Disc Grinder Wear Detection Using Force Sensor Moments
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Solution Overview
Problem
Existing disc grinders lack a method for detecting the worn state of the disc tool, relying solely on operator judgment.
Innovation Solution
Incorporating a force sensor to detect moments acting on the disc tool and a controller to analyze these moments to determine the worn state, with additional features like input devices for tool information and displays for notification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If operator visual inspection is used to determine disc tool wear, then no additional sensors or detection systems are needed, but the detection precision and reliability are insufficient
Solution Approach 1:
The patent replaces the mechanical/visual inspection method with a force sensor-based detection system. The force sensor measures forces and moments during disc tool operation to detect wear states, substituting human visual judgment with automated mechanical sensing that provides objective, precise measurements of tool condition.
Solution Approach 2:
The force sensor acts as an intermediary between the disc tool and the control system. It indirectly detects wear by measuring forces and moments generated during operation, translating physical tool degradation into measurable signals that the controller can process to determine wear states.
2Productivity
If no wear detection system is implemented, then the device complexity remains low, but the productivity decreases due to frequent manual inspections and premature replacements
Solution Approach 1:
The force sensor continuously monitors forces and moments during disc tool operation and feeds this information to the controller. The controller processes these signals to detect wear states and can provide feedback for timely tool replacement decisions, optimizing tool utilization by replacing tools based on actual wear conditions rather than fixed schedules.
Solution Approach 2:
The wear detection system enables the grinding machine to automatically monitor its own tool condition without requiring external manual inspection. The force sensor and controller work together to self-diagnose disc tool wear states, allowing the system to optimize its own performance and maintenance scheduling.
3Reliability
If manual visual inspection is used for disc tool wear determination, then the ease of operation is maintained, but the reliability of wear state assessment is insufficient
Solution Approach 1:
The patent replaces subjective visual inspection with objective force-based measurement. The force sensor provides quantitative data about disc tool wear through force and moment measurements, eliminating the subjectivity and variability inherent in manual visual assessment and providing reliable, consistent wear state determination.
Solution Approach 2:
The force sensor serves as an intermediary that objectively measures tool wear through physical force measurements rather than relying on operator visual judgment. This intermediary provides reliable, consistent data that is independent of individual operator skill or fatigue levels.
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 of disc tool wear, allowing for timely replacement and controlled rotation speed adjustment, potentially automating the replacement process.
Implementation Method 1
a force sensor configured to detect a moment around the rotation shaft, the moment acting on the disc tool
Data Source
AI summary
Detected is a worn state of a disc tool. A grinder includes: a disc tool configured to rotate around a rotation shaft; a force sensor configured to detect a moment around the rotation shaft, the moment acting on the disc tool; and a controller, the controller carrying out a detection process of detecting a worn state of the disc tool on the basis of the moment obtained from the force sensor.