Laser Vibrometry in Coating Dressing to Prevent Substrate Damage

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Solution Overview

Problem

Existing cutting tools can damage substrate surfaces during coating dressing operations due to the inability to accurately detect the boundary between the coating and substrate, leading to manual or automatic operations that risk exceeding the coating material boundary.

Innovation Solution

A coating dressing system utilizing a laser Doppler vibrometer to measure substrate vibrations during the dressing process, detecting vibration levels and comparing them against a database of predetermined thresholds to control the cutting tool's movement and prevent contact with the substrate surface.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If manual or automatic cutting tools are used for coating dressing operations, then coating dimensions can be modified, but the cutting tool may damage the substrate surface when exceeding the coating boundary

Engineering Contradiction:

Improvecoating dimension accuracyVSAvoidsubstrate surface damage

Core Design Contradiction:

Manufacturing precisionVSObject-affected harmful factors

Solution Approach 1:

The laser Doppler vibrometer performs preliminary detection of the coating-substrate boundary by measuring vibration signals before the cutting tool reaches the boundary. This advance detection allows the system to prepare stopping signals, preventing substrate damage while maintaining coating dimension accuracy.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The system continuously monitors vibration signals during cutting operations and provides real-time feedback to the cutting tool control. When the vibration signal indicates proximity to the coating boundary, the feedback mechanism automatically adjusts or stops the cutting tool, preventing substrate damage.

Inventive Principle:

Principle #23Feedback

2Manufacturing precision

If the cutting tool operates close to the coating boundary to achieve precise dimensions, then manufacturing precision improves, but the risk of substrate damage increases

Engineering Contradiction:

Improvecoating surface finishVSAvoidsubstrate integrity

Core Design Contradiction:

Manufacturing precisionVSReliability

Solution Approach 1:

The laser Doppler vibrometer acts as an intermediary sensing system between the cutting tool and the coating boundary. It detects subtle vibration changes caused by tool proximity to the boundary and translates these into control signals, enabling precise cutting while maintaining substrate integrity through non-contact measurement.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The system replaces direct mechanical contact sensing with optical laser Doppler vibrometry for boundary detection. This substitution eliminates the need for physical contact between the sensing system and the workpiece, allowing ultra-precise measurement of vibration signals that indicate coating boundary proximity without mechanical interference.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If the laser Doppler vibrometer is used to detect vibration at multiple locations, then measurement precision improves, but device complexity increases

Engineering Contradiction:

Improvevibration detection accuracyVSAvoidsystem configuration

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The laser Doppler vibrometer is designed with multi-functionality to perform multiple detection tasks using a single integrated system. It can measure vibrations at multiple locations, track coating boundary position, and provide real-time feedback control, thereby achieving high measurement precision without proportionally increasing device complexity.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The system merges the laser source, Doppler signal processing, and vibration analysis functions into a single integrated measurement system. By combining these functions, the system achieves precise multi-location vibration detection while minimizing the number of separate components and reducing overall system complexity.

Inventive Principle:

Principle #5Merging (Combining)

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 system effectively prevents substrate damage by providing precise control over cutting tool movement, reducing operation time and enhancing part quality through non-contact vibration measurement and automated adjustments.

Implementation Method 1

a laser configured to emit a laser beam toward a side surface of a substrate... a sensor configured to sense a reflected laser pattern

Methodology Applied

Scientific EffectLaser Doppler vibrometry: Laser Doppler Velocimetry

Implementation Method 2

laser Doppler vibrometer... reflected laser pattern indicates a level of vibration that the substrate is experiencing

Methodology Applied

Scientific EffectDoppler effect: Doppler Effect

Data Source

PatentUS20250377238A1System and method to dress a coating using laser doppler vibrometer

Publication Date: 2025.12.11 RTX CORP

AI summary

A coating dressing system including a laser Doppler vibrometer in operative communication with a controller; the laser Doppler vibrometer comprising a laser configured to emit a laser beam toward an object, the laser Doppler vibrometer comprising a sensor configured to sense a reflected laser pattern, wherein the reflected laser pattern comprises a reflection of the laser beam bouncing off the object; and a cutting tool in operative communication with the controller.