Power tool, robotic abrading system, abrasive sensing system, and method of use

Abstract

A power tool includes an eccentric portion including a second rotational axis located radially eccentrically relative to a first rotational axis of a first drive shaft. The power tool further includes a second drive shaft rotationally coupled to the eccentric portion. The second drive shaft freely rotates about the second rotational axis. The power tool further includes a sensor configured to generate a speed signal indicative of a current rotational speed of a tool coupled to the second drive shaft. The power tool further includes a force control unit configured to actuate the tool to apply a force on a substrate. The power tool further includes a controller configured to receive the speed signal from the sensor and, based on the received speed signal, generate a control signal for at least one of the drive unit and the force control unit based on the current rotational speed of the tool.

Description

PA103053W002POWER TOOL, ROBOTIC ABRADING SYSTEM, ABRASIVE SENSING SYSTEM, AND METHOD OF USETechnical Field

[0001] The present disclosure generally relates to a power tool, a robotic abrading system, an abrasive sensing system, and a method of using a power tool.Background

[0002] Grinding and other surface repair operations are increasingly being automated with robotic systems or fixed machinery. When using a random orbital power tool (e.g., a random orbital sanding or polishing tool) with such automated applications, it may be difficult to predict process parameters for a stable operating process since a tool (e.g., an abrasive disc) associated with the random orbital power tool rotates at a random rotational speed. Thus, it may be difficult to use the abrasive disc in its best working environment. This is due to several variables that may change during the operating process, e.g., a type of substrate (composites, steel, wood, etc.), a type of abrasive (grit sizes, diameters, etc.), workpiece contours that may lead to different contact surfaces, wear of abrasive consumable, heat generation, etc. For example, process compliance units may only follow the workpiece contours with a preset force but not adapt to such changes in real time.

[0003] Operators / users may often compensate these variations by adopting steps / procedures to guarantee a stable and high-quality automated process, e.g., abrasive consumables may be changed unnecessarily. This may cause abrasive consumables to not last to their typical lifetime, unknown abrasive wear status, unequal or unstable grinding output in quality and removal rate, lack of a constant and an efficient output with automation, unnecessary downtimes with automation, failure to automatically adapt to substrate changes, etc.Summary

[0004] In a first aspect, the present disclosure provides a power tool. The power tool includes a drive unit including a first drive shaft. The first drive shaft is configured to rotate about a first rotational axis. The power tool further includes an eccentric portion fixedly coupled to the first drive shaft and including a second rotational axis located radially eccentrically relative to the first rotational axis. The power tool further includes a second drive shaft rotationally coupled to the eccentric portion and configured to be driven by the eccentric portion. The second drive shaft freely rotates about the second rotational axis. The power tool further includes a tool coupled to the second drive shaft. The power tool further includes a sensorconfigured to generate a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with a substrate. The power tool further includes a force control unit configured to actuate the tool to apply a force on the substrate when the tool is in contact with the substrate. The power tool further includes a controller communicably coupled to the drive unit, the sensor, and the force control unit. The controller is configured to receive the speed signal from the sensor and, based on the received speed signal, generate a control signal for at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft.

[0005] In a second aspect, the present disclosure provides a method for using a power tool. The method includes rotating, by a drive unit, a first drive shaft about a first rotational axis. An eccentric portion is fixedly coupled to the first drive shaft. The eccentric portion includes a second rotational axis located radially eccentrically relative to the first rotational axis. The method further includes rotating, by the eccentric portion, a second drive shaft rotationally coupled to the eccentric portion. The second drive shaft freely rotates about the second rotational axis. The method further includes actuating, by a force control unit, a tool coupled to the second drive shaft for applying a force on a substrate when the tool is in contact with the substrate. The method further includes generating, by a sensor, a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with the substrate. The method further includes receiving, by a controller, the speed signal from the sensor. The controller is communicably coupled to the drive unit, the force control unit, and the sensor. The method further includes controlling at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft.

[0006] In a third aspect, the present disclosure provides a robotic abrading system. The robotic abrading system includes a motive robotic unit configured to rotationally move an abrasive article at a rotational speed setting. The robotic abrading system further includes a force control unit configured to apply a force to the abrasive article. The robotic abrading system further includes a signal receiver configured to receive a speed signal indicative of a rotational speed of the abrasive article. The robotic abrading system further includes a controller communicably coupled to the motive robotic unit, the force control unit, and the signal receiver. The controller is configured to, based on the received speed signal, determine a current rotational speed of the abrasive article. The controller is further configured to compare the current rotational speed to a threshold speed. The controller is further configured to, based on the comparison, generate a control signal. The control signal includes a new force to apply or a new rotational speed setting.

[0007] In a fourth aspect, the present disclosure provides an abrasive sensing system. The abrasive sensing system includes a sensing pad configured to couple to an abrasive article along a major surface. The sensing pad includes a position indicator. The sensing pad is further configured to couple to a drive shaft. The abrasive sensing system further includes a processing circuitry and an associated memory configured to, while the sensing pad is rotationally driven by the drive shaft, receive a first position signal from a sensor. The sensor is configured to detect the position indicator. The first position signal is indicative of a first time the position indicator is detected. The processing circuitry is further configured to receive a second position signal from the sensor. The second position signal is indicative of a second time the position indicator is detected. The processing circuitry is further configured to, based on the first and second position signals, determine a current rotational speed of the sensing pad. The processing circuitry is further configured to compare the current rotational speed of the sensing pad to a threshold speed. The processing circuitry is further configured to, based on the comparison, generate a new tool setting for a power tool associated with the drive shaft. The abrasive sensing system further includes a communication component configured to communicate the new tool setting to the power tool.

[0008] In a fifth aspect, the present disclosure provides a controller for a sanding tool. The controller includes a position signal receiver configured to receive a first indication of a first position of an abrasive article at a first time and a second indication of a second position of the abrasive article at a second time. The controller further includes a tool setting receiver configured to retrieve a speed setting or an applied force setting from the sanding tool. The controller further includes a current speed calculator configured to, based on the received first and second indications, determine a current speed of the abrasive article. The controller further includes a tool setting update generator configured to, based on the comparison of the current speed with an expected speed, generate a tool setting update including a new speed setting or a new applied force setting for the sanding tool. The expected speed is based on the retrieved speed setting or the retrieved applied force setting. The controller further includes a control signal communication component configured to communicate the tool setting update to the sanding tool.Brief Description of Drawings

[0009] Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numbers used in the figures refer to likecomponents. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0010] FIG. 1 is a schematic perspective view of an example robotic abrading system, according to embodiments of the present disclosure;

[0011] FIG. 2 is a block diagram of an example robotic abrading system, according to embodiments of the present disclosure;

[0012] FIG. 3 is a schematic side view of an example power tool, according to embodiments of the present disclosure;

[0013] FIG. 4 illustrates a block diagram of a method of using a power tool, according to embodiments of the present disclosure;

[0014] FIG. 5 is a block diagram of an example abrasive sensing system, according to embodiments of the present disclosure;

[0015] FIG. 6 is a block diagram of an example controller for a sanding tool, according to embodiments of the present disclosure;

[0016] FIG. 7 is a block diagram of an example remote server architecture for a setting selection system of an automated robotic abrading system, in accordance with embodiments herein;

[0017] FIGS. 8-9 show examples of computing devices that can be used in accordance with embodiments herein; and

[0018] FIG. 10 is a block diagram of a computing environment that can be used in embodiments shown in previous figures.Detailed Description

[0019] In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0020] In the following disclosure, the following definitions are adopted.

[0021] As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.

[0022] As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readilyrecognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / - 20 % for quantifiable properties).

[0023] The term “substantially”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 10% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0024] The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / - 5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0025] As used herein, the terms “first” and “second” are used as identifiers. Therefore, such terms should not be construed as limiting of this disclosure. The terms “first” and “second” when used in conjunction with a feature or an element can be interchanged throughout the embodiments of this disclosure.

[0026] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0027] As used herein, the recitations of numerical ranges by endpoints include all numbers subsumed within that range as well as the endpoints (e.g., 1 to 5 includes 1, 1.5, 2, 2.75, 3, 3.80, 4, 5, etc.).

[0028] As used herein, the term “real-time” generally refers to data that is processed within seconds or milliseconds so that it is available virtually immediately. While some delay due to processing is inevitable, “real-time” is intended to cover systems and methods where data can be collected or entered without any noticeable delay. For example, a data entry into a system is substantially immediately available for further processing.

[0029] Grinding and other surface repair operations are increasingly being automated with robotic systems or fixed machinery. When using a random orbital power tool (e.g., a random orbital sanding or polishing tool) with such automated applications, it may be difficult to predict process parameters for a stable operating process since a tool (e.g., an abrasive disc) associated with the random orbital power tool rotates at a random rotational speed. Thus, it may be difficult to use the abrasive disc in its best working environment. This is due to several variables that may change during the operating process, e.g., a type of substrate (composites, steel, wood, etc.), a type of abrasive (grit sizes, diameters, etc.), workpiece contours that may lead to different contact surfaces, wear of abrasive consumable, heat generation, etc. For example, process compliance units may only follow the workpiece contours with a preset force but not adapt to such changes in real time. Operators / users may often compensate these variations by adopting steps / procedures to guarantee a stable and high-quality automated process, e.g., abrasiveconsumables may be changed unnecessarily. This may cause abrasive consumables to not last to their typical lifetime, unknown abrasive wear status, unequal or unstable grinding output in quality and removal rate, lack of a constant and an efficient output with automation, unnecessary downtimes with automation, failure to automatically adapt to substrate changes, etc.

[0030] The present disclosure provides a power tool. The power tool includes a drive unit including a first drive shaft. The first drive shaft is configured to rotate about a first rotational axis. The power tool further includes an eccentric portion fixedly coupled to the first drive shaft and including a second rotational axis located radially eccentrically relative to the first rotational axis. The power tool further includes a second drive shaft rotationally coupled to the eccentric portion and configured to be driven by the eccentric portion. The second drive shaft freely rotates about the second rotational axis. The power tool further includes a tool coupled to the second drive shaft. The power tool further includes a sensor configured to generate a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with a substrate. The power tool further includes a force control unit configured to actuate the tool to apply a force on the substrate when the tool is in contact with the substrate. The power tool further includes a controller communicably coupled to the drive unit, the sensor, and the force control unit. The controller is configured to receive the speed signal from the sensor and, based on the received speed signal, generate a control signal for at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft.

[0031] The power tool of the present disclosure includes the sensor that is configured to generate the speed signal indicative of the current rotational speed of the tool or the second drive shaft when the tool is in contact with the substrate. Thus, the sensor may allow the power tool to recognize and measure the current rotational speed of the tool. This may enable the controller to control at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft. A relation between the current rotational speed of the tool and different conditional changes, e.g., tool wear, process temperature, substrate type, etc.) may be established that may allow control of process parameters for a stable and high-quality automated process. For example, the power tool may be able to adapt to sudden contour changes which would have otherwise resulted in a lower quality or inefficient process.

[0032] The power tool of the present disclosure adapts continuously to the conditional changes during execution of machining process while considering all the conditional changes affecting the machining process. This is applicable to any type of random orbital power tool, e.g., grinding tools, polishing tools, cleaning tools, etc. In contrast to the existing power toolswhere process parameters are calculated and applied before the machining process based on preset process conditions, the current power tool may adapt to the conditional changes automatically. The power tool may be used with any platform, e.g., robotic or fixed automation. The controller of the power tool may control either or both the drive unit and the force control unit for controlling the rotational speed of the tool or the second drive shaft.

[0033] FIG. 1 is a schematic perspective view of an example robotic abrading system 100, according to embodiments of the present disclosure. The robotic abrading system 100 may be stationary in some embodiments or may be mobile in other embodiments. The robotic abrading system 100 includes a motive robotic unit 102 configured to rotationally move an abrasive article 108. In some embodiments, the abrasive article 108 may be selected from any suitable abrasive article including bonded abrasive articles, nonwoven abrasive articles, or coated abrasive articles. In some embodiments, the robotic abrading system 100 may be used for defect-specific repairs, e.g., grinding and paint applications (e.g., primer sanding, clear coat defect removal, clear coat polishing, etc.).

[0034] As shown in FIG. 1, in some embodiments, the motive robotic unit 102 includes an articulating arm 104 extending from a base 103 of the robotic abrading system 100 and coupled to the abrasive article 108. However, it is expressly contemplated that the motive robotic unit 102 may include multiple articulating arms extending from the base 103. In some embodiments, the base 103 and the articulating arm 104 may have multiple degrees of freedom for movement. Additionally, while the base 103 is illustrated in FIG. 1 as stationary, it is expressly contemplated that, in some embodiments, the base 103 is coupled to a movement mechanism (not shown in FIG. 1) as well.

[0035] In some embodiments, the articulating arm 104 may be moveable in both a lateral direction, e.g., toward or away from the base 103, as well as a rotational, a vertical, or any other direction as needed. For example, the articulating arm 104 may be configured to move the abrasive article 108 proximate a work surface 110 of a substrate 112 (e.g., a car body). The abrasive article 108 is configured to abrade the work surface 110 of the substrate 112.Specifically, the motive robotic unit 102 is configured to drive the abrasive article 108 to abrade the work surface 110 of the substrate 112. In some embodiments, the motive robotic unit 102 may move the abrasive article 108 within a three-dimensional space as desired while the abrasive article 108 is operable to abrade the work surface 110. In FIG. 1, the substrate 112 is shown schematically for the purpose of illustration. In some embodiments, the substrate 112 may be made from any suitable material, including, metal, alloy, plastic, ceramic, carbon fiber, wood, composites, etc.

[0036] In some embodiments, the motive robotic unit 102 may further include an end effector (not shown) coupled to the articulating arm 104, either directly or through a force control unit (not shown), for example, that may control a movement of the abrasive article 108 in a rotational direction. For example, the end effector may exert a pressing force (e.g., using the force control unit) for forcing the abrasive article 108 into contact with the work surface 110.

[0037] In some embodiments, the robotic abrading system 100 may be a computer numerical control (CNC) or a direct numerical control (DNC) machine. The robotic abrading system 100 may include a user interface through which the motive robotic unit 102 may be programmed to follow a predetermined path for a machining process.

[0038] FIG. 2 is a block diagram of an example robotic abrading system 200, according to embodiments of the present disclosure. The robotic abrading system 200 may be functionally similar to the robotic abrading system 100 of FIG. 1, or may differ in at least some aspects.

[0039] The robotic abrading system 200 includes a motive robotic unit 202 configured to rotationally move an abrasive article 208 at a rotational speed setting 214. Specifically, the motive robotic unit 202 includes a drive unit 216 configured to rotationally move the abrasive article 208 at the rotational speed setting 214. In some embodiments, the drive unit 216 includes at least one of an electric motor, a fluid motor, and a pneumatic motor. In some embodiments, the rotational speed setting 214 may be based on parameters, such as a type of abrasive associated with the abrasive article 208, a type of substrate (e.g., the substrate 112 shown in FIG.1), etc.

[0040] The robotic abrading system 200 may further include a substrate 212 worked upon by the abrasive article 208. In some embodiments, the motive robotic unit 202 includes an articulating arm 204 configured to move the abrasive article 208 proximate a work surface 210 of the substrate 212. The abrasive article 208 is configured to abrade the work surface 210. Specifically, the motive robotic unit 202 is configured to drive the abrasive article 208 via the articulating arm 204 to abrade the work surface 210. In some embodiments, the motive robotic unit 202 may move the abrasive article 208 within a three-dimensional space as desired while the abrasive article 208 is operable to abrade the work surface 210.

[0041] In some embodiments, the motive robotic unit 202 further includes an end effector load setter 217 which may adjust an end effector load of an end effector (not shown) associated with the motive robotic unit 102. In some embodiments, the motive robotic unit 202 further includes a lateral speed setter 218 for adjusting a rotational speed N of the abrasive article 208. In some embodiments, the motive robotic unit 202 further includes a grinding angle setter 219 for adjusting an angle of the abrasive article 208 with respect to a rotational direction of theabrasive article 208. Other settings of the motive robotic unit 202 may also be individually adjustable. Settings may be adjusted to increase an efficiency of the robotic abrading system 200, e.g., to increase a predicted material removal rate, or to reduce a risk of burning the substrate 212, etc.

[0042] In some embodiments, a plurality of workpiece parameters 215 are associated with the work surface 210. For example, the plurality of workpiece parameters 215 may include a material of the substrate 212, surface contours of the work surface 210, a temperature of the work surface 210, a current surface roughness of the work surface 210, etc.

[0043] The robotic abrading system 200 further includes a force control unit 222 configured to apply a force F to the abrasive article 208. The force control unit 222 may be a part of the motive robotic unit 202 in some embodiments or may be separate from the motive robotic unit 202 in other embodiments. The force control unit 222 may apply the force F to the abrasive article 208 against the work surface 210 of the substrate 212 when the abrasive article 208 is in contact with the work surface 210.

[0044] The robotic abrading system 200 further includes a sensor 224 configured to sense a speed signal S. The sensor 224 may be any suitable type of sensor, including, for example, an inductive sensor and an optical sensor (or a photoelectric sensor). In some embodiments, the sensor 224 is positioned on the motive robotic unit 202. In some other embodiments, the sensor 224 may be positioned remote from the motive robotic unit 202 or may be located in another suitable position. The robotic abrading system 200 further includes a signal receiver 226 configured to receive the speed signal S indicative of the rotational speed N of the abrasive article 208. In some embodiments, the signal receiver 226 is configured to receive the speed signal S while the abrasive article 208 is rotationally moving. In some embodiments, the received speed signal S includes a sensed induction value or a sensed optical value.

[0045] The robotic abrading system 200 further includes a controller 228 communicably coupled to the motive robotic unit 202, the force control unit 222, and the signal receiver 226. In some embodiments, the controller 228 is configured to adjust one or more operating parameters of the motive robotic unit 202 and / or the force control unit 222 for controlling the abrasion / grinding process. In some embodiments, the controller 228 further includes a rotational speed setter 246 for controlling the rotational speed N of the abrasive article 208. In some embodiments, the controller 228 further includes a force value setter 248 and a force value changer 250. The force value setter 248 may control the force F applied by the force control unit 222 to the abrasive article 208 and the force value changer 250 may determine a change in a magnitude of the force F applied by the force control unit 222 to the abrasive article 208.

[0046] In some embodiments, the robotic abrading system 200 further includes one or more other sensors 220 for retrieving information about a current abrading operation. The one or more other sensors 220 may include any type of sensor, e.g., acoustic sensor, electric sensor, environmental sensor, optical sensor, imaging sensor, light sensor, pressure sensor, force sensor, thermal sensor, temperature sensor, proximity sensor, among others. In some embodiments, the one or more other sensors 220 may be a part of the motive robotic unit 202, or a part of a cell associated with the robotic abrading system 200, or may be located in another suitable position. The controller 228 is communicably coupled to the one or more other sensors 220. For example, a material removal rate may be predicted based on the information retrieved from the one or more other sensors 220. Additionally, a current abrasive condition of the abrasive article 208 may be estimated, including a level of wear and a temperature of the abrasive article 208.

[0047] Based on the information retrieved from the one or more other sensors 220 (e.g., the material removal rate, the current abrasive condition, etc.), the controller 228 may adjust the one or more operating parameters of the force control unit 222 or the motive robotic unit 202. For example, an angle of the abrasive article 208 may be adjusted by grinding angle setter 219, the rotational speed N of the abrasive article 208 may be adjusted by the rotational speed setter 246, etc. Operating parameters may be adjusted to increase an efficiency of the robotic abrading system 200, e.g., to increase a predicted material removal rate, or to reduce a risk of burning the work surface 210, etc.

[0048] The controller 228 is further configured to, based on the received speed signal S, determine a current rotational speed 230 of the abrasive article 208. In some embodiments, the received speed signal S includes a first speed signal SI. In some embodiments, the current rotational speed 230 is determined in substantially real-time. In some embodiments, the controller 228 is further configured to determine the current rotational speed 230 by detecting the abrasive article 208 in a first position Pl, at a first time Tl, and detecting the abrasive article 208 in a second position P2, at a second time T2. For example, the controller 228 may determine the current rotational speed 230 by detecting a movement of the abrasive article 208 between the first position Pl and second position P2 in a time difference between the first time Tl and the second time T2.

[0049] In some embodiments, the first position Pl and the second position P2 are the same position. For example, the controller 228 may determine the current rotational speed 230 by detecting time elapsed between the first time Tl and the second time T2 for the abrasive article 208 to move to the same position, i.e., time required by the abrasive article 208 to make one complete rotation in case the abrasive article 208 is a disc.

[0050] In some embodiments, the determined current rotational speed 230 differs from an expected speed 213 for the rotational speed setting 214. This may be due to variation in operating conditions of the abrasive / grinding process, e.g., due to variation in a type of the substrate 212, abrasives (grit sizes, diameters, etc.) associated with the abrasive article 208, contour changes on the work surface 210, a wear of the abrasive article 208, heat generation, etc.

[0051] The controller 228 is further configured to compare the current rotational speed 230 to a threshold speed 232. In some embodiments, threshold speed 232 may be indicative of a tolerance associated with the difference in the current rotational speed 230 and the expected speed 213. The controller 228 is further configured to, based on the comparison, generate a control signal 234 including a new force Fl to apply or a new rotational speed setting 238.Specifically, the controller 228 is further configured to transmit the control signal 234 to the force control unit 222 for the new force Fl to be applied and / or transmit the control signal 234 to the motive robotic unit 202 for the new rotational speed setting 238. This may allow the rotational speed N of the abrasive article 208 to be adjusted during the abrasive / grinding process to obtain a desired rotational speed N.

[0052] In some embodiments, the controller 228 is further configured to determine, compare, and generate the control signal 234 while the abrasive article 208 is rotationally moving. The generated control signal 234 is applied while the abrasive article 208 is rotationally moving. In some embodiments, the generated control signal 234 is calculated during a first abrasive operation 252 and applied before a second abrasive operation 254. For example, the controller 228 may apply the new force Fl or the new rotational speed setting 238 in the second abrasive operation 254 which may be subsequent to the first abrasive operation 252.

[0053] In some embodiments, the controller 228 is further configured to, based on a received second speed signal S2, determine a second current rotational speed 242 of the abrasive article 208. The controller 228 is further configured to compare the second current rotational speed 242 to the threshold speed 232. The controller 228 is further configured to, based on the comparison, generate a second control signal 236. The second control signal 236 includes a second new force F2 to apply or a second new rotational speed setting 244. Specifically, the controller 228 is further configured to transmit the second control signal 236 to the force control unit 222 for the second new force F2 to be applied and / or transmit the second control signal 236 to the motive robotic unit 202 for the second new rotational speed setting 244.

[0054] It should be noted that FIG. 2 illustrates one example setup of the robotic abrading system 200 and other suitable setups are expressly contemplated. For example, the controller228 may be a part of the robotic abrading system 200 in some embodiments. Controller 228 may be located on a device remote from the robotic abrading system 200, in some embodiments. Controller 228 may also be accessed through a wireless or cloud-based network, in some embodiments. In some embodiments, the robotic abrading system 200 may be accessible through a graphical user interface on a computing device.

[0055] FIG. 3 illustrates a schematic side view of an example power tool 300 including a tool 308 (e.g., an abrasive article), according to embodiments of the present disclosure. In some embodiments, a motive robotic unit (e.g., the motive robotic unit 102, 202 shown in FIGS. 1 and 2) of a robotic abrading system (e.g., the robotic abrading system 100, 200 shown in FIGS. 1 and 2) is operatively coupled to the power tool 300. In such cases, the motive robotic unit may rotationally move the tool 308 via the power tool 300 and the power tool 300 may be operated and powered by the motive robotic unit. In some embodiments, the power tool 300 is a random orbital tool, e.g., a random orbital sanding tool, a random orbital polishing tool, etc. In some embodiments, the power tool 300 is used to sand or abrade a work surface 310 of a substrate 312.

[0056] Exemplary materials for the substrate 312 may include metals, metal alloys, steel, steel alloys, aluminum, exotic metal alloys, ceramics, glass, wood, wood-like materials, composites, painted surfaces, plastics, reinforced plastics, stone, and / or combinations thereof. The work surface 310 of the substrate 312 may be flat or have a shape or contour associated with it. Exemplary substrates 312 may include metal components, plastic components, particleboard, camshafts, crankshafts, furniture, car body parts, and turbine blades.

[0057] The power tool 300 includes a drive unit 302 including a first drive shaft 304a. In some embodiments, the drive unit 302 includes at least one of an electric motor, a fluid motor, and a pneumatic motor. In case the drive unit 302 is an electric motor, the drive unit 302 is a brushless motor, but it may instead be a brushed (commutated) motor. In some embodiments, the first drive shaft 304a may be supported by bearings (not shown) fixedly mounted on a housing of the drive unit 302. The first drive shaft 304a is configured to rotate about a first rotational axis 306a. In some embodiments, the first drive shaft 304a may be a linear shaft with a cross-sectional shape, e.g., a circular shape, a polygonal shape, or an irregular shape.

[0058] The power tool 300 further includes an eccentric portion 314 fixedly coupled to the first drive shaft 304a. In some embodiments, the eccentric portion 314 may be in the form of an eccentric bearing. The eccentric portion 314 includes a second rotational axis 306b located radially eccentrically relative to the first rotational axis 306a. In other words, the second rotational axis 306b may be radially offset with respect to the first rotational axis 306a. Thepower tool 300 further includes a second drive shaft 304b rotationally coupled to the eccentric portion 314 and configured to be driven by the eccentric portion 314. In some embodiments, the second drive shaft 304b rotates about the second rotational axis 306b in an oscillating orbital motion. Further, the second drive shaft 304b freely rotates about the second rotational axis 306b. In other words, the second drive shaft 304b freely rotates in a random orbital motion about the second rotational axis 306b when the drive unit 302 rotationally drives the eccentric portion 314 via the first drive shaft 304a.

[0059] The power tool 300 further includes the tool 308 coupled to the second drive shaft 304b. In some embodiments, the tool 308 is fixedly coupled to the second drive shaft 304b. When the drive motor drives the first drive shaft 304a, the tool 308 freely rotates in a random orbital motion about the second rotational axis 306b as the second rotational axis 306b is radially offset with respect to the first rotational axis 306a. Specifically, the tool 308 freely rotates in the random orbital motion when the tool 308 is in contact with the work surface 310 of the substrate 312. Further, as the tool 308 freely rotates in the random orbital motion, a rotational speed of the tool 308 differs from a rotational speed of the first drive shaft 304a when the tool 308 is in contact with the substrate 312.

[0060] In some embodiments, the tool 308 is an abrasive disc including an abrasive media 324 and a backup pad 338. Suitable materials for the backup pad 338 may include polymeric films or discs, metal foils, woven fabrics, knitted fabrics, paper, nonwovens, foams, screens, laminates, combinations thereof, and treated versions thereof.

[0061] Examples of suitable abrasive particles included in the abrasive media 324 may 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. However, other abrasive particle compositions may be appropriate for some applications. In some embodiments, the abrasive media 324 may be in the form of a layer or a combination of layers.

[0062] In some embodiments, commercially available products from 3M company, St. Paul, MN, may also be utilized for the abrasive disc, e.g., those available under the trade designation “3M™ Trizact™ Hookit™ Disc”, “3M™ Finesse-it Hookit™ Disc”, “3M™ Finesse-it BuffingPad”, and “3M™ Perfect-it Buffing Pad”. Buffing pads may be available in various materials, including foam, felt, wool, and synthetic fibers.

[0063] In some embodiments, the power tool 300 further includes a readable media 326 disposed on a major surface 320 of the tool 308 opposite to the substrate 312. Specifically, the readable media 326 may be attached to the backup pad 338 of the tool 308. In an embodiment, the readable media 326 may include any suitable mechanism or media that can be detected as the abrasive media moves. The readable media 326 be in the form of a metallic pin, an optical marker, or any other suitable marker fixed over the major surface 320 of the tool 308.

[0064] The power tool 300 further includes a sensor 316 configured to generate a speed signal S3 indicative of a current rotational speed 330 of the tool 308 or the second drive shaft 304b when the tool 308 is in contact with the substrate 312. In some embodiments, the sensor 316 is configured to generate the speed signal S3 based on the current rotational speed 330, calculated based on detection of the readable media 326 about the second rotational axis 306b. In some embodiments, the sensor 316 may be an inductive sensor or an optical sensor. In the former case, the readable media 326 may be made of any material adapted to disrupt an electromagnetic field generated by the inductive sensor. For example, the readable media 326 may be a metallic pin fixed over the major surface 320 of the tool 308. In some embodiments, the readable media 326 may be integrally formed with the major surface 320 of the tool 308 or attached separately to the major surface 320 of the tool 308.

[0065] The power tool 300 further includes a force control unit 322 configured to actuate the tool 308 to apply a force F2 on the substrate 312 when the tool 308 is in contact with the substrate 312. In other words, the force control unit 322 may press the tool 308 against the work surface 310 of the substrate 312, at a desired pressure, when the tool 308 is in contact with the substrate 312.

[0066] The power tool 300 further includes a controller 328 communicably coupled to the drive unit 302, the sensor 316, and the force control unit 322. The controller 328 is configured to receive the speed signal S3 from the sensor 316 and, based on the received speed signal S3, generate a control signal 334 for at least one of the drive unit 302 and the force control unit 322 based on the current rotational speed 330 of the tool 308 or the second drive shaft 304b.

[0067] In some embodiments, the controller 328 is further configured to determine a difference between the current rotational speed 330 of the tool 308 or the second drive shaft 304b and a predetermined rotational speed 318. The predetermined rotational speed 318 may be a preset rotational speed based on standard process parameters, such as a type of the substrate 312, a type of abrasive associated with the abrasive media 324 of the tool 308, etc. Due tovariation in certain process parameters, such as contour changes on the work surface 310, a wear of the abrasive media 324 of the tool 308, heat generation, etc. during the abrasive process, the current rotational speed 330 may differ from the predetermined rotational speed 318 for the abrasive process. In some cases, due to a change in a friction between the tool 308 and the work surface 310, the current rotational speed 330 may differ from the predetermined rotational speed 318. Other factors may also cause the current rotational speed 330 to deviate from the predetermined rotational speed 318.

[0068] In some embodiments, the controller 328 is further configured to control at least one of the drive unit 302 and the force control unit 322 further based on the difference, such that the tool 308 rotates about the second rotational axis 306b at the predetermined rotational speed 318. For example, the controller 328 is further configured to control a shaft rotational speed 336 of the first drive shaft 304a of the drive unit 302. Specifically, the controller 328 is further configured to control the shaft rotational speed 336 of the first drive shaft 304a of the drive unit 302 based on the difference between the current rotational speed 330 of the tool 308 or the second drive shaft 304b and the predetermined rotational speed 318. For example, the controller 328 may control the drive unit 302 to increase or decrease the shaft rotational speed 336 of the first drive shaft 304a based on the difference. Increasing the shaft rotational speed 336 of the first drive shaft 304a may correspondingly increase the current rotational speed 330 of the tool 308 or the second drive shaft 304b, and vice versa.

[0069] Alternatively, in some embodiments, the controller 328 is further configured to control the force control unit 322 for modifying the force F2 applied by the tool 308 on the substrate 312. For example, increasing the force F2 applied by the tool 308 on the substrate 312 may reduce the current rotational speed 330 of the tool 308 while decreasing the force F2 may increase the current rotational speed 330 of the tool 308. In some other embodiments, the controller 328 may control both the drive unit 302 and the force control unit 322 simultaneously.

[0070] FIG. 4 illustrates a block diagram of a method 400 of using a power tool (e.g., the power tool 300 shown in FIG. 3), according to embodiments of the present disclosure.

[0071] At block 402, the method 400 includes rotating, by a drive unit, a first drive shaft about a first rotational axis. In some embodiments, the drive unit includes at least one of an electric motor, a fluid motor, and a pneumatic motor. An eccentric portion is fixedly coupled to the first drive shaft. The eccentric portion includes a second rotational axis located radially eccentrically relative to the first rotational axis. For example, as shown in FIG. 3, the drive unit 302 rotates the first drive shaft 304a about the first rotational axis 306a. The eccentric portion314 is fixedly coupled to the first drive shaft 304a. The eccentric portion 314 includes the second rotational axis 306b located radially eccentrically relative to the first rotational axis 306a.

[0072] At block 404, the method 400 further includes rotating, by the eccentric portion, a second drive shaft rotationally coupled to the eccentric portion. The second drive shaft freely rotates about the second rotational axis. The method 400 further includes rotating the second drive shaft about the second rotational axis in an oscillating motion. For example, as shown in FIG. 3, the eccentric portion 314 rotates the second drive shaft 304b rotationally coupled to the eccentric portion 314. The second drive shaft 304b freely rotates about the second rotational axis 306b. The second drive shaft 304b rotates about the second rotational axis 306b in the oscillating motion.

[0073] At block 406, the method 400 further includes actuating, by a force control unit, a tool coupled to the second drive shaft for applying a force on a substrate when the tool is in contact with the substrate. In some embodiments, the tool is an abrasive disc including an abrasive media and a backup pad. For example, as shown in FIG. 3, the force control unit 322 actuates the tool 308 coupled to the second drive shaft 304b for applying the force F2 on the substrate 312 when the tool 308 is in contact with the substrate 312. The tool 308 is an abrasive disc including the abrasive media 324 and the backup pad 338.

[0074] At block 408, the method 400 further includes generating, by a sensor, a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with the substrate. In some embodiments, the sensor is an inductive sensor or an optical sensor. For example, as shown in FIG. 3, the sensor 316 generates the speed signal S3 indicative of the current rotational speed 330 of the tool 308 or the second drive shaft 304b when the tool 308 is in contact with the substrate 312.

[0075] In some embodiments, the method 400 further includes providing a readable media disposed on the tool opposite to the substrate. The method 400 further includes detecting, by the sensor, the readable media as the tool rotates about the second rotational axis. Generating the speed signal further includes generating the speed signal based on the current rotational speed of the readable media about the second rotational axis. For example, as shown in FIG. 3, the power tool 300 further includes the readable media 326 disposed on the major surface 320 of the tool 308 opposite to the substrate 312. The sensor 316 detects the readable media 326 as the tool 308 rotates about the second rotational axis 306b. The sensor 316 is configured to generate the speed signal S3 based on the current rotational speed 330 of the readable media 326 about the second rotational axis 306b.

[0076] At block 410, the method 400 further includes receiving, by a controller, the speed signal from the sensor. The controller is communicably coupled to the drive unit, the force control unit, and the sensor. For example, as shown in FIG. 3, the controller 328 receives the speed signal S3 from the sensor 316. The controller 328 is communicably coupled to the drive unit 302, the force control unit 322, and the sensor 316.

[0077] At block 412, the method 400 further includes controlling at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft. For example, as shown in FIG. 3, the controller 328 controls at least one of the drive unit 302 and the force control unit 322 based on the current rotational speed 330 of the tool 308 or the second drive shaft 304b.

[0078] In some embodiments, the method 400 further includes determining a difference between the current rotational speed of the tool or the second drive shaft and a predetermined rotational speed. The method 400 further includes controlling at least one of the drive unit and the force control unit further based on the difference, such that the tool rotates about the second rotational axis at the predetermined rotational speed. In some embodiments, controlling at least one of the drive unit and the force control unit further includes controlling a shaft rotational speed of the first drive shaft of the drive unit. In some embodiments, controlling at least one of the drive unit and the force control unit further includes controlling the force control unit for modifying the force applied by the tool on the substrate.

[0079] For example, as shown in FIG. 3, the controller 328 determines a difference between the current rotational speed 330 of the tool 308 or the second drive shaft 304b and the predetermined rotational speed 318. The controller 328 controls at least one of the drive unit 302 and the force control unit 322 further based on the difference, such that the tool 308 rotates about the second rotational axis 306b at the predetermined rotational speed 318. In some embodiments, the controller 328 controls the shaft rotational speed 336 of the first drive shaft 304a of the drive unit 302. In some embodiments, the controller 328 controls the force control unit 322 for modifying the force F2 applied by the tool 308 on the substrate 312.

[0080] While the method 400 is described in context of FIG. 3, it is expressly contemplated that the method 400 may operate in alternative arrangements of the power tool. It is further contemplated that the method 400 may be practiced with other suitable machines and / or systems.

[0081] FIG. 5 illustrates a block diagram of an example abrasive sensing system 500, according to embodiments of the present disclosure. The abrasive sensing system 500 includes a sensing pad 538 configured to couple to an abrasive article 508 along a major surface 520. Insome embodiments, the abrasive article 508 is in the form of an abrasive disc for abrading a work surface of a substrate (not shown). In some embodiments, the sensing pad 538 may be in the form of a layer or a disc. Suitable materials for the sensing pad 538 may include polymeric fdms or discs, metal foils, woven fabrics, knitted fabrics, paper, nonwovens, foams, screens, laminates, combinations thereof, and treated versions thereof.

[0082] The sensing pad 538 includes a position indicator 526. In some embodiments, the position indicator 526 may be in the form of a metallic pin, an optical marker, or any other suitable marker fixedly coupled to the sensing pad 538. For example, the position indicator 526 includes a metal. The sensing pad 538 is further configured to couple to a drive shaft 504. Further, the abrasive article 508 is coupled to the drive shaft 504, such that both the sensing pad 538 and the abrasive article 508 are rotationally driven by the drive shaft 504 at a same rotational speed.

[0083] The abrasive sensing system 500 further includes a processing circuitry 528 and an associated memory 558. The abrasive sensing system 500 further includes a power tool 506. The power tool 506 may be similar to the power tool 300 shown in FIG. 3. In some embodiments, the power tool 506 includes the processing circuitry 528. In some other embodiments, the processing circuitry 528 is remote from the power tool 506. The power tool 506 is configured to move the drive shaft 504.

[0084] The abrasive sensing system 500 further includes a sensor 516. In some embodiments, the sensor 516 includes an induction sensor or an optical sensor. The sensor 516 is configured to detect the position indicator 526. Specifically, the sensor 516 is configured to detect the position indicator 526 as the sensing pad 538 is rotationally driven by the drive shaft 504.

[0085] The processing circuitry 528 and the associated memory 558 is configured to, while the sensing pad 538 is rotationally driven by the drive shaft 504, receive a first position signal Cl from the sensor 516. The first position signal Cl is indicative of a first time T1 the position indicator 526 is detected. The processing circuitry 528 is further configured to receive a second position signal C2 from the sensor 516. The second position signal C2 is indicative of a second time T2 the position indicator 526 is detected. In some embodiments, the processing circuitry 528 is further configured to receive the first and second position signals Cl, C2 while the sensing pad 538 is rotationally moving.

[0086] The processing circuitry 528 is further configured to, based on the first and second position signals Cl, C2, determine a current rotational speed 530 of the sensing pad 538. For example, the processing circuitry 528 may determine the current rotational speed 530 bydetecting a movement of the position indicator 526 between the first position signal Cl and the second position signal C2 in a time difference between the first time T1 and the second time T2. In some embodiments, the current rotational speed 530 is determined in substantially real-time.

[0087] The processing circuitry 528 is further configured to compare the current rotational speed 530 of the sensing pad 538 to a threshold speed 532. The threshold speed 532 is based on a retrieved tool setting 514 of the power tool 506 associated with the drive shaft 504. In some embodiments, the retrieved tool setting 514 may be based on parameters, such as a type of abrasive associated with the abrasive article 508, a type of substrate (e.g., the substrate 112 shown in FIG. 1), etc.

[0088] The processing circuitry 528 is further configured to, based on the comparison, generate a new tool setting 560 for the power tool 506 associated with the drive shaft 504. In some embodiments, the processing circuitry 528 is further configured to determine, compare, and generate the new tool setting 560 while the sensing pad 538 is rotationally moving.

[0089] In some embodiments, the new tool setting 560 includes a new rotational speed setting 562, a new torque setting 564, or a new applied force setting 566 for a force control unit 522 of the power tool 506. In some embodiments, the new rotational speed setting 562, the new torque setting 564, and the new applied force setting 566 may be such that a rotational speed of the abrasive article 508 becomes closer to the threshold speed 532. In some embodiments, the new rotational speed setting 562 may modify a drive power of the power tool 506 for driving the drive shaft 504. In some embodiments, the new torque setting 564 may modify a torque applied by the power tool 506 on the drive shaft 504. In some embodiments, the new applied force setting 566 may modify a force applied by the force control unit 522 on the abrasive article 508.

[0090] The abrasive sensing system 500 further includes a communication component 568 configured to communicate the new tool setting 560 to the power tool 506. In some embodiments, the new tool setting 560 is configured to be applied while the abrasive article 508 is rotationally moving. The new tool setting 560 is generated during a first abrasive operation 552 and applied before a second abrasive operation 554. For example, the processing circuitry 528 may apply the new tool setting 560 in the second abrasive operation 554 which may be subsequent to the first abrasive operation 552.

[0091] FIG. 6 illustrates a block diagram of an example controller 600 for a sanding tool 606, according to embodiments of the present disclosure. The controller 600 includes a position signal receiver 670 configured to receive a first indication 672 of a first position DI of an abrasive article 608 at a first time T1 and a second indication 674 of a second position D2 of the abrasive article 608 at a second time T2.

[0092] In some embodiments, the controller 600 is configured to receive the first indication 672 and the second indication 674 from a sensor (e.g., the sensor 224 shown in FIG. 2, or the sensor 316 shown in FIG. 3, or the sensor 516 shown in FIG. 5). The sensor is configured to detect the first position DI and the second position D2 of the abrasive article 608. In some embodiments, the received first indication 672 or the second indication 674 includes a sensed induction. For example, the sensor may be an indication sensor.

[0093] The controller 600 further includes a tool setting receiver 676 configured to retrieve a speed setting 614 or an applied force setting 678 from the sanding tool 606. In some embodiments, the speed setting 614 may be based on parameters, such as a type of abrasive associated with the abrasive article 608, a type of substrate (e.g., the substrate 112 shown in FIG.1), etc.

[0094] The controller 600 further includes a current speed calculator 680 configured to, based on the received first indication 672 and second indication 674, determine a current speed 630 of the abrasive article 608. In some embodiments, the current speed 630 is a rotational speed. Alternatively, the current speed 630 may be a linear speed or any other type of speed.

[0095] The controller 600 further includes a tool setting update generator 682 configured to, based on the comparison of the current speed 630 with an expected speed 632, generate a tool setting update 660. The expected speed 632 is based on the retrieved speed setting 614 or the retrieved applied force setting 678. The tool setting update 660 includes a new speed setting 662 or anew applied force setting 666 for the sanding tool 606.

[0096] In some embodiments, the new speed setting 662 and the new applied force setting 666 may be such that a rotational speed of the abrasive article 608 becomes closer to the expected speed 632. In some embodiments, the new speed setting 662 may modify a drive power of the sanding tool 606 for driving the abrasive article 608. In some embodiments, the new applied force setting 666 may modify a force applied by a force control unit (e.g., the force control unit 222 shown in FIG. 2, or the force control unit 322 shown in FIG. 3, or the force control unit 522 shown in FIG. 5, or another suitable force control mechanism) on the abrasive article 608.

[0097] The controller 600 further includes a control signal communication component 668 configured to communicate the tool setting update 660 to the sanding tool 606. In some embodiments, the tool setting update 660 is communicated to the sanding tool 606 in-situ. In some embodiments, the first indication 672 and second indication 674 are received, the current speed 630 is determined, and the tool setting update 660 is generated and communicated in substantially real-time.

[0098] FIG. 7 illustrates a remote server architecture 700 for a setting selection system 710 of an automated robotic abrading system (e.g., the robotic abrading system 100, 200 shown in FIGS. 1 and 2, respectively) when hosted in a cloud-based architecture. The remote server architecture 700 illustrates one embodiment of an implementation of the setting selection system 710. As an example, the remote server architecture 700 may provide computation, software, data access, and storage services that do not require end-user knowledge of a physical location or configuration of the setting selection system 710 that delivers the services. In various embodiments, the remote server architecture 700 may deliver services over a wide area network, such as the internet, using appropriate protocols. For instance, the remote server architecture 700 may deliver applications over a wide area network and they can be accessed through a web browser or any other computing component.

[0099] Software or components shown or described in FIGS. 1-6 as well as the corresponding data may be stored on servers at a remote location. The computing resources in a remote server environment may be consolidated at a remote data center location or they may be dispersed. The remote server architecture 700 may deliver services through shared data centers, even though they appear as a single point of access for a user. Thus, components and functions described herein may be provided from a remote server at a remote location using the remote server architecture 700. Alternatively, they can be provided by a conventional server, installed on client devices directly, or in other ways.

[0100] In the example shown in FIG. 7, some items are similar to those shown in earlier figures. FIG. 7 specifically shows that the setting selection system 710 may be located at a remote server location 702. Therefore, a computing device 720 accesses those systems through remote server location 702. An operator 750 can use the computing device 720 to access a user interface 722 as well. Embodiments described herein have focused on systems and methods that automatically retrieve data to estimate a current rotational speed and, based on that estimation, adjust parameters of a current grinding operation, all in-situ. However, it is expressly contemplated that the retrieved data, the adjustments, or other information may be presented on the user interface 722 for action or approval from the operator 750. For example, the operator 750 may need to approve a proposed parameter adjustment before it is effected in the robotic abrading system 770. Alternatively, the operator 750 may be able to provide changes to the proposed parameter adjustments. Or, in some embodiments, the operator 750 may only be able to view current parameters and / or updated parameter values.

[0101] FIG. 7 shows that it is also contemplated that some elements of systems described herein are disposed at the remote server location 702 while others are not. By way of example, astorage 740 or 760 of the robotic abrading system 770 can be disposed at a location separate from remote server location 702 and accessed through the remote server location 702.Regardless of where they are located, they can be accessed directly by the computing device 720, 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, data can be stored in substantially any location and intermittently accessed by, or forwarded to, interested parties. For instance, physical carriers may be used instead of, or in addition to, electromagnetic wave carriers.

[0102] It will also be noted that 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. Any suitable computing device with a display may be able to service as the computing device 720 with the user interface 722.

[0103] FIG. 8 is a simplified block diagram of one illustrative example of a handheld or mobile computing device that may be used as a user's or client's (handheld) device 816 (e.g., as the computing device 720 shown in FIG. 7), in which the present system (or parts of it) may be deployed. For instance, the mobile device may be deployed in an operator compartment of the computing device 720 for use in generating, processing, or displaying the data. FIG. 9 is another example of a handheld or mobile device.

[0104] FIG. 8 provides a general block diagram of the components of a client device 816 that can run some components shown and described herein. Client device 816 interacts with them, or runs some and interacts with some. In the client device 816, a communications link 813 is provided that allows the client device 816 to communicate with other computing devices, and under some embodiments, provides a channel for receiving information automatically, such as by scanning. Examples of the communications link 813 may include allowing communication 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.

[0105] In other examples, applications can be received on a removable Secure Digital (SD) card that is connected to an interface 815. The interface 815 and the communication link 813 may communicate with a processor 817 (which may also embody a processor) along a bus 819 that is also connected to a memory 821 and input / output (I / O) components 823, as well as a clock 825 and a location system 827.

[0106] I / O components 823, in one embodiment, are provided to facilitate input and output operations and the client device 816 may 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 823 may be used as well.

[0107] The clock 825 illustratively comprises a real time clock component that outputs a time and date. It can also provide timing functions for the processor 817.

[0108] Illustratively, the location system 827 includes a component that outputs a current geographical location of the client device 816. This may 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 may also include, e.g., a mapping software or a navigation software that generates desired maps, navigation routes, and other geographic functions.

[0109] The memory 821 may store an operating system 829, network settings 831, applications 833, application configuration settings 835, a contact or phone book application 843, a client system 824, a data store 837, communication drivers 839, and communication configuration settings 841. The memory 821 may include all types of tangible volatile and nonvolatile computer-readable memory devices. The memory 821 may also include computer storage media (described below). The memory 821 may store computer readable instructions that, when executed by the processor 817, cause the processor 817 to perform computer-implemented steps or functions according to the instructions. The processor 817 may be activated by other components to facilitate their functionality as well.

[0110] FIG. 9 shows that the client device 816 shown in FIG. 8 can be a smart phone 971. The smart phone 971 includes a touch sensitive display 973 that displays icons or tiles or other user input mechanisms 975. The user input mechanisms 975 may be used by a user to run applications, make calls, perform data transfer operations, etc. In general, the smart phone 971 is built on a mobile operating system and offers more advanced computing capability and connectivity than a feature phone. A setting selection system (e.g., the setting selection system 710 shown in FIG. 7) may be an installed application, or accessible through a website on the Internet, or another suitable configuration accessible by the smart device 971.

[0111] FIG. 10 is a block diagram of a computing environment that may be used in embodiments shown in previous Figures.

[0112] FIG. 10 is one example of a computing environment 1000 in which elements of systems and methods described herein, or parts of them, may be deployed. With reference toFIG. 10, an example system for implementing some embodiments includes a general -purpose computing device in the form of a computer 1010. Components of the computer 1010 may include, but are not limited to, a processing unit 1020 (which may include a processor), a system memory 1030, and a system bus 1021 that couples various system components including the system memory 1030 to the processing unit 1020. The system bus 1021 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 may be deployed in corresponding portions of FIG. 10.

[0113] The computer 1010 typically includes a variety of computer readable media.Computer readable media may be any available media that may be accessed by the computer 1010 and includes both volatile / nonvolatile 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, a modulated data signal or a carrier wave. 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. Computer storage media 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.

[0114] Computer storage media includes, but is not limited to, random access memory (RAM), read only memory (ROM), electrically erasable programmable read-only memory (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 may be used to store the desired information and which may be accessed by the computer 1010. Communication media may embody computer readable instructions, data structures, program modules or other data in a transport mechanism and includes any information delivery media.

[0115] The system memory 1030 includes computer storage media in the form of volatile and / or nonvolatile memory, such as read only memory (ROM) 1031 and random access memory (RAM) 1032. A basic input / output system 1033 (BIOS) containing basic routines that helps to transfer information between elements within the computer 1010, such as during start-up, is typically stored in the ROM 1031. The RAM 1032 typically contains data and / or program modules that are immediately accessible to and / or presently being operated on by the processingunit 1020. By way of example, and not limitation, FIG. 10 illustrates an operating system 1034, application programs 1035, other program modules 1036, and program data 1037.

[0116] The computer 1010 may also include other removable / non-removable and volatile / nonvolatile computer storage media. By way of example only, FIG. 10 illustrates a hard disk drive 1041 that reads from or writes to non-removable, nonvolatile magnetic media, a nonvolatile magnetic disk, an optical disk drive 1055, and a nonvolatile optical disk 1056. The hard disk drive 1041 is typically connected to the system bus 1021 through a non-removable memory interface, such as an interface 1040, and the optical disk drive 1055 is typically connected to the system bus 1021 by a removable memory interface, such as an interface 1050.

[0117] Alternatively, or in addition, the functionality described herein may 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 may be used include Field-programmable Gate Arrays (FPGAs), Application-specific Integrated Circuits (ASICs), Application-specific Standard Products (ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), etc.

[0118] The drives and their associated computer storage media discussed above and illustrated in FIG. 10, provide storage of computer readable instructions, data structures, program modules, and other data for the computer 1010. In FIG. 10, e.g., the hard disk drive 1041 is illustrated as storing an operating system 1044, application programs 1045, other program modules 1046, and program data 1047. Note that these components can either be the same as or different from operating system 1034, application programs 1035, the other program modules 1036, and the program data 1037.

[0119] A user may enter commands and information into the computer 1010 through input devices, such as a keyboard 1062, a microphone 1063, and a pointing device 1061, such as a mouse, trackball or touch pad. Other input devices (not shown) may include a joystick, a game pad, a satellite receiver, a scanner, or the like. These and other input devices are often connected to the processing unit 1020 through a user input interface 1060 that is coupled to the system bus 1021, but may be connected by other interface and bus structures. A visual display 1091 or other type of display device is also connected to the system bus 1021 via an interface, such as a video interface 1090. In addition to the monitor, the computer 1010 may also include other peripheral output devices, such as speaker 1097 and printer 1096, which may be connected through an output peripheral interface 1095.

[0120] The computer 1010 is operated 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 a remote computer 1080.

[0121] When used in a LAN networking environment, the computer 1010 is connected to the LAN 1071 through anetwork interface or adapter 1070. When used in a WAN networking environment, the computer 1010 typically includes a modem 1072 or other means for establishing communications over a WAN 1073, such as the Internet. In a networked environment, program modules may be stored in a remote memory storage device. FIG. 10 illustrates, e.g., that remote application programs 1085 can reside on the remote computer 1080.

[0122] Referring to FIGS. 1-10, the power tool 300 and the method 400 of the present disclosure includes the sensor 316 that is configured to generate the speed signal S indicative of the current rotational speed 330 of the tool 308 or the second drive shaft 304b when the tool 308 is in contact with the substrate 312. Thus, the sensor 316 may allow the power tool 300 to recognize and measure the current rotational speed 330 of the tool 308. This may enable the controller 328 to control at least one of the drive unit 302 and the force control unit 322 based on the current rotational speed 330 of the tool 308 or the second drive shaft 304b. A relation between the current rotational speed 330 of the tool 308 and different conditional changes, e.g., disc wear, process temperature, substrate type, etc.) may be established that may allow control of process parameters for a stable and high-quality automated process. For example, the power tool 300 may be able to adapt to sudden contour changes which would have otherwise resulted in a lower quality or inefficient process.

[0123] The power tool 300 and the method 400 of the present disclosure adapts continuously and automatically to the conditional changes during execution of machining process while considering all the conditional changes affecting the machining process. This is applicable to any type of random orbital power tool, e.g., grinding tools, polishing tools, cleaning tools, etc. The power tool 300 may be used with any platform, e.g., robotic or fixed automation. The controller 328 of the power tool 300 may control either or both the drive unit 302 and the force control unit 322 for controlling the rotational speed N of the tool 308 or the second drive shaft 304b.

[0124] A power tool including a drive unit is presented. The drive unit includes a first drive shaft. The first drive shaft is configured to rotate about a first rotational axis. An eccentric portion is fixedly coupled to the first drive shaft. The eccentric portion includes a second rotational axis located radially eccentrically relative to the first rotational axis. A second drive shaft is rotationally coupled to the eccentric portion. The second drive shaft is configured to bedriven by the eccentric portion. The second drive shaft freely rotates about the second rotational axis. A tool is coupled to the second drive shaft. A sensor is configured to generate a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with a substrate. A force control unit is configured to actuate the tool to apply a force on the substrate when the tool is in contact with the substrate. A controller is communicably coupled to the drive unit, the sensor, and the force control unit. The controller is configured to receive the speed signal from the sensor. Based on the received speed signal, the controller generates a control signal for at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft.

[0125] The power tool may be implemented such that the controller is further configured to determine a difference between the current rotational speed of the tool or the second drive shaft and a predetermined rotational speed. The controller may control at least one of the drive unit and the force control unit further based on the difference, such that the tool rotates about the second rotational axis at the predetermined rotational speed.

[0126] The power tool may be implemented such that the controller is further configured to control a shaft rotational speed of the first drive shaft of the drive unit.

[0127] The power tool may be implemented such that the controller is further configured to control the force control unit for modifying the force applied by the tool on the substrate.

[0128] The power tool may be implemented such that the tool is an abrasive disc including an abrasive media and a backup pad.

[0129] The power tool may be implemented such that the second drive shaft rotates about the second rotational axis in an oscillating orbital motion.

[0130] The power tool may be implemented such that the tool includes a readable media disposed on a major surface of the tool opposite to the substrate. The sensor may be configured to generate the speed signal based on the current rotational speed of the readable media about the second rotational axis.

[0131] The power tool may be implemented such that the sensor is an inductive sensor or an optical sensor.

[0132] The power tool may be implemented such that the drive unit includes at least one of an electric motor, a fluid motor, and a pneumatic motor.

[0133] The power tool may be implemented such that the power tool is a random orbital tool.

[0134] A robotic abrading system includes a motive robotic unit. The motive robotic unit is coupled to the power tool.

[0135] A method of using a power tool is presented that includes rotating, by a drive unit, a first drive shaft about a first rotational axis. An eccentric portion is fixedly coupled to the first drive shaft. The eccentric portion includes a second rotational axis located radially eccentrically relative to the first rotational axis. The method includes rotating, by the eccentric portion, a second drive shaft rotationally coupled to the eccentric portion. The second drive shaft freely rotates about the second rotational axis. The method includes actuating, by a force control unit, a tool coupled to the second drive shaft for applying a force on a substrate when the tool is in contact with the substrate. The method includes generating, by a sensor, a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with the substrate. The method includes receiving, by a controller, the speed signal from the sensor. The controller is communicably coupled to the drive unit, the force control unit, and the sensor. The method includes controlling at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft.

[0136] The method may further include determining a difference between the current rotational speed of the tool or the second drive shaft and a predetermined rotational speed. The method may include controlling at least one of the drive unit and the force control unit further based on the difference, such that the tool rotates about the second rotational axis at the predetermined rotational speed.

[0137] The method may be implemented such that controlling at least one of the drive unit and the force control unit further includes controlling a shaft rotational speed of the first drive shaft of the drive unit.

[0138] The method may be implemented such that controlling at least one of the drive unit and the force control unit further includes controlling the force control unit for modifying the force applied by the tool on the substrate.

[0139] The method may be implemented such that the tool is an abrasive disc including an abrasive media and a backup pad.

[0140] The method may further include rotating the second drive shaft about the second rotational axis in an oscillating orbital motion.

[0141] The method may further include providing a readable media disposed on a major surface of the tool opposite to the substrate. The method may include detecting, by the sensor, the readable media as the tool rotates about the second rotational axis. Generating the speed signal may further include generating the speed signal based on the current rotational speed of the readable media about the second rotational axis.

[0142] The method may be implemented such that the sensor is an inductive sensor or an optical sensor.

[0143] The method may be implemented such that the drive unit includes at least one of an electric motor, a fluid motor, and a pneumatic motor.

[0144] A robotic abrading system is presented that includes a motive robotic unit configured to rotationally move an abrasive article at a rotational speed setting. The system includes a force control unit configured to apply a force to the abrasive article. The system includes a signal receiver configured to receive a speed signal indicative of a rotational speed of the abrasive article. The system includes a controller communicably coupled to the motive robotic unit, the force control unit, and the signal receiver. The controller is configured to, based on the received speed signal, determine a current rotational speed of the abrasive article. The controller compares the current rotational speed to a threshold speed. Based on the comparison, the controller generates a control signal. The control signal includes a new force to apply or a new rotational speed setting.

[0145] The robotic abrading system may be implemented such that the determined current rotational speed differs from an expected speed for the rotational speed setting.

[0146] The robotic abrading system may be implemented such that the current rotational speed is determined in substantially real-time.

[0147] The robotic abrading system may be implemented such that the signal receiver is configured to receive the speed signal while the abrasive article is rotationally moving.

[0148] The robotic abrading system may be implemented such that the controller is further configured to determine, compare, and generate the control signal while the abrasive article is rotationally moving.

[0149] The robotic abrading system may be implemented such that the generated control signal is applied while the abrasive article is rotationally moving.

[0150] The robotic abrading system may be implemented such that the generated control signal is calculated during a first abrasive operation and applied before a second abrasive operation.

[0151] The robotic abrading system may be implemented such that the controller is further configured to determine the current rotational speed by detecting the abrasive article in a first position, at a first time, and detecting the abrasive article in a second position, at a second time.

[0152] The robotic abrading system may be implemented such that the first position and the second position are the same position.

[0153] The robotic abrading system may be implemented such that the received speed signal includes a sensed induction value or a sensed optical value.

[0154] The robotic abrading system may be implemented such that the received speed signal includes a first speed signal. The controller may be further configured to, based on a received second speed signal, determine a second current rotational speed of the abrasive article. The controller may compare the second current rotational speed to the threshold speed. Based on the comparison, the controller may generate a second control signal. The second control signal includes a second new force to apply or a second new rotational speed setting.

[0155] The robotic abrading system may further include a sensor configured to sense the speed signal.

[0156] The robotic abrading system may be implemented such that the sensor is positioned on the mobile robotic unit.

[0157] The robotic abrading system may be implemented such that the motive robotic unit includes a drive unit configured to rotationally move the abrasive article at the rotational speed setting.

[0158] The robotic abrading system may be implemented such that the drive unit includes at least one of an electric motor, a fluid motor, and a pneumatic motor.

[0159] The robotic abrading system may be implemented such that the motive robotic unit includes an articulating arm configured to move the abrasive article proximate a work surface.

[0160] An abrasive sensing system is presented that includes a sensing pad configured to couple to an abrasive article along a major surface. The sensing pad includes a position indicator. The sensing pad is further configured to couple to a drive shaft. The system includes processing circuitry and an associated memory configured to, while the sensing pad is rotationally driven by the drive shaft, receive a first position signal from a sensor. The sensor is configured to detect the position indicator. The first position signal is indicative of a first time the position indicator is detected. The system includes receiving a second position signal from the sensor. The second position signal is indicative of a second time the position indicator is detected. Based on the first and second position signals, the system determines a current rotational speed of the sensing pad. The system compares the current rotational speed of the sensing pad to a threshold speed. Based on the comparison, the system generates a new tool setting for a power tool associated with the drive shaft. The system includes a communication component configured to communicate the new tool setting to the power tool.

[0161] The abrasive sensing system may be implemented such that the threshold speed is based on a retrieved tool setting of the power tool associated with the drive shaft.

[0162] The abrasive sensing system may further include the power tool.

[0163] The abrasive sensing system may be implemented such that the power tool includes the processing circuitry.

[0164] The abrasive sensing system may be implemented such that the processing circuitry is remote from the power tool.

[0165] The abrasive sensing system may be implemented such that the new tool setting includes a new rotational speed setting, a new torque setting, or a new applied force setting for a force control unit of the power tool.

[0166] The abrasive sensing system may further include the sensor configured to detect the position indicator as the sensing pad is rotationally driven by the drive shaft.

[0167] The abrasive sensing system may be implemented such that the position indicator includes a metal.

[0168] The abrasive sensing system may be implemented such that the sensor includes an induction sensor or an optical sensor.

[0169] The abrasive sensing system may be implemented such that the current rotational speed is determined in substantially real-time.

[0170] The abrasive sensing system may be implemented such that the processing circuitry is further configured to receive the first and second position signals while the sensing pad is rotationally moving.

[0171] The abrasive sensing system may be implemented such that the processing circuitry is further configured to determine, compare, and generate the new tool setting while the sensing pad is rotationally moving.

[0172] The abrasive sensing system may be implemented such that the new tool setting is configured to be applied while the abrasive article is rotationally moving.

[0173] The abrasive sensing system may be implemented such that the new tool setting is generated during a first abrasive operation and applied before a second abrasive operation.

[0174] A controller for a sanding tool is presented that includes a position signal receiver configured to receive a first indication of a first position of an abrasive article at a first time and a second indication of a second position of the abrasive article at a second time. The controller includes a tool setting receiver configured to retrieve a speed setting or an applied force setting from the sanding tool. The controller includes a current speed calculator configured to, based on the received first and second indications, determine a current speed of the abrasive article. The controller includes a tool setting update generator configured to, based on the comparison of the current speed with an expected speed, generate a tool setting update including a new speedsetting or a new applied force setting for the sanding tool. The expected speed is based on the retrieved speed setting or the retrieved applied force setting. The controller includes a control signal communication component configured to communicate the tool setting update to the sanding tool.

[0175] The controller may be implemented such that the current speed is a rotational speed.

[0176] The controller may be implemented such that the received first indication or the second indication includes a sensed induction.

[0177] The controller may be implemented such that the first and second indications are received, the current speed is determined, and the tool setting update is generated and communicated in substantially real-time.

[0178] The controller may be implemented such that the tool setting update is communicated to the sanding tool in-situ.

Claims

CLAIMS:

1. A power tool comprising :a drive unit comprising a first drive shaft, wherein the first drive shaft is configured to rotate about a first rotational axis;an eccentric portion fixedly coupled to the first drive shaft and comprising a second rotational axis located radially eccentrically relative to the first rotational axis; a second drive shaft rotationally coupled to the eccentric portion and configured to be driven by the eccentric portion, wherein the second drive shaft freely rotates about the second rotational axis;a tool coupled to the second drive shaft;a sensor configured to generate a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with a substrate; a force control unit configured to actuate the tool to apply a force on the substrate when the tool is in contact with the substrate; anda controller communicably coupled to the drive unit, the sensor, and the force control unit, wherein the controller is configured to receive the speed signal from the sensor and, based on the received speed signal, generate a control signal for at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft.

2. The power tool of claim 1, wherein the controller is further configured to:determine a difference between the current rotational speed of the tool or the second drive shaft and a predetermined rotational speed; andcontrol at least one of the drive unit and the force control unit further based on the difference, such that the tool rotates about the second rotational axis at the predetermined rotational speed.

3. The power tool of claim 1, wherein the controller is further configured to control a shaft rotational speed of the first drive shaft of the drive unit.

4. The power tool of claim 1, wherein the controller is further configured to control the force control unit for modifying the force applied by the tool on the substrate.

5. The power tool of claim 1, wherein the tool is an abrasive disc comprising an abrasive media and a backup pad.

6. The power tool of claim 1, wherein the second drive shaft rotates about the second rotational axis in an oscillating orbital motion.

7. The power tool of claim 1, wherein the tool comprises a readable media disposed on a major surface of the tool opposite to the substrate, and wherein the sensor is configured to generate the speed signal based on the current rotational speed of the readable media about the second rotational axis.

8. The power tool of claim 1, wherein the sensor is an inductive sensor or an optical sensor.

9. The power tool of claim 1, wherein the drive unit comprises at least one of an electric motor, a fluid motor, and a pneumatic motor.

10. The power tool of claim 1, wherein the power tool is a random orbital tool.

11. A robotic abrading system comprising a motive robotic unit, wherein the motive robotic unit is coupled to the power tool of claim 1.

12. A method of using a power tool comprising:rotating, by a drive unit, a first drive shaft about a first rotational axis, wherein an eccentric portion is fixedly coupled to the first drive shaft, and wherein the eccentric portion comprises a second rotational axis located radially eccentrically relative to the first rotational axis;rotating, by the eccentric portion, a second drive shaft rotationally coupled to the eccentric portion, wherein the second drive shaft freely rotates about the second rotational axis;actuating, by a force control unit, a tool coupled to the second drive shaft for applying a force on a substrate when the tool is in contact with the substrate; generating, by a sensor, a speed signal indicative of a current rotational speed of the tool or the second drive shaft when the tool is in contact with the substrate;receiving, by a controller, the speed signal from the sensor, wherein the controller is communicably coupled to the drive unit, the force control unit, and the sensor; and controlling at least one of the drive unit and the force control unit based on the current rotational speed of the tool or the second drive shaft.

13. The method of claim 12, further comprising:determining a difference between the current rotational speed of the tool or the second drive shaft and a predetermined rotational speed; andcontrolling at least one of the drive unit and the force control unit further based on the difference, such that the tool rotates about the second rotational axis at the predetermined rotational speed.

14. The method of claim 12, wherein controlling at least one of the drive unit and the force control unit further comprises controlling a shaft rotational speed of the first drive shaft of the drive unit.

15. The method of claim 12, wherein controlling at least one of the drive unit and the force control unit further comprises controlling the force control unit for modifying the force applied by the tool on the substrate.

16. The method of claim 12, wherein the tool is an abrasive disc comprising an abrasive media and a backup pad.

17. The method of claim 12, further comprising rotating the second drive shaft about the second rotational axis is an oscillating orbital motion.

18. The method of claim 12, further comprising:providing a readable media disposed on a major surface of the tool opposite to the substrate; anddetecting, by the sensor, the readable media as the tool rotates about the second rotational axis;wherein generating the speed signal further comprises generating the speed signal based on the current rotational speed of the readable media about the second rotational axis.

19. The method of claim 12, wherein the sensor is an inductive sensor or an optical sensor.

20. The method of claim 12, wherein the drive unit comprises at least one of an electric motor, a fluid motor, and a pneumatic motor.

21. A robotic abrading system comprising:a motive robotic unit configured to rotationally move an abrasive article at a rotational speed setting;a force control unit configured to apply a force to the abrasive article;a signal receiver configured to receive a speed signal indicative of a rotational speed of the abrasive article; anda controller communicably coupled to the motive robotic unit, the force control unit, and the signal receiver, the controller configured to, based on the received speed signal: determine a current rotational speed of the abrasive article;compare the current rotational speed to a threshold speed; andbased on the comparison, generate a control signal, wherein the control signal comprises a new force to apply or a new rotational speed setting.

22. The robotic abrading system of claim 21, wherein the determined current rotational speed differs from an expected speed for the rotational speed setting.

23. The robotic abrading system of claim 21, wherein the current rotational speed is determined in substantially real-time.

24. The robotic abrading system of claim 21, wherein the signal receiver is configured to receive the speed signal while the abrasive article is rotationally moving.

25. The robotic abrading system of claim 21, wherein the controller is further configured to determine, compare, and generate the control signal while the abrasive article is rotationally moving.

26. The robotic abrading system of claim 21, wherein the generated control signal is applied while the abrasive article is rotationally moving.

27. The robotic abrading system of claim 21 , wherein the generated control signal is calculated during a first abrasive operation and applied before a second abrasive operation.

28. The robotic abrading system of claim 21, wherein the controller is further configured to determine the current rotational speed by detecting the abrasive article in a first position, at a first time, and detecting the abrasive article in a second position, at a second time.

29. The robotic abrading system of claim 28, wherein the first position and the second position are the same position.

30. The robotic abrading system of claim 21, wherein the received speed signal comprises a sensed induction value or a sensed optical value.

31. The robotic abrading system of claim 21, wherein the received speed signal comprises a first speed signal, and wherein the controller is further configured to, based on a received second speed signal:determine a second current rotational speed of the abrasive article;compare the second current rotational speed to the threshold speed; andbased on the comparison, generate a second control signal, wherein the second control signal comprises a second new force to apply or a second new rotational speed setting.

32. The robotic abrading system of claim 21, further comprising a sensor configured to sense the speed signal.

33. The robotic abrading system of claim 32, wherein the sensor is positioned on the mobile robotic unit.

34. The robotic abrading system of claim 21, wherein the motive robotic unit comprises a drive unit configured rotationally move the abrasive article at the rotational speed setting.

35. The robotic abrading system of claim 34, wherein the drive unit comprises at least one of an electric motor, a fluid motor, and a pneumatic motor.

36. The robotic abrading system of claim 21, wherein the motive robotic unit comprises an articulating arm configured to move the abrasive article proximate a work surface.

37. An abrasive sensing system comprising:a sensing pad configured to couple to an abrasive article along a major surface, wherein the sensing pad comprises a position indicator, and wherein the sensing pad is further configured to couple to a drive shaft;a processing circuitry and an associated memory configured to, while the sensing pad is rotationally driven by the drive shaft:receive a first position signal from a sensor, the sensor being configured to detect the position indicator, wherein the first position signal is indicative of a first time the position indicator is detected;receive a second position signal from the sensor, the second position signal being indicative of a second time the position indicator is detected;based on the first and second position signals, determine a current rotational speed of the sensing pad;compare the current rotational speed of the sensing pad to a threshold speed; and based on the comparison, generate a new tool setting for a power tool associated with the drive shaft; anda communication component configured to communicate the new tool setting to the power tool.

38. The abrasive sensing system of claim 37, wherein the threshold speed is based on a retrieved tool setting of the power tool associated with the drive shaft.

39. The abrasive sensing system of claim 37, wherein the new tool setting comprises a new rotational speed setting, a new torque setting, or a new applied force setting for a force control unit of the power tool.

40. The abrasive sensing system of claim 37, further comprising the sensor configured to detect the position indicator as the sensing pad is rotationally driven by the drive shaft.

1. The abrasive sensing system of claim 37, wherein the processing circuitry is further configured to receive the first and second position signals while the sensing pad is rotationally moving.

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