Disc Grinder Posture Detection Using Force Sensor Moments
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Solution Overview
Problem
Existing disc grinders lack a method for accurately recognizing the posture of the disc tool with respect to the workpiece, relying solely on operator evaluation, which affects processing accuracy.
Innovation Solution
Incorporating a force sensor to detect moments acting on the disc tool and a controller to analyze these signals to determine the posture of the disc tool relative to the workpiece, with visual and auditory feedback to maintain proper alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If operator evaluation is used to recognize disc tool posture, then device complexity is reduced, but measurement precision of posture detection deteriorates
Solution Approach 1:
The patent replaces the operator's visual evaluation (mechanical/perceptual system) with a force sensor-based detection system. The force sensor measures moments acting on the disc tool, and the controller calculates posture angles from these moments, substituting human judgment with an automated measurement system that provides objective, precise posture detection.
Solution Approach 2:
The patent introduces a force sensor as an intermediary between the disc tool and the control system. This intermediary device measures the moments acting on the disc tool during operation, and the controller uses these measurements to calculate the posture angles, enabling indirect but accurate detection of disc tool orientation without requiring direct visual observation.
2Measurement precision
If force sensor and controller are added to detect posture, then measurement precision of posture detection is improved, but device complexity increases
Solution Approach 1:
The force sensor serves multiple functions: it detects moments acting on the disc tool during grinding operations, and this data is used to calculate posture angles. The same force sensor also provides data for monitoring grinding forces and detecting abnormal conditions, making it a multi-functional component that justifies its addition to the system.
Solution Approach 2:
The patent implements a feedback mechanism where the controller continuously monitors the moments detected by the force sensor, calculates the current posture angles, and compares them against predetermined acceptable ranges. When the posture deviates from the acceptable range, the system provides feedback to alert the operator, creating a closed-loop control system that maintains precision.
3Manufacturing precision
If posture detection is implemented, then processing accuracy is improved, but ease of operation deteriorates
Solution Approach 1:
The patent implements a feedback mechanism where the controller continuously monitors the moments detected by the force sensor, calculates the current posture angles, and compares them against predetermined acceptable ranges. When the posture deviates from the acceptable range, the system provides feedback to alert the operator, creating a closed-loop control system that maintains precision.
Solution Approach 2:
The system performs self-diagnosis and self-correction by automatically detecting posture deviations and alerting the operator without requiring manual intervention. The force sensor and controller work autonomously to monitor and maintain proper disc tool orientation, reducing the operator's cognitive load while ensuring processing 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 detection and maintenance of the disc tool's posture relative to the workpiece, enhancing processing accuracy and guiding operators to correct deviations.
Implementation Method 1
a force sensor configured to detect a moment acting on the disc tool
Data Source
AI summary
Detected is a posture of a disc tool with respect to a workpiece. A grinder includes: a disc tool configured to process a workpiece; a force sensor configured to detect a moment acting on the disc tool; and a controller, the controller carrying out a detection process of detecting a posture of the disc tool with respect to the workpiece on the basis of an output signal obtained from the force sensor.