3D Robotic Tool Sharpening for Complex Cutting Geometries
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Solution Overview
Problem
Existing cutting tool sharpening technologies lack automation and precision, particularly in handling cutting tools of various shapes and sizes, often relying on two-dimensional profiling and physical contact for measurement.
Innovation Solution
A robotic system capable of manipulating cutting tools, performing three-dimensional profiling, and grinding using counter-rotating stones, with features like force-torque sensors, 3D scanning, and PID control for precise motion and force control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If traditional sharpening machines are used, then the sharpening process can be performed, but the system lacks automation and precision for handling cutting tools of various shapes and sizes
Solution Approach 1:
The robotic system is designed to handle multiple types of cutting tools with various shapes and sizes using a single automated platform. The system incorporates 3D scanning capabilities, force-torque sensing, and adaptive control algorithms that enable it to automatically adjust to different tool geometries, eliminating the need for multiple specialized sharpening machines while maintaining high precision across diverse tool types.
Solution Approach 2:
The patent replaces traditional mechanical contact-based measurement and positioning systems with advanced sensing technologies including 3D optical scanning and force-torque sensors. This substitution enables non-contact or minimal-contact measurement, providing higher precision and automation while reducing mechanical complexity through software-based control algorithms rather than complex mechanical linkages.
2Manufacturing precision
If two-dimensional profiling is used for measurement, then the measurement process is simple, but the sharpening accuracy is insufficient for complex tool geometries
Solution Approach 1:
The system transitions from two-dimensional profiling to three-dimensional scanning and measurement. The 3D scanning capability captures the complete geometry of cutting tools with complex surfaces and angles, enabling accurate reconstruction of tool profiles. This dimensional enhancement allows the system to handle arbitrary tool shapes while maintaining sharpness and geometric fidelity that 2D systems cannot achieve.
Solution Approach 2:
The robotic system incorporates force-torque sensors that provide real-time feedback during the sharpening process. This feedback mechanism allows the system to detect contact forces between the grinding wheel and the cutting tool, enabling adaptive adjustment of grinding parameters to maintain optimal contact and achieve high sharpening accuracy while compensating for variations in tool geometry and material properties.
3Measurement precision
If physical contact measurement is used, then the measurement method is straightforward, but the measurement precision and automation capability are limited
Solution Approach 1:
The system replaces traditional mechanical contact measurement with 3D optical scanning technology. This non-contact measurement method captures detailed surface geometry without physical interference, providing superior measurement precision for complex tool shapes. The scanned data is then processed by automated algorithms to generate accurate tool profiles and guide the sharpening process, significantly enhancing both precision and automation capability.
Solution Approach 2:
The system introduces 3D scanning technology as an intermediary between the cutting tool and the sharpening process. Instead of direct mechanical contact for measurement, the scanner creates a digital representation of the tool geometry, which serves as an intermediate model for planning and executing the sharpening operation. This intermediary approach enables high-precision measurement and fully automated process control.
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 achieves precise and automated sharpening of cutting tools of various shapes and sizes, improving sharpening accuracy and efficiency by utilizing 3D profiling and advanced robotic control.
Implementation Method 1
a force-torque sensor capable of many directions of force and/or torque
Implementation Method 2
PID control for precise motion and force control
Implementation Method 3
grinding using counter-rotating stones
Data Source
AI summary
This disclosure describes systems, methods, and devices related to robotic control for tool sharpening. The device may determine a first location associated with a first cutting tool of the one or more cutting tools relative to the first container. The device may grip the first cutting tool based on the first location of the first cutting tool relative to the first container. The device may move the robotic device to one more scanning sensors. The device may collect three dimensional data. The device may extract a profile of the first cutting tool. The device may determine a top edge and a bottom edge based on the profile. The device may determine a tip of the first cutting tool. The device may generate a sharpening path based on the tip and the profile of the first cutting tool.