Systems and methods for wear measurement and evaluation of abrasive articles

Abstract

A system for measuring wear of an abrasive article is disclosed. The system includes a sensor configured to capture a plurality of sensed indications. Each of the plurality of sensed indications is captured at a position on a surface of the abrasive article. The system further includes a processing circuitry and associated memory. The processing circuitry is configured to process each of the plurality of sensed indications. The system further includes a wear calculator configured to calculate an amount of wear for each of the positions based on the processed indications.

Description

PA102888W002SYSTEMS AND METHODS FOR WEAR MEASUREMENT AND EVALUATION OF ABRASIVE ARTICLESTechnical Field

[0001] The present disclosure relates to a system for measuring wear of an abrasive article. The present disclosure further relates to a robotic abrading system. The present disclosure further relates to a method of evaluating an abrasive article. The present disclosure further relates to a method of generating a wear evaluation for an abrasive article.Background

[0002] Abrasive articles are useful for shaping, finishing, or grinding a wide variety of materials and surfaces, such as wood and metals. There remains a need for systems and methods that can evaluate the abrasive articles before or during use.Summary

[0003] In a first aspect, a system for measuring wear of an abrasive article is provided. The system includes a sensor configured to capture a plurality of sensed indications. Each of the plurality of sensed indications is captured at a position on a surface of the abrasive article. The system further includes a processing circuitry and associated memory. The processing circuitry is configured to process each of the plurality of sensed indications. The system further includes a wear calculator configured to, based on the processed indications, calculate an amount of wear for each of the positions.

[0004] In a second aspect, a robotic abrading system is provided. The robotic abrading system includes a motive robotic unit configured to position an abrasive article with respect to a work surface. The motive robotic unit is further configured to move the abrasive article along the work surface. The robotic abrading system further includes a force control unit configured to apply a force to the abrasive article while the abrasive article is contacting the work surface. The robotic abrading system further includes a wear detection system. The wear detection system includes a sensor configured to sense a first wear indication at a first position on a surface of the abrasive article and a second wear indication at a second position on the surface of the abrasive article. The wear detection system further includes a wear calculator configured to, based on the first and second wear indications, calculate an amount of wear for the abrasive article. The wear detection system further includes a communication component configured to communicate the amount of wear to a device.

[0005] In a third aspect, a method of evaluating an abrasive article is provided. The method includes positioning the abrasive article proximate to a sensor. The method further includes analyzing, using a signal analyzer, a received sensor signal, from the sensor. The received sensor signal is indicative of a sensed indication at a position on a surface of the abrasive article. The method further includes determining, based on the analysis, a status of the abrasive article at the position. The method further includes outputting the status of the abrasive article.

[0006] In a fourth aspect, a method of generating a wear evaluation for an abrasive article is provided. The method includes receiving, using a signal receiver, a first sensed indication of a first amount of wear at a first position on the abrasive article. The method further includes receiving, using the signal receiver, a second sensed indication of a second amount of wear at a second position on the abrasive article. The second position is at a different distance from a center of the abrasive article than the first position. The method further includes receiving a default wear indication for the abrasive article. The method further includes comparing the received first and second sensed indications to the default wear indication. The method further includes, based on the comparison, using a wear evaluator, characterizing a wear profile for the abrasive article. The wear profile includes the first amount of wear and the second amount of wear.

[0007] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.Brief Description of Drawings

[0008] 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 like components. 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.

[0009] FIG. 1 illustrates a block diagram of an exemplary system for measuring wear of an abrasive article, according to embodiments of the present disclosure;

[0010] FIG. 2 illustrates a schematic top view of an exemplary abrasive article, according to embodiments of the present disclosure;

[0011] FIG. 3A illustrates a photograph of an abrasive disc;

[0012] FIG. 3B illustrates a zoomed-in photograph of a first portion of the abrasive disc of FIG. 3A;

[0013] FIG. 3C illustrates a zoomed-in photograph of a second portion of the abrasive disc of FIG. 3A;

[0014] FIG. 3D illustrates a zoomed-in photograph of a third portion of the abrasive disc of FIG. 3A;

[0015] FIG. 4 illustrates a block diagram of an exemplary robotic abrading system, according to embodiments of the present disclosure;

[0016] FIG. 5 illustrates a schematic diagram of a motive robotic unit that may benefit from embodiments herein;

[0017] FIG. 6 illustrates a block diagram of a method of evaluating an abrasive article, according to embodiments of the present disclosure;

[0018] FIG. 7 illustrates a block diagram of a method of generating a wear evaluation for an abrasive article, according to embodiments of the present disclosure;

[0019] FIG. 8 illustrates an automated robotic abrading system, according to embodiments of the present disclosure;

[0020] FIG. 9 illustrates a system architecture for embodiments herein;

[0021] FIGS . 10-11 illustrate examples of mobile devices that can be used in the embodiments shown in previous Figures; and

[0022] FIG. 12 is a block diagram illustrating an example computing device that can be used in embodiments shown in previous Figures.Detailed Description

[0023] 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.

[0024] In the following disclosure, the following definitions are adopted.

[0025] As used herein, all numbers should be considered modified by the term “about.”

[0026] As used herein, “a,” “an,” “the,” “at least one,” and “one or more” are used interchangeably.

[0027] 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 readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / - 20 % for quantifiable properties).

[0028] 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.

[0029] 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.

[0030] 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.

[0031] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B.”

[0032] 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.).

[0033] As used herein, the term “coupled” generally means either a direct connection between two or more elements that are connected or an indirect connection through one or more passive or active intermediary devices.

[0034] As used herein, the term “machine learning model” refers to a computer model trained to perform one or more tasks by learning to approximate functions or parameters based on training input. A machine learning model may come in a variety of forms, such as a neural network or a regression model. Additionally, the machine learning model may be a predictive machine learning model. The term “neural network” refers to a machine learning model patterned after a network of biological neurons that can be trained to learn non-linear functions based on training input. In particular, the term “neural network” can include a model of interconnected digital neurons that communicate and learn to approximate complex functions and generate outputs based on inputs provided to the model. A neural network includes an algorithm that implements deep learning techniques, that is, machine learning that utilizes a set of algorithms to attempt to model high-level abstractions in data. A neural network can include a variety of deep learning models, including convolutional neural networks, deep belief networks, or deep stacking networks. The term “regression model” refers to a statistical model for estimating relationship among parameters. For instance, a “regression model” includes a linear regression or a logistic regression that estimates a parameter for a function based on independent variables. A regression model may likewise use Stochastic Gradient Descent, Adaptive Gradient Algorithm (“AdaGrad”), AdaptiveMoment Estimation (“Adam”), Alternating Direction Method of Multipliers (“ADMM”), or other optimization algorithms. A machine learning model may be global or local. A “global machine learning model” refers to a machine learning model stored or implemented on a server or group of servers. A “local machine learning model” refers to a machine learning model stored or implemented on a client device.

[0035] In embodiments herein, one or more machine learning models may be used. The machine learning models may be trained using classified data related to various abrasive articles. For example, the machine learning models may be trained using information related to the abrasive article, such as article type (disc, pad, etc.), wear amount, level of use, and from which position on the abrasive article sensed indications are captured. The machine learning models may be configured to quantify amount of wear and / or detect damage based on abrasive particle sizes, sharpness of abrasive particles, abruptness of abrasive particles, color changes of abrasive article, scratches on abrasive article, and so forth. The machine learning models may be configured to process color intensities, segment different regions of images, and perform post-processing operations to quantify an amount of wear of abrasive articles. In some implementations, Gaussian Mixture Model (GMM), K-means, and / or Regression Models may be used.

[0036] Referring now to the Figures, FIG. 1 illustrates a block diagram of a system 100 for measuring wear of an abrasive article, according to embodiments of the present disclosure. The system 100 may include, or be part of, another system.

[0037] The system 100 may be suitable for various types of abrasive articles. For example, the abrasive article may include coated abrasive articles, bonded abrasive articles with resin or vitreous bond matrices, nonwoven abrasive articles, brushes, or other abrasive articles. The abrasive article may have any suitable shape and form. The abrasive article may be an abrasive disc, an abrasive pad, or an abrasive belt in embodiments herein.

[0038] The system 100 includes a sensor 104 configured to capture a plurality of sensed indications 105 (schematically depicted by arrows). Each of the plurality of sensed indications 105 is captured at a position on a surface of the abrasive article. The sensor 104 may capture the plurality of sensed indications 105 at a corresponding plurality of positions on the surface of the abrasive article. In some embodiments, a first sensed indication may be captured at a first distance from an edge of the abrasive article, and a second indication may be captured at a second distance from the edge of the abrasive article. The first and second distances may be different.

[0039] The surface of the abrasive article may be an abrasive surface that is used to perform abrasive operations, such as sanding, polishing, etc. Each of the plurality of sensed indications 105 may relate to data that is indicative of abrasive wear properties at a respective position on theabrasive surface. The sensed indication 105 may include, for example, image data of the abrasive surface and / or topographical data of the abrasive surface at the respective positions. In some embodiments, the sensed indication 105 may include a color of the abrasive article at the position. In some embodiments, the sensed indication 105 may include a surface roughness of the abrasive article at the position. In some embodiments, the sensed indication 105 may include an average height of abrasive particles at the position. In some embodiments, the sensed indication 105 may include an abruptness of the abrasive article at the position. The abruptness of the abrasive article may refer to a discontinuity on the abrasive surface of abrasive article at the position. In some embodiments, the sensed indication 105 may include height of abrasive particles, size of abrasive particles, angles of abrasive particles, density of abrasive particles, condition of binding agents holding together abrasive particles, or color of binding agents.

[0040] The system 100 further includes a processing circuitry 106 and associated memory 108. The processing circuitry 106 is configured to process each of the plurality of sensed indications 105. The processing circuitry 106 may generate processed indications 107 (schematically depicted by arrows) by processing the plurality of sensed indications 105.

[0041] The system 100 further includes a wear calculator 110 configured to calculate an amount of wear for each of the positions based on the processed indications 107. It should be noted that the wear calculator 110 may calculate one or more measures of the wear of the abrasive article. For example, the wear calculator 110 may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear. In some embodiments, the wear calculator 110 may be a part of the processing circuitry 106. In some other embodiments, the wear calculator 110 may be separate from the processing circuitry 106. The wear calculator 110 may employ one or more machine learning models to calculate the amount of wear for each of the positions based on the processed indications 107. Thus, the wear calculator 110 may be trained on training data correlating the sensed indications with amounts of wear.

[0042] The system 100 may facilitate quantifying wear of the abrasive article. Specifically, the system 100 may facilitate quantifying the amount of wear for each of the positions on the surface by calculating the amount of wear based on the plurality of sensed indications 105. As an example, an unused abrasive article may have an initial color. As the abrasive article wears, its color may change. A percentage of color change may be correlated with a percentage of wear. The wear calculator 110, once trained, may quantify the percentage of wear based on the percentage of color change.

[0043] In some implementations, the system 100 may provide an overall wear assessment of the abrasive article. For example, the wear calculator 110 may provide a percentage valuedenoting how much wear the surface of the abrasive article has undergone due to use in abrasive operations. The system 100 may allow determining, for example, a remaining service life of the abrasive article. Moreover, in some embodiments, the system 100 may provide recommendations based on the determined wear. For example, the system 100 may automatically change robotic settings (such as force, speed, attack angle) to account for the determined wear. In another example, the system 100 may facilitate an automated process for the abrasive article without any human intervention to account for the determined wear. Further, in another example, the system 100 may indicate areas of the abrasive article that are relatively less worn.

[0044] The system 100 may be used to track the wear of the abrasive article, thereby avoiding premature disposal of the abrasive article and promoting use of the abrasive article throughout its service life. The system 100 may also allow assessing the quality of the abrasive article (e.g., by tracking a wear rate of the abrasive article). The system 100 may also address loading and recommend redressing of the abrasive article. The system 100 may detect if the abrasive article has experienced capping (e.g., upon detecting reflective / silver-colored abrasive surface) and notify to perform a redressing step to remove the capping.

[0045] Further, the system 100 may measure wear of abrasive binding agents. Measuring the wear of abrasive binding agents may allow the system 100 to suggest suitable timing for using the abrasive article and / or an area of the abrasive article to be used for an abrasive operation. For example, measuring wear of the abrasive binding agents may allow the system 100 to inform whether the abrasive article needs to be cooled or be cleaned before starting an abrasive operation.

[0046] In some embodiments, the processing circuitry 106 may be remote from the sensor 104. In such embodiments, the processing circuitry 106 may be communicably coupled to the sensor 104 via any suitable connection (wired or a wireless). The processing circuitry 106 may remotely receive the plurality of sensed indications 105 from the sensor 104 and process each of the plurality of sensed indications 105.

[0047] In some embodiments, the processing circuitry 106 may receive the plurality of sensed indications 105 using a wireless communication protocol. The wireless communication protocol may be, for example, a cellular networking protocol such as a 3GPP, 4G, or 5G standard, a wireless local area network protocol such as IEEE 802.11 / Wi-Fi, a wireless wide area network protocol, Bluetooth®, Bluetooth Low Energy, and so forth.

[0048] In some examples, the processing circuitry 106 may include one or more devices, circuits, and / or processing cores configured to process each of the plurality of sensed indications 105. The processing circuitry 106 may include, for example, one or more of a general -purpose processor (e.g., ARM-based processor), a Digital Signal Processor (DSP), a Programmable LogicDevice (PLD), an Application-Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), a fixed function circuitry, a programmable circuitry, any combination of fixed function circuitry, a programmable circuitry, an equivalent discrete logic circuitry or an integrated logic circuitry, and the like. The processing circuitry 106 may be local to the system 100, in some embodiments, or may be remote from the system 100, such that the plurality of sensed indications 105 is received by the one or more processing circuitry, processed, and then a result is transmitted back to the system 100. The term “processing circuitry,” as used herein, is intended to broadly cover both physical processing devices as well as cloud-computing solutions. Similarly, “processing circuitry” is intended to cover embodiments where a single processing device completes the functionality described herein, as well as embodiments where the functionality is spread across multiple processing devices, which may run independently, in sequence, or in parallel.

[0049] As such, whether configured by hardware or by a combination of hardware and software, the processing circuitry 106 may represent an entity (e.g., physically embodied in circuitry) capable of performing operations according to some embodiments. Thus, for example, when the processing circuitry 106 is embodied as an executor of software instructions, the instructions may specifically configure the processing circuitry 106 to perform the operations described herein. Alternatively, as another example, when the processing circuitry 106 is embodied as the ASIC, FPGA, or the like, the processing circuitry 106 may have specifically configured hardware for conducting the operations described herein.

[0050] The memory 108 may be configured to store information. The memory 108 may include any form of memory for storing data and executable software instructions, such as randomaccess memory (RAM), read-only memory (ROM), programmable read only memory (PROM), erasable programmable read-only memory (EPROM), electronically erasable programmable read only memory (EEPROM), and flash memory. In some embodiments, the memory 108 and processing circuitry 106 may be integrated into a single hardware unit, such as a system on a chip (SoC) or integrated circuit (IC).

[0051] In some embodiments, at least some of the processing functionality described herein may be completed at a location remote from the system 100, such as by a second system or by a cloud-based processing unit.

[0052] In some embodiments, the system 100 may further include a communication component 114 configured to communicate abrasive article indications to a device 112. For example, the communication component 114 may be configured to transmit the amount of wear for at least one of the positions calculated by the wear calculator 110 to the device 112. The device112 may include a suitable configuration to output the amount of wear to an individual.

[0053] Communicating an amount of wear may include communicating an overall indication of wear of the abrasive article, in some embodiments. In some embodiments, communicating an amount of wear includes communicating a wear profile indicating amounts of wear across an abrasive article. In some embodiments, communicating an amount of wear includes displaying one or more captured wear indicia on a display component 116 of device 112.

[0054] In some embodiments, the device 112 may include a display component 116. The display component 116 may include any visual output device suitable for displaying a graphical user interface. In some embodiments, the display component 116 may also function as an input device for the device 112. For example, the display component 116 may include atouch sensitive display. However, it is expressly contemplated that device 112 may have a separate I / O mechanism such as a keyboard, mouse, or other user-actuatable mechanisms.

[0055] The device 112 may further a graphical user interface generation component 118. The graphical user interface generation component 118 may be configured to generate a graphical user interface 120 for the display component 116. The display component 116 may be configured to display the graphical user interface 120 generated by the graphical user interface generation component 118.

[0056] The graphical user interface 120 may include the calculated amount of wear for at least one of the positions. In other words, the calculated amount of wear for at least one of the positions may be presented in the graphical user interface 120. In some embodiments, the graphical user interface 120 may include an overall wear assessment of the abrasive article. The overall wear assessment may be determined based on the amount of wear calculated for each of the positions on the surface of the abrasive article. In some embodiments, the graphical user interface 120 may be periodically updated.

[0057] In some embodiments, the device 112 may include the sensor 104 and the processing circuitry 106 (or a separate processing component). In some embodiments, the device 112 may further include the memory 108 associated with the processing circuitry 106 (or a separate memory component). The device 112 may be portable, in some examples. The device 112 may be communicably coupled to the wear calculator 110, for example, via the communication component 114.

[0058] In some embodiments, the sensor 104 may include a plurality of sensors 104. The plurality of sensors 104 may capture the plurality of sensed indications 105 for measuring different wear characteristics of the abrasive article. Based on the plurality of sensed indications 105, the wear calculator 110 may determine one or more measurements of the wear of the abrasive article.For example, the wear calculator 110 may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear of the abrasive article.

[0059] In some embodiments, the sensor 104 may include any or multiple of a camera, atime-of-flight sensor, a laser, or a pressure sensor. A camera may generate one or more images of the surface of the abrasive article. The plurality of sensed indications 105 may include the one or more images generated by the camera. A time-of-flight sensor may generate three-dimensional images and / or depth data representative of the surface of the abrasive article. A plurality of sensed indications 105 may include the three-dimensional images and / or the depth data. Similarly, a laser and / or a pressure sensor may generate sensed outputs representative of wear of the surface of the abrasive article. The plurality of sensed indications 105 may include the sensed outputs generated by the laser or the pressure sensor.

[0060] In some embodiments, the sensor 104 may include a tactile sensor. The tactile sensor may be configured to sense topographical data of the surface of the abrasive article. As an example, the tactile sensor may include a stylus instrument having a suitable resolution. The plurality of sensed indications 105 may include the topographical information.

[0061] In some embodiments, the sensor 104 may include a camera. The camera may be of any suitable type. In some embodiments, the camera may be configured to capture images in the visible light spectrum (e.g., a digital camera). In some embodiments, the camera may be configured to capture images in the infrared spectrum (i.e., an infrared camera). In some embodiments, the camera may be configured to capture images in the ultraviolet light spectrum. In some implementations, the camera may be a part of a microscope that captures microscopic images.

[0062] In some embodiments, the plurality of sensed indications 105 may include images of portions of the surface of the abrasive article at the one or more positions. In some other embodiments, the camera may capture an image of the surface of the abrasive article. Each of the plurality of sensed indications 105 may include a portion of the image corresponding to an area around the position on the surface. In other words, in some embodiments, the camera may capture a single image of the entirety of the surface of the abrasive article, and the plurality of sensed indications 105 may include a plurality of image portions of the single image including the positions. In such embodiments, the camera may be a high-resolution camera.

[0063] In some embodiments, the camera may be configured to capture images using hyperspectral imaging. In such embodiments, the processing circuitry 106 and the wear calculator 110 may analyze unique spectral signatures of the surface of the abrasive article to calculate the amount of wear.

[0064] In some embodiments, the sensor 104 may include multiple cameras. The multiple cameras may be used for stereo imaging. The multiple cameras may capture three-dimensional images of the abrasive article.

[0065] In some embodiments, the system 100 may further include a light source 122. The light source 122 may be configured to illuminate the surface of the abrasive article while camera(s) is (are) capturing one or more images ofthe surface. The light source 122 may improve the quality of the images captured by cameras.

[0066] In some embodiments, the sensed indication 105 may include a color of the abrasive article at the position. The processing circuitry 106 may be configured to detect the color at each of the positions. In such embodiments, the wear calculator 110 may be configured to calculate the amount of wear for each of the positions based on the color detected at each of the positions. The color of the abrasive article (or more specifically, the portion of the surface of the abrasive article that is used for abrasive operations) may change as the abrasive article undergoes wear. This change in color may be detected and used to calculate the amount of wear for each of the positions, and for the abrasive article.

[0067] In some embodiments, the processing circuitry 106 may be configured to compare the detected color to a default color for the abrasive article. The default color may be an unworn or unused color of the abrasive article (e.g., the color of the abrasive article prior to being used in abrasive operations). The wear calculator 110 may calculate the amount of wear for each of the positions based on comparison of the color detected at each of the positions and the default color for the abrasive article.

[0068] In some embodiments, the default color may be a detected color at a center of the abrasive article. For some abrasive articles (e.g., abrasive discs), the center of the abrasive articles is generally not used for performing abrasive operations. For such abrasive articles, the center of the abrasive articles may retain the default color of the abrasive articles, and may serve as a representation of an unused abrasive article having 100% of its useful life left.

[0069] In some other embodiments, the default color may be retrieved based on an identification of the abrasive article. For example, the default color may be retrieved from a database storing default colors for a plurality of abrasive articles. Upon identification of the abrasive article, the relevant default color may be retrieved from the database. Identification of the abrasive article may be performed manually (e.g., by manually selecting the abrasive article from a list of abrasive articles) or automatically.

[0070] The system 100 may identify irregularities in color change of the abrasive article. The system 100 may determine improper use of the abrasive article and suggest changes to optimizethe wear rate of the abrasive article. The system 100 may identify and suggest which portion(s) of the abrasive article should be used for performing further abrasive operations. The system 100 may also facilitate using a less damaged area of the abrasive article instead of a relatively more damaged area of the abrasive article, thereby increasing the operational lifespan of the abrasive article. The system 100 may also suggest optimized pressure and / or use pattern to be applied to a work surface to be abraded.

[0071] In some embodiments, the system 100 may further include an abrasive article identifier 124 configured to identify a make or model of the abrasive article from the plurality of sensed indications 105. In some embodiments, the abrasive article identifier 124 may employ one or more machine learning models that are trained on various different known abrasive articles. The abrasive article identifier 124 may be capable of identifying an abrasive article among the known abrasive articles based on the plurality of sensed indications 105. Alternatively, the abrasive article identifier 124 may identify the make or model of the abrasive article based on an information encoded on the abrasive article (e.g., QR codes, barcodes, model identifier text / symbols, etc.). Additionally, or alternatively, the abrasive article identifier 124 may identify the make or model of the abrasive article based on a radio frequency identification (RFID) or other radio tags disposed on the abrasive article.

[0072] In some embodiments, the abrasive article may include an abrasive disc. In some embodiments, the camera may be configured to capture an image of the center of the abrasive disc. The abrasive article identifier 124 may identify the make or model of the abrasive disc based on the image of the center of the abrasive disc. Since the center of the abrasive disc is generally not used for performing abrasive operations, the center of the abrasive disc may retain the default color of the abrasive disc, based on which the abrasive article identifier 124 may identify the make or model of the abrasive disc.

[0073] In some embodiments, the system 100 may further include a parameter generator 126 configured to, based on the identified make or model and the calculated amount of wear, generate a parameter change for an abrading system 150 including the abrasive article. The abrading system 150 may be any system that utilizes the abrasive article to perform abrasive operations on awork surface. For example, the abrading system 150 may be a robotic abrading system including a motive robotic unit that can position the abrasive article with respect to the work surface and move the abrasive article along the work surface.

[0074] In some embodiments, such as where the abrading system 150 is a robotic abrading system, the communication component 114 may be further configured to transmit a control signal 151 to the abrading system 150 that includes the abrasive article. The control signal 151 mayinclude the generated parameter change.

[0075] As discussed above, the parameter change may be generated based on the identified make or model and the calculated amount of wear. The parameter change may improve or optimize the abrading system 150. As an example, the parameter change may optimize a quality of abrasive operation (such as the amount of material removal and process speed) based on the identified make or model and / or the amount of wear of the abrasive article. In some embodiments, the parameter change may optimize the service life of the abrasive article (e.g., increase its service life) based on the identified make or model and the calculated amount of wear. In some embodiments, the parameter change may include a change in angle, a change in applied pressure, a change in position, or a change in speed. The parameter change may also include a change in a movement of a robotic arm of a robotic abrading system.

[0076] In some embodiments, the parameter generator 126 may retrieve a wear profile for the abrasive article. Further, the parameter change may be generated based on the retrieved wear profile. The wear profile may include current wear characteristics of the abrasive article. As an example, the wear profile may include the current wear of the abrasive article and a tendency of the abrasive article to wear under certain operational parameters. The parameter generator 126 may retrieve the wear profile (e.g., from a database) and generate the parameter change based on the retrieved wear profile to improve abrasive operations with the abrasive article.

[0077] In some embodiments, the system 100 may further include a damage detector 128 configured to, based on the sensed indications 105, detect damage to the abrasive article at the position. The damage detector 128 may detect various types of damage at the position. In some embodiments, the damage may include heat damage, abrasive article warping, or capping. The damage detector 128 may function in conjunction with the wear calculator 110 to provide a more exhaustive assessment of the abrasive article. The detected damage may also be used by the parameter generator 126 to generate the parameter change for the abrading system 150.

[0078] In some embodiments, one or more of the wear calculator 110, the abrasive article identifier 124, and the damage detector 128 may employ machine learning models.

[0079] In some embodiments, the system 100 may further include an impression maker 130 configured to make an impression 131 (schematically depicted by an arrow) of the abrasive article . The impression 131 may be a one-to-one representation of the surface (or more specifically, the abrasive surface) of the abrasive article. In such embodiments, the sensed indications 105 may be sensed from the impression 131. That is, the sensor 104 may capture the plurality of sensed indications 105 at positions on the impression 131 instead of the surface of the abrasive article.

[0080] FIG. 2 shows a schematic top view of an exemplary abrasive article 200, according toembodiments of the present disclosure. In FIG. 2, the abrasive article 200 is depicted as an abrasive disc. However, the abrasive article 200 may be any of a number of suitable abrasive articles including, for example, a belt or a wheel.

[0081] Generally, the abrasive article 200 includes a plurality of abrasive features, structures, or particles that form an abrasive surface of the abrasive article 200. In operation, the abrasive article 200 is moved relative to a work surface such that the plurality of abrasive features, structures, or particles contact the work surface to abrade the work surface.

[0082] The abrasive article 200 may include, for example, coated abrasive articles, in which a binder make coat bonds the abrasive particles to a backing material; lapping coated abrasive articles, in which the abrasive particles are dispersed in a binder to form an abrasive composite, which is bonded to a backing to form an abrasive article; three-dimensional shaped composite abrasive articles, in which the abrasive particles are dispersed in a binder to form a plurality of abrasive composites, which are bonded to a backing to form an abrasive article; bonded abrasive articles, in which the binder bonds the particles together to form a shaped mass; and nonwoven abrasive articles, in which the binder bonds the abrasive particles onto the fibers of a nonwoven fibrous substrate in either a make coat or dispersed format.

[0083] The abrasive article 200 may include an edge 212. The edge 212 may define a periphery of the abrasive article 200. The abrasive article 200 may further include a work area boundary 210 (depicted by a dashed circle) defined at a distance 211 from the edge 212 on the surface. In the case of an abrasive disc, the work area boundary 210 may be circular.

[0084] The abrasive article 200 may further include a work area 216 defined between the work area boundary 210 and the edge 212 on the surface. The work area 216 may be the area of the surface of the abrasive article 200 that is generally used for performing abrasive operations (such as sanding, grinding, etc.). The abrasive article 200 may further include a non-use area 218 defined between the center of the abrasive article 200 and the work area boundary 210 on the surface. The non-use area 218 may be the area of the surface of the abrasive article 200 that is generally not used for performing abrasive operations.

[0085] According to some embodiments of the present disclosure, sensed indications may be captured at positions on the abrasive surface of the abrasive article 200. The sensed indications may be processed and an amount of wear for each of the positions may be calculated. In one example, a first sensed indication 205A may be captured at a first distance 206A from the edge 212 of the abrasive article 200. Further, a second indication 205B may be captured at a second distance 206B from the edge 212 of the abrasive article 200. The first and second distances 206A, 206B are different. While the second sensed indication 205B is depicted as being disposed in thenon-use area 218, it is expressly contemplated that the second sensed indication 205B may be disposed in the work area 216.

[0086] In some embodiments, the sensed indications may include images of the abrasive surface. The images may be captured from the center of the abrasive article 200 to the edge 212. As a result, the images may include the non-use area 218 of the abrasive article 200 as well as the work area 216 of the abrasive article 200. These images may be used to calculate, for example using a wear calculator, an amount of wear of the abrasive article 200.

[0087] FIGS. 3A-3D show photographs of different portions of a surface of an abrasive disc 300. Specifically, FIG. 3A shows a photograph of a surface of the abrasive disc 300, FIG. 3B shows a zoomed-in photograph of a first portion 301 A of the surface of the abrasive disc 300, FIG.3C shows a zoomed-in photograph of a second portion 30 IB the surface of the abrasive disc 300, and FIG. 3D shows a zoomed-in photograph of a third portion 301C the surface of the abrasive disc 300.

[0088] The first portion 301 A may include a position on the surface that lies in a non-use area of the abrasive disc 300. The third portion 301C may include a position on the surface that lies in a work area of the abrasive disc 300. Further, the second portion 30 IB may include a position on the surface that lies in a transition area disposed between the non-use area and the work area.

[0089] Embodiments of the present disclosure may utilize an image or multiple images (such as the photograph of FIG. 3B) of the surface captured at positions in the first portion 301 A (or in the non-use area) to identify the make or model of the abrasive disc 300. Additionally, or alternatively, embodiments of the present disclosure may utilize an image or multiple images of the surface captured at positions in the first portion 301 A to detect a default color of the abrasive disc 300.

[0090] Embodiments of the present disclosure may utilize an image or multiple images (such as the photograph of FIG. 3C) of the surface captured at positions in the second portion 30 IB to calculate the amount of wear for the positions. Furthermore, embodiments of the present disclosure may utilize an image or multiple images (such as the photograph of FIG. 3D) of the surface captured at positions in the third portion 301C to calculate the amount of wear for the positions.

[0091] Embodiments of the present disclosure, upon calculating the amount of wear for the positions in the work area and / or in the transition area, may calculate an amount of wear for the abrasive disc 300. As an example, the amount of wear for the abrasive disc 300 may be represented as a percentage value, where 0% means no wear and 100% means fully worn (or used). Furthermore, the amount of wear for the abrasive disc 300 may be indicative of the remainingservice life of the abrasive disc 300. For example, the amount of wear for the abrasive disc 300 may indicate a number of abrasive operations left before the abrasive disc 300 becomes unfit for use.

[0092] FIG. 4 illustrates a block diagram of a robotic abrading system 450, according to embodiments of the present disclosure. While abrasive wear detection systems may be useful for a number of abrasive systems, they may be particularly useful for robotic systems. FIG. 4 illustrates one such example system.

[0093] The robotic abrading system 450 includes a motive robotic unit 451. The motive robotic unit 451 is configured to position an abrasive article 452 with respect to a work surface 453. The motive robotic unit 451 is further configured to move the abrasive article 452 along the work surface 453.

[0094] The abrasive article 452 may include one or more of coated abrasive articles, bonded abrasive articles with resin or vitreous bond matrices, nonwoven abrasive articles, brushes, or other abrasive articles. The abrasive article 452 may have any suitable shape and form. The abrasive article 452 may be an abrasive disc, an abrasive pad, or an abrasive belt in embodiments herein.

[0095] In some embodiments, the motive robot unit 451 may be configured to move in at least two degrees of freedom. In some embodiments, the motive robotic unit 451 may be configured to rotationally move the abrasive article 452 along the work surface 453. The motive robotic unit 451 may provide both rotational and translational motion to the abrasive article 452.

[0096] The robotic abrading system 450 further includes a force control unit 454 configured to apply a force to the abrasive article 452 while the abrasive article 452 is contacting the work surface 453. However, it is expressly contemplated that, in some embodiments, the force control unit 454 may be an integral part of the motive robot unit 451.

[0097] The robotic abrading system 450 further includes a wear detection system 400. The wear detection system 400 may be similar to the system 100 of FIG. 1 in one or more aspects. In some embodiments, at least some components of wear detection system 400 are mounted to the motive robotic unit 451. However, it is expressly contemplated that, in some embodiments, at least some components of wear detection system 400 are remotely located from motive robotic unit 451.

[0098] The wear detection system 400 includes a sensor 404 configured to sense a first wear indication 405A at a first position on a surface of the abrasive article 452 and a second wear indication 405B at a second position on the surface of the abrasive article 452. The first wear indication 405A may be captured at a first distance from an edge of the abrasive article 452. Thesecond wear indication 405B may be captured at a second distance from the edge of the abrasive article 452. The first and second distances may be different.

[0099] The surface of the abrasive article 452 may be an abrasive surface that is used to perform abrasive operations, such as sanding, polishing, etc. The first and second wear indications 405 A, 405B may relate to data that is indicative of abrasive wear properties at the first and second positions, respectively, on the abrasive surface. The first and second wear indications 405A, 405B may include, for example, image data of the abrasive surface and / or topographical data of the abrasive surface at the first and second positions, respectively. In some embodiments, each of the first and second wear indications 405A, 405B may include a color of the abrasive article 452 at the position. In some embodiments, each of the first and second wear indications 405A, 405B may include a surface roughness of the abrasive article 452 at the position. In some embodiments, each of the first and second wear indications 405A, 405B may include an average height of abrasive particles at the position. In some embodiments, each of the first and second wear indications 405A, 405B may include an abruptness of the abrasive article 452 at the position. In some embodiments, the sensed indications 405A, 405B may include height of abrasive particles, size of abrasive particles, angles of abrasive particles, density of abrasive particles, condition of binding agents holding together abrasive particles, or color of binding agents.

[0100] The wear detection system 400 further includes a wear calculator 410 configured to, based on the first and second wear indications 405A, 405B, calculate an amount of wear for the abrasive article 452.

[0101] It should be noted that the wear calculator 410 may perform one or more measurements of the wear characteristics of the abrasive article 452. For example, the wear calculator 410 may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear. The wear calculator 410 may employ one or more machine learning models to calculate the amount of wear for the abrasive article 452.

[0102] Further, the wear detection system 400 may measure wear of abrasive binding agents. Measuring the wear of abrasive binding agents may allow the wear detection system 400 to suggest suitable timing for using the abrasive article 452 and / or an area of the abrasive article 452 to be used for an abrasive operation. For example, measuring wear of the abrasive binding agents may allow the wear detection system 400 to inform whether the abrasive article 452 needs to be cooled or be cleaned before starting an abrasive operation.

[0103] The wear detection system 400 further includes a communication component 414 configured to communicate the amount of wear to a device 440. Specifically, the communication component 414 may be configured to transmit the amount of wear for the abrasive article 452calculated by the wear calculator 410 to the device 440. The device 440 may include a suitable configuration to output the amount of wear to an individual.

[0104] The robotic abrading system 450 may facilitate quantifying wear of the abrasive article 452. Specifically, the wear detection system 400 may facilitate quantifying the amount of wear for the abrasive article 452 by calculating the amount of wear for the abrasive article 452 based on the first and second wear indications 405A, 405B.

[0105] The wear detection system 400 may determine the amount of wear for the abrasive article 452 as a percentage value denoting how much wear the surface of the abrasive article has undergone due to use in abrasive operations. The wear detection system 400 may further output the amount of wear to an individual via the device 440. The wear detection system 400 may allow determining, for example, a remaining service life of the abrasive article 452.

[0106] The robotic abrading system 450 may be used to track wear of the abrasive article 452, thereby avoiding premature disposal of the abrasive article 452 and promoting use of the abrasive article 452 throughout its service life. The robotic abrading system 450 may also allow assessing the quality of the abrasive article 452 (e.g., by tracking a wear rate of the abrasive article 452).

[0107] The robotic abrading system 450 may also improve the abrading performance of the motive robotic unit 451. The amount of wear for the abrasive article 452 may be used to modify operational parameters of the motive robotic unit 451 so as to improve the abrading performance.

[0108] In some embodiments, the robotic abrading system 450 may further include a display component 416. The display component 416 may include any visual output device suitable for displaying a graphical user interface. The robotic abrading system 450 may further include a graphical user interface generation component 418. The graphical user interface generation component 418 may be configured to generate a graphical user interface 420 for the display component 416. The display component 416 may be configured to display the graphical user interface 420 generated by the graphical user interface generation component 418.

[0109] The graphical user interface 420 may include, in some embodiments, the calculated amount of wear for the abrasive article 452. In other words, the calculated amount of wear for the abrasive article 452 may be presented in the graphical user interface 420. In some embodiments, the graphical user interface 420 may be periodically updated. In some embodiments, the graphical user interface 420 may display the sensed indicia 405 A and / or 405B. For example, images captured of the surface of the abrasive article 452 may be displayed. In some embodiments, the device 440 may include the display component 416 and / or the graphical user interface generation component 418. The device 440 may be portable, in some examples. The device 440 may be communicably coupled to the wear calculator 410, for example, via the communicationcomponent 114.

[0110] In some embodiments, the wear detection system 400 may be coupled to the motive robotic unit 451. In some other embodiments, the wear detection system 400 may be separate from the motive robotic unit 451. In such embodiments, the motive robotic unit 451 may be configured to move the abrasive article 452 from the work surface 453 to a position proximate the wear detection system 400. In some embodiments, the position proximate the wear detection system 400 may include the abrasive article 452 at a distance from the sensor 404. In some embodiments, the position proximate the wear detection system 400 may include the abrasive article 452 oriented with respect to the sensor 404. The motive robotic unit 451 may position the abrasive article 452 relative to the sensor 404 at a suitable distance and orientation, such that the sensor 404 can sense the first and second wear indications 405A, 405B.

[0111] In some embodiments, the sensor 404 may include a camera, a time-of-flight sensor, a laser, or a pressure sensor. The camera may generate one or more images of the surface of the abrasive article 452. The first and second wear indications 405 A, 405B may include the one or more images generated by the camera. The time-of-flight sensor may generate three-dimensional images and / or depth data representative of the surface of the abrasive article 452. The first and second wear indications 405 A, 405B may include the three-dimensional images and / or the depth data. Similarly, the laser and the pressure sensor may generate sensed outputs representative of wear of the surface of the abrasive article 452. The first and second wear indications 405A, 405B may include the sensed outputs generated by the laser and / or the pressure sensor.

[0112] In some embodiments, the sensor 404 may include a tactile sensor. The tactile sensor may sense topographical data of the surface of the abrasive article 452. As an example, the tactile sensor may include a stylus instrument having a suitable resolution. The first and second wear indications 405A, 405B may include the topographical data.

[0113] In some embodiments, the sensor 404 may include a camera. The camera may be of any suitable type. In some embodiments, the camera may be configured to capture images in the visible light spectrum (e.g., a digital camera). In some embodiments, the camera may be configured to capture images in the infrared spectrum (i.e., an infrared camera). In some embodiments, the camera may be configured to capture images in ultraviolet light spectrum. In some implementations, the camera may be a part of a microscope that captures microscopic images.

[0114] In some embodiments, the first and second wear indications 405A, 405B may include images of portions of the surface of the abrasive article 452 at the respective position. In some other embodiments, the camera may capture an image of the surface of the abrasive article 452.The first and second wear indications 405A, 405B may include portions of the image corresponding to areas around the positions on the surface. In other words, in some embodiments, the camera may capture a single image of the entirety of the surface of the abrasive article 452, and the first and second wear indications 405A, 405B may include, respectively, first and second image portions of the single image including the respective first and second positions. In such embodiments, the camera may be a high-resolution camera.

[0115] In some embodiments, the camera may be configured to capture images using hyperspectral imaging. In such embodiments, the wear detection system 400 calculate the amount of wear further on the basis of the analysis of unique spectral signatures of the surface of the abrasive article 452.

[0116] In some embodiments, the sensor 404 may include a plurality of sensors 404. The plurality of sensors 404 may capture the plurality of sensed indications 405 A, 405B for measuring different wear characteristics of the abrasive article 452. Based on the plurality of sensed indications 405A, 405B, the wear calculator 410 may determine one or more measurements of the wear of the abrasive article 452. For example, the wear calculator 410 may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear of the abrasive article 452.

[0117] In some embodiments, the sensor 404 may include includes a pair of cameras. The pair of cameras may be used for stereo imaging. The pair of cameras may capture three-dimensional images of the abrasive article 452.

[0118] In some embodiments, the robotic abrading system 450 may further include a light source 422. The light source 422 may be configured to illuminate the surface while camera(s) is (are) capturing one or more images of the surface of the abrasive article 452. The light source 422 may improve the quality of the images captured by cameras.

[0119] The robotic abrading system 450 may further include a signal processing circuitry 406 and associated memory 408. The signal processing circuitry 406 may be configured to process the first and second wear indications 405A, 405B.

[0120] In some embodiments, the signal processing circuitry 406 may be remote from the sensor 404. In such embodiments, the signal processing circuitry 406 may be communicably coupled to the sensor 404 via any suitable connection (wired or a wireless). The signal processing circuitry 406 may remotely receive the first and second wear indications 405A, 405B from the sensor 404 and process the first and second wear indications 405 A, 405B.

[0121] In some embodiments, the signal processing circuitry 406 may receive the first and second wear indications 405A, 405B using a wireless communication protocol. The wirelesscommunication protocol may be, for example, a cellular networking protocol such as a 3GPP 4G or 5G standard, a wireless local area network protocol such as IEEE 802.11 / Wi-Fi@, a wireless wide area network protocol, Bluetooth®, Bluetooth Low Energy, and so forth.

[0122] In some examples, the signal processing circuitry 406 may include one or more devices, circuits, and / or processing cores configured to process the first and second wear indications 405 A, 405B. The signal processing circuitry 406 may include, for example, one or more of a general-purpose processor (e.g., ARM-based processor), a Digital Signal Processor (DSP), a Programmable Logic Device (PLD), an Application-Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), a fixed function circuitry, a programmable circuitry, any combination of fixed function circuitry, a programmable circuitry, an equivalent discrete logic circuitry or an integrated logic circuitry, and the like. The signal processing circuitry 406 may be local to the robotic abrading system 450, in some embodiments, or may be remote from the robotic abrading system 450, such that the first and second wear indications 405 A, 405B may be received by the one or more processing circuitry, processed, and then a result is transmitted back to the robotic abrading system 450. The signal processing circuitry 406 is intended to broadly cover both physical processing devices as well as cloud-computing solutions.

[0123] As such, whether configured by hardware or by a combination of hardware and software, the signal processing circuitry 406 may represent an entity (e.g., physically embodied in circuitry) capable of performing operations according to some embodiments. Thus, for example, when the signal processing circuitry 406 is embodied as an executor of software instructions, the instructions may specifically configure the signal processing circuitry 406 to perform the operations described herein. Alternatively, as another example, when the signal processing circuitry 406 is embodied as the ASIC, FPGA, or the like, the signal processing circuitry 406 may have specifically configured hardware for conducting the operations described herein.

[0124] The memory 408 may be configured to store information. The memory 408 may include any form of memory for storing data and executable software instructions, such as randomaccess memory (RAM), read-only memory (ROM), programmable read only memory (PROM), erasable programmable read-only memory (EPROM), electronically erasable programmable read only memory (EEPROM), and flash memory. In some embodiments, the memory 408 and signal processing circuitry 406 may be integrated into a single hardware unit, such as a system on a chip (SoC) or integrated circuit (IC).

[0125] In some embodiments, at least some of the processing functionality described herein may be completed at a location remote from the robotic abrading system 450, such as by a second system or by a cloud-based processing unit.

[0126] In some embodiments, each of the first and second wear indications 405A, 405B may include a color of the abrasive article 452 at the position. The signal processing circuitry 406 may be configured to detect the color at each of the positions. In such embodiments, the wear calculator 410 may be configured to calculate the amount of wear for each of the positions based on the color detected at each of the positions. The color of the abrasive article 452 (or more specifically, the portion of the surface of the abrasive article 452 that is used for abrasive operations) may change as the abrasive article 452 undergoes wear. This change in color may be detected and used to calculate the amount of wear for each of the positions, and for the abrasive article 452.

[0127] In some embodiments, the signal processing circuitry 406 may be configured to compare the detected color to a default color for the abrasive article 452. The default color may be an unworn or unused color of the abrasive article 452 (e.g., the color of the abrasive article prior to being used in abrasive operations). The wear calculator 410 may calculate the amount of wear for the abrasive article 452 based on comparison of the color detected at each of the positions and the default color for the abrasive article 452.

[0128] In some embodiments, the default color may be a detected color at a center of the abrasive article 452. For some abrasive articles (e.g., abrasive discs), the center of the abrasive articles is generally not used for performing abrasive operations. For such abrasive articles, the center of the abrasive articles may retain the default color of the abrasive articles.

[0129] In some other embodiments, the default color may be retrieved based on an identification of the abrasive article 452. For example, the default color may be retrieved from a database storing default colors for a plurality of abrasive articles. Upon identification of the abrasive article 452, relevant default color may be retrieved from the database. Identification of the abrasive article 452 may be performed manually (e.g., by manually selecting the abrasive article 452 from a list of abrasive articles) or automatically.

[0130] The wear detection system 400 may identify irregularities in color change of the abrasive article 452. The wear detection system 400 may determine improper use of the abrasive article 452 and suggest changes to optimize the wear rate of the abrasive article 452. The wear detection system 400 may identify and suggest which portion(s) of the abrasive article 452 should be used for performing further abrasive operations. The wear detection system 400 may also facilitate using a less damaged area of the abrasive article 452 instead of a relatively more damaged area of the abrasive article 452, thereby increasing the operational lifespan of the abrasive article 452. The wear detection system 400 may also suggest optimized pressure and / or use pattern to be applied to a work surface to be abraded.

[0131] In some embodiments, the robotic abrading system 450 may further include an abrasivearticle identifier 424 configured to identify a make or model of the abrasive article 452 from the wear indications 405 A, 405B. In some embodiments, the abrasive article identifier 424 may employ one or more machine learning models that are trained on various different known abrasive articles. The abrasive article identifier 424 may be capable of identifying an abrasive article among the known abrasive articles based on the wear indications 405 A, 405B. Alternatively, the abrasive article identifier 424 may identify the make or model of the abrasive article based on an information encoded on the abrasive article 454 (e.g., QR codes, model identifier text / symbols, etc.) using a lookup table or other suitable method.

[0132] In some embodiments, the abrasive article 452 includes an abrasive disc. The camera may be configured to capture an image of the center of the abrasive disc. The abrasive article identifier 424 may identify the make or model of the abrasive disc based on the image of the center of the abrasive disc. Since the center of the abrasive disc is generally not used for performing abrasive operations, the center of the abrasive disc may retain the default color of the abrasive disc, based on which the abrasive article identifier 424 may identify the make or model of the abrasive disc.

[0133] In some embodiments, the robotic abrading system 450 may further include a parameter generator 426 configured to, based on the identified make or model and the calculated amount of wear, generate a parameter change for an abrading system 460 including the abrasive article 452. The abrading system 460 may be the robotic abrading system 450 in some embodiments, or an abrading system different from the robotic abrading system 450 in some other embodiments.

[0134] In some embodiments, the communication component 414 may be further configured to transmit a control signal 461 to the abrading system 460 including the abrasive article. The control signal 461 may include the identified parameter change.

[0135] As discussed above, the parameter change may be generated based on the identified make or model and the calculated amount of wear. The parameter change may improve or optimize the abrading system 460. As an example, the parameter change may optimize a quality of abrasive operation (such as the amount of material removal and process speed) based on the identified make or model and / or the amount of wear of the abrasive article 452. In some embodiments, the parameter change may optimize the service life of the abrasive article 452 (e.g., increase its service life) based on the identified make or model and the calculated amount of wear. In some embodiments, the parameter change may include a change in angle, a change in applied pressure, a change in position, or a change in speed.

[0136] In some embodiments, the parameter generator 426 may retrieve a wear profile for theabrasive article 452. Further, the parameter change may be generated based on the retrieved wear profde. The wear profile may include current wear characteristics of the abrasive article. As an example, the wear profile may include the current wear of the abrasive article and a tendency of the abrasive article to wear under certain operational parameters. The parameter generator 426 may retrieve the wear profile (e.g., from a database) and generate the parameter change based on the retrieved wear profile to improve abrasive operations with the abrasive article.

[0137] In some embodiments, the signal processing circuitry 406 may be configured to, based on the first or second wear indications 405A, 405B, detect damage to the abrasive article 452. The signal processing circuitry 406 may detect various types of damage to the abrasive article 452. In some embodiments, the detected damage may include heat damage, abrasive article warping, or capping. As a result, the robotic abrading system 450 may provide a more exhaustive assessment of the abrasive article 452. The detected damage may also be used by the parameter generator 426 to generate the parameter change for the abrading system 460.

[0138] In some embodiments, one or more of the signal processing circuitry 406, the wear calculator 410, and the abrasive article identifier 424, may employ machine learning models.

[0139] In some embodiments, the robotic abrading system 450 may further include an impression maker 430 configured to make an impression 431 (schematically depicted by an arrow) of the abrasive article 452. The impression 431 may be a one-to-one representation of the surface (or more specifically, the abrasive surface) of the abrasive article 452. In such embodiments, the wear indications 405A, 405B may be sensed from the impression 431. That is, the sensor 404 may capture the first and second wear indications 405A, 405B at positions on the impression 431 instead of the surface of the abrasive article 452.

[0140] FIG. 5 illustrates a schematic diagram of a motive robotic unit 500 that may benefit from embodiments disclosed herein. The motive robotic unit 500 may be a robotic arm in some embodiments.

[0141] In some embodiments, the motive robotic unit 500 has a base 502, which may be stationary. In other embodiments, the base 502 can move in any of six dimensions, translations or rotations about an x-axis, y-axis and / or z-axis. For example, the base 502 may be fixed to a rail system that is configured to travel along with a moving substrate being repaired. Depending on a particular operation, the motive robotic unit 500 may need to move closer, or further away from a substrate, or may need to move higher or lower with respect to an abrading area. The moveable base 502 may thus increase functionality of the motive robotic unit 500.

[0142] The motive robotic unit 500 may have an end effector 504 that can interact with (and support) one or more tools 506. The one or more tools 506 may include a backup pad, in oneembodiment, or another suitable abrasive tool. During an abrasive operation, the one or more tools 506 may have an abrasive disc, or other suitable abrasive article, attached using adhesive, hook and loop, clip system, vacuum or other suitable attachment system. However, as the abrasive article moves in conjunction with the backup pad to which it is attached, the abrasive article is not necessarily considered as adding additional degrees of freedom to the movement of the motive robotic unit 500. As mounted to the motive robotic unit 500, the one or more tools 506 may have the ability to be positioned within the provided degrees of freedom by the motive robotic unit 500 (6 degrees of freedom in most cases) and any other degrees of freedom (e.g., a compliant force control unit 508).

[0143] The backup pad may be coupled to the end effector 504 which has an orbit that provides some additional degrees of freedom. The end effector 504 may be coupled to a force control unit 508 output. The end effector 504 may rotate such that the one or more tools 506 align with the force control unit 508 during operation. The force control unit 508 may be coupled to a flange 510. The flange 510 may provide a soft (i.e., not stiff) displacement curve. In most force control units, a single degree of freedom is provided by a sliding (prismatic) joint along the active axis. Movements of the base 502, the end effector 504, the one or more tools 506, the force control unit 508, and the flange 510 may be controllable using a robotic controller (e.g., a robotic controller 515). The movements may be based on the parameters of an abrasive operation. In some embodiments, the robotic controller 515 may adjust parameters based on information received from an abrasive article evaluation system 520, such as the system 100 of FIG. 1 or the wear detection system 400 of FIG. 4.

[0144] Robotic controller 515 may also adjust parameters based on information received the abrasive article evaluation system 520. For example, if the abrasive article evaluation system 520 indicates that an abrasive article has reached an end of life, the robotic controller 515 may instruct the motive robotic unit 500 to stop an abrasive operation, change out the old abrasive article for a new abrasive article, and then continue an abrasive operation. Additionally, for example, the robotic controller 515 may provide new parameters for abrading based on the feedback from the abrasive article evaluation system 520. The new parameters may include a change in angle, a change in applied pressure, a change in position, or a change in speed.

[0145] FIG. 6 illustrates a block diagram of a method 600 of evaluating an abrasive article, according to embodiments of the present disclosure. The method 600 may be performed by any suitable device, unit, cell, or system. The method 600 may be performed, for example, the system 100 of FIG. 1 or the robotic abrading system 450 of FIG. 4 or another suitable system.

[0146] The method 600 may be suitable for evaluating various types of abrasive articles. Forexample, the abrasive article may include coated abrasive articles, bonded abrasive articles with resin or vitreous bond matrices, nonwoven abrasive articles, brushes, or other abrasive articles. The abrasive article may have any suitable shape and form. The abrasive article may be an abrasive disc, an abrasive pad, or an abrasive belt in embodiments herein.

[0147] In block 602, the abrasive article is positioned proximate to a sensor. For example, a motive robotic arm or unit may position the abrasive article proximate to the sensor. In some embodiments, positioning the abrasive article may include positioning the abrasive article at a distance from, and at an orientation with respect to, the sensor. The abrasive article may be positioned relative to the sensor at any suitable distance and orientation, such that the sensor can sense indications at different positions on a surface of the abrasive article.

[0148] In block 604, a received sensor signal from the sensor is analyzed using a signal analyzer. The received sensor signal is indicative of a sensed indication at a position on a surface of the abrasive article. The sensed indication may be indicative of the abrasive wear properties at the position on the surface of the abrasive article. The signal analyzer may be configured to analyze the received sensor signal to determine the abrasive wear properties at the position on the surface of the abrasive article. The signal analyzer may also provide confirmation of a position of abrasive article relative to the sensor, confirmation of the presence of the abrasive article, and the like.

[0149] In some embodiments, the received sensor signal may include a first sensed indication captured at a first distance from an edge of the abrasive article. In some embodiments, the method 600 may further include receiving a second indication captured at a second distance from the edge of the abrasive article. The first and second distances may be different. The sensor may capture the first sensed indication and the second sensed indication in between steps of a multi-step or in between sequences of a multi-sequence operation.

[0150] The sensed indications may relate to data that is indicative of abrasive wear properties at the first and second positions, respectively, on the abrasive surface. The sensed indications may include, for example, image data of the abrasive surface and / or topographical data of the abrasive surface at the respective positions. In some embodiments, the sensed indication may include a color of the abrasive article at the position. In some embodiments, the sensed indication may include a surface roughness of the abrasive article at the position. In some embodiments, the sensed indication may include an average height of abrasive particles at the position. In some embodiments, the sensed indication may include an abruptness of the abrasive article at the position. In some embodiments, the sensed indication may include a measure of contamination of the abrasive article. In some embodiments, the sensed indication may include height of abrasiveparticles, size of abrasive particles, angles of abrasive particles, density of abrasive particles, condition of binding agents holding together abrasive particles, or color of binding agents.

[0151] In block 606, a status of the abrasive article at the position is determined based on the analysis. The status may be determined using a status determination unit. The status of the abrasive article may include an amount of wear, amount of damage, and so forth. For example, the status may include a wear amount of the abrasive surface, a length of abrasive remaining, a contamination of abrasive, and the like.

[0152] In some embodiments, the status determination unit may include a wear calculator. The wear calculator may employ one or more machine learning models to determine the amount of wear of the abrasive article at the position. It should be noted that the wear calculator may perform one or more measures of the wear of the abrasive article. For example, the wear calculator may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear.

[0153] In block 608, the status of the abrasive article is outputted. The status of the abrasive article may be outputted to any suitable device which is capable of outputting the status.

[0154] In some embodiments, outputting may include communicating the amount of wear to a graphical user interface generator for a device having a display. The display may include any visual output device suitable for displaying a graphical user interface. The graphical user interface generator may generate the graphical user interface for the display. The graphical user interface may include the amount of wear of the abrasive article. In other words, the calculated amount of wear for the position may be presented in the graphical user interface. In some embodiments, the graphical user interface may include an overall wear assessment of the abrasive article. The overall wear assessment may be determined based on the amount of wear calculated for a plurality of positions on the surface of the abrasive article. In some embodiments, the graphical user interface may be periodically updated.

[0155] In some alternative embodiments, outputting may include generating and outputting a parameter change for an abrading system including the abrasive article. The abrading system may be any system that utilizes the abrasive article to perform abrasive operations on a work surface. For example, the abrading system may be a robotic abrading system including a motive robotic unit that can position the abrasive article with respect to the work surface and move the abrasive article along the work surface. The parameter change may improve or optimize the abrading system. As an example, the parameter change may optimize a quality of abrasive operation (such as the amount of material removal and process speed) based on the identified make or model and / or the amount of wear of the abrasive article. In some embodiments, the parameter changemay optimize the service life of the abrasive article (e.g., increase its service life) based on the identified make or model and the calculated amount of wear. In some embodiments, the parameter change may include a change in angle, a change in applied pressure, a change in position, or a change in speed. The parameter change may also include a change in a movement of a robotic arm of a robotic abrading system.

[0156] In some embodiments, the device may include the sensor and the signal analyzer. The device may be portable, in some examples. The device may be communicably coupled to the wear calculator, for example, via a communication component.

[0157] The method 600 may facilitate quantifying wear of the abrasive article. Specifically, the method 600 may facilitate quantifying the amount of wear for the abrasive article at the position based on the sensed indication(s).

[0158] In some implementations, the method 600 may provide an overall wear assessment of the abrasive article. For example, the wear calculator may provide a percentage value denoting how much wear the surface of the abrasive article has undergone due to use in abrasive operations. The method 600 may allow determining, for example, a remaining service life of the abrasive article.

[0159] The method 600 may be used to track wear of the abrasive article, thereby avoiding premature disposal of the abrasive article and promoting use of the abrasive article throughout its service life. The method 600 may also allow assessing the quality of the abrasive article (e.g., by tracking a wear rate of the abrasive article). The method 600 may also be useful for planning a next abrasive operation, for example adjusting a movement speed, force, and / or attack angle to achieve a target cut rate, or lengthening a time of a next abrasive operation to achieve a desired amount of material removed.

[0160] The method 600 may be further used to measure wear of abrasive binding agents of the abrasive article. By measuring the wear of the abrasive binding agents, the method 600 may allow suggesting suitable timing for using the abrasive article and / or an area of the abrasive article to be used for an abrasive operation. For example, the method 600 may be used to inform whether the abrasive article needs to be cooled or be cleaned before starting an abrasive operation based on the measurement of the wear of the abrasive binding agents.

[0161] In some embodiments, the signal analyzer may be remote from the sensor. In such embodiments, the signal analyzer may be communicably coupled to the sensor via any suitable connection (wired or a wireless). The signal analyzer may remotely receive the sensor signal from the sensor and process the sensed indications.

[0162] In some embodiments, the signal analyzer may receive the sensed indications using awireless communication protocol. The wireless communication protocol may be, for example, a cellular networking protocol such as a 3GPP 4G or 5G standard, a wireless local area network protocol such as IEEE 802.11 / Wi-Fi, a wireless wide area network protocol, Bluetooth®, Bluetooth Low Energy, and so forth.

[0163] In some examples, the signal analyzer may include one or more devices, circuits, and / or processing cores configured to process the sensed indications. The signal analyzer may include, for example, one or more of a general-purpose processor (e.g., ARM-based processor), a Digital Signal Processor (DSP), a Programmable Logic Device (PLD), an Application-Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), a fixed function circuitry, a programmable circuitry, any combination of fixed function circuitry, a programmable circuitry, an equivalent discrete logic circuitry or an integrated logic circuitry, and the like. The signal analyzer is intended to broadly cover both physical processing devices as well as cloud-computing solutions.

[0164] As such, whether configured by hardware or by a combination of hardware and software, the signal analyzer may represent an entity (e.g., physically embodied in circuitry) capable of performing operations according to some embodiments. Thus, for example, when the signal analyzer is embodied as an executor of software instructions, the instructions may specifically configure the signal analyzer to perform the operations described herein. Alternatively, as another example, when the signal analyzer is embodied as the ASIC, FPGA, or the like, the signal analyzer may have specifically configured hardware for conducting the operations described herein.

[0165] The signal analyzer may have associated memory, which may be configured to store information. The memory may include any form of memory for storing data and executable software instructions, such as random-access memory (RAM), read-only memory (ROM), programmable read only memory (PROM), erasable programmable read-only memory (EPROM), electronically erasable programmable read only memory (EEPROM), and flash memory. In some embodiments, the memory and signal analyzer may be integrated into a single hardware unit, such as a system on a chip (SoC) or integrated circuit (IC).

[0166] In some embodiments, at least some of the processing functionality described herein may be completed at a location remote from the system 100, such as by a second system or by a cloud-based processing unit.

[0167] In some embodiments, the sensor may include any one or more of a camera, a time-of-flight sensor, a laser, or a pressure sensor. The camera may generate one or more images of the surface of the abrasive article. The sensed indications may include the one or more imagesgenerated by the camera. The time-of-flight sensor may generate three-dimensional images and / or depth data representative of the surface of the abrasive article. The sensed indications may include the three-dimensional images and / or the depth data. Similarly, the laser and the pressure sensor may generate sensed outputs representative of wear of the surface of the abrasive article. The sensed indications may include the sensed outputs generated by the laser and / or the pressure sensor.

[0168] In some embodiments, the sensor may include a tactile sensor. The tactile sensor may sense topographical data of the surface of the abrasive article. As an example, the tactile sensor may include a stylus instrument having a suitable resolution. The sensed indications may include the topographical data.

[0169] In some embodiments, the sensor may include a camera. The method 600 may further include capturing an image of the position on the surface of the abrasive article. The capturing an image may include capturing an image in the visible light spectrum. In some other embodiments, the capturing an image may include capturing an image in the infrared spectrum or the ultraviolet spectrum.

[0170] In some embodiments, the image may include an image of an area of the surface of the abrasive article that includes the position. That is, the area may include the position at which the sensor captured the sensed indication. For a plurality of sensed indications captured at a corresponding plurality of positions on the surface of the abrasive article, the image may include a plurality of images of the surface of the abrasive article, where each image from the plurality of images is of an area including the position at which the sensed indication is captured.

[0171] In some other embodiments, capturing an image may further include capturing an image of the entire surface of the abrasive article with the camera, and isolating a portion of the image that includes an area of the surface of the abrasive article including the position. In such embodiments, the camera may capture a single image of the entirety of the surface of the abrasive article, and a portion of the single image that corresponds to an area including the position on the surface of the abrasive article at which the sensed indication is captured may be isolated. In such embodiments, the camera may be a high-resolution camera.

[0172] In some embodiments, the camera may be configured to capture images using hyperspectral imaging. In such embodiments, the method 600 may include analyzing unique spectral signatures of the surface of the abrasive article to calculate the amount of wear.

[0173] In some embodiments, the sensor may include a plurality of sensors. The plurality of sensors may capture the plurality of sensed indications for measuring different wear characteristics of the abrasive article. Based on the plurality of sensed indications, the wear calculator maydetermine one or more measurements of the wear of the abrasive article. For example, the wear calculator may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear of the abrasive article.

[0174] In some embodiments, the sensor includes a pair of cameras. The pair of cameras may be used for stereo imaging. The pair of cameras may capture three-dimensional images of the abrasive article.

[0175] In some embodiments, the sensor may further include a light source. The light source may be configured to illuminate the surface while the camera(s) is (are) capturing one or more images of the surface of the abrasive article. The light source may improve the quality of the images captured by cameras.

[0176] As discussed above, in some embodiments, the sensed indication may include a color of the abrasive article at the position. In such embodiments, the signal analyzer may be configured to detect the color at each of the positions. The color of the abrasive article (or more specifically, the portion of the surface of the abrasive article that is used for abrasive operations) may change as the abrasive article undergoes wear. This change in color may be detected and used to calculate the amount of wear for each of the positions, and for the abrasive article.

[0177] The method 600 may be used to identify irregularities in color change of the abrasive article. The method 600 may be used to determine improper use of the abrasive article and suggest changes to optimize the wear rate of the abrasive article. By use of the method 600, it may be possible to identify and suggest which portion(s) of the abrasive article should be used for performing further abrasive operations. The method 600 may also facilitate using a less damaged area of the abrasive article instead of a relatively more damaged area of the abrasive article, thereby increasing the operational lifespan of the abrasive article. Use of the method 600 may also allow suggesting optimized pressure and / or use pattern to be applied to a work surface to be abraded.

[0178] In some embodiments, analyzing the received sensor signal (for example, in block 604) may include comparing the detected color to a default color for the abrasive article. The default color may be an unworn or unused color of the abrasive article (e.g., the color of the abrasive article prior to being used in abrasive operations). The wear calculator may calculate the amount of wear for the abrasive article at the position based on comparison of the color detected at the position and the default color for the abrasive article.

[0179] In some embodiments, the default color may be a detected color at a center of the abrasive article. For some abrasive articles (e.g., abrasive discs), the center of the abrasive articles is generally not used for performing abrasive operations. For such abrasive articles, the center ofthe abrasive articles may retain the default color of the abrasive articles.

[0180] In some other embodiments, the default color may be retrieved based on an identification of the abrasive article. For example, the default color may be retrieved from a database storing default colors for a plurality of abrasive articles. Upon identification of the abrasive article, relevant default color may be retrieved from the database. Identification of the abrasive article may be performed manually (e.g., by manually selecting the abrasive article from a list of abrasive articles) or automatically.

[0181] In some embodiments, the method 600 may further include identifying, using an abrasive article identifier, a make or model of the abrasive article from the sensed indications. In some embodiments, the abrasive article identifier may employ one or more machine learning models that are trained on various different known abrasive articles. The abrasive article identifier may be capable of identifying an abrasive article among the known abrasive articles based on the sensed indications. Alternatively, the method 600 may include identifying the make or model of the abrasive article based on an information encoded on the abrasive article (e.g., QR codes, model identifier text / symbols, etc.).

[0182] In some embodiments, the abrasive article may include an abrasive disc. The camera may be configured to capture an image of the center of an abrasive disc. The abrasive article identifier may identify the make or model of the abrasive disc based on the image of the center of the abrasive disc. Since the center of the abrasive disc is generally not used for performing abrasive operations, the center of the abrasive disc may retain the default color of the abrasive disc, based on which the abrasive article identifier may identify the make or model of the abrasive disc.

[0183] In some embodiments, the method 600 may further include retrieving a set of parameters for an abrasive operation using the abrasive article. The method 600 may further include generating, based on the analysis, a process parameter change for the abrasive operation. The process parameter change may improve or optimize the abrasive operation. As an example, the process parameter change may optimize a quality of the abrasive operation (such as the amount of material removal and process speed) based on the calculated wear of the abrasive article. In some embodiments, the process parameter change may optimize the service life of the abrasive article (e.g., increase the service life) based on the amount of wear. In some embodiments, the process parameter change may include a change in angle, a change in applied pressure, a change in position, or a change in speed.

[0184] In some embodiments, outputting (e.g. in block 608) may further include communicating the process parameter change. For example, the process parameter change maybe communicated to an abrading system, and the abrading system may employ the process parameter change to modify the abrasive operation.

[0185] In some embodiments, the abrasive operation may be a robotic abrasive operation. The method 600 may further include generating a control signal for a robotic abrading unit associated with the robotic abrasive operation. The control signal may include the process parameter change. Outputting (In block 608) may further include communicating the control signal to a controller of the robotic abrading unit. The controller may receive the control signal, determine the process parameter change, and employ the process parameter change to optimize the robotic abrasive operation.

[0186] In some embodiments, the method 600 may further include retrieving a current set of parameters for an abrasive tool associated with the abrasive article. The abrasive tool may be configured to, for example, maneuver the abrasive article along a work surface to perform an abrasive operation. The method 600 may further include generating, using a parameter generator, a parameter change for the abrasive operation based on the identified make or model, the calculated amount of wear, and the current set of parameters. The method 600 may further include transmitting control signal, using a communication component, to the abrasive tool. The control signal may include the identified parameter change.

[0187] The parameter change may improve or optimize the abrasive operation. As an example, the parameter change may optimize a quality of the abrasive operation (such as the amount of material removal and process speed) based on the identified make or model, the calculated amount of wear, and the current set of parameters. In some embodiments, the parameter change may optimize the service life of the abrasive article (e.g., increase its service life) based on the identified make or model, the calculated amount of wear, and the current set of parameters. In some embodiments, the parameter change may include a change in angle, a change in applied pressure, a change in position, or a change in speed.

[0188] In some embodiments, the parameter change may include a time delay or other indication of when parameters should be changed, e.g., increase force gradually from a current parameter to a new parameter, or to wait until a next abrading step starts to increase the force.

[0189] In some embodiments, the method 600 may further include retrieving, using a wear profile retriever, a wear profile for the abrasive article. The parameter change may be generated based on the retrieved wear profile. The wear profile may include current wear characteristics of the abrasive article. As an example, the wear profile may include the current wear of the abrasive article and a tendency of the abrasive article to wear under certain operational parameters. The wear profile may be retrieved (e.g., from a database) and the parameter change based on theretrieved wear profile may be generated to improve abrasive operations with the abrasive article.

[0190] In some embodiments, the method 600 may further include, based on the received sensor signal, detecting damage to an abrasive surface of the abrasive article. Specifically, in some embodiments, the method 600 may further include determining, using a damage detector, that damage to the abrasive article is present at the position. The damage detector may detect various types of damage to the abrasive surface based on the sensed indications. In some embodiments, the damage may include heat damage, abrasive article warping, or capping. The damage detector may function in conjunction with the wear calculator to provide a more exhaustive assessment of the abrasive article. The detected damage may also be used by the parameter generator to generate the parameter change for an abrading system.

[0191] In some embodiments, one or more of the wear calculator, the abrasive article identifier, and the damage detector may employ machine learning models.

[0192] In some embodiments, positioning the abrasive article (i.e., in block 602) may include making an impression, using an impression maker, of the abrasive article, and positioning the impression with respect to the sensor such that the sensed indications are sensed from the impression. The impression may be a one-to-one representation of the surface (or more specifically, the abrasive surface) of the abrasive article. In such embodiments, the sensor may capture the sensed indications at positions on the impression instead of the surface of the abrasive article.

[0193] FIG. 7 illustrates a block diagram of a method 700 of generating a wear evaluation for abrasive article, according to embodiments of the present disclosure. The method 700 may be performed by any suitable device, unit, cell, or system. The method 700 may be performed, for example, the system 100 of FIG. 1 or the robotic abrading system 450 of FIG. 4.

[0194] The method 700 may be suitable for evaluating various types of abrasive articles. For example, the abrasive article may include coated abrasive articles, bonded abrasive articles with resin or vitreous bond matrices, nonwoven abrasive articles, brushes, or other abrasive articles. The abrasive article may have any suitable shape and form. The abrasive article may be an abrasive disc, an abrasive pad, or an abrasive belt in embodiments herein.

[0195] In block 702, a first sensed indication of a first amount of wear at a first position on an abrasive article is received using a signal receiver.

[0196] In block 704, a second sensed indication of a second amount of wear at a second position on the abrasive article is received using the signal receiver. The second position is at a different distance from a center of the abrasive article than the first position. In other words, the second position is distinct from the first position.

[0197] The sensed indications (e.g., the first and second sensed indications) may be captured by a sensor. The sensed indications may be indicative of the abrasive wear properties at the respective positions on a surface of the abrasive article. The surface of the abrasive article may be an abrasive surface that is used to perform abrasive operations, such as sanding, polishing, etc.

[0198] Specifically, the first and second sensed indications may relate to data that is indicative of abrasive wear properties at the first and second positions, respectively, on the abrasive surface. The sensed indications may include, for example, image data of the abrasive surface and / or topographical data of the abrasive surface. In some embodiments, the sensed indication may include a color of the abrasive article at the position. In some embodiments, the sensed indication may include a surface roughness of the abrasive article at the position. In some embodiments, the sensed indication may include an average height of abrasive particles at the position. In some embodiments, the sensed indication may include an abruptness of the abrasive article at the position. In some embodiments, the sensed indication may include height of abrasive particles, size of abrasive particles, angles of abrasive particles, density of abrasive particles, condition of binding agents holding together abrasive particles, or color of binding agents.

[0199] As discussed above, the sensed indications may be captured by the sensor. The signal receiver may receive a signal from the sensor. The received signal may include at least the first and second sensed indications.

[0200] In some embodiments, the method 700 may further include positioning the abrasive article at a distance from, and at an orientation with respect to, the sensor. For example, a motive robotic arm may position the abrasive article proximate to the sensor. The abrasive article may be positioned relative to the sensor at any suitable distance and orientation, such that the sensor can capture indications at different positions on the surface of the abrasive article.

[0201] In block 706, a default wear indication for the abrasive article is received. The default wear indication for the abrasive article may relate to data that is indicative of abrasive wear properties at an unworn (or unused) position on the surface of the abrasive article. The default wear indication may be representative of an unworn or unused state of the abrasive article.

[0202] In some embodiments, the default wear indication may be captured by the sensor at a position on the surface of the abrasive article. For example, the default wear indication may be a sensed indication at a position on the surface of the abrasive article that has not been used for abrasive operations.

[0203] For some abrasive articles (e.g., abrasive discs), the center of the abrasive articles is generally not used for performing abrasive operations. In such embodiments, the method 700 may further include receiving, using the signal receiver, a third sensed indication proximate a center ofthe abrasive article. The third sensed indication may be the default wear indication. The third sensed indication may be captured by the sensor.

[0204] In some other embodiments, the default wear indication may be retrieved from a database storing default wear indications for a plurality of abrasive articles. The database may be queried for the abrasive article and the default wear indication for the abrasive article may be retrieved from the database.

[0205] In block 708, the received first and second sensed indications are compared to the default wear indication. The received first and second sensed indications may be compared to the default wear indication, for example, using a signal analyzer, which will be discussed in more detail later.

[0206] In block 710, a wear profile for the abrasive article is characterized based on the comparison using a wear evaluator. The wear profile includes the first amount of wear and the second amount of wear.

[0207] The method 700 may further include calculating, based on the wear profile, using a wear calculator, an amount of wear for the abrasive article at the first position and the second position. In some embodiments, the method 700 may further include, based on at least the calculated wear for the abrasive article at the first position and the second position, using the wear calculator, calculating an amount of wear for the abrasive article.

[0208] The method 700 may facilitate quantifying wear of the abrasive article. Specifically, the method 700 may facilitate quantifying the amount of wear for the abrasive article at the position(s) based on the sensed indication(s). The wear profile generated using the method 700 may be used to calculate an amount of wear for the first and second positions of the surface of the abrasive article and / or for the abrasive article.

[0209] In some implementations, the wear profile may be used to determine an overall wear assessment of the abrasive article. For example, the wear calculator may retrieve the wear profile and calculate a percentage value denoting how much wear the surface of the abrasive article has undergone due to use in abrasive operations. It should be noted that the wear calculator may perform one or more measurements of the wear of the abrasive article. For example, the wear calculator may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear. The method 700 may allow determining, for example, a remaining service life of the abrasive article.

[0210] The method 700 may be used to track wear of the abrasive article, thereby avoiding premature disposal of the abrasive article and promoting use of the abrasive article throughout its service life. The method 700 may also allow assessing the quality of the abrasive article (e.g., bytracking a wear rate of the abrasive article).

[0211] The method 700 may be further used to measure wear of abrasive binding agents of the abrasive article. By measuring the wear of the abrasive binding agents, the method 700 may allow suggesting suitable timing for using the abrasive article and / or an area of the abrasive article to be used for an abrasive operation. For example, the method 700 may be used to inform whether the abrasive article needs to be cooled or be cleaned before starting an abrasive operation based on the measurement of the wear of the abrasive binding agents.

[0212] In some embodiments, the method 700 may further include communicating the amount of wear to a graphical user interface generator for a device having a display. The display may include any visual output device suitable for displaying a graphical user interface. The graphical user interface generator may generate the graphical user interface for the display. The graphical user interface may include the amount of wear of the abrasive article. Specifically, the graphical user interface may include the first amount of wear and the second amount of wear.

[0213] In some embodiments, the signal analyzer may be remote from the sensor. In such embodiments, the signal analyzer may be communicably coupled to the sensor via any suitable connection (wired or a wireless). The signal analyzer may remotely receive the sensor signal from the sensor and process the sensed indications.

[0214] In some embodiments, the signal analyzer may receive the sensed indications using a wireless communication protocol. The wireless communication protocol may be, for example, a cellular networking protocol such as a 3GPP 4G or 5G standard, a wireless local area network protocol such as IEEE 802.11 / Wi-Fi, a wireless wide area network protocol, Bluetooth®, Bluetooth Low Energy, and so forth.

[0215] In some examples, the signal analyzer may include one or more devices, circuits, and / or processing cores configured to process the sensed indications. The signal analyzer may include, for example, one or more of a general-purpose processor (e.g., ARM-based processor), a Digital Signal Processor (DSP), a Programmable Logic Device (PLD), an Application-Specific Integrated Circuit (ASIC), a Field-Programmable Gate Array (FPGA), a fixed function circuitry, a programmable circuitry, any combination of fixed function circuitry, a programmable circuitry, an equivalent discrete logic circuitry or an integrated logic circuitry, and the like. The signal analyzer is intended to broadly cover both physical processing devices as well as cloud-computing solutions.

[0216] As such, whether configured by hardware or by a combination of hardware and software, the signal analyzer may represent an entity (e.g., physically embodied in circuitry) capable of performing operations according to some embodiments. Thus, for example, when thesignal analyzer is embodied as an executor of software instructions, the instructions may specifically configure the signal analyzer to perform the operations described herein. Alternatively, as another example, when the signal analyzer is embodied as the ASIC, FPGA, or the like, the signal analyzer may have specifically configured hardware for conducting the operations described herein.

[0217] The signal analyzer may have associated memory, which may be configured to store information. The memory may include any form of memory for storing data and executable software instructions, such as random-access memory (RAM), read-only memory (ROM), programmable read only memory (PROM), erasable programmable read-only memory (EPROM), electronically erasable programmable read only memory (EEPROM), and flash memory. In some embodiments, the memory and signal analyzer may be integrated into a single hardware unit, such as a system on a chip (SoC) or integrated circuit (IC).

[0218] In some embodiments, the sensor may include a plurality of sensors. The plurality of sensors may capture the plurality of sensed indications for measuring different wear characteristics of the abrasive article. Based on the plurality of sensed indications, the wear calculator may determine one or more measurements of the wear of the abrasive article. For example, the wear calculator may perform a specific wear measurement or multiple wear measurements capturing regularity and / or uniformity of the wear of the abrasive article.

[0219] In some embodiments, the sensor may include a camera, a time-of-flight sensor, a laser, or a pressure sensor. The camera may generate one or more images of the surface of the abrasive article. The sensed indications may include the one or more images generated by the camera. The time-of-flight sensor may generate three-dimensional images and / or depth data representative of the surface of the abrasive article. The sensed indications may include the three-dimensional images and / or the depth data. Similarly, the laser and the pressure sensor may generate sensed outputs representative of wear of the surface of the abrasive article. The sensed indications may include the sensed outputs generated by the laser and / or the pressure sensor.

[0220] In some embodiments, the sensor may include a tactile sensor. The tactile sensor may sense topographical data of the surface of the abrasive article. As an example, the tactile sensor may include a stylus instrument having a suitable resolution. The sensed indications may include the topographical data.

[0221] In some embodiments, the sensor may include a camera. The method 700 may further include capturing an image of the surface of the abrasive article using the camera. The capturing an image may include capturing an image in the visible light spectrum. In some other embodiments, the capturing an image may include capturing an image in the infrared spectrum orthe ultraviolet spectrum.

[0222] Specifically, the method 700 may further include capturing an image of the first position on the surface of the abrasive article. The image may include an image of an area of the surface of the abrasive article including the first position.

[0223] In some embodiments, capturing an image may include: capturing an image, with the camera, of the entire surface of the abrasive article, and isolating a first portion of the image, where the first portion includes a first area of the surface of the abrasive article including the first position; and isolating a second portion of the image, where the second portion includes a second area of the surface of the abrasive particle including the second position. In such embodiments, the camera may be a high-resolution camera.

[0224] In some embodiments, the camera may be configured to capture images using hyperspectral imaging. In such embodiments, the method 700 may include analyzing unique spectral signatures of the surface of the abrasive article to calculate the amount of wear.

[0225] In some embodiments, the sensor includes a pair of cameras. The pair of cameras may be used for stereo imaging. The pair of cameras may capture three-dimensional images of the abrasive article.

[0226] In some embodiments, the sensor may further include a light source. The light source may be configured to illuminate the surface while the camera(s) is (are) capturing one or more images of the surface of the abrasive article. The light source may improve the quality of the images captured by cameras.

[0227] As discussed above, in some embodiments, the sensed indication may include a color of the abrasive article at the position. In some embodiments, the first sensed indication may include an image of the abrasive article at the first position. The method 700 may further include detecting a first color of the abrasive article at the first position. The method 700 may further include comparing the first color of the abrasive article to a default color. The method 700 may further include calculating an amount of wear at the first position (i.e., the first amount of wear) based on the comparison. That is, the amount of wear at the first position may be calculated based on the comparison of the first color with the default color.

[0228] The color of the abrasive article (or more specifically, the portion of the surface of the abrasive article that is used for abrasive operations) may change as the abrasive article undergoes wear. This change in color may be detected and used to calculate the amount of wear for the position.

[0229] The default color may include a color of a substantially unused portion of the abrasive article. In some embodiments, the default color may be a detected color at the center of theabrasive article. For some abrasive articles (e.g., abrasive discs), the center of the abrasive articles is generally not used for performing abrasive operations. For such abrasive articles, the center of the abrasive articles may retain the default color of the abrasive articles.

[0230] In some embodiments, the method 700 may further include capturing an image of the second position on the surface of the abrasive article. The method 700 may further include detecting a second color of the abrasive article at the second position. The method 700 may further include comparing the second color of the abrasive article to the default color. The method 700 may further include calculating an amount of wear at the second position (i.e., the second amount of wear) based on the comparison. That is, the amount of wear at the second position may be calculated based on the comparison of the second color with the default color.

[0231] The method 700 may be used to identify irregularities in color change of the abrasive article. The method 700 may be used to determine improper use of the abrasive article and suggest changes to optimize the wear rate of the abrasive article. By use of the method 700, it may be possible to identify and suggest which portion(s) of the abrasive article should be used for performing further abrasive operations. The method 700 may also facilitate using a less damaged area of the abrasive article instead of a relatively more damaged area of the abrasive article, thereby increasing the operational lifespan of the abrasive article. Use of the method 700 may also allow suggesting optimized pressure and / or use pattern to be applied to a work surface to be abraded.

[0232] In some other embodiments, the default color of the abrasive article may be retrieved based on an identification of the abrasive article. For example, the default color may be retrieved from a database storing default colors for a plurality of abrasive articles. Upon identification of the abrasive article, the relevant default color may be retrieved from the database. Identification of the abrasive article may be performed manually (e.g., by manually selecting the abrasive article from a list of abrasive articles) or automatically.

[0233] In some embodiments, the method 700 may further include identifying, using an abrasive article identifier, the make or model of the abrasive article from the sensed indications. In some embodiments, the abrasive article identifier may employ one or more machine learning models that are trained on various different known abrasive articles. The abrasive article identifier may be capable of identifying an abrasive article among the known abrasive articles based on the sensed indications. Alternatively, the abrasive article identifier may identify the make or model of the abrasive article based on an information encoded on the abrasive article (e.g., QR codes, model identifier text / symbols, etc.).

[0234] In some embodiments, the signal receiver may receive a first image captured by thecamera including the first sensed indication. The first image may be of a first area of the abrasive article that includes the first position. In some embodiments, the first image may include both the first area which includes the first position and a second area which includes the second position. As discussed above, the default wear indication may be a sensed indication at a position on the surface of the abrasive article that is not used for abrasive operations (e.g., the center of the abrasive article). Therefore, in some embodiments, receiving the default wear indication may include receiving a second image including a center area of the abrasive article. The second image may include a portion of the first image. In some embodiments, the method 700 may further include identifying, based on the second image, the make or model of the abrasive article. That is to say, the first image and the second image captured by the camera may be used to determine the first indication, the second indication, the default indication, and the make or model of the abrasive article. Thus, the amount of wear for the abrasive article may be calculated using the first and second images captured by the camera.

[0235] In some embodiments, the abrasive article may include an abrasive disc. In some embodiments, the camera may be configured to capture an image of the center of the abrasive disc. The abrasive article identifier may identify the make or model of the abrasive disc based on the image of the center of the abrasive disc. Since the center of the abrasive disc is generally not used for performing abrasive operations, the center of the abrasive disc may retain the default color of the abrasive disc, based on which the abrasive article identifier may identify the make or model of the abrasive disc.

[0236] In some embodiments, the method 700 may further include retrieving a wear profile for the abrasive article. The wear profile may be the wear profile characterized by the wear evaluator in block 710 or a previously characterized wear profile. As mentioned before, the wear profile includes the first amount of wear and the second amount of wear. In such embodiments, comparing (in block 708) may further include comparing the first color of the abrasive article to the wear profile. Furthermore, the amount of wear may include an indication of life remaining. The indication of life remaining may include, for example, an estimated number of abrasive operations remaining for the abrasive article.

[0237] In some embodiments, the method 700 may further include retrieving a set of abrasive operating parameters for an abrasive tool associated with the abrasive article. The method 700 may further include determining, based on the amount of wear and the set of abrasive operations, the indication of life remaining. The indication of life remaining may include an indication of a number of abrasive operations remaining for the abrasive article. The number of abrasive operations remaining for the abrasive article may be dependent on the set of abrasive operatingparameters.

[0238] The method 700 may further include generating a parameter change for the abrasive tool, based on the retrieved set of abrasive operating parameters and the wear profile. In some embodiments, the parameter change may extend a number of abrasive operations remaining for the abrasive article compared to the retrieved set of abrasive operating parameters. That is, the parameter change may be generated so as to optimize a wear rate of the abrasive article, such that when the abrasive tool is operated with the parameter change, a reduced wear rate of the abrasive article is observed. In some embodiments, the parameter change may include a change in rotational speed, a change in angle of contact with an abrasive article, a change in position, or an applied pressure.

[0239] In some embodiments, the abrasive operation may be a robotic abrasive operation. The method 700 may further include generating a control signal for a robotic abrading unit associated with the robotic abrasive operation. The control signal may include the parameter change. The method 700 may further include communicating the control signal to a controller of the robotic abrading unit. The controller may receive the control signal, determine the parameter change, and employ the parameter change to optimize the robotic abrasive operation.

[0240] In some embodiments, the parameter change may include a time delay or other indication of when parameters should be changed, e.g., increase force gradually from a current parameter to a new parameter, or to wait until a next abrading step starts to increase the force.

[0241] In some embodiments, the method 700 may further include analyzing the first or second sensed indication for detecting damage to the abrasive article. The analyzing may be performed for example, using a damage detector. The damage detector may detect various types of damage to the abrasive surface based on the sensed indications. The damage detector may function in conjunction with the wear calculator to provide a more exhaustive assessment of the abrasive article. The detected damage may also be used by the parameter generator to generate the parameter change for an abrading system. In some embodiments, the damage may include contamination, heat damage, capping, or abrasive article warping.

[0242] In some embodiments, the method 700 may be performed by a device including the sensor and the wear calculator. The device may be portable, in some examples. The device may be communicably coupled to the wear calculator, for example, via a communication component.

[0243] In some embodiments, one or more of the wear calculator, the abrasive article identifier, and the damage detector may include machine learning models.

[0244] FIG. 8 illustrates a robotic abrading system in accordance with embodiments herein. System 800 may be an automated robotic abrading system that conducts an abrasive operation ona workpiece 812, using an abrasive article 820. System 800 may operate on a closed circuit feedback loop such that a machine learning model 846 uses data, stored in datastore 840, to progressively improve a settings generator 862. However, while system 800 is illustrated as self-contained in FIG. 8, it is expressly contemplated that, in some embodiments, components may be remote from each other, and communicably coupled using a wired, wireless, or cloud-based network.

[0245] A robotic abrading system 810 includes a robotic arm 802 that causes interaction between abrasive article 820 and workpiece 812. It is expressly contemplated that, in some embodiments, robotic arm 802 is coupled to abrasive article 820. However, in other embodiments, robotic arm is coupled to workpiece 812. In some embodiments, robotic abrading system 810 includes multiple robotic arms 802, e.g. one coupled to abrasive article 820 while a second is coupled to workpiece 812. Other suitable configurations are expressly contemplated. Robotic abrading system 810 includes one or more movement mechanisms 804. Movement mechanisms 804 may include mechanical joints that allow robotic arm 802 to move from a first position to a second position, as well as movement mechanisms 804 that allow robotic abrading system 810 to move physically within the cell.

[0246] Abrasive article 820 is a consumable abrasive article that includes abrasive particles 822 that wear or fracture during use, a backing or resin structure is bonded to the abrasive article. Abrasive article 820 may include other features 826, such as grinding aids, a second set of particles 822, etc. Particles 822, as described herein, may be crushed abrasive particles, formed abrasive particles, shaped abrasive particles or microreplicated abrasive surface features.

[0247] Workpiece 812 has a surface contour 814 that changes as it is abraded. Workpiece 812 is composed of a material 816, or more than one material 816. Workpiece 812 may have other features 818.

[0248] A sensor system 830 may be used to obtain status information of abrasive article 820 and / or workpiece 812 during an abrasive process. For example, robotic system 810 may bring sensor system 830 to abrasive article 820 and / or workpiece 812 in some embodiments. In other embodiments, robotic system 810 brings abrasive article 820 and / or workpiece 812 into position with respect to sensor system 830. In yet other embodiments, sensor system 830 is fixed in a position to capture information about abrasive article 820 and / or workpiece 812. While only a single sensor system 830 is illustrated in system 800, it is expressively contemplated that multiple sensor systems 830 may be present within a system 800, for example each with a different use. Additionally, a single sensor system 830 may include one or more sensors 832. Sensor 832 may be an optical sensor, thermal sensor, or other suitable sensor. Sensor 832 may include aprofilometer, a 2D camera or video camera, a 3D camera or video camera, a camera or video camera array, or another suitable sensor.

[0249] Sensor system 830 may include a movement controller 834 that controls movement of a movement mechanism (not shown) of sensor system 830, or movement mechanism 804. A sensor signal communicator 836 may communicate captured sensor signals to system controller 850, or to datastore 840, or to another receiving device. Sensor system 830 may also include other features 838. For example, sensor system 830 may include a light array to improve the quality of captured photos.

[0250] Robotic system 800 also includes, or is communicably coupled to, datastore 840. Datastore 840 includes a number of historical operational fingerprints 842. Each operational fingerprint 842 may include some or all of: operational parameters (e.g. force, dwell time, movement speed), environmental conditions (e.g. temperature, humidity), and other abrasive parameters (e.g. abrasive article, lubricant used, grinding aids used), target operational results (e.g. goal abrasive wear rate, goal material removed) as well as operational results (e.g. actual abrasive wear, actual material removal rate). Datastore 840 may also include job specifications 844, such as a final surface contour 814 for workpiece 812. Job specifications 844 may also include target abrasive wear rate and / or target operation time (e.g. wear rate of all abrasive steps).

[0251] A machine learning model 846 is illustrated in FIG. 8 as stored in datastore 840. However, in some embodiments, machine learning model is housed on a processing unit of system controller 850 and accesses data within datastore 840. As described herein, machine learning model 846 may learn from seed data about a number of abrasive operations conducted, and actual wear and material removal rates resulting from known operational parameters. Machine learning model 846 may then be used to inform settings generator 862, which selects settings for a next abrasive operation.

[0252] Datastore 840 may also include other information 848, such as pre and post operation images, surface profiles, renderings, etc. Other information 848 may also include information about other options that may be used by robotic abrading system, such as other abrasive articles or materials that may be used.

[0253] System controller 850 includes a specifications retriever 852 which retrieves job specifications 844, a sensor signal retriever 854 that retrieves sensor signals directly from system 830 or retrieves operational fingerprints from datastore 840. A material removed calculator 856 may compare a current operational fingerprint 842 to a previously captured operational fingerprint 842. A previous surface contour 814 is compared to a current surface contour 814 to determine an actual amount of material removed in a last abrasive step.

[0254] Based on the actual rate of material removal, and the information from the current operational fingerprint, wear rate calculator 858 generates an abrasive wear rate, and / or actual abrasive wear of abrasive article 820.

[0255] Settings generator 862, informed by machine learning model 846, selects operational parameters and, therefore, operational settings for robotic abrading system 810, for a next abrasive pass. Settings generator 862 may determine that a current surface contour 814 is not sufficient to move to a next abrasive step (e.g. from sanding to polishing, or from grinding to sanding) and may instead indicate that the last abrasive step be repeated with new parameters (e.g. dwell time and force selected based on the calculated wear of the abrasive article, etc.). Settings generator 862, however, may also determine that the current surface contour 814 is not a target surface contour, but is sufficient enough to proceed to the next abrasive step, but with adjusted parameters to “catch up” to the desired target surface contour.

[0256] Command generator 864 generates movement instructions and settings adjustment instructions for controllers and components within system 800. For example, command generator 864 may send commands to movement mechanism 804 and to movement controller 845 directly, in some embodiments. However, it is expressly contemplated that, in some embodiments, robotic abrading system 810 has a local controller that receives a command from a command communicator 866 and causes the command to be implemented locally. Similarly, sensor system(s) 830 may also have local controllers.

[0257] In some embodiments, system 800 has a display component 870 for a human operator to view during an operation. Display component 870 may present a user interface generated by graphical user interface generator 868 based on information in datastore 840 or generated by system controller 850. Display component may present current operational parameters, or settings 872 of robotic abrading system 810. Display component may also present a surface profile 874 of workpiece 812. This may be, in some embodiments, a surface contour 814 of a most recent operational fingerprint 842, or, in other embodiments, a video feed of workpiece 812 or, in yet other embodiments, a target surface contour set by job specifications 844. Display component 870 may also, in some embodiments, display status information 876 about abrasive article 820, such as a type, a brand, an expected amount of wear for a current step (e.g. next grinding step will consume 2% of total abrasive life) or an expected remaining service life (e.g. 88% remaining abrasive life, or 56 cycles to next abrasive article replacement). Other information of interest 878 may also be presented.

[0258] Robotic system 800 enables the gathering of 3 dimensional geometric and topographical measurement data of a worksurface, through targeted inspection and in-processtelemetry, allowing the system controller 850 to predict the amount of useful work an abrasive consumable can perform. This prediction can be measured in numbers of percentage wear, or total time performing abrasion.

[0259] The effect of an abrasive process on a component being abraded can be measured by macro and micro-scale three dimensional (3D) geometric and surface topographical inspection data. Technologies which may be used include Coordinate measurement machines (CMM); structured light scanning; laser scanning; laser photogrammetry; white light interferometry; confocal microscopy; and focus variation. When used appropriately, each of these technologies can gather accurate point cloud data that provides insights into the target surfaces of a component and detect the effect of both the abrasive process on the component, and the performance of the consumable abrasive material. The effect of an abrasive process may include a change in the shape of the component, removal of contaminants (e.g., rust removal or other contaminant removal), a desired finish (polished or patterned finish) provided to the component, and so forth.

[0260] The environmental, and abrasive process’, parameters can be measured by in-process telemetry. Sensors may include those suitable for recording (either as analogue voltage or current signals, or encoded digital signals); environmental temperature, humidity, sound pressure levels, localized vibration frequency, accelerations, temperatures, contact forces and tool speeds.

[0261] Systems and methods herein provide a more direct assessment of consumable wear, using a machine vision system, which takes digital images of the abrasive article and / or a component being abraded itself during the abrasive process. The vision system can identify changes between subsequent abrading steps and identify stages of wear as a direct result of the recorded process parameters. Through analytics, that information can be correlated to the part quality metrics obtained through geometric and surface topographical inspection. This provides an understanding of the limits of consumable material wear, given the component’s tolerances, and thus the expected lifespan of the consumable for its intended task.

[0262] For example, a particular abrasive belt may be selected for performing several consecutive abrasive processes on a component.

[0263] E.g., starting with a fresh belt with no prior usage, several abrasive processes can be performed, during which primary parameters are controlled, and secondary parameters are monitored. The quality of the process outputs are recorded (through geometric and / or topographical inspection) after each individual abrasive process or process step. This provides a summation of all prior usage of the abrasive consumable (for example, cumulative amount of time the belt has been in contact with the component, with weighting of this time as a function of process parameters). Over time, this can be used to understand the conditions required to bringan abrasive consumable to the point where it no longer produces useful results.

[0264] This relationship between historical usage and measured quality of outputs can then be used to make minimize or reduce the consumption of “life” on new instances of abrasive consumable (i.e. a replacement belt after the initial one is fully worn) when used in controlled abrasive processes. Using abrasive articles to their full service life, as well as extending the service life of an abrasive article can improve overall efficiency of robotic system 800, even if individual steps take longer, as robotic cell system experiences downtime each time an abrasive article needs to be replaced, treated for loading or capping, etc. Alternatively, when speed is important, knowing how an abrasive article is wearing can allow systems herein to calculate process parameters to improve cut rate so as to maintain a target cycle time.

[0265] Using systems and methods described herein, process parameters can be selected to find a compromise between process quality outputs (such as the amount of material removal and process speed), and consumption of abrasive life.

[0266] Systems and methods herein enable visualization of cut performance and / or abrasive article useful life. For abrasive articles without visible grains, it is possible to detect the microreplicated abrasive block height, which is linked directly life of the product. Process outputs such as acoustics, vibration, and temperature can potentially inform the state of decay of the abrasive surface. However, for all abrasive articles, knowing an ‘End of life’ of the article prevents a final product being damaged by an abrasive that is about to run out of life in mid robotic cycle.

[0267] FIG. 9 illustrates a networked architecture for a setting selection system for an automated robotic abrading system. FIG. 9 is a networked architecture 900 for a setting selection system 910. Architecture 900 illustrates one embodiment of an implementation of a system 910, however others are possible. In various embodiments, remote servers can deliver the services over a wide area network, such as the internet, using appropriate protocols. For instance, remote servers can deliver applications over a wide area network, and they can be accessed through a web browser or any other computing component.

[0268] Software or components, as well as the corresponding data, can be stored on servers at a remote location. The computing resources in a remote server environment can be consolidated at a remote data center location or they can be dispersed. Remote server infrastructures can deliver services through shared data centers, even though they appear as a single point of access for the user. Thus, the components and functions described herein can be provided from a remote server at a remote location using a remote server architecture. Alternatively, they can be provided by a conventional server, installed on client devices directly, or in other ways.

[0269] As described herein, setting selection system 910 selects operational settings forcomponents of a robotic abrading system based on information received from one or more sensors 980, which may detect information about an abrasive article, workpiece, or other operational information about robotic abrading system 970. As illustrated, setting selection system 910 may communicate directly with settings 980 and robotic abrading system 970, in some embodiments herein.

[0270] FIG. 9 specifically shows that a system 910 can be located at a remote server location 902. Therefore, computing device 920 accesses those systems through remote server location 902. Operator 950 can use computing device 920 to access user interfaces 922 as well. For example, user interface 922 may provide an indication of how worn an abrasive article is, changes that are made to any of networked systems 904, or suggested changes to the operation by the operator -such as increasing force, increasing RPMs, etc.

[0271] FIG. 9 shows that it is also contemplated that some elements of systems described herein are disposed at remote server location 902 while others are not. By way of example, storage 930, 940 or 960 or robotic abrading system 970 can be disposed at a location separate from location 902 and accessed through the remote server at location 902. Regardless of where they are located, they can be accessed directly by computing device 920, through a network (either a wide area network or a local area network), hosted at a remote site by a service, provided as a service, or accessed by a connection service that resides in a remote location. Also, the data can be stored in substantially any location and intermittently accessed by, or forwarded to, interested parties. For instance, physical carriers can be used instead of, or in addition to, electromagnetic wave carriers.

[0272] It will also be noted that the elements of systems described herein, or portions of them, can be disposed on a wide variety of different devices. Some of those devices include servers, desktop computers, laptop computers, imbedded computer, industrial controllers, tablet computers, or other mobile devices, such as palm top computers, cell phones, smart phones, multimedia players, personal digital assistants, etc.

[0273] FIG. 10 is a simplified block diagram of one illustrative example of a handheld or mobile computing device 1000 that can be used as a user's or client's handheld device 1016, in which the present system (or parts of it) can be deployed. For instance, a mobile device can be used to connect to a hearing protection device via a wireless channel and adjust the adjustable band setting according to the present disclosure. FIG. 11 is another example of a handheld or mobile device.

[0274] FIG. 10 provides a general block diagram of the components of a client device 1016 that can run some components shown and described herein. Client device 1016 interacts withthem or runs some and interacts with some. In the device 1016, a communications link 1013 is provided that allows the handheld device to communicate with other computing devices and under some embodiments provides a channel for receiving information automatically, such as by scanning. Examples of communications link 813 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.

[0275] In other examples, applications can be received on a removable Secure Digital (SD) card that is connected to an interface 1015. Interface 1015 and communication links 1013 communicate with a processor 1017 (which can also embody a processor) along a bus 1019 that is also connected to memory 1021 and input / output (I / O) components 1023, as well as clock 1025 and location system 1027.

[0276] I / O components 1023, in one embodiment, are provided to facilitate input and output operations and the device 1016 can include input components such as buttons, touch sensors, optical sensors, microphones, touch screens, proximity sensors, accelerometers, orientation sensors and output components such as a display device, a speaker, and or a printer port. Other I / O components 1023 can be used as well.

[0277] Clock 1025 illustratively comprises a real time clock component that outputs a time and date. It can also provide timing functions for processor 1017.

[0278] Illustratively, location system 1027 includes a component that outputs a current geographical location of device 1016. This can include, for instance, a global positioning system (GPS) receiver, a LORAN system, a dead reckoning system, a cellular triangulation system, or other positioning system. It can also include, for example, mapping software or navigation software that generates desired maps, navigation routes and other geographic functions.

[0279] Memory 1021 stores operating system 1029, network settings 1031, applications 1033, application configuration settings 1035, contact or phone book application 1043, client system 1024, data store 1037, communication drivers 1039, and communication configuration settings 1041. Memory 1021 can include all types of tangible volatile and non-volatile computer-readable memory devices. It can also include computer storage media (described below). Memory 1021 stores computer readable instructions that, when executed by processor 1017, cause the processor to perform computer-implemented steps or functions according to the instructions. Processor 1017 can be activated by other components to facilitate their functionality as well.

[0280] FIG. 11 shows that a device 1050 can be a smart phone 1071. Smart phone 1071 has a touch sensitive display 1073 that displays icons or tiles or other user input mechanisms 1075. Mechanisms 1075 can be used by a user to run applications, make calls, perform data transferoperations, etc. In general, smart phone 1071 is built on a mobile operating system and offers more advanced computing capability and connectivity than a feature phone. Note that other forms of the devices 1071 are possible.

[0281] FIG. 12 illustrates an example computing device that can be used in embodiments shown in previous Figures. FIG. 12 is one example of a computing environment 1100 in which elements of systems and methods described herein, or parts of them (for example), can be deployed. With reference to FIG. 12, an example system for implementing some embodiments includes a general-purpose computing device in the form of a computer 1110. Components of computer 1110 may include, but are not limited to, a processing unit 1120 (which can comprise a processor), a system memory 1130, and a system bus 1121 that couples various system components including the system memory to the processing unit 1120. The system bus 1121 may be any of several types of bus structures including a memory bus or memory controller, a peripheral bus, and a local bus using any of a variety of bus architectures. Memory and programs described with respect to systems and methods described herein can be deployed in corresponding portions of FIG. 12.

[0282] Computer 1110 typically includes a variety of computer readable media. Computer readable media can be any available media that can be accessed by computer 1110 and includes both volatile / nonvolatile media and removable / non-removable media. By way of example, and not limitation, computer readable media may comprise computer storage media and communication media. Computer storage media is different from, and does not include a modulated data signal or carrier wave. It includes hardware storage media including both volatile / nonvolatile and removable / non-removable media implemented in any method or technology for storage of information such as computer readable instructions, data structures, program modules or other data. Computer storage media includes, but is not limited to, RAM, ROM, EEPROM, flash memory or other memory technology, CD-ROM, digital versatile disks (DVD) or other optical disk storage, magnetic cassettes, magnetic tape, magnetic disk storage or other magnetic storage devices, or any other medium which can be used to store the desired information and which can be accessed by computer 1110. Communication media may embody computer readable instructions, data structures, program modules or other data in a transport mechanism and includes any information delivery media. The term “modulated data signal” means a signal that has one or more of its characteristics set or changed in such a manner as to encode information in the signal.

[0283] The system memory 1130 includes computer storage media in the form of volatile and / or nonvolatile memory such as read only memory (ROM) 1131 and random access memory(RAM) 1132. A basic input / output system 1133 (BIOS) containing the basic routines that help to transfer information between elements within computer 1110, such as during start-up, is typically stored in ROM 1131. RAM 1132 typically contains data and / or program modules that are immediately accessible to and / or presently being operated on by processing unit 1120. By way of example, and not limitation, FIG. 12 illustrates operating system 1134, application programs 1135, other program modules 1136, and program data 1137.

[0284] The computer 1110 may also include other removable / non-removable and volatile / nonvolatile computer storage media. By way of example only, FIG. 12 illustrates a hard disk drive 1141 that reads from or writes to non-removable, nonvolatile magnetic media, nonvolatile magnetic disk 1152, an optical disk drive 1155, and nonvolatile optical disk 1156. The hard disk drive 1141 is typically connected to the system bus 1121 through a non-removable memory interface such as interface 1140, and optical disk drive 1155 are typically connected to the system bus 1121 by a removable memory interface, such as interface 1150.

[0285] Alternatively, or in addition, the functionality described herein can be performed, at least in part, by one or more hardware logic components. For example, and without limitation, illustrative types of hardware logic components that can be used include Field-programmable Gate Arrays (FPGAs), Application-specific Integrated Circuits (e.g., ASICs), Application-specific Standard Products (e.g., ASSPs), System-on-a-chip systems (SOCs), Complex Programmable Logic Devices (CPLDs), etc.

[0286] The drives and their associated computer storage media discussed above and illustrated in FIG. 12, provide storage of computer readable instructions, data structures, program modules and other data for the computer 1110. In FIG. 12, for example, hard disk drive 1141 is illustrated as storing operating system 1144, application programs 1145, other program modules 1146, and program data 1147. Note that these components can either be the same as or different from operating system 1134, application programs 1135, other program modules 1136, and program data 1137.

[0287] A user may enter commands and information into the computer 1110 through input devices such as a keyboard 1162, a microphone 1163, and a pointing device 1161, such as a mouse, trackball or touch pad. Other input devices (not shown) may include a joystick, game pad, satellite receiver, scanner, or the like. These and other input devices are often connected to the processing unit 1120 through a user input interface 1160 that is coupled to the system bus, but may be connected by other interface and bus structures. A visual display 1191 or other type of display device is also connected to the system bus 1121 via an interface, such as a video interface 1190. In addition to the monitor, computers may also include other peripheral output devices such asspeakers 1197 and printer 1196, which may be connected through an output peripheral interface 1195.

[0288] The computer 1110 is operated in a networked environment using logical connections, such as a Local Area Network (LAN) or Wide Area Network (WAN) to one or more remote computers, such as a remote computer 1180.

[0289] When used in a LAN networking environment, the computer 1110 is connected to the LAN 1171 through a network interface or adapter 1170. When used in a WAN networking environment, the computer 1110 typically includes a modem 1172 or other means for establishing communications over the WAN 1173, such as the Internet. In a networked environment, program modules may be stored in a remote memory storage device. FIG. 12 illustrates, for example, that remote application programs 1185 can reside on remote computer 1180.

[0290] By gathering macro and micro-scale three dimensional geometric and topographical measurement data, through targeted inspection and in-process telemetry, systems and method herein can be used to extend the amount of useful work an abrasive consumable can perform. This extension in work is typically measured in numbers of components processed or total time performing abrasion.

[0291] Geometric and topographical inspection technologies which may be used include structured light scanning, laser photogrammetry, white light interferometry, confocal microscopy, and focus variation) and in-process telemetry sensors may include those suitable for recording (either as analogue voltage or current signals, or encoded digital signals): environmental temperature, humidity, sound pressure levels, and localized vibration frequency and accelerations, temperatures, and tool speeds.

[0292] Then, by forming an understanding of how well an abrasive consumable performs in achieving desired process results (geometric or topographical) on a component, in the context of all the historical usage which that abrasive consumable article has seen, an approximation of the percentage of useful abrasive “life” consumed as a function of a range of process parameters can be determined.

[0293] Objects and advantages of this disclosure are further illustrated by the following nonlimiting examples, but the particular materials and amounts thereof recited in these examples, as well as other conditions and details, should not be construed to unduly limit this disclosure.

[0294] It will be apparent to those skilled in the art that the specific exemplary embodiments, elements, structures, features, details, arrangements, configurations, etc., that are disclosed herein can be modified and / or combined in numerous ways. In summary, numerous variations and combinations are contemplated as being within the bounds of the conceived invention, not merelythose representative designs that were chosen to serve as exemplary illustrations. Thus, the scope of the present invention should not be limited to the specific illustrative structures described herein, but rather extends at least to the structures described by the language of the claims, and the equivalents of those structures. Any of the elements that are positively recited in this specification as alternatives may be explicitly included in the claims or excluded from the claims, in any combination as desired. Any of the elements or combinations of elements that are recited in this specification in open-ended language (e.g., comprise and derivatives thereof), are considered to additionally be recited in closed-ended language (e.g., consist and derivatives thereof) and in partially closed-ended language (e.g., consist essentially, and derivatives thereof). Although various theories and possible mechanisms may have been discussed herein, in no event should such discussions serve to limit the claimable subject matter. To the extent that there is any conflict or discrepancy between this specification as written and the disclosure in any document that is incorporated by reference herein but to which no priority is claimed, this specification as written will control. In the present detailed description of the preferred embodiments, reference is made to the accompanying drawings, which illustrate specific embodiments in which the invention may be practiced. The illustrated embodiments are not intended to be exhaustive of all embodiments according to the invention. It is to be understood that other embodiments may be utilized, and structural or logical changes may be made without departing from the scope of the present invention. The following detailed description, therefore, is not to be taken in a limiting sense, and the scope of the present invention is defined by the appended claims.

[0295] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0296] As used in this specification and the appended claims, the singular forms “a,” “an,” and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise. As used in this specification and the appended claims, the term “or” is generally employed in its sense including “and / or” unless the content clearly dictates otherwise.

[0297] Spatially related terms, including but not limited to, “proximate,” “distal,” “lower,” “upper,” “beneath,” “below,” “above,” and “on top,” if used herein, are utilized for ease of description to describe spatial relationships of an element(s) to another. Such spatially related terms encompass different orientations of the device in use or operation in addition to the particularorientations depicted in the figures and described herein. For example, if an object depicted in the figures is turned over or flipped over, portions previously described as below or beneath other elements would then be above or on top of those other elements.

[0298] As used herein, when an element, component, or layer for example is described as forming a “coincident interface” with, or being “on,” “connected to,” “coupled with,” “stacked on” or “in contact with” another element, component, or layer, it can be directly on, directly connected to, directly coupled with, directly stacked on, in direct contact with, or intervening elements, components or layers may be on, connected, coupled or in contact with the particular element, component, or layer, for example. When an element, component, or layer for example is referred to as being “directly on,” “directly connected to,” “directly coupled with,” or “directly in contact with” another element, there are no intervening elements, components, or layers for example.

[0299] Various examples have been described. These and other examples are within the scope of the following claims.

[0300] A system for measuring wear of an abrasive article includes a sensor configured to capture a plurality of sensed indications, each of the plurality of sensed indications being captured at a position on a surface of the abrasive article. The system also includes processing circuitry and associated memory, with the processing circuitry being configured to process each of the plurality of sensed indications. Additionally, a wear calculator is configured to, based on the processed indications, calculate an amount of wear for each of the positions.

[0301] The system can include a first sensed indication captured at a first distance from an edge of the abrasive article, and a second indication captured at a second distance from the edge of the abrasive article, with the first and second distances being different.

[0302] The system can include a sensor that includes a camera.

[0303] The camera can be configured to capture images in the visible light spectrum.

[0304] The plurality of sensed indications can include images of portions of the surface of the abrasive article at the position.

[0305] The camera can capture an image of the surface of the abrasive article, with each of the plurality of sensed indications including a portion of the image corresponding to an area around the position on the surface.

[0306] The sensor can include a pair of cameras.

[0307] The system can further include a light source.

[0308] A device can include the sensor and the processing circuitry.

[0309] The processing circuitry can be remote from the sensor.

[0310] The processing circuitry can receive the plurality of sensed indications using a wireless communication protocol.

[0311] The system can further include a communication component configured to communicate the amount of wear to a device.

[0312] The device can include a display component and a graphical user interface generation component configured to generate a graphical user interface for the display component that includes the calculated amount of wear for at least one of the positions.

[0313] The system can further include an abrasive article identifier configured to identify a make or model of the abrasive article from the plurality of sensed indications.

[0314] The system can further include a parameter generator configured to, based on the identified make or model and the calculated amount of wear, generate a parameter change for an abrading system including the abrasive article.

[0315] The parameter change can include a change in angle, a change in applied pressure, a change in position, or a change in speed.

[0316] The system can further include a communication component configured to transmit a control signal to the abrading system including the abrasive article, with the control signal including the generated parameter change.

[0317] The sensor can include a camera, the abrasive article can include an abrasive disc, and the camera can be configured to capture an image of the center of the abrasive disc, with the abrasive article identifier identifying the make or model of the abrasive disc based on the image of the center of the abrasive disc.

[0318] The parameter generator can retrieve a wear profile for the abrasive article, with the parameter change being generated based on the retrieved wear profile.

[0319] The sensor can include a camera, a time-of-flight sensor, a laser, or a pressure sensor.

[0320] The system can further include an impression maker configured to make an impression of the abrasive article, with the sensed indications being sensed from the impression.

[0321] The sensed indication can include a color of the abrasive article at the position, with the processing circuitry being configured to detect the color at each of the positions.

[0322] The processing circuitry can be configured to compare the detected color to a default color for the abrasive article.

[0323] The default color can be a detected color at a center of the abrasive article.

[0324] The default color can be retrieved based on an identification of the abrasive article.

[0325] The sensed indication can include a surface roughness of the abrasive article at the position.

[0326] The sensed indication can include an average height of abrasive particles at the position.

[0327] The sensed indication can include an abruptness of the abrasive article at the position.

[0328] The system can further include a damage detector configured to, based on the sensed indications, detect damage to the abrasive article at the position.

[0329] The damage can include heat damage, abrasive article warping, or capping.

[0330] The camera can be configured to capture images in an infrared spectrum.

[0331] The camera can be configured to capture images in the ultraviolet light spectrum.

[0332] The camera can be configured to capture images using hyperspectral imaging.

[0333] The sensor can be a tactile sensor.

[0334] A robotic abrading system includes a motive robotic unit configured to position an abrasive article with respect to a work surface and move the abrasive article along the work surface. The system also includes a force control unit configured to apply a force to the abrasive article while the abrasive article is contacting the work surface. Additionally, a wear detection system includes a sensor configured to sense a first wear indication at a first position on a surface of the abrasive article and a second wear indication at a second position on the surface of the abrasive article. A wear calculator is configured to, based on the first and second wear indications, calculate an amount of wear for the abrasive article. A communication component is configured to communicate the amount of wear to a device.

[0335] The motive robot unit can be configured to move in at least two degrees of freedom.

[0336] The motive robotic unit can be configured to rotationally move the abrasive article along the work surface.

[0337] The wear detection system can be coupled to the motive robotic unit.

[0338] The wear detection system can be separate from the motive robotic unit, with the motive robotic unit being configured to move the abrasive article from the work surface to a position proximate the wear detection system.

[0339] The position proximate the wear detection system can include the abrasive article at a distance from the sensor.

[0340] The position proximate the wear detection system can include the abrasive article oriented with respect to the sensor.

[0341] The system can further include a signal processing circuitry and associated memory configured to, based on the first or second wear indications, detect damage to the abrasive article.

[0342] The detected damage can include heat damage, abrasive article warping, or capping.

[0343] The first wear indication can be captured at a first distance from an edge of the abrasivearticle, and the second wear indication can be captured at a second distance from the edge of the abrasive article, with the first and second distances being different.

[0344] The sensor can include a camera.

[0345] The camera can be configured to capture images in the visible light spectrum.

[0346] The first and second wear indications can include images of portions of the surface of the abrasive article at the respective positions.

[0347] The camera can capture an image of the surface of the abrasive article, with the first and second wear indications including a portion of the image corresponding to an area around the positions on the surface.

[0348] The sensor can include a pair of cameras.

[0349] The system can further include a light source.

[0350] The signal processing circuitry can be remote from the sensor.

[0351] The signal processing circuitry can receive the first and second wear indications using a wireless communication protocol.

[0352] The system can further include a display component and a graphical user interface generation component configured to generate a graphical user interface for the display component that includes the calculated amount of wear for the abrasive article.

[0353] The system can further include an abrasive article identifier configured to identify a make or model of the abrasive article from the wear indications.

[0354] The system can further include a parameter generator configured to, based on the identified make or model and the calculated amount of wear, generate a parameter change for an abrading system including the abrasive article.

[0355] The parameter change can include a change in angle, a change in applied pressure, a change in position, or a change in speed.

[0356] The communication component can be further configured to transmit a control signal to an abrading system including the abrasive article, with the control signal including the identified parameter change.

[0357] The sensor can include a camera, the abrasive article can include an abrasive disc, and the camera can be configured to capture an image of the center of the abrasive disc, with the abrasive article identifier identifying the make or model of the abrasive disc based on the image of the center of the abrasive disc.

[0358] The parameter generator can retrieve a wear profile for the abrasive article, with the parameter change being generated based on the retrieved wear profile.

[0359] The sensor can include a camera, a time-of-flight sensor, a laser, or a pressure sensor.

[0360] The system can further include an impression maker configured to make an impression of the abrasive article, with the sensed indications being sensed from the impression.

[0361] Each of the first and second wear indications can include a color of the abrasive article at the position, with a signal processing circuitry being configured to detect the color at each of the positions.

[0362] The signal processing circuitry can be configured to compare the detected color to a default color for the abrasive article.

[0363] The default color can be a detected color at a center of the abrasive article.

[0364] The default color can be retrieved based on an identification of the abrasive article.

[0365] Each of the first and second wear indications can include a surface roughness of the abrasive article at the position.

[0366] Each of the first and second wear indications can include an average height of abrasive particles at the position.

[0367] Each of the first and second wear indications can include an abruptness of the abrasive article at the position.

[0368] A method of evaluating an abrasive article includes positioning the abrasive article proximate to a sensor, analyzing, using a signal analyzer, a received sensor signal from the sensor, with the received sensor signal being indicative of a sensed indication at a position on a surface of the abrasive article. The method also includes determining, based on the analysis, a status of the abrasive article at the position, and outputting the status of the abrasive article.

[0369] Outputting can include communicating the amount of wear to a graphical user interface generator for a device having a display.

[0370] The method can further include retrieving a set of parameters for an abrasive operation using the abrasive article, generating, based on the analysis, a process parameter change for the abrasive operation, and outputting can further include communicating the process parameter change.

[0371] If the abrasive operation is a robotic abrasive operation, the method can further include generating a control signal for a robotic abrading unit associated with the robotic abrasive operation, with the control signal including the process parameter change, and outputting can include communicating the control signal to a controller of the robotic abrading unit.

[0372] The method can further include, based on the received sensor signal, detecting damage to an abrasive surface of the abrasive article.

[0373] The damage can include heat damage, abrasive article warping, or capping.

[0374] Positioning the abrasive article can include positioning the abrasive article at a distancefrom, and at an orientation with respect to, the sensor.

[0375] The received sensor signal can include a first sensed indication captured at a first distance from an edge of the abrasive article, and the method can further include receiving a second indication captured at a second distance from the edge of the abrasive article, with the first and second distances being different.

[0376] The sensor can include a camera, and the method can further include capturing an image of the position on the surface of the abrasive article.

[0377] Capturing an image can include capturing an image in the visible light spectrum.

[0378] The image can include an image of an area of the surface of the abrasive article, with the area including the position.

[0379] Capturing an image can include capturing an image, with the camera, of the entire surface of the abrasive article, and isolating a portion of the image, with the portion including an area of the surface of the abrasive article including the position.

[0380] The sensor can include a pair of cameras.

[0381] The sensor can further include a light source.

[0382] The method can be performed by a device including a sensor and a signal analyzer.

[0383] The signal analyzer can be remote from the sensor.

[0384] The signal analyzer can receive the sensed indications using a wireless communication protocol.

[0385] The method can further include identifying, using an abrasive article identifier, a make or model of the abrasive article from the sensed indications.

[0386] The method can further include retrieving a current set of parameters for an abrasive tool associated with the abrasive article, and generating, using a parameter generator, a parameter change for an abrasive operation based on the identified make or model, the calculated amount of wear, and the current set of parameters.

[0387] The parameter change can include a change in angle, a change in applied pressure, a change in position, or a change in speed.

[0388] The method can further include transmitting a control signal, using a communication component, to the abrasive tool, with the control signal including the identified parameter change.

[0389] The sensor can include a camera, the abrasive article can include an abrasive disc, and the camera can be configured to capture an image of the center of the abrasive disc, with the abrasive article identifier identifying the make or model of the abrasive disc based on the image of the center of the abrasive disc.

[0390] The method can further include retrieving, using a wear profile retriever, a wear profilefor the abrasive article, with the parameter change being generated based on the retrieved wear profde.

[0391] The sensor can include a camera, a time-of-flight sensor, a laser, or a pressure sensor.

[0392] Positioning the abrasive article can include making an impression, using an impression maker, of the abrasive article, and positioning the impression with respect to the sensor such that the sensed indications are sensed from the impression.

[0393] The sensed indication can include a color of the abrasive article at the position, with the signal analyzer being configured to detect the color at each of the positions.

[0394] Analyzing the received sensor signal can include comparing the detected color to a default color for the abrasive article.

[0395] The default color can be a detected color at a center of the abrasive article.

[0396] The default color can be retrieved based on an identification of the abrasive article.

[0397] The sensed indication can include a surface roughness of the abrasive article at the position.

[0398] The sensed indication can include an average height of abrasive particles at the position

[0399] The sensed indication can include an abruptness of the abrasive article at the position.

[0400] The method can further include determining, using a damage detector, based on the sensed indications, that damage to the abrasive article is present at the position.

[0401] The damage can include heat damage, abrasive article warping, or capping.

[0402] A method of generating a wear evaluation for an abrasive article includes receiving, using a signal receiver, a first sensed indication of a first amount of wear at a first position on the abrasive article, and receiving, using the signal receiver, a second sensed indication of a second amount of wear at a second position on the abrasive article, with the second position being at a different distance from a center of the abrasive article than the first position. The method also includes receiving a default wear indication for the abrasive article, comparing the received first and second sensed indications to the default wear indication, and based on the comparison, using a wear evaluator, characterizing a wear profile for the abrasive article, with the wear profile including the first amount of wear and the second amount of wear.

[0403] The method can further include analyzing the first or second sensed indication for detecting damage to the abrasive article.

[0404] The damage can include contamination, heat damage, capping, or abrasive article warping.

[0405] The first sensed indication can include an image of the abrasive article at the first position, and the method can further include detecting a first color of the abrasive article at thefirst position, comparing the first color of the abrasive article to a default color, with the default color including a color of a substantially unused portion of the abrasive article, and calculating an amount of wear at the first position based on the comparison.

[0406] The method can further include receiving, using the signal receiver, a third sensed indication proximate a center of the abrasive article, with the third sensed indication being the default wear indication.

[0407] The method can further include retrieving a wear profile for the abrasive article, and comparing can further include comparing the first color of the abrasive article to the wear profile, with the amount of wear including an indication of life remaining.

[0408] The method can further include retrieving a set of abrasive operating parameters for an abrasive tool associated with the abrasive article, and determining, based on the amount of wear and the set of abrasive operations, the indication of life remaining, with the indication of life remaining including an indication of a number of abrasive operations remaining for the abrasive article.

[0409] The method can further include retrieving a set of abrasive operating parameters for an abrasive tool associated with the abrasive article, generating a parameter change for the abrasive tool, based on the retrieved set of abrasive operating parameters and the wear profile, with the parameter change extending a number of abrasive operations remaining for the abrasive article compared to the retrieved set of abrasive operating parameters.

[0410] The parameter change can include a change in rotational speed, a change in angle of contact with an abrasive article, or an applied pressure.

[0411] The method can further include communicating the parameter change to the abrasive tool.

[0412] The method can further include communicating the amount of wear to a graphical user interface generator for a device having a display.

[0413] If the abrasive operation is a robotic abrasive operation, the method can further include generating a control signal for a robotic abrading unit associated with the robotic abrasive operation, with the control signal including the parameter change, and communicating the control signal to a controller of the robotic abrading unit.

[0414] The method can further include positioning the abrasive article at a distance from, and at an orientation with respect to, a sensor.

[0415] The sensor can include a camera, and the method can further include capturing an image of the first position on the surface of the abrasive article.

[0416] Capturing an image can include capturing an image in the visible light spectrum.

[0417] The image can include an image of an area of the surface of the abrasive article, with the area including the first position.

[0418] Capturing an image can include capturing an image, with the camera, of the entire surface of the abrasive article, and isolating a first portion of the image, with the first portion including a first area of the surface of the abrasive article including the first position, and isolating a second portion of the image, with the second portion including a second area of the surface of the abrasive particle including the second position.

[0419] The sensor can include a pair of cameras.

[0420] The sensor can further include a light source.

[0421] The method can be performed by a device including a sensor and a wear calculator.

[0422] A signal analyzer can be remote from the sensor.

[0423] The signal analyzer can receive the sensed indications using a wireless communication protocol.

[0424] The method can further include identifying, using an abrasive article identifier, a make or model of the abrasive article from the sensed indications.

[0425] The signal receiver can receive a first image captured by a camera, with the first image including the first sensed indication.

[0426] The first image can be of a first area of the abrasive article that includes the first position.

[0427] The first image can include both a first area, including the first position, and a second area, including the second position.

[0428] Receiving the default wear indication can include receiving a second image including a center area of the abrasive article.

[0429] The second image can include a portion of the first image.

[0430] The method can further include identifying, based on the second image, a make or model of the abrasive article.

[0431] The signal receiver can receive a signal from a sensor, with the sensor including a camera, atime-of-flight sensor, a laser, or a pressure sensor.

[0432] The default color can be a detected color at a center of the abrasive article.

[0433] The sensed indication can include a surface roughness of the abrasive article at the position.

[0434] The sensed indication can include an average height of abrasive particles at the position.

[0435] The sensed indication can include an abruptness of the abrasive article at the position.

Claims

ClaimsWhat is claimed is:

1. A system for measuring wear of an abrasive article, the system comprising:a sensor configured to capture a plurality of sensed indications, each of the plurality of sensed indications being captured at a position on a surface of the abrasive article;a processing circuitry and associated memory, the processing circuitry being configured to process each of the plurality of sensed indications; anda wear calculator configured to, based on the processed indications, calculate an amount of wear for each of the positions.

2. The system of claim 1, wherein a first sensed indication is captured at a first distance from an edge of the abrasive article, a second indication is captured at a second distance from the edge of the abrasive article, and wherein the first and second distances are different.

3. The system of claim 1 or 2, wherein the sensor comprises a camera.

4. The system of claim 3, wherein the plurality of sensed indications comprises images of portions of the surface of the abrasive article at the position.

5. The system of any of claims 3-4, wherein the camera captures an image of the surface of the abrasive article, and wherein each of the plurality of sensed indications comprises a portion of the image corresponding to an area around the position on the surface.

6. The system of any of claims 1-5, further comprising a light source.

7. The system of any of claims 1-6, wherein a device comprises the sensor and the processing circuitry.

8. The system of any of claims 1-7, wherein the processing circuitry is remote from the sensor.

9. The system of any of claims 1-8, and further comprising a communication component configured to communicate the amount of wear to a device.

10. The system of any of claims 1-9, and further comprising an abrasive article identifier configured to identify a make or model of the abrasive article from the plurality of sensed indications.

11. The system of claim 10, and further comprising a parameter generator configured to, based on the identified make or model and the calculated amount of wear, generate a parameter change for an abrading system comprising the abrasive article , and wherein the parameter change comprises a change in angle, a change in applied pressure, a change in position, or a change in speed , and wherein the system further comprises a communication component configured to transmit a control signal to the abrading system comprising the abrasive article, wherein the control signal comprises the generated parameter change.

12. The system of claim 11, wherein the sensor comprises a camera, the abrasive article comprises an abrasive disc, and wherein the camera is configured to capture an image of the center of the abrasive disc, and wherein the abrasive article identifier identifies the make or model of the abrasive disc based on the image of the center of the abrasive disc.

13. The system of claim 12, wherein the parameter generator retrieves a wear profile for the abrasive article, and wherein the parameter change is generated based on the retrieved wear profile.

14. The system of any of claims 1-13, wherein the sensed indication comprises a color of the abrasive article at the position, and wherein the processing circuitry is configured to detect the color at each of the positions.

15. The system of claim 14, wherein the processing circuitry is configured to compare the detected color to a default color for the abrasive article , and wherein the default color is a detected color at a center of the abrasive article.

16. The system of claim 15, wherein the default color is retrieved based on an identification of the abrasive article.

17. The system of any of claims 1-16, wherein the sensed indication comprises a surface roughness of the abrasive article at the position.

18. The system of any of claims 1-17, wherein the sensed indication comprises an average height of abrasive particles at the position.

19. The system of any of claims 1-18, wherein the sensed indication comprises an abruptness of the abrasive article at the position.

20. The system of any of claims 1-19, and further comprising a damage detector configured to, based on the sensed indications, detect damage to the abrasive article at the position.

21. A robotic abrading system comprising:a motive robotic unit configured to position an abrasive article with respect to a work surface, and configured to move the abrasive article along the work surface;a force control unit configured to apply a force to the abrasive article while the abrasive article is contacting the work surface; anda wear detection system comprising:a sensor configured to sense a first wear indication at a first position on a surface of the abrasive article and a second wear indication at a second position on the surface of the abrasive article;a wear calculator configured to, based on the first and second wear indications, calculate an amount of wear for the abrasive article; anda communication component configured to communicate the amount of wear to a device.

22. The robotic abrading system of claim 21, wherein the motive robot unit is configured to move in at least two degrees of freedom.

23. The robotic abrading system of any of claims 21-22, wherein the wear detection system is coupled to the motive robotic unit.

24. The robotic abrading system of any of claims 21-23, wherein the wear detection system is separate from the motive robotic unit, and wherein the motive robotic unit is configured to move the abrasive article from the work surface to a position proximate the wear detection system.

25. The robotic abrading system of any of claims 21-24, and further comprising a signal processing circuitry and associated memory configured to, based on the first or second wear indications, detect damage to the abrasive article.

26. The robotic abrading system of claim 25, wherein the detected damage comprises heat damage, abrasive article warping or capping.

27. The robotic abrading system of any of claims 21-26, wherein the first wear indication is captured at a first distance from an edge of the abrasive article, the second wear indication is captured at a second distance from the edge of the abrasive article, and wherein the first and second distances are different.

28. The robotic abrading system of any of claims 21-27, wherein the sensor comprises a camera.

29. The robotic abrading system of claim 28, wherein the first and second wear indications comprise images of portions of the surface of the abrasive article at the respective positions.

30. The robotic abrading system of claim 28, wherein the camera captures an image of the surface of the abrasive article, and wherein the first and second wear indications comprise a portion of the image corresponding to an area around the positions on the surface.

31. A method of evaluating an abrasive article, the method comprising:positioning the abrasive article proximate to a sensor;analyzing, using a signal analyzer, a received sensor signal, from the sensor, the received sensor signal being indicative of a sensed indication at a position on a surface of the abrasive article;determining, based on the analysis, a status of the abrasive article at the position; and outputting the status of the abrasive article.

32. The method of claim 31, and further comprising:retrieving a set of parameters for an abrasive operation using the abrasive article; generating, based on the analysis, a process parameter change for the abrasive operation; andwherein outputting further comprises communicating the process parameter change.

33. The method of claim 32, wherein the abrasive operation is a robotic abrasive operation, the method further comprises:generating a control signal for a robotic abrading unit associated with the robotic abrasive operation, the control signal comprising the process parameter change; and wherein outputting comprises communicating the control signal to a controller of the robotic abrading unit.

34. The method of any of claims 31-33, and further comprising:based on the received sensor signal, detecting damage to an abrasive surface of the abrasive article , wherein the damage comprises heat damage, abrasive article warping or capping.

35. The method of any of claims 32-34, wherein positioning the abrasive article comprises positioning the abrasive article at a distance from, and at an orientation with respect to, the sensor.

36. The method of any of claims 32-35, wherein the received sensor signal comprises a first sensed indication captured at a first distance from an edge of the abrasive article, and wherein the method further comprises receiving a second indication captured at a second distance from the edge of the abrasive article, and wherein the first and second distances are different.

37. The method of any of claims 32-36, wherein the sensor comprises a camera, and wherein the method further comprises capturing an image of the position on the surface of the abrasive article.

38. The method of any of claims 32-37, and further comprising:identifying, using an abrasive article identifier, a make or model of the abrasive article from the sensed indications.

39. The method of claim 38, and further comprising:retrieving a current set of parameters for an abrasive tool associated with the abrasive article; andgenerating, using a parameter generator, a parameter change for an abrasive operation based on the identified make or model, the calculated amount of wear, and the current set of parameters , wherein the parameter change comprises a change in angle, a change in applied pressure, a change in position, or a change in speed and wherein the method further comprises transmitting a control signal, using a communication component, to the abrasive tool, wherein the control signal comprises the identified parameter change.

40. The method of any of claims 32-39, wherein the sensed indication comprises a color of the abrasive article at the position, and wherein the signal analyzer is configured to detect the color at each of the positions.

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