Bounding Model Wear Measurement for Irregular Tool Surfaces
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Solution Overview
Problem
Existing methods for determining part wear, such as those described in U.S. Patent No. 9,613,413, may not accurately reflect irregular wear patterns on ground-engaging tools, leading to inaccurate wear percentage calculations and potential premature or delayed replacement of parts.
Innovation Solution
A computer-implemented method and system that uses sensor data to determine wear metrics by comparing the sensor data of a worn part to models of an unworn and wear-limit part, with the aid of a bounding contour to accurately measure distances and calculate wear, ensuring more precise wear assessment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If distance measurement techniques from prior patent are used, then wear quantification is achieved, but measurement precision deteriorates due to irregular wear patterns
Solution Approach 1:
The wear measurement process is segmented into multiple directional measurements. Instead of a single distance measurement, the system performs measurements along multiple directions (radial and tangential components) to capture the complex irregular wear pattern. This segmentation allows each measurement to focus on a specific aspect of wear, improving overall measurement precision and reliability.
Solution Approach 2:
The invention transitions from one-dimensional distance measurement to multi-dimensional wear characterization. By measuring wear along multiple directions (radial, tangential, and intermediate angles) and combining these measurements, the system captures the three-dimensional nature of irregular wear patterns, thereby improving both measurement precision and reliability.
2Ease of operation
If simple distance measurement is used, then ease of operation is improved, but measurement precision deteriorates
Solution Approach 1:
The system introduces intermediate calculation steps and reference models as mediators between the simple distance measurement and the final wear percentage. Multiple distance measurements are taken along different directions, then processed through mathematical relationships that account for the part geometry and wear patterns. This intermediary processing layer maintains ease of operation while significantly improving measurement precision.
Solution Approach 2:
The invention changes the parameters being measured from a single distance value to multiple distance values at different angular positions. By measuring radial and tangential components separately and then combining them, the system transforms simple distance measurements into accurate wear percentage calculations, resolving the contradiction between operational simplicity and measurement precision.
Data Source
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AI summary
A method for determining part wear, such as using a wear metric, includes receiving, from a sensor (108, 110), sensor data representing a surface of a wear part (116). The method further includes determining distances between measured points (310) in the sensor data and points on one or more part models, which part models (214, 216) may include new part models (214) and/or worn or wear limit part models (216). The method further includes using a bounding model (222) that at least partially envelopes the part model(s) (214, 216) and the measured points (310) to determine a direction along which the distances are measured. The method may also include quantifying wear using the measured distances.