Autonomous Grinding Path Control With 3D Modeling and Force Feedback
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Solution Overview
Problem
Existing grinding technologies lack the ability to autonomously and accurately grind workpieces to precise dimensions and contours without manual intervention, particularly in identifying and processing regions such as welds and blemishes, while maintaining consistent force application.
Innovation Solution
A system and method that utilizes an optical sensor to capture and compile images into a virtual three-dimensional model of the workpiece, identifies a set of markers, and implements a robotic arm with a grinding head that navigates the workpiece, and implements closed-loop controls to maintain consistent force application, and a grinding head that autonomously captures and compiles the set of images into a virtual model of the workpiece, and autonomously captures and compiles the set of images into a virtual three-dimensional model of the workpiece, and autonomously navigates the grinding head to remove material to achieve precise dimensions and contours.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional grinding technologies are used, then manual intervention is required for operation, but automation level remains low and productivity is reduced
Solution Approach 1:
The system enables autonomous operation through self-service mechanisms: the optical sensor automatically captures images, the controller autonomously processes data to identify grinding regions, and the grinding head self-navigates based on generated toolpaths. This eliminates manual intervention while maintaining operational effectiveness, directly resolving the contradiction between automation level and ease of operation
Solution Approach 2:
The patent replaces manual mechanical operation with an automated control system that uses optical sensing, computer vision, and algorithmic toolpath generation. The controller substitutes human decision-making with automated image processing and autonomous navigation, achieving high automation while simplifying operation through systematic control
2Manufacturing precision
If conventional grinding methods are used, then measurement precision is insufficient, but manufacturing precision to tight tolerances cannot be achieved
Solution Approach 1:
The system creates a virtual copy of the workpiece through optical imaging and 3D modeling. The controller generates a virtual model that replicates the workpiece geometry, allowing precise measurement and analysis before actual grinding. This virtual copying enables both high measurement precision for detecting deviations and high manufacturing precision for achieving target dimensions
Solution Approach 2:
The system implements closed-loop feedback by continuously comparing the virtual model against target specifications, identifying deviations, and adjusting the toolpath accordingly. The optical sensor provides real-time measurement feedback during grinding operations, enabling dynamic correction to maintain both measurement and manufacturing precision within tight tolerances
3Productivity
If automated grinding systems are implemented, then productivity increases, but device complexity increases
Solution Approach 1:
The system achieves multi-functionality by integrating optical sensing, image processing, 3D modeling, toolpath generation, and grinding execution into a single unified platform. The controller performs multiple functions including data processing, decision-making, and motion control, reducing the need for separate specialized devices and managing complexity while maintaining high productivity
Solution Approach 2:
The patent merges previously separate operations (inspection, programming, and grinding) into an integrated autonomous system. The optical sensor, controller, and grinding head function as a coordinated unit, combining measurement and manufacturing functions to improve productivity while managing overall system complexity through integration
4Reliability
If force control is not implemented, then operation is simpler, but consistency of force application deteriorates
Solution Approach 1:
The system implements force feedback control by monitoring grinding forces in real-time and adjusting the toolpath or grinding parameters to maintain consistent force application. This closed-loop control ensures reliability of force consistency while managing complexity through systematic feedback mechanisms
Data Source
AI summary
A method for autonomously grinding a workpiece includes: accessing a virtual model defining a geometry of the workpiece; identifying a grinding region on the workpiece; and projecting a target grinding profile onto the grinding region on the workpiece. The method also includes: based a geometry of the workpiece and the target grinding profile, generating a tool path for removal of material from the grinding region to the target grinding profile; and assigning a target force to the target region. The method also includes, during a processing cycle: accessing a sequence of force values output by a force sensor coupled to a grinding head; navigating the grinding head across the grinding region according to the tool path; and, based on the sequence of force values, deviating the grinding head from the tool path to maintain forces of the grinding head on the grinding region proximal the target force.