Robot Grinding Tool Wear Correction Using Constant-Force Sensing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing grinding apparatuses face challenges in maintaining grinding quality due to tool wear, which requires dedicated measurement apparatuses to assess abrasion, increasing operational costs and time.
Innovation Solution
A grinding apparatus equipped with a robot, a force sensor, and a controller that uses a constant force pressing function to measure tool wear by comparing the present position of a worn grinding tool to a reference position, allowing for precise correction of the grinding start point without the need for a dedicated sensor.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a dedicated measurement apparatus (such as an optical sensor) is installed to measure tool abrasion, then measurement precision is improved, but device complexity and working cost increase
Solution Approach 1:
The force sensor is designed to serve dual purposes: it functions as both a control sensor for maintaining constant pressing force during grinding operations and as a measurement sensor for detecting tool abrasion. By making the force sensor perform multiple functions, the patent eliminates the need for separate dedicated measurement apparatus, thereby reducing device complexity while maintaining measurement capability
Solution Approach 2:
The system uses its own existing force sensor to measure tool abrasion without requiring external dedicated measurement equipment. The control unit processes the force sensor data to calculate abrasion amounts, enabling the grinding apparatus to self-diagnose tool wear using resources already available within the system
2Measurement precision
If a dedicated measurement apparatus is used to measure tool abrasion, then measurement precision is improved, but productivity decreases due to increased working hours
Solution Approach 1:
The force sensor continuously monitors pressing force during normal grinding operations, and the control unit continuously calculates tool abrasion in real-time based on this data. This continuous measurement approach eliminates the need for separate measurement steps, allowing grinding operations to proceed without interruption while tool wear is monitored, thereby maintaining high productivity
Solution Approach 2:
The system performs self-measurement of tool abrasion using its own force sensor during normal operation, eliminating the need for external measurement procedures that would consume additional working hours and reduce overall productivity
3Ease of operation
If the grinding tool position is not corrected for wear, then ease of operation is maintained, but manufacturing precision deteriorates
Solution Approach 1:
The control unit continuously receives feedback from the force sensor about pressing force variations, calculates tool abrasion amounts based on this feedback, and automatically corrects the grinding tool position accordingly. This closed-loop feedback system maintains grinding precision without requiring manual intervention, preserving ease of operation while ensuring manufacturing quality
Solution Approach 2:
The system dynamically adjusts the grinding tool position parameters based on detected force variations and calculated abrasion amounts. By changing the position parameters in response to tool wear, the system maintains grinding precision automatically, keeping the operation simple while ensuring quality results
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 method enables accurate measurement and correction of tool wear, maintaining grinding quality without additional sensors, reducing operational time and costs by integrating the force sensor within the grinding apparatus.
Implementation Method 1
a force sensor configured to detect a force exerted on the grinding tool
Data Source
AI summary
A grinding apparatus including a robot, a grinding tool attached to the robot, a force sensor configured to detect a force exerted on the grinding tool, and a controller connected with the force sensor and configured to control the robot. The controller includes a variation acquiring section configured to acquire the present position of the robot by pressing the grinding tool against a reference surface in such a manner that a pressing force detected by the force sensor is constant, and to acquire a difference between the acquired present position and a reference position of the robot stored in advance, the difference being acquired as a variation of the grinding tool.