Laser Doppler Vibrometer Coating Dressing for Substrate Protection
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Solution Overview
Problem
Existing cutting tools during coating dressing operations risk damaging the substrate surface by exceeding the coating material boundary, and manual or automatic cutting tool operations lack precise control to avoid such damage.
Innovation Solution
A coating dressing system utilizing a laser Doppler vibrometer to measure substrate vibration during machining, detecting the cutting tool's impact and comparing it with a database of vibration data to determine a predetermined acceleration threshold, which triggers a controller to adjust the cutting tool's movement and prevent contact with the substrate surface.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If cutting tools are operated to remove excess portions of the coating, then coating dimensions are modified, but the cutting tool may damage the substrate surface by exceeding the coating material boundary
Solution Approach 1:
The system employs a laser Doppler vibrometer to continuously monitor substrate vibration during cutting operations. When the cutting tool approaches the coating boundary and contacts the substrate, characteristic vibration patterns are detected. The controller receives this feedback and automatically adjusts the cutting tool's position or stops the operation, preventing substrate damage while maintaining precise coating dimension control
Solution Approach 2:
The patent replaces manual operator control with an automated control system that uses optical sensing (laser Doppler vibrometry) instead of mechanical contact measurement. This substitution enables real-time detection of substrate contact through vibration analysis, providing precise control without the delays and inaccuracies of manual operation
2Manufacturing precision
If manual dressing operations are performed, then cutting tool operators can control the process, but operation time increases and precision may be compromised
Solution Approach 1:
The system enables self-service operation where the cutting tool automatically adjusts its own position and operation parameters based on real-time vibration feedback from the laser Doppler vibrometer. The controller autonomously interprets vibration signals and modifies cutting parameters without human intervention, achieving both high precision and reduced operation time
Solution Approach 2:
The laser Doppler vibrometer continuously monitors substrate vibration throughout the entire cutting process, allowing the controller to make real-time adjustments without stopping the operation. This continuous monitoring and adjustment maintains precise control while minimizing idle time and maximizing productivity
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 provides precise control to prevent substrate surface damage by automatically adjusting the cutting tool's path, reducing operation time and enhancing part quality through non-contact vibration measurement and debris removal.
Implementation Method 1
a 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
Implementation Method 2
the reflected laser pattern comprises a reflection of the laser beam bouncing off the object
Data Source
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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.