for instance, a global positioning system (GPS) receiver, a LORAN system, a dead reckoning system, a cellular triangulation system, or other positioning system. It can also include, for example, mapping software or navigation software that generates desired maps, navigation routes and other geographic functions.

[0087] Memory 721 stores operating system 729, network settings 731, applications 733, application configuration settings 735, data store 737, communication drivers 739, and communication configuration settings 741. Memory 721 can include all types of tangible volatile and non-volatile computer-readable memory devices. It can also include computer storage media (described below). Memory 721 stores computer readable instructions that, when executed by processor 717, cause the processor to perform computer- implemented steps or functions according to the instructions. Processor 717 can be activated by other components to facilitate their functionality as well.

[0088] FIG. 8 is a block diagram of a computing environment that can be used in embodiments shown in previous Figures.

[0089] FIG. 8 is one example of a computing environment in which elements of systems and methods described herein, or parts of them (for example), can be deployed. With reference to FIG. 8, an example system for implementing some embodiments includes a general-purpose computing device in the form of a computer 810. Components of computer 810 may include, but are not limited to, a processing unit 820 (which can comprise a processor), a system memory 830, and a system bus 821 that couples various system components including the system memory to the processing unit 820. The system bus 821 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. Memory and programs described with respect to systems and methods described herein can be deployed in corresponding portions of FIG. 8.

[0090] Computer 810 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 810 and includes both volatile / nonvolatile mediaand removable / non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media is different from, and does not include, a modulated data signal or carrier wave. It includes hardware storage media including both volatile / nonvolatile and removable / non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computer 810. Communication media may embody computer readable instructions, data structures, program modules or other data in a transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal.

[0091] The system memory 830 includes computer storage media in the form of volatile and / or nonvolatile memory such as read only memory (ROM) 831 and random access memory (RAM) 832. A basic input / output system 833 (BIOS) containing the basic routines that help to transfer information between elements within computer 810, such as during start-up, is typically stored in ROM 831. RAM 832 typically contains data and / or program modules that are immediately accessible to and / or presently being operated on by processing unit 820. By way of example, and not limitation, FIG. 8 illustrates operating system 834, application programs 835, other program modules 836, and program data 837.

[0092] The computer 810 may also include other removable / non-removable and volatile / nonvolatile computer storage media. By way of example only, FIG. 8 illustrates a hard disk drive 841 that reads from or writes to non-removable, nonvolatile magnetic media, nonvolatile magnetic disk 852, an optical disk drive 855, and nonvolatile optical disk 856. The hard disk drive 841 is typically connected to the system bus 821 through a non-removable memory interface such as interface 840, and optical disk drive 855 are typically connected to the system bus 821 by a removable memory interface, such as interface 850.

[0093] Alternatively, or in addition, the functionality described herein can be performed, at least in part, by one or more hardware logic components. For example, and without limitation, illustrative types of hardware logic components that can be used include Field-programmable Gate Arrays (FPGAs), Applicationspecific Integrated Circuits (e.g., ASICs), Application-specific Standard Products (e.g., ASSPs), System-on-a- chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), etc.

[0094] The drives and their associated computer storage media discussed above and illustrated in FIG. 8, provide storage of computer readable instructions, data structures, program modules and other data for the computer 810. In FIG. 8, for example, hard disk drive 841 is illustrated as storing operating system 844, application programs 845, other program modules 846, and program data 847. Note that these components can either be the same as or different from operating system 834, application programs 835, other program modules 836, and program data 837.

[0095] A user may enter commands and information into the computer 810 through input devices such as a keyboard 862, a microphone 863, and a pointing device 861, such as a mouse, trackball or touch pad. Other input devices (not shown) may include a joystick, game pad, satellite receiver, scanner, or the like. These and other input devices are often connected to the processing unit 820 through a user input interface 860 that is coupled to the system bus, but may be connected by other interface and bus structures. A visual display 891 or other type of display device is also connected to the system bus 821 via an interface, such as a video interface 890. In addition to the monitor, computers may also include other peripheral output devices such as speakers 897 and printer 896, which may be connected through an output peripheral interface 895.

[0096] The computer 810 is operated in a networked environment using logical connections, such as a Local Area Network (LAN) or Wide Area Network (WAN) to one or more remote computers, such as a remote computer 880.

[0097] When used in a LAN networking environment, the computer 810 is connected to the LAN 871 through a network interface or adapter 870. When used in a WAN networking environment, the computer 810 typically includes a modem 872 or other means for establishing communications over the WAN 873, such as the Internet. In a networked environment, program modules may be stored in a remote memory storage device. FIG. 8 illustrates, for example, that remote application programs 885 can reside on remote computer 880.

[0098] Objects and advantages of this disclosure are further illustrated by the following non-limiting examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this disclosure.

[0099] All cited references, patents, and patent applications in the above application for letters patent are herein incorporated by reference in their entirety in a consistent manner. In the event of inconsistencies or contradictions between portions of the incorporated references and this application, the information in the preceding description shall control. The preceding description, given in order to enable one of ordinary skill in the art to practice the claimed disclosure, is not to be construed as limiting the scope of the disclosure, which is defined by the claims and all equivalents thereto.

[0100] A loading detection system is presented that includes an inductive sensor that senses an induction value for an abrasive article when in proximity to it, an abrasive article evaluator that receives the sensed induction value, identifies a loaded material on the abrasive article, and quantifies an amount of the loaded material based on the induction value, and a communication component that communicates an indication of the amount of loaded material.

[0101] The abrasive article evaluator may identify the loaded material based on the sensed induction value.

[0102] The abrasive article evaluator may compare the sensed induction value to a datastore of induction values to identify the identity of the loaded material.

[0103] The system may include a memory containing calibration data.

[0104] The memory may store historic sensed induction values.

[0105] The abrasive article evaluator may generate a parameter change for a tool associated with the abrasive article.

[0106] The generated parameter change may be communicated to a display component.

[0107] If the system includes a robotic abrading unit with the abrasive article mounted to it, the generated parameter change may include a command to implement the parameter change.

[0108] The inductive sensor may include the abrasive article evaluator.

[0109] The loading detection system may include a display component to show the indication of the amount of loaded material.

[0110] A detection device may include the inductive sensor and the display component.

[0111] The detection device may also include the abrasive article evaluator, and the communication component may generate a graphical user interface for the display component.

[0112] The inductive sensor may sense a first induction value at a first time, sense a second induction value at a second time, and the communication component may update the graphical user interface upon receiving the second induction value.

[0113] The display component may show a graphical representation of the sensed induction value.

[0114] The display component may display alphanumeric text representing the sensed induction value.

[0115] If the system includes a robotic controller with the abrasive article evaluator, the controller may implement the parameter change based on the command.

[0116] An abrasive tool may include the abrasive article evaluator.

[0117] The inductive sensor may include the abrasive article evaluator.

[0118] The inductive sensor may include a PCB coil.

[0119] A method of quantifying loading on an abrasive article is presented that involves bringing an inductive sensor in proximity to the abrasive article, sensing an induction value with the inductive sensor, detecting a loaded material on the abrasive article based on the induction value, quantifying an amount of loaded material on the abrasive article based on the induction value, and using a communication component to communicate an indication of the amount of loaded material.

[0120] The communication component may communicate the indication to a graphical user interface generator for a display component.

[0121] The method may include sensing an induction value at a first time, sensing a second induction value at a second time, communicating the second induction value to the graphical user interface generator, and updating the display component to show the second induction value.

[0122] The inductive sensor may be a mobile inductive sensor.

[0123] The method may include identifying the loaded material based on the induction value.

[0124] Identifying the loaded material may involve comparing the sensed induction value to a datastore of induction values and matching the sensed induction value to a loaded material induction value based on the comparison.

[0125] The inductive sensor may include the datastore.

[0126] The datastore may be remote from the inductive sensor.

[0127] If the abrasive article is coupled to a robotic abrading unit, the method may include generating a parameter change for the robotic abrading unit and communicating the generated parameter change to a controller of the unit.

[0128] A detection device may include the inductive sensor and a display component.

[0129] A controller for a robotic abrading unit may include a processing unit with a non-transitory computer-readable medium storing instructions that, when executed, cause the controller to act based on the amount of loaded material.

[0130] The inductive sensor may include a PCB coil.

[0131] A robotic abrading system is presented that includes a robotic abrading unit that causes an abrasive article to contact a worksurface along a trajectory, at a force, at a rotational speed, a loading sensor that senses an amount of loaded material on the abrasive article, and a robotic controller with a non-transitory computer-readable medium storing instructions that, when executed by a processing unit, cause the unit to bring the abrasive article in proximity to the loading sensor, sense an induction value, quantify the amount of loaded material based on the induction value, and adjust an operating condition for the next abrasive article operation.

[0132] The operating condition may include the trajectory, the force, or the rotational speed.

[0133] Adjusting an operating condition may involve replacing the abrasive article.

[0134] Adjusting an operating condition may involve re-dressing the abrasive article.

[0135] The system may include a display component to show the sensed induction value, the quantified amount of loaded material, or an indication of the operation condition adjustment.

[0136] The loading sensor may include an induction coil.

[0137] The loading sensor may include both a first and second induction coil.

[0138] The processing unit may include one or more processors or microprocessors.

[0139] The processing unit may also identify the loaded material.

[0140] The processing unit may compare the sensed induction value to a datastore of sensed induction values and identify the type of loaded material based on the comparison.

[0141] The inductive sensor may include a PCB coil.

[0142] EXAMPLES

[0143] In the following examples, inductive sensor is LDC1614EVM, which is commercially available from Texas Instruments. It is connected to a computer and raw data was converted to inductance value by the software (Sensing Solutions EVM GUI vl.10.0 from Texas Instruments). In the measurement condition, distance between the target surface and the sensor surface is 0.1 mm.Table 1 : MaterialsExamples 1-4Inductance Measurement Test Method

[0144] The inductance measurement of the abrasive disc surface was conducted using an inductive sensor, specifically the LDC1614EVM, which was interfaced with a computer running Sensing Solutions EVM GUI v 1.10.0 software from Texas Instruments.

[0145] For Each Example, the abrasive disc, a 3MTM CubitronTM II TS disc 987C 80+, was prepared by adhering metal and metal oxide powders to its surface using 3M TM Masking tape 183. The powders used were Mn02, Cu, and FeO, sourced from Hayashi Pure Chemical Ind., Ltd., with specified purities. The amounts of each powder were carefully measured and distributed over a defined area of 400 mm2 on the disc. The amounts are specified in Table 2.Table 2: Metal Powder Application

[0146] During measurement, the distance between the target surface of the abrasive disc and the sensor surface was maintained at 0.1 mm. The inductive sensor was then used to measure the change in inductance caused by the presence of the metal and metal oxide powders. The raw data collected by the sensor was converted to inductance values using the Sensing Solutions EVM GUI vl.10.0 software from Texas Instruments.

[0147] The results are illustrated in Table 3.Table 3 : Measured Inductance ValuesExample 5

[0148] The surface of an abrasive disc (available from 3M Company TM under the trade name CubitronTM II TS disc 987C 80+) was used for manual grinding of an aluminum plate with 4 inch electric angle grinder for 1 minute. In the measurement condition, loaded disc showed the inductance decrease of 0.005 pH while clean disc showed the inductance increase of 0.001 pH.

[0149] This shows that the abrasive disc containing resin and aluminum oxide causes inductance increase and metal aluminum causes inductance decrease. From this result, we can detect the loading phenomenon by measuring inductance value of the disc with inductive sensor.

Claims

AMENDED CLAIMS received by the International Bureau on 01 December 2025 (01.12.2025)1. A loading detection system comprising: an inductive sensor configured to, when in proximity of an abrasive article, sense an induction value for the abrasive article; an abrasive article evaluator configured to: receive the sensed induction value; identify a loaded material on the abrasive article; and based on the induction value, quantify an amount of the loaded material on the abrasive article; and a communication component configured to communicate an indication of the amount of loaded material.

2. The system of claim 1, wherein the abrasive article evaluator identifies the loaded material based on the sensed induction value.

3. The system of claim 2, wherein the abrasive article evaluator, to identify the loaded material: compares the sensed induction value to a datastore of induction values; and identifies an identity of the loaded material based on the comparison.

4. The sensor of any of claims 1-3, wherein the system comprises a memory, the memory comprising calibration data.

5. The sensor of claim 4, wherein the memory comprises a historic sensed induction value.

6. The sensor of any of claims 1-5, wherein the abrasive article evaluator is further configured to generate a parameter change for a tool associated with the abrasive article.

7. The sensor of claim 6, wherein the generated parameter change is communicated, by the communication component, to a display component.

8. The sensor of claim 6, wherein the system comprises a robotic abrading unit, the abrasive article being mounted to the robotic abrading unit, and wherein the generated parameter change comprises a command to implement the parameter change.

9. The sensor of any of claims 1-8, wherein the inductive sensor comprises the abrasive article evaluator.

10. The sensor of any of claims 1-9, wherein the loading detection system comprises a display component configured to display the indication of the amount of loaded material.

11. The sensor of claim 10, wherein a detection device comprises the inductive sensor and the display component.

12. The sensor of claim 11, wherein the detection device also comprises the abrasive article evaluator, wherein the communication component is configured to generate a graphical user interface for the display component.

13. The sensor of claim 12, wherein the inductive sensor is configured to sense the first induction value at a first time, sense a second induction value at a second time, and wherein thecommunication component is configured to update the graphical user interface based receiving the second induction value.

14. The sensor of claim 10, wherein the display component is configured to display a graphical representation of the sensed induction value.

15. The sensor of claim 10, wherein the display component is configured to display alphanumeric text as a representation of the sensed induction value.

16. The sensor of any of claims 8-15, wherein a robotic controller comprises the abrasive article evaluator, and wherein, based on the command, implements the parameter change.

17. The sensor of any of claims 1-16, wherein an abrasive tool comprises the abrasive article evaluator.

18. The sensor of any of claims 1-17, wherein the inductive sensor comprises the abrasive article evaluator.

19. The sensor of any of claims 1-18, wherein the inductive sensor comprises a PCB coil.

20. A method of quantifying loading on an abrasive article, the method comprising: bringing an inductive sensor in proximity of an abrasive article; sensing an induction value with the inductive sensor; detecting, based on the induction value, a loaded material on the abrasive article; quantifying, based on the induction value, an amount of loaded material on the abrasive article; and communicating, using a communication component, an indication of the amount of loaded material.

21. The method of claim 20, wherein the communication component communicates the indication to a graphical user interface generator for a display component.

22. The method of claim 21, wherein the induction value is sensed at a first time, a second induction value is sensed at a second time, and wherein the method further comprises: communicating the second induction value to the graphical user interface generator; and updating the display component to display the second induction value.

23. The method of any of claims 20-22, wherein the inductive sensor is a mobile inductive sensor.

24. The method of any of claims 20-23, and further comprising: identifying the loaded material based on the induction value.

25. The method of claim 24, wherein identifying comprises: comparing the sensed induction value to a datastore of induction values; matching the sensed induction value to a loaded material induction value, based on the comparison.

26. The method of claim 24, wherein the inductive sensor comprises the datastore.

27. The method of claim 24, wherein the datastore is remote from the inductive sensor.

28. The method of any of claims 20-27, wherein the abrasive article is coupled to a robotic abrading unit, and wherein the method further comprises:generating a parameter change for the robotic abrading unit; and wherein the communication component communicates the generated parameter change to a controller of the robotic abrading unit.

29. The method of any of claims 20-28, wherein a detection device comprises the inductive sensor and a display component.

30. The method of any of claims 20-29, wherein a controller for a robotic abrading unit comprises a processing unit, wherein the controller comprises a non-transitory computer readable medium storing one or more instructions that, when executed by the processing unit, causes the controller to, based on the amount of loaded material.

31. The method of any of claims 20-30, wherein the inductive sensor comprises a PCB coil.

32. A robotic abrading system comprising: a robotic abrading unit configured to cause an abrasive article to contact a worksurface along a trajectory, at a force, at a rotational speed; a loading sensor configured to sense an amount of loaded material on the abrasive article; and a robotic controller comprising a non-transitory computer readable medium storing one or more instructions that, when executed by a processing unit that causes the processing unit to: bring the abrasive article in proximity of the loading sensor; sense an induction value; quantify, based on induction value, the amount of loaded material; and adjust an operating condition for a next abrasive article operation.

33. The robotic abrading system of claim 32, wherein the operating condition comprises the trajectory, the force or the rotational speed.

34. The robotic abrading system of claim 32 or 33, wherein adjusting an operating condition comprises replacing the abrasive article.

35. The robotic abrading system of any of claims 32-34, wherein adjusting an operating condition comprises re-dressing the abrasive article.

36. The robotic abrading system of any of claims 32-35, and further comprising: a display component configured to display the sensed induction value, the quantified amount of loaded material, or an indication of the operation conduction adjustment.

37. The robotic abrading system of any of claims 32-36, wherein the loading sensor comprises an induction coil.

38. The robotic abrading system of claim 37, wherein the loading sensor comprises a first and second induction coil.

39. The robotic abrading unit of any of claims 32-38, wherein the processing unit comprises one or more processors or microprocessors.

40. The robotic abrading unit of any of claims 32-39, wherein the inductive sensor comprises a PCB coil.

Images