Conductive Tool Edge Sensing Through Dielectric Coatings
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Solution Overview
Problem
Existing edge finding methods struggle to accurately locate the edges of substrates coated with dielectric materials like polymer, ceramic, or thermal barrier coatings, which have inconsistent thicknesses, making manual removal laborious and imprecise.
Innovation Solution
A system utilizing an electrical circuit between a conductive tool and a coated assembly, where a sensor detects changes in electrical parameters to determine the edge of a conductive substrate beneath a dielectric coating, allowing for precise edge detection and automated adjustment of the tool path during machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual methods or traditional touch probes are used to find the edge of a coated substrate, then the process is simple to implement, but the detection precision deteriorates due to inconsistent coating thickness and obscured edges
Solution Approach 1:
The patent replaces mechanical edge detection methods (touch probes, manual grinding) with an electrical detection system. A conductive tool forms an electrical circuit with the conductive substrate through the dielectric coating, and a sensor detects circuit closure to precisely identify the edge location. This substitution enables accurate edge detection despite variable coating thickness.
Solution Approach 2:
The dielectric coating itself serves as an intermediary element in the detection system. Rather than trying to see through or remove the coating, the system uses the coating's electrical properties as part of the detection mechanism. The conductive tool establishes an electrical circuit through the dielectric material, and the sensor detects when the circuit closes at the substrate edge, making the coating thickness variation irrelevant to detection accuracy.
2Ease of operation
If manual removal of coating is used to expose the edge, then the edge becomes accessible for detection, but the process becomes laborious and time-consuming
Solution Approach 1:
The patent eliminates the need for mechanical coating removal by substituting it with an electrical detection method. The conductive tool and sensor system can detect the substrate edge through the intact dielectric coating, completely avoiding laborious manual grinding or coating removal processes while maintaining edge accessibility for precise machining.
Solution Approach 2:
The detection system uses the electrical properties of the materials already present in the workpiece (conductive substrate and dielectric coating) to perform the detection function. The substrate and coating themselves provide the necessary electrical characteristics for the circuit-based detection, eliminating the need for separate preparation steps to expose the edge.
3Measurement precision
If the conductive tool is allowed to contact the substrate directly, then accurate edge detection is achieved, but damage to the coated substrate may occur
Solution Approach 1:
The sensor provides real-time feedback about the electrical circuit status to the control system. When the conductive tool approaches the substrate edge and the circuit is about to close, the sensor detects the change in electrical parameters and signals the control system to stop the tool's advance. This feedback mechanism enables accurate edge detection while preventing the tool from making damaging contact with the substrate.
Solution Approach 2:
The system takes preliminary action by detecting the impending circuit closure before actual contact occurs. The sensor monitors electrical parameters and triggers a stop command in advance, preventing the harmful action of tool-substrate contact while still achieving the desired edge detection accuracy.
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 precise edge detection and minimizes damage to coated substrates by ensuring the conductive tool accurately stops at the substrate surface, reducing manual intervention and improving machining accuracy.
Implementation Method 1
the sensor is configured to sense a change in a parameter of the electrical circuit according to machining of the coated assembly
Implementation Method 2
A system utilizing an electrical circuit between a conductive tool and a coated assembly, where a sensor detects changes in electrical parameters
Data Source
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AI summary
A system (100) for detecting an edge of a substrate (110) comprises a coated assembly (150; ...; 650) including a conductive substrate (110; 410; 610) having an edge portion (125; 425; 625) and a dielectric coating (120; 420; 620) covering the edge portion (125; 425; 625) of the conductive substrate (110; 410; 610). The system (100) also includes a conductive tool (160; ...; 660) configured to interact with the coated assembly (150; ...; 650) and a substrate (110) sensing system (100). The substrate (110) sensing system (100) is configured to sense a change between an open configuration and a closed configuration of an electrical circuit (305) in which the conductive tool engages the conductive substrate.