Coated Substrate Edge Detection Using Electrical Circuit Sensing
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Solution Overview
Problem
Existing edge finding methods struggle to accurately locate the edges of substrates coated with non-conductive materials like polymers, ceramics, or thermal barrier coatings (TBCs) due to their irregular thickness, making it difficult to form chamfered edges without manual labor and potential damage.
Innovation Solution
A system utilizing an electrical circuit between a conductive tool and a coated assembly, where a sensor detects changes in electrical parameters such as voltage, current, or capacitance to determine the edge of a conductive substrate beneath a dielectric coating, allowing for precise control of the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual edge finding methods are used on coated substrates, then the process can be performed without specialized equipment, but the accuracy is reduced and manual labor increases
Solution Approach 1:
The patent replaces manual mechanical edge-finding methods with an automated electrical detection system. A conductive tool connected to a power source and sensor creates an electrical circuit that detects substrate edges through changes in electrical parameters (voltage, current, or capacitance) when the tool transitions from coating to substrate, eliminating the need for manual visual inspection and positioning.
Solution Approach 2:
The patent introduces an electrical circuit as an intermediary between the operator and the substrate edge detection process. The circuit includes a power source, conductive tool, and sensor that work together to detect edge locations automatically, serving as a mediator that translates physical edge position into detectable electrical signal changes.
2Measurement precision
If traditional touch probes or optical edge finders are used, then edge location can be detected, but they cannot accurately distinguish substrate edges from coating surfaces
Solution Approach 1:
The patent utilizes changes in electrical parameters (voltage, current, or capacitance) as the conductive tool moves from the dielectric coating to the conductive substrate. The sensor detects these parameter changes to accurately identify the edge location, leveraging the fundamental electrical property difference between the coating and substrate materials.
Solution Approach 2:
The patent replaces mechanical touch probes and optical edge-finding systems with an electrical detection system that uses conductive properties to identify edges. This substitution enables accurate differentiation between non-conductive coating and conductive substrate, overcoming the limitations of mechanical and optical methods.
3Reliability
If the dielectric coating has irregular thickness, then the coating provides better protective properties, but edge detection becomes more difficult
Solution Approach 1:
The patent detects edge locations by monitoring changes in electrical parameters (voltage, current, or capacitance) that occur when the conductive tool transitions from the dielectric coating to the conductive substrate. This method is insensitive to coating thickness variations because it detects the fundamental electrical property boundary rather than relying on mechanical contact or optical reflection that would be affected by thickness irregularities.
Solution Approach 2:
The patent replaces mechanical and optical detection methods with an electrical detection system that measures changes in electrical parameters. This substitution allows accurate edge detection even with irregular coating thickness, as the electrical circuit detection is based on material conductivity differences rather than geometric uniformity.
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
Enables accurate and automated detection of substrate edges, reducing manual intervention and minimizing damage by adjusting the tool path in real-time, ensuring precise machining of chamfered surfaces.
Implementation Method 1
A system for detecting an edge of a substrate includes an electrical circuit. The system utilizes the electrical resistivity of the conductive substrate as part of an electrical circuit
Implementation Method 2
A sensor detects changes in electrical parameters such as voltage, current, or capacitance to determine the edge of a conductive substrate beneath a dielectric coating
Data Source
AI summary
A system for detecting an edge of a substrate, comprising a coated assembly. The coated assembly includes a conductive substrate having at least one edge portion and a dielectric coating coupled along the conductive substrate, the dielectric coating covering the at least one edge portion of the conductive substrate. The system also includes a conductive tool configured to interact with the coated assembly and a substrate sensing system. The substrate sensing system includes a power source coupled with the conductive tool, the coated assembly, and an electrical circuit including the power source and the coated assembly and a sensor configured to sense a change between an open configuration and a closed configuration of the electrical circuit. In an open configuration the conductive tool is engaged with the coated assembly and disengaged from the conductive substrate and in a closed configuration the conductive tool is engaged with the conductive substrate.