Sensor-Guided Abrasion Control for Precise Surface Removal
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Solution Overview
Problem
Current abrasion processes, such as sanding, lack automated control over material removal, risking damage to finished parts and lacking repeatability, especially in industries like aeronautics where precise surface preparation is crucial.
Innovation Solution
An abrasion process that tracks and analyzes the material remaining on the workpiece surface, adjusting abrasion parameters and trajectory based on sensor data to ensure precise material removal without damaging underlying layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual sanding is used to control material removal, then some control over material removal is achieved, but the process cannot be automated and lacks repeatability
Solution Approach 1:
The system uses sensors to detect surface characteristics in real-time during the sanding process and feeds this information back to the control unit, which automatically adjusts sanding parameters to maintain precise material removal control while enabling full automation
Solution Approach 2:
The patent replaces manual mechanical sanding operations with an automated robotic system that uses sensor-based detection and computer-controlled actuation to perform sanding tasks with consistent precision and full automation capability
2Extent of automation
If automated sanding is implemented without precise control, then automation is achieved, but material removal cannot be precisely controlled and parts may be damaged
Solution Approach 1:
Real-time sensor feedback during automated sanding allows the control system to continuously monitor surface characteristics and adjust sanding parameters, ensuring precise material removal control is maintained throughout the automated process
Solution Approach 2:
The system dynamically adjusts sanding parameters such as speed, pressure, and trajectory based on real-time surface condition detection, enabling the automated process to adapt to varying material characteristics and maintain precision throughout operation
3Shape
If more material is removed during sanding to ensure smooth surface, then surface smoothness is improved, but structural integrity and functional performance may be compromised
Solution Approach 1:
The system uses pneumatic or hydraulic actuation to apply precisely controlled, variable pressure to the sanding tool, enabling smooth surface preparation while maintaining exact control over material removal depth to preserve structural integrity
Solution Approach 2:
The sanding process dynamically adapts pressure and trajectory based on real-time surface detection, removing only the necessary amount of material to achieve smoothness while automatically preventing excessive removal that would compromise structural strength
4Shape
If manual sanding is performed to achieve smooth surface, then some surface preparation is achieved, but achieving a truly smooth surface is very difficult and each piece exhibits different defects
Solution Approach 1:
Sensor feedback systems detect surface characteristics on each workpiece and provide real-time information to the control unit, enabling automatic adjustment of sanding parameters to achieve consistent smooth surface results with high repeatability across all pieces
Solution Approach 2:
Replacing manual sanding with automated robotic systems eliminates human variability and enables consistent, repeatable surface preparation across all workpieces through computer-controlled precision and sensor-based feedback
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 safe, fast, and cost-effective automation of surface preparation by precisely controlling material removal, ensuring structural and functional integrity of parts.
Implementation Method 1
at least one sensor, in particular optical sensor
Implementation Method 2
Said at least one characteristic of the part is preferably chosen from the group consisting of a colour, a dimension, in particular a thickness, a surface condition such as a gloss or roughness
Implementation Method 3
Abrasion processes include sanding, polishing and grinding, sandblasting and water jet blasting
Data Source
Figure 1~2
Figure 3~5
Figure 6
AI summary
Method for abrading a surface (S) of a workpiece (1) by means of an abrasion machine, comprising the following steps: (a) acquiring, with at least one sensor, on at least one portion of the surface of the workpiece, data in relation to at least one characteristic of the workpiece in at least two basic zones (2) defined on the surface, (b) processing, for each basic zone (2), the data in relation to the at least one characteristic in order to assign, to each basic zone (2) and/or at least one group (3) of basic zones (2), a value for this characteristic, (c) determining and/or adjusting at least one abrasion parameter for the abrasion machine and/or an abrasion trajectory in accordance with the values attributed for the basic zones (2) or group(s) (3) of basic zones (2), (d) abrading at least a portion of the surface (S) with the abrasion machine with the at least one abrasion parameter and the abrasion trajectory.