Lapping Machine Surface Contouring via Feedback Conditioning
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Solution Overview
Problem
Lapping and polishing machines face challenges in achieving high accuracy and precision due to surface irregularities and ripples caused by conditioning tools, which can result in undesirable surface characteristics on work items.
Innovation Solution
A method and apparatus that utilize a small conditioning tool with a second finishing surface to configure and correct the first finishing surface of a lapping or polishing machine, allowing for real-time measurement and adjustment to achieve a specified surface contour, using a measuring tool with micron resolution and computer-controlled motion and pressure profiles to process work items like glass, ceramics, or metals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a conventional finishing surface is used without real-time measurement and conditioning, then the machine structure remains simple, but surface irregularities and ripples are introduced causing poor manufacturing precision
Solution Approach 1:
The patent implements a feedback mechanism where a measurement tool continuously monitors the contour of the finishing surface and feeds this information back to a controller. The controller then actuates a conditioning tool to correct deviations from the desired contour, creating a closed-loop system that maintains high manufacturing precision through real-time adjustment.
Solution Approach 2:
The system performs preliminary measurement of the finishing surface contour before actual work item processing. By measuring and identifying surface irregularities in advance, the system can prepare correction actions through the conditioning tool, ensuring that the finishing surface is properly configured before processing work items, thus preventing ripple effects.
2Manufacturing precision
If real-time measurement and conditioning are implemented, then surface irregularities are eliminated, but measurement and processing time increase
Solution Approach 1:
The measurement tool operates continuously during the conditioning process, and the conditioning tool makes incremental adjustments rather than complete reconditioning. This continuous approach allows the system to maintain high precision while minimizing downtime, as corrections are made progressively during operation rather than requiring separate measurement and conditioning cycles.
3Manufacturing precision
If a large conditioning tool is used to process the entire finishing surface, then manufacturing precision improves, but the machine becomes more complex and harder to control
Solution Approach 1:
The conditioning tool is designed as a smaller, more manageable element that processes localized portions of the finishing surface rather than requiring a large tool to cover the entire surface. The measurement tool maps the complete surface, and the controller directs the smaller conditioning tool to make multiple targeted passes, segmenting the conditioning task into manageable operations that reduce control complexity while maintaining precision.
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
This approach enables high-accuracy processing of work items by eliminating ripple effects and ensuring precise surface contouring, allowing for deterministic shaping with reduced operator intervention and improved predictability, effectively addressing the limitations of conventional small-tool finishing methods.
Implementation Method 1
using a capacitive gauge to measure the positions of the measurement object
Implementation Method 2
using a displacement measuring interferometer to measure positions of a mirror or retro-reflector attached to the measurement object
Implementation Method 3
The removal process takes place as the result of mechanical interaction or a combination of chemical and mechanical interaction between the item being finished, an abrasive, and the lap surface
Implementation Method 4
The removal process takes place as the result of mechanical interaction or a combination of chemical and mechanical interaction between the item being finished, an abrasive, and the lap surface
Data Source
AI summary
A lapping or polishing machine includes a material having a first finishing surface to process a surface of a work item, a measuring tool to measure a contour of the first finishing surface, and a conditioning tool having a second finishing surface to process the first finishing surface to reduce a difference between the measured contour and a desired contour of the first finishing surface.