Thermal Imaging Surface Processing Auxiliary System
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Solution Overview
Problem
Existing surface processing technologies face challenges in accurately measuring the distance between grinding tools and workpieces, leading to inefficiencies and increased consumption of grinding slurry and consumables due to unnecessary processing time.
Innovation Solution
A thermal imaging surface processing auxiliary system and method that utilizes a thermal imaging sensor and a computing device to monitor temperature changes between a grinding tool and a workpiece, adjusting the grinding speed based on predefined critical temperature values to optimize processing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the grinding tool is moved toward the workpiece at a higher speed to reduce processing time, then productivity is improved, but the risk of collision and excessive extrusion increases
Solution Approach 1:
The thermal imaging sensor continuously monitors temperature changes in the observation area, providing real-time feedback to the control device. When temperature change exceeds the critical value, the system automatically reduces speed to prevent collision, and when temperature change is within limits, the system maintains higher speed for improved productivity.
Solution Approach 2:
The patent replaces traditional mechanical distance measurement systems with thermal imaging technology. Instead of using mechanical sensors or optical interferometers to measure the gap between tool and workpiece, the system uses thermal radiation detection to indirectly determine contact status through temperature changes, achieving non-contact measurement.
2Reliability
If the stroke between the abrasive tool and workpiece is increased to avoid collision, then reliability is improved, but unnecessary processing time and consumable usage increase
Solution Approach 1:
The system uses thermal feedback to dynamically adjust the stroke distance. The control device monitors temperature changes in real-time and adjusts the gap between tool and workpiece accordingly, maintaining the minimum necessary stroke to prevent collision while eliminating excessive gaps that cause unnecessary processing time and consumable usage.
Solution Approach 2:
The patent transforms the static stroke distance into a dynamic parameter that automatically adjusts based on thermal conditions. The system continuously modifies the gap between abrasive tool and workpiece according to real-time temperature feedback, optimizing the balance between collision avoidance and processing efficiency.
3Reliability
If the stroke between the abrasive tool and workpiece is increased to avoid collision, then reliability is improved, but consumable usage increases
Solution Approach 1:
The thermal imaging feedback system enables precise control of the tool-workpiece interaction, maintaining the minimum necessary stroke to prevent collision while reducing excessive gaps. This precise control minimizes unnecessary grinding actions and reduces consumption of grinding slurry and other consumables.
Solution Approach 2:
By replacing mechanical measurement systems with thermal imaging, the patent achieves more precise detection of contact conditions. This substitution enables finer control over the stroke distance, reducing both collision risk and unnecessary consumable usage caused by overly conservative gap settings.
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 effectively reduces unnecessary processing time and consumable usage by accurately determining contact between the grinding tool and workpiece, allowing for optimized speed adjustments and precise processing.
Implementation Method 1
a thermal imaging sensor configured to photograph at least one of the grinding tool and the at least one workpiece to generate at least one thermal image
Data Source
AI summary
A thermal imaging surface processing auxiliary system applicable for apparatus using a grinding tool to perform surface processing, includes a thermal imaging sensor and a computing device. The thermal imaging sensor photographs at least one of the grinding tool and the workpiece to generate thermal image. The computing device obtains a temperature change of an observation area in the thermal image. When the temperature change is not greater than a preset critical value, the computing device controls the apparatus to move the grinding tool toward the workpiece at a speed greater than a preset processing speed. When the temperature change is greater than the preset critical value, the computing device controls the apparatus to move the grinding tool toward the workpiece at the preset processing speed, wherein the observation area corresponds to a portion other than the contact portion between the grinding tool and the workpiece.