Abrasive Disc Testing Device with Sensor Feedback
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Solution Overview
Problem
Current methods for testing abrasive discs are either highly operator-dependent and subjective or expensive and cumbersome, making them non-repeatable and inaccessible in many settings.
Innovation Solution
A compact, portable device equipped with sensors and a processing module that ensures consistent test parameters by monitoring and adjusting the orientation, pressure, and rotation of the abrasive disc during machining, providing real-time feedback to the operator.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If manual testing is performed by an operator, then the test can be carried out with simple equipment, but the test results are not repeatable and are dependent on operator variability
Solution Approach 1:
The patent employs sensors (force sensor, orientation sensor, rotation sensor) that provide real-time feedback to the operator during the machining test. The processing module receives data from these sensors and provides guidance signals to help the operator maintain constant test parameters (pressure, orientation, rotation speed), thereby eliminating operator variability while keeping the testing system simple and accessible.
2Reliability
If automatic machines are used to maintain constant test parameters, then repeatable and objective test results are achieved, but the equipment becomes expensive and cumbersome
Solution Approach 1:
The system enables the operator to self-correct and maintain proper test conditions through real-time feedback from sensors and processing module guidance. Instead of requiring complex automatic machinery to enforce constant parameters, the operator actively participates in maintaining test conditions based on sensor feedback, thereby achieving repeatable results with simpler, more accessible equipment.
3Reliability
If complex automatic testing machines are deployed, then consistent test conditions are maintained, but the device becomes less portable and more difficult to transport
Solution Approach 1:
The testing system is divided into separate functional components: sensors (force sensor, orientation sensor, rotation sensor), a processing module, and a display unit. This segmentation allows the system to be configured in different ways and makes it more adaptable to portable applications, as components can be distributed or integrated based on specific testing needs rather than requiring a single complex machine.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The device enables objective, repeatable, and cost-effective testing of abrasive discs, ensuring consistent results and reducing operator variability, while being easily transportable and accessible.
Implementation Method 1
a first sensor (2), set up to detect the orientation of the disc (D) in space
Implementation Method 2
a second sensor (3), set up to detect a contact force between the disc (D) and the surface to be machined
Implementation Method 3
a third sensor (4), set up to detect a rotation speed of the tool (T)
Data Source
Figure 1
Figure 2
AI summary
A device for testing an abrasive disc, comprising: a first sensor (2), applicable to an electric tool (T) for activation in rotation about an axis of rotation (Z) of an abrasive disc (D), which is set up to detect the orientation of the disc (D) in space; a second sensor (3), set up to detect a force with which the disc (D) is pressed in contact with a work surface; a processing module (C), provided with an algorithm set up to detect the transmitted data of the first and second sensor (2,3), so as to compare said data with prefixed threshold intervals and to process a signal which indicates to an operator whether the data transmitted from the first and second sensor (2,3) are within the prefixed threshold intervals.