A SYSTEM FOR MONITORING ONE OR MORE OF AN ABRADING TOOL, A CONSUMABLE ABRASIVE PRODUCT AND A WORKPIECE

Info

Publication number: 20210308825
Type: Application
Filed: Aug 15, 2019
Publication Date: Oct 7, 2021
Inventors: Nicholas T. Gabriel (Grand Rapids, MN), Ankit Mahajan (Cupertino, CA), Joseph B. Eckel (Vadnais Heights, MN), Mikhail L. Pekurovsky (Bloomington, MN), Roger W. Barton (Afton, MN)
Application Number: 17/250,670

Abstract

A system for monitoring one or more of an abrading tool, a consumable abrasive product and a workpiece, the system can optionally comprise: a data storage device; a sensor; a communication unit; a consumable abrasive product that is attachable to and detachable from the abrading tool and configured to abrade the workpiece; a computing system comprising one or more computing devices configured to: receive a first data from the communication unit regarding the sensor, the first data indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece; identify if the at least one operating parameter falls outside a predetermined operating parameter range; and if the at least one operating parameter falls outside a predetermined operating parameter range, store a second data based upon the first data in the data storage device.

Description

Description

TECHNICAL FIELD

This disclosure relates to abrading tools and consumable abrasive products.

BACKGROUND

Abrading tools and associated consumable abrasive products are used in numerous industries. For example, consumable abrasive products are used in the woodworking industries, marine industries, automotive industries, construction industries, and so on. Common abrading tools include orbital sanders, random orbital sanders, belt sanders, angle grinders, die grinders, and other tools for abrading surfaces. Consumable abrasive products can include sanding disks, sanding belts, grinding wheels, burrs, wire wheels, polishing discs/belts, deburring wheels, convolute wheels, unitized wheels, flap discs, flap wheels, cut-off wheels, and other products for physically abrading workpieces. Consumable abrasive products are consumable in the sense that they can be consumed and replaced much more frequently than the abrading tools with which they are used. For instance, a grinding wheel for an angle grinder can only last for a few days of work before needing to be replaced, but the angle grinder itself can last many years.

SUMMARY

This disclosure describes systems and techniques related to communication equipped abrading tools, consumable abrasive products, workpieces, and/or operating devices (e.g., robotic devices). As described herein, communication among components of the system (e.g., the abrading tools, consumable abrasive products, workpieces, operating devices, etc.) and potentially one or more other computing systems can provide/utilize data that can be used enhance safety, quality, asset security, regulatory compliance, and inventory management.

The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description, drawings, and claims.

The disclosure herein includes but is not limited to the following illustrative Examples:

Example 1 is a system for monitoring one or more of an abrading tool, a consumable abrasive product and a workpiece, the system can optionally comprise: a data storage device; a sensor; a communication unit; a consumable abrasive product that is attachable to and detachable from the abrading tool and configured to abrade the workpiece; a computing system comprising one or more computing devices configured to: receive a first data from the communication unit regarding the sensor, the first data indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece; identify if the at least one operating parameter falls outside a predetermined operating parameter range; and if the at least one operating parameter falls outside a predetermined operating parameter range, store a second data based upon the first data in the data storage device.

In Example 2, the subject matter of Example 1 optionally includes wherein the first data comprises one or more of safety related data, quality related data and use related data.

In Example 3, the subject matter of any one or more of Examples 1-2 optionally include wherein the first data comprises one or more of: revolutions per minute of the abrading tool or the consumable abrasive product, a type of the abrading tool; a type of the consumable abrasive product; a force applied on one or more of the abrading tool, the consumable abrasive product and the workpiece; a temperature of one or more of the abrading tool, the consumable abrasive product and the workpiece; a heat flux into or out of one or more of the abrading tool, the consumable abrasive product, and the work piece; a finish imparted to the workpiece; a duration of operation; a type of backing used for the consumable abrasive product; a type of attachment used to couple the abrading tool to the consumable abrasive product; an identity of a tool operator; a location of the system; a date and time of use; and an indication the abrading tool is coupled with the consumable abrasive product.

In Example 4, the subject matter of any one or more of Examples 1-3 optionally include a robotic device configured to operate the abrading tool, and wherein the robotic device is configured to change an operation or a parameter based on at least one of the first data and the second data.

In Example 5, the subject matter of any one or more of Examples 1-4 optionally include wherein the first data is regarding the consumable abrasive product, and wherein the computing system is configured to identify the consumable abrasive product has been damaged or is about to be potentially damaged based upon the at least one operating parameter falling outside the predetermined operating parameter range.

In Example 6, the subject matter of Example 5 optionally includes wherein, in response to receiving data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged, the computing system is configured to store the second data in the data storage device.

In Example 7, the subject matter of any one or more of Examples 5-6 optionally include wherein, in response to receiving data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged, the computing system is configured to perform one or more of: generate a warning, send instructions to the abrading tool or a robotic device configured to operate the abrading tool, prevent use of the abrading tool while the consumable abrasive product is attached to the abrading tool, and store the data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged as the second data.

In Example 8, the subject matter of any one or more of Examples 5-7 optionally include wherein the data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged is derived from one or more of a voltage measurement from a crack detection system, the temperature of the consumable abrasive product, the heat flux into or out of the consumable abrasive product, the revolutions per minute of the consumable abrasive product and the force on the consumable abrasive product.

In Example 9, the subject matter of any one or more of Examples 1-8 optionally include wherein the sensor or communication unit comprises one or more of: an electronic identifier and a readout system; a timer configured to measure elapsed time from a reference time; a temperature sensor configured to measure the temperature within the system; an ammeter configured to measure an electrical current draw of the abrading tool during use of the abrading tool; a tachometer configured to measure rotation of the consumable abrasive product; a pressure sensor configured to measure force applied to the abrading tool by a user of the abrading tool.

In Example 10, the subject matter of any one or more of Examples 1-9 optionally include wherein the data storage device is located at one or more of a remote cloud based location, a device attached to or positioned within the consumable abrasive product, in a memory of the abrading tool, and in a memory of the robotic device configured to operate the abrading tool.

In Example 11, the subject matter of Example 10 optionally includes wherein the device attached to or positioned within the consumable abrasive product comprises a Radio Frequency Identification (RFID) tag, and wherein the RFID tag comprises at least one of the data storage device and the communication unit.

Example 12 is a system for monitoring one or more of an abrading tool, a consumable abrasive product and a workpiece, the system can optionally comprise: a data storage device; a sensor; a communication unit; a consumable abrasive product that is attachable to and detachable from the abrading tool and configured to abrade the workpiece; and a computing system comprising one or more computing devices configured to: receive a first data from the communication unit regarding the sensor, the first data indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece; and continuously store a second data in the data storage device, wherein the second data is based upon the first data.

In Example 13, the subject matter of Example 12 optionally includes wherein the first data is continuously gathered by the sensor, and wherein the second data is saved for a predetermined length of time and continuously overwritten in a predetermined manner.

In Example 14, the subject matter of any one or more of Examples 12-13 optionally include wherein the data storage device is located at one or more of a remote cloud based location, a device attached to or positioned within the consumable abrasive product, in a memory of the abrading tool, and in a memory of the robotic device configured to operate the abrading tool.

In Example 15, the subject matter of any one or more of Examples 12-14 optionally include wherein the data storage device is configured such that the second data is saved in a quasi-temporal manner such that an oldest data in the data storage device is not necessarily overwritten and replaced when the second data is stored.

In Example 16, the subject matter of any one or more of Examples 12-15 optionally include wherein the data storage device is configured to cyclically organize the second data based upon a time the second data was stored and associate the second data with further stored data therein that was previously stored in predetermined time intervals related to the time the second data was stored.

In Example 17, the subject matter of Example 16 optionally includes wherein the predetermined time intervals comprise at least a first time interval and a second time interval, and the second time interval is on an order of magnitude of equal to or greater than ten times that of the first time interval.

In Example 18, the subject matter of any one or more of Examples 16-17 optionally include wherein the predetermined time intervals are spaced in time on a log scale.

In Example 19, the subject matter of any one or more of Examples 12-18 optionally include wherein the first data comprises one or more of safety related data, quality related data and use related data.

In Example 20, the subject matter of any one or more of Examples 12-19 optionally include wherein the first data comprises one or more of: revolutions per minute of the abrading tool or the consumable abrasive product, a type of the abrading tool; a type of the consumable abrasive product; a force applied on one or more of the abrading tool, the consumable abrasive product and the workpiece; a temperature of one or more of the abrading tool, the consumable abrasive product and the workpiece; a heat flux into or out of one or more of the abrading tool, the consumable abrasive product, and the work piece; a finish imparted to the workpiece; a duration of operation; a type of backing used for the consumable abrasive product; a type of attachment used to couple the abrading tool to the consumable abrasive product; an identity of a tool operator; a location of the system; a date and time of use; and an indication the abrading tool is coupled with the consumable abrasive product.

In Example 21, the subject matter of any one or more of Examples 12-20 optionally include a robotic device configured to operate the abrading tool, and wherein the robotic device is configured to change an operation or a parameter based on at least one of the first and the second data.

In Example 22, the subject matter of any one or more of Examples 12-21 optionally include wherein the first data is regarding the consumable abrasive product, and wherein the second data is retrievable from the data storage device after the consumable abrasive product has been damaged or potentially damaged.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a block diagram illustrating an example system for monitoring an abrading tool, a consumable abrasive product, and/or a workpiece, in accordance with one example of the present application.

FIG. 2 is a flowchart illustrating example actions of a computing system, in accordance with one example of the present application.

FIG. 3 is a block diagram illustrating an example implementation on or in one of the abrading tool, the consumable abrasive product or workpiece, in accordance with one example of the present application.

FIG. 4 is a diagram of a consumable abrasive product having other components of the system mounted thereon or therein, in accordance with one example of the present application.

FIG. 5 is a diagram illustrating an example of the consumable abrasive product with a communication unit, in accordance with one example of the present application.

FIG. 6 is a diagram illustrating an example CAP that includes electrodes for detecting cracks in the CAP, in accordance with one example of the present application.

FIGS. 7 and 7A are schematic view of a bonded abrasive wheel having a circuit that comprises a communication unit and embedded therein, in accordance with one example of the present application.

FIGS. 7B and 7C are schematic cross-sectional views of an example circuit that can be used within the bonded abrasive wheel, in accordance with one example of the present application.

FIG. 8A is a flowchart illustrating an example system and operation that monitors data from one or more sensors within one or more of the abrading tool, the CAP, and/or the workpiece in accordance with one example of the present application.

FIG. 8B is a flowchart illustrating an example operation that detects cracks in a CAP, in accordance with one example of the present application.

FIG. 9 is a flowchart illustrating another example system and operation that monitors data from one or more sensors within one or more of the abrading tool, the CAP, and/or the workpiece in accordance with one example of the present application

FIG. 10 is a diagram of data storage device with a continuous loop recording structure in accordance with one example of the present application.

FIG. 11 is a diagram of a memory block structure that can be used with the various disclosed systems including the data storage device in accordance with one example of the present application.

FIG. 12 is a schematic of a system for monitoring one or more of the abrading tool, the consumable abrasive product and the workpiece, the system implemented with a robotics device, in accordance with one example of the present application.

FIG. 13 is schematic of another system one or more of the abrading tool, the consumable abrasive product and the workpiece, the system including a learning component and cloud-based process planning and optimization, in accordance with one example of the present application.

DETAILED DESCRIPTION

Abrading tools and associated consumable abrasive products present various challenges for individuals and organizations. In one example, inventory of tools, worker information, and consumable abrasive products may not be centrally managed, leading to inconsistent tracking of tool usage. In another example, damaged or worn consumable abrasive products can damage workpieces or can have the potential to cause injury. In yet another example, abrading tools can be used improperly, which can result in excessive use of consumable abrasive products, damage to abrading tools or workpieces, potential injury to workers, or the like. Furthermore, abrading tools and associated consumable abrasive products are frequently stolen. In still another example, over time workers frequently develop an intuitive sense of when a workpiece is of desired quality or when a consumable abrasive product is wearing out. However, a robot using an abrading tool may not acquire such an intuitive sense. In another example, consumable abrasive products are consumed, and therefore, accurate planning and managing of inventory of consumable abrasive products is desirable.

According to one aspect of this disclosure, a system is disclosed that includes communication-equipped abrading tools, communication-equipped consumable abrasive products (CAPs) and/or communication-equipped workpieces. As described herein, in some examples, the abrading tool can read information from the CAP and can send information to the CAP for storage in a data storage device (memory). This data storage device can be located in various places including the cloud, within or on the CAP, within or on the abrading tool (e.g., in a memory of the abrading tool), within or on a robotic device (e.g., in a memory of the robotic device), etc. Conversely, in some examples, the CAP can send information to the abrading tool, receive data from the abrading tool, and store data based on the received data. Furthermore, in some examples, the abrading tool sends and/or receives data from a computing system that stores and retrieves information from the data storage device. Thus, the data storage device can comprise a database according to some examples. In some examples, the CAP sends and/or receives data from the computing system that stores and retrieves information from the database.

According to one aspect of the present application, the system includes a computing system that is configured to: receive a first data from the communication unit regarding the sensor, the first data indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece, identify if the at least one operating parameter falls outside a predetermined operating parameter range, and if the at least one operating parameter falls outside a predetermined operating parameter range, store a second data based upon the first data in the data storage device. In yet another aspect of the present application, the system includes a computing system that is configured to: receive a first data from the communication unit regarding the sensor, the first data indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece, and continuously store a second data in the data storage device, wherein the second data is based upon the first data.

As described in detail below, such communication and storage of data can help to address various challenges associated with abrading tools and associated CAPs. These challenges include, but are not limited to, safety challenges, quality challenges and use challenges. For instance, the systems disclosed herein can enable the collection of vibration dosimetry data for individual workers. Some examples of this disclosure can reduce the likelihood of using CAPs in a manner that would produce a poor-quality or undesired quality workpiece. Some examples of this disclosure can reduce the chances of using damaged CAPs. Furthermore, some examples of this disclosure can help to prevent improper use of abrading tools and associated CAPs. Some examples of this disclosure can reduce the potential of injury. Additionally, some examples of this disclosure can help to prevent theft of abrading tools and associated CAPs.

FIG. 1 is a block diagram illustrating an example system 2 for monitoring abrading tools CAPs, and/or workpieces, in accordance with one or more techniques of this disclosure. In the example of FIG. 1, system 2 includes a computing system 4, a data storage device 6, an abrading tool 8, a workpiece 9, a consumable abrasive product (CAP) 10, and a user identification (ID) 22. As depicted by arrow 12, computing system 4 can read and write data to the data storage device 6, which can comprise a database. Additionally, as depicted by arrow 14, the computing system 4 can communicate with the abrading tool 8. Furthermore, as depicted by arrow 16, the computing system 4 can communicate with the CAP 10. As depicted by arrow 17, the computing system 4 can communicate with the workpiece 9. Additionally, as depicted by arrow 18A, abrading tool 8 can communicate with CAP 10. The abrading tool 8 can communicate with the workpiece 9 as indicated by arrow 18B. Furthermore, as depicted by arrow 24, the computing system 4 can communicate with user ID 22. Additionally, as depicted by arrow 26, the abrading tool 8 can communicate with user ID 22. Communication between one or more of the system 2 components can be facilitated by a communication unit (indicated by arrows 14, 16, 17, 18A, 24 and/or 26). The system 2 can include a sensor(s) 19 that can be implanted in one or more of the abrading tool 8, workpiece 9 and CAP 10.

Thus, system 2 optionally includes one or more of the data storage device 6, the computing system 4, the abrading tool 8, the workpiece 9, the CAP 10, the user ID 22 and the sensor 19. The CAP 10 can be attachable to and detachable from the abrading tool 8. The user ID 22 can comprise user identification information, and the computing system 4 can comprise one or more computing devices configured to receive first data and store second data in the data storage device 6. In the disclosed example, the second data can be based on the first data. For instance, the second data can be the same as the first data or determined in various ways using the first data.

As previously discussed, in one example the computing system 4 can receive the first data from the communication unit regarding the sensor 19. The first data can be indicative of at least one operating parameter of one or more of the abrading tool 8, the CAP 10 and the workpiece 9. The computing system 4 can identify if the at least one operating parameter falls outside a predetermined operating parameter range, and if the at least one operating parameter falls outside a predetermined operating parameter range, can store the second data in the data storage unit.

In another example, the computing system 4 receive the first data from the communication unit regarding the sensor 19. The first data can be indicative of at least one operating parameter of one or more of the abrading tool 8, the CAP 10 and the workpiece 9. The computing system 4 can continuously store the second data in the data storage device 6.

In some examples, the first data comprises data received from abrading tool 8. In some instances, the first data is based on the sensor(s) 19 in or on abrading tool 8. Furthermore, in some examples, the first data comprises data received from and regarding the CAP 10 and/or the workpiece 9. As described elsewhere in this disclosure, the first data can be based on the sensor(s) 19 in or on the CAP 10 and/or the workpiece 9. Additionally, in some examples, the first data can comprise user identification information from user ID 22.

In examples of this disclosure, the computing system 4, the abrading tool 8, the workpiece 9, the CAP 10, and the user ID 22 can communicate various types of data, in various ways, at various times, and in response to various events. For instance, in some examples, the CAP 10 can send to the abrading tool 8 and/or the computing system 4 one or more of: use data, quality data, safety data other types of data regarding CAP 10. Use data can include a manufacture data of the CAP 10 (a type of CAP), indication the abrading tool 8 is coupled to the CAP 10, a type of backing used for the CAP 10, a duration of use, a date and time of use, and product authentication data. Use, safety and quality data can include sensor data (e.g., wear, maximum rotations per minute (RPM), other RPM related data, temperature, pressure, force, torque) measured by the sensor(s) 19 generated during usage, or other types of data regarding CAP 10.

In some examples, the user ID 22 can send to abrading tool 8, the CAP 10 and/or computing system 4 the user identification information. In some instances, the CAP 10 can communicate data indicating whether the CAP 10 has been, is or can potentially be damaged (this data is included in the safety data discussed herein). In some examples, certain data (e.g., manufacture date, maximum recommended RPM) can be stored on or within the CAP 10 prior to initial use of CAP 10.

In some examples, the CAP 10 receives, from the abrading tool 8, the workpiece 9 and/or the computing system 4, one or more of the use data, quality data and/or safety data discussed above (e.g., CAP usage time, an operator identifier, operator usage time, abrasive wear state, data enabling dosimetry and wear reporting, and the like). In some examples, certain data (e.g., usage time, operator identification) can be generated during use of the CAP 10, written to the data storage device 6 (which can be coupled to or positioned within the CAP 10), and then subsequently read from the data storage device 6 (which can be coupled to or positioned within the CAP 10).

In some examples, the abrading tool 8 and/or the workpiece 9 receives, from the CAP 10 (the other of the abrading tool 8 and/or workpiece 9) and/or the computing system 4, one or more of the use data, quality data and/or safety data discussed above (e.g., usage time, an operator identifier, operator usage time, finish imparted to the workpiece, data enabling dosimetry and wear reporting, and the like). In some examples, certain data (e.g., usage time, operator identification) can be generated during use of the abrading tool 8, written to the data storage device 6 (which can be coupled to or positioned within the abrading tool 8 such as within the memory), and then subsequently read from the data storage device 6 (which can be coupled to or positioned within the abrading tool 8 such as within the memory). In some examples, the workpiece 9 can include sensor(s) 19 from which sensor data regarding use data, quality data and/or safety data is derived.

Computing system 4 can comprise one or more computing devices, such as personal computers, server devices, mainframe computers, and other types of devices. The data storage device 6 comprises the database with an organized collection of data. The data storage device 6 can be implemented in various ways. For example, the data storage device 6 can comprise one or more relational databases such as a quasi-logarithmic database discussed in reference to FIG. 10, object-oriented databases, data cubes, and so on. Although FIG. 1 shows the data storage device 6 as a single database, data described in the disclosure as being stored in the data storage device 6 can be distributed across one or more separate databases, the cloud, etc. These database/databases can be stored on non-transitory computer readable data storage media.

The abrading tool 8 can comprise various types of abrading tools, such as but not limited to: orbital sanders, random orbital sanders, belt sanders, angle grinders, die grinders, floor buffers, reciprocating sanders, file sanders, and other tools for abrading surfaces. The CAP 10 can comprise but is not limited to: a sanding disk, sanding belt, grinding wheel, burr, wire wheel, polishing discs/belts, deburring wheels, convolute wheels, unitized wheels, flap discs, flap wheels, cut-off wheels, and other product for physically abrading workpieces. While initially separate, a worker or robotic device can attach the CAP 10 to the abrading tool 8 prior to work and can detach the CAP 10 from the abrading tool 8. Likewise, this process can include addition of one or more backings between the CAP 10 and the abrading tool 8. For example, a worker or robotic device can attach a sanding disk to a random orbital sander prior to using the random orbital sander on the workpiece 9. In this example, the worker or robotic device can detach the sanding disk from the random orbital sander after it is done using the random orbital sander on the workpiece 9.

The CAP 10, the workpiece 9 and/or the abrading tool 8 can communicate in various ways that can be facilitated by the communication unit (or indeed via multiple communication units). For example, the CAP 10 can have the communication unit mounted therein or mounted thereto. The communication unit in this case can be a Radio Frequency Identifier (RFID) or Near Field Communication (NFC) interface (i.e., a tag). In some examples, the abrading tool 8 can have the communication unit mounted therein or mounted thereto. In such cases, this communication unit can be RFID or NFC reader, configured to read data from and/or write data to the RFID or NFC interface of the CAP 10 when the CAP 10 is brought sufficiently close to the abrading tool 8. Thus, in this example, the CAP 10 and the abrading tool 8 can communicate without the use of Wi-Fi, Bluetooth or other similar wireless technologies.

In some examples, the communication unit can use energy harvesting techniques to derive power needed for charging, communication, sensing, data storage, and other operations. These techniques can be applied from external to the CAP 10, such as from the abrading tool 8. In some examples, the communication unit comprises an optical code. The optical code can comprise a machine-readable representation of data, such as a barcode or Quick Response (QR) code. The abrading tool 8, the CAP 10, the workpiece 9 or another device can receive data from the communication unit by reading the optical code.

Furthermore, the CAP 10, the workpiece 9 and/or the abrading tool 8 can communicate with one another and with the computing system 4 in various other ways using other types of communication unit(s). For example, the CAP 10 can have a communication unit, such as an RFID or NFC tag. In this example, a tag reading device, such as a fixed location device or wand, can read data from the communication unit mounted on or within the CAP 10. The tag reading device can send the data to the computing system 4. In another example, a mobile device 20 such as shown in FIG. 1 (such as a worker's mobile phone) can read data from the communication unit and send the data to the computing system 4 via a communications network. In some examples, mobile device 20 can perform some or all of the functionality described in this disclosure with respect to the computing system 4. Indeed, the mobile device 20 can receive alerts, notifications, etc. in some cases of certain events (e.g., a notification that the CAP 10 is in an unsafe condition and is subject to breakage or possible breakage). Thus, in some examples, the communication network used by the communication unit(s) can include the Internet, a cellular data network, a Wi-Fi network, and/or another type of communication networks.

The user ID 22 and the abrading tool 8 can communicate in various ways. For example, the user ID 22 can utilize a communication unit, such as a Radio Frequency Identifier (RFID) or Near Field Communication (NFC) interface (i.e., tag). In some examples, the abrading tool 8 can utilize the communication unit, such as an RFID or NFC reader, configured to read data from and/or write data to the RFID or NFC interface of the user ID 22 when user ID 22 is brought sufficiently close to the abrading tool 8. Thus, in this example, the CAP 10 and the abrading tool 8 can communicate without Wi-Fi or Bluetooth infrastructure. In some examples, the communication unit of the user ID 22 can use energy harvesting techniques as previously discussed herein. In some examples, the user ID 22 can utilize an optical code as the communication unit. The optical code can comprise a machine-readable representation of data, such as a barcode or Quick Response (QR) code. The abrading tool 8 or another device can receive data from the user ID 22 by reading the optical code, and such data can allow the abrading tool 8 to become operable, for example.

The user ID 22 and the computing system 4 can communicate in various ways via the communication unit (indicated by arrow 24). For example, the user ID 22 can utilize an RFID or NFC tag. In this example, a tag reading device, such as a fixed location device or wand, can read data from the communication unit of the user ID 22. The tag reading device can send the data to the computing system 4 via a communications network. In another example, the mobile device 20 (such as a worker's mobile phone) can read data from the communication unit of user ID 22 and send the data to the computing system 4 via a communications network. In yet another example, the mobile device 20 can comprise the user ID 22 and can send the data to the computing system 4 via the communications network. In some examples, the mobile device 20 can perform some or all of the functionality described in this disclosure with respect to the computing system 4. The communication network utilized can include the Internet, a cellular data network, a Wi-Fi network, and/or another type of communication networks.

The abrading tool 8 and the computing system 4 can communicate in various ways. For example, the abrading tool 8 can utilize the communication unit, such as an RFID or NFC interface (e.g., an RFID or NFC tag). In this example, a tag reading device, such as a fixed location device or wand, can read data from the communication unit of the abrading tool 8 and send the data to the computing system 4 via a communications network. In some examples, the abrading tool 8 can utilize a wireless network interface, such as a Wi-Fi interface, Bluetooth interface, cellular data network interface (e.g., a 4G LTE interface), and/or another type of wireless network interface. In such examples, the abrading tool 8 can use the wireless network interface to send and/or receive data from the computing system 4. In some examples, abrading tool 8 can use a communication unit that is a wire-based communication interface, such as a Universal Serial Bus (USB) interface or another type of interface. In such examples, the abrading tool 8 can use the wire-based communications interface to send and/or receive data from the computing system 4. For instance, the abrading tool 8 can use a USB connection with another device, such as the mobile device 20, that is configured to communicate with the computing system 4. In this example, the abrading tool 8 can communicate with the computing system 4 while connected to the mobile device 20. In some examples, the abrading tool 8 can utilize an internal communication bus, such as a serial peripheral interface (SPI) bus or I2C bus. In such examples, the abrading tool 8 can use the internal communication bus to send and/or receive data from the computing system 4.

Furthermore, in some examples, abrading tool 8 has a communication unit that communicates with the computing system 4 via hub wireless hardware. The hub wireless hardware can comprise a device located at a worksite to which multiple assets (e.g., tools, personal protection equipment, consumable products, etc.) communicate. In this example, the hub wireless hardware can communicate via another network (e.g., the internet) to the computing system 4.

In some examples, the abrading tool 8, the workpiece 9, and/or the CAP 10 can communicate with the computing system 4 via the mobile device 20. For instance, the abrading tool 8 can utilize a communication unit, such as an RFID or NFC tag, Bluetooth interface, or other short-range wireless communication interface. In this example, the mobile device 20 can relay data between computing system 4 and abrading tool 8.

In some examples, the communication unit of the abrading tool 8 does not communicate directly with the communication unit of the CAP 10. For instance, the abrading tool 8 can send data to the computing system 4 and the computing system 4, in response, can send data to the communication unit and/or the data storage device 6 housed within the CAP 10. Similarly, the CAP 10 can send data to the computing system 4 and the computing system 4, in response, can send data to the abrading tool 8 (e.g., to memory of the abrading tool 8). In some examples, the mobile device 20 can read data from the CAP 10 and, in response, send data to the abrading tool 8. Similarly, the abrading tool 8 can send data to the mobile device 20 and the mobile device 20 can send the data to the CAP 10. In further examples, the mobile device 20 can read data from the workpiece 9, and in response, send data to the abrading tool 8 and/or the CAP 10. Similarly, the workpiece 9 can send data to the mobile device 20 and the mobile device 20 can send the data to the CAP 10 and/or the abrading tool 8.

In some examples, communication between the abrading tool 8, the workpiece 9 and/or the CAP 10 and computing system 4 can occur asynchronously. For instance, data from the computing system 4 can be stored at an intermediary device (e.g., the mobile device 20, wireless hub hardware, an RFID or NFC reader, etc.) until a communication link between the abrading tool 8, the workpiece 9 and/or the CAP 10 and the intermediary device is established. When the communication link is established, the intermediary device transmits or receives the data to or from the abrading tool 8, the workpiece 9 and/or the CAP 10. A similar asynchronous communication style can be used for communication between CAP 10 and computing system 4.

In some examples, abrading tool 8, the workpiece 9, and/or the CAP 10, and the user ID 22 can communicate with the computing system 4 in a similar way. For example, the abrading tool 8, the CAP 10, and the user ID 22 can all utilize a same communication unit, such as an RFID or NFC tag, while the computing system 4 can include or be communicatively coupled, such as through a USB cable, to a tag reading device, such as an RFID or NFC tag reader. In this example, the tag reading device, such as a fixed location device or wand, can read data from the communication unit of abrading tool 8, the workpiece 9, the CAP 10, and/or user ID 22. The tag reading device can send the data to the computing system 4 via a communications network. In another example, the mobile device 20 (such as a worker's mobile phone) can read data from the communication unit of the abrading tool 8, the workpiece 9, the CAP 10, and/or the user ID 22 and send the data to the computing system 4 via a communications network. The communication network can include the Internet, a cellular data network, a Wi-Fi network, and/or another type of communication network as previously discussed.

In some examples, the computing system 4 can mine data stored in the data storage device 6. For instance, the computing system 4 can mine data in the data storage device 6 for data that is then report to and receive fed back from appropriate entities, e.g., safety or compliance manager, production foreman, maintenance manager, and so on such a via a text or another alert notification method. In some examples, the computing system 4 can associate the reported data with an urgency level. For instance, reporting that the abrading tool 8 is being operated beyond recommended Rotation Per Minute (RPM) level can be designated as more urgent than reporting that a sanding disk inventory is running low. The RPM reporting can be a safety, compliance, or productivity issue which might need to be reported as soon as possible to the safety officer or shop foreman; low inventory can be reported to a purchasing agent with less urgency.

In further examples, the computing system 4 can be configured to only store data to the data storage device 6 in certain instances when the computing system 4 identifies if the at least one operating parameter falls outside a predetermined operating parameter range. This can reduce power and memory burden for the system, for example. In such instances, data can be written to the data storage device 6, such operating parameter range(s) can include, but is not limited to: revolutions per minute of the abrading tool or the consumable abrasive product, a type of the abrading tool; a type of the consumable abrasive product; a force applied on one or more of the abrading tool, the consumable abrasive product and the workpiece; a temperature of one or more of the abrading tool, the consumable abrasive product and the workpiece; a finish imparted to the workpiece; a duration of operation; a type of backing used for the consumable abrasive product; a type of attachment used to couple the abrading tool to the consumable abrasive product; an identity of a tool operator; a location of the system; a date and time of use; and an indication the abrading tool is coupled with the consumable abrasive product.

Thus, for example, if the revolutions per minute maximum for the CAP 10 is exceeded, data regarding such event/operation is written to the data storage device 6. In another example, if the force applied on one or more of the abrading tool, the consumable abrasive product and the workpiece exceeds a maximum recommended force (or indeed is less than a recommended force) data regarding such event/operation is written to the data storage device 6. In yet a further example, if the temperature of one or more of the abrading tool, the consumable abrasive product and the workpiece exceeds a maximum recommended temperature data regarding such event/operation is written to the data storage device 6.

In some examples, the computing system 4 can be configured to only store data to the data storage device 6 in certain instances where the computing system 4 identifies the CAP 10 has been damaged or is about to be potentially damaged based upon the at least one operating parameter falling outside the predetermined operating parameter range. Thus, in response to receiving data indicating that the CAP 10 has been damaged or is about to be potentially damaged, the computing system 4 can be configured to store the data in the data storage device 6. Furthermore, in some examples, in response to receiving data indicating that the CAP 10 has been damaged or is about to be potentially damaged, the computing system 4 can be configured to perform one or more of: generate a warning, send instructions to the abrading tool or a robotic device configured to operate the abrading tool, prevent use of the abrading tool while the consumable abrasive product is attached to the abrading tool, and store the data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged as the second data. The data indicating that the CAP 10 has been damaged or is about to be potentially damaged can be derived from one or more of a voltage measurement from a crack detection system, the temperature the consumable abrasive product, the revolutions per minute of the consumable abrasive product and the force on the consumable abrasive product as is further elaborated upon herein.

Additionally, in further examples, the computing system 4 can mine and/or analyze data in the data storage device 6 for information on productivity, security, inventory, safety, quality or other topics. For example, the computing system 4 can generate various types of reports on these topics. Productivity: reporting on tool RPM, runtime, force, etc., basically how the tool and abrasive is being used. Security: has abrading tool 8 disappeared? Inventory: is the site running low on a specific product, such as CAPs? Computing system 4 can automatically place orders. Safety: is PPE being used correctly? Is a worker using the proper abrading tool? Is the worker using an abrading tool properly? Quality: is a desired finish to the workpiece being achieved?

Examples of this disclosure can be used separately or in combination. Some examples of the disclosure can omit certain components of the system 2, for example, the computing system 4, the data storage device 6, the sensor 19, the communication unit, the mobile device 20, and any of the abrading tool 8, the workpiece 9, the CAP 10, and/or the user ID 22. Examples of this disclosure can be configured in any operable configuration. Certain components such as the sensor 19 and the communication unit(s) can comprise a single component, for example. In another example, while the computing system 4 and the data storage device 6 have been described as separate units, either or both can be part of the same network. Similarly, the computing system 4 and/or the communication unit(s) described need not be coupled to or part of any of the abrading tool 8, the CAP 10, the mobile device 20, but can be located on an external device, such as in proximity to a workstation or on a local server or remote server, for example.

FIG. 2 is a flowchart illustrating example actions of the computing system 4, in accordance with a technique of this disclosure. FIG. 2 is provided as an example. Other examples can omit actions shown in FIG. 2, can include more actions, can include actions in different orders, other actions, and so on.

As shown in the example of FIG. 2, the computing system 4 can receive check-out data (50). In response to receiving the check-out data, the computing system 4 can store the check-out data (or data determined based on the check-out data) to the data storage device 6 (52). The check-out data can indicate assets checked out from a storage location, including asset identification information such as an asset serial number, a type of asset, and other information regarding the asset. Assets can include an abrading tool (e.g., the abrading tool 8), a workpiece (e.g., the workpiece 9), a CAP (e.g., the CAP 10), personal protective equipment (PPE), and so on. Additionally, the check-out data can include user identification information that identifies an individual who is checking out the assets and associates the usage data of the abrading tool 8, the workpiece 9, and/or the CAP 10 with the user during a period that the abrading tool 8, the workpiece 9, and/or the CAP 10 is checked out and operated. Checking out an asset can involve removing the asset from a storage location or checking out the asset at a kiosk or station. Thus, the computing system 4 can receive an indication that a worker has checked out abrading tool 8, the workpiece 9, and/or the CAP 10 and can store, in the data storage device 6, data pairing the worker with at least one of: abrading tool 8, the workpiece 9, and/or the CAP 10.

The computing system 4 can receive the check-out data in various ways. For example, a reader device can be situated at an exit of the storage location. When a worker passes by the reader device, the reader device receives data from an identification badge of the worker and data from assets carried past the reader device. In some examples, the abrading tools, workpieces, CAPs, PPEs, identification badges, and/or other assets can use RFID tags and the reader device comprises an RFID reader. In other examples, the abrading tools, workpieces, CAPs, PPEs, identification badges, and/or other assets can utilize NFC tags. In other examples, other communication technologies can be used.

The computing system 4 can store the check-out data in various ways, including those discussed specifically with regard to FIGS. 8A, 8B, 9, 10 and 11, for example. In one example, the computing system 4 can be communicatively coupled to a reader device and a user input device. A user can bring a tag of the abrading tool 8 or CAP 10 in close proximity to the reader device. The computing system 4 can recognize the tag and receive data regarding the abrading tool 8 or CAP 10, such as data from the tag of the abrading tool 8, the CAP 10 or data from the data storage device 6 based on data from the tag of the abrading tool 8 or CAP 10. The user can bring a tag of the user ID 22 in close proximity to the reader device. The computing system 4 can recognize the tag and receive user identification information, such as information from the tag of the user ID 22 or information from the data storage device 6 based on information from the tag of the user ID 22. An authorized user, such as the user checking out the abrading tool 8, the CAP 10, etc. or a supervisor managing abrading tool inventory, can operate the user input device, such as by pressing a button, to send an indication to the computing system 4 to pair the abrading tool 8, workpiece 9, and/or CAP 10 and the user ID 22. In response to receiving the pairing indication, the computing system 4 can store data regarding such pairing (e.g., time and date of checkout, user identification, tool/CAP utilized, etc.). In some examples, the computing system 4 can centrally store the data pairing abrading tool 8, the workpiece 9 and/or the CAP 10 and the user ID 22 by sending the data pairing to one or more external devices, such as the data storage device 6. Other components communicatively coupled to the computing system 4 and/or the data storage device 6 such as a robotics device can access the pairing data. Inventory of the abrading tools, workpieces, CAPs and users can be centrally maintained, accessed, and associated with the usage data and pairing data.

According to the example of FIG. 2, the computing system 4 can perform a check-out response routine in response to receiving the check-out data (54). In some examples, the check-out response routine can determine whether the worker has all of the appropriate PPE for use of the abrading tool 8. For instance, the check-out response routine can determine whether the worker has safety glasses, gloves, etc. The computing system 4 can also be configured to provide information related to the appropriate PPE, such as a location of the PPE. Thus, the computing system 4 can be configured to determine, in response to receiving the indication that the worker has checked out at least one of the abrading tool 8, the workpiece 9 and/or CAP 10, that the worker has also checked out personal protection equipment appropriate for use with such item(s). Furthermore, in some examples, the computing system 4 can determine, based on the remaining quantity of personal protection equipment in an inventory, whether to order more personal protection equipment and display, in response to determining that more PPE should be ordered, a link to purchase additional PPE.

In some examples, the check-out response routine can determine whether the worker is allowed or qualified to check-out the assets. In some examples, the check-out response routine can determine whether a checked-out CAP is compatible with the checked-out abrading tool. In some examples, the check-out response routine can include determining whether the abrading tool 8 is checked by a worker. For example, the computing system 4 can receive check-out data regarding the abrading tool that is currently paired with another user. The computing system 4 can look up the check-out data for the abrading tool, determine that the abrading tool is checked out by another user, and send an indication, such as a warning, that the abrading tool is currently checked out or can display data, such as data pairing the abrading tool with the current user, on a display device that identifies the current user.

In some examples, the check-out response routine can perform one or more actions (e.g., generate a warning, instruct the abrading tool 8 not to allow a worker to use the abrading tool 8 with the CAP 10, etc.) if any of the assets checked out are damaged, are determined to be about to be potentially damaged or excessively worn. For instance, the check-out response routine can perform one or more actions in response to determining the CAP 10 is cracked, has been used at too high a RPM level, been subjected to excessively high temperatures, is worn out, and so on. In some examples, a warning can be audible (e.g., an alarm) and/or visible ((e.g., lighting a lamp, such as a Light Emitting Diode (LED), on an abrading tool or other device), sending a message, send instructions to the abrading tool 8 or a robotic device configured to operate the abrading tool 8, prevent use of the abrading tool while the CAP 10 is attached to the abrading tool 8, and store the data indicating that the CAP 10 has been damaged or is about to be potentially damaged, such storage can occur at the data storage device 6 or can perform another action to alert a person.

In some examples, the check-out response routine can include determining whether the worker has already received a vibration dose exceeding a limit. If so, the check-out response routine can perform an action, such as outputting a warning or instructing the abrading tool 8 not to allow the worker to use the abrading tool 8 with the CAP 10. In other words, the computing system 4 can determine, in response to receiving the indication that the worker has checked out at least one of the abrading tool 8 or the CAP 10, whether the worker has already received a vibration dose exceeding a threshold. In this example, the computing system 4 can perform an action in response to determining that the worker has already received a vibration dose exceeding the threshold or would likely exceed the threshold should the abrading tool 8 and the CAP 10 be checked out. For example, if a maximum vibration dosage level (e.g., vibration dose value (VDV)) for the worker is 9.1 m/s^1.75per day, and the worker's vibration dosage level for the day is already 9.1 m/s^1.75or greater, the check-out response routine can generate a warning. In another example, if a maximum vibration dosage level for the worker is 9.1 m/s^1.75per day and the worker's vibration dosage level for the day is already 8.0 m/s^1.75, the check-out response routine can generate a warning.

The computing system 4 can send instructions to a device (e.g., the abrading tool 8, the mobile device 20, etc.) to activate a warning indicator, such as a visible and/or audible alarm. The warning can be directed to the worker, a supervisor, or another person. In this way, someone can be warned that the worker should not use the abrading tool 8 with the CAP 10 for a period of time. In some examples, the threshold and the warnings can be user configurable. In some examples, the check-out response routine can send instructions to abrading tool 8 to prevent the worker from using the abrading tool 8 with the CAP 10.

A device (e.g., a device of the computing system 4, the abrading tool 8, etc.) can generate a warning in various ways. For example, the computing system 4 can send a text message to a mobile device of a user (e.g., worker, supervisor, or another person). In another example, the device (e.g., a device of computing system 4) can transmit instructions to the reader device or abrading tool 8 to output an audible and/or visible warning.

Furthermore, in the example of FIG. 2, the computing system 4 can receive tool/CAP coupling data (56). The computing system 4 can store the tool/CAP coupling data in the data storage device 6 (58). The tool/CAP coupling data can comprise data indicating that a CAP has been coupled to an abrading tool. In some examples, the abrading tool can send the tool/CAP coupling data to the computing system 4. In some examples, the CAP sends the tool/CAP coupling data to the computing system 4. In some examples, the CAP and the abrading tool separately send parts of the tool/CAP coupling data to the computing system 4. The tool/CAP coupling data can include various types of data. For instance, tool/CAP coupling data can identify the abrading tool and the CAP, a time at which the CAP and the abrading tool were coupled, data that the abrading tool reads from the CAP, data regarding a status of the abrading tool, etc.

Additionally, in the example of FIG. 2, the computing system 4 can perform a tool/CAP coupling routine (60). In various examples, the tool/CAP coupling routine includes various actions. For example, the computing system 4 can receive, from abrading tool 8, a request identifying the CAP 10. For instance, the request can comprise an identifier of the CAP 10. In this example, in response to the request, computing system 4 can send data regarding the CAP 10 to the abrading tool 8. In some examples, the tool/CAP coupling routine includes determining a usage limit, such as a maximum amount of time the worker can use the abrading tool, a maximum vibration dose, or other appropriate thresholds for use in determining a limit on the worker's vibration dosage. Furthermore, in this example, computing system 4 can send an indication of the determined usage limit to the abrading tool 8. In this example, the abrading tool 8 can be configured to shut off or generate a warning in response to the abrading tool 8 determining the worker has attempted to use the abrading tool 8 with the CAP 10 beyond the usage limit. The warning can be directed to the worker, a supervisor, or another person. In this way, chances of the worker being exposed to excessive vibration can be reduced. In some instances, the computing system 4 can send the warning to a mobile device (e.g., a mobile phone of the worker or another person). This process can be performed at other times as well, such as during check-out, or when the worker starts using the abrading tool 8.

In some examples, the usage limit can be determined in various ways as disclosed in co-owned and co-pending Patent Cooperation Treaty Patent Application Nos. PCT/US18/20160 and PCT/US18/20176, filed Feb. 28, 2018, the entire disclosures of which are incorporated in their entirety by reference.

Storage of data such as acceleration data (acceleration vs time, frequency, or points) can be local, such as on a memory of the abrading tool 8, the robotic device, etc. or remote. For example, acceleration data can be presented to an operator, compliance officer, or other interested party to help maintain an operator and tool within threshold limits or provide information as to product performance, quality or the like. Feedback can be local and immediate (e.g. on the tool to the operator), or delayed (e.g. uploaded in real-time, or periodically) to the computing system 4, smart phone 20, etc. and presented to an operator, compliance officer, or other interested party.

In another example, the CAP 10 can store data regarding whether the CAP 10 has been or can potentially become damaged or excessively worn (e.g., from excessive heat, excessive RPM, drops, excessive use time, crack detection, etc.). In this example, as part of the tool/CAP coupling routine (or at another event, such as check-out or during one of the other steps of FIG. 2), the computing system 4 can determine whether the CAP 10 can be safely used with the abrading tool 8. In this example, if the CAP 10 cannot be safely used with abrading tool 8, computing system 4 can send instructions to the abrading tool 8 to output a warning, prevent use, and/or perform some other action such as save operational parameters (e.g., one or more of temperature, force, RPM, usage data, etc.) to the data storage device 6.

Thus, in this example, in response to receiving data indicating that the CAP 10 has been damaged or is likely about to be potentially damaged or excessively worn, the computing system 4 can be configured to send instructions to the abrading tool 8 to instruct the abrading tool 8 to perform an action, such as generating a warning or preventing use of abrading tool 8 while the CAP 10 is attached to abrading tool 8. As discussed above, the CAP 10 or another component of the system can have a thermometer that measures a temperature of CAP 10 and the data indicating whether the CAP 10 has been damaged or is about to be potentially damaged can comprise data indicating whether the temperature of CAP 10 has exceeded a threshold. In some examples, the data indicating whether the CAP 10 has been damaged or is about to be potentially damaged comprises at least one of: data indicating whether the CAP 10 has been subject to an impact of sufficient force to damage CAP 10, data regarding a force on the CAP 10 has exceeded a threshold force (torque, load, etc.) sufficient to damage the CAP 10, and/or data indicating whether the CAP 10 has been used at an RPM level exceeding a maximum allowable RPM level for the CAP 10. In some examples, the data indicating whether the CAP 10 is excessively worn or is about to be potentially damaged can comprise data derived from an electrical resistance between electrodes mounted on CAP 10. In this example, the electrical resistance can change over time as the CAP 10 is used and the electrical resistance crossing a particular threshold can indicate that the CAP 10 is excessively worn or is at a higher likelihood of being about to be potentially damaged.

Furthermore, in the example of FIG. 2, the computing system 4 can receive other usage data (62) not directly related to safety data. The computing system 4 can store the usage data in the data storage device 6 (64) as desired such as in the manners discussed above (e.g., operational parameter has been exceeded, continuously, routinely at certain desired intervals, etc.). In some examples, the abrading tool 8 can send the usage data to the computing system 4. In some examples, the CAP 10 sends the usage data to the computing system 4. In some examples, the workpiece 9 sends the usage data to the computing system 4. In some examples, components such as two or more of the CAP 10, the workpiece 9 and the abrading tool 8 separately send parts of the usage data to the computing system 4. For instance, the computing system 4 can receive the usage data in response to stoppage of use of the abrading tool 8 (e.g., for a given amount of time). In some examples, the computing system 4 can receive the usage data when abrading tool 8 and/or CAP 10 are checked back in to a storage area. Thus, in this example, the usage data can be part of the check-in data described elsewhere in this disclosure. In some examples, the computing system 4 can receive the usage data when the CAP 10 is decoupled from the abrading tool 8. The usage data can comprise data indicating a tool run time, an operator use time, an abrasive use time, electrical current, CAP temperature data, vibration data (e.g., acceleration data), and other usage data regarding the abrading tool 8 or the CAP 10.

In some examples, the computing system 4 can receive usage data in real-time from the abrading tool 8, the workpiece 9 and/or the CAP 10. Real-time receipt of usage data can include any receipt of usage data during or immediately after generation or storage of the usage data. For example, the abrading tool 8 can continuously send usage data regarding the abrading tool 8 to the computing system 4 as the abrading tool 8 stores the usage data to memory. As another example, the abrading tool 8 can locally store the usage data on the abrading tool 8 (such as in memory) and send the usage data to the computing system 4 periodically before operation of the abrading tool 8 is complete.

In some examples, the stored usage data can be associated with the abrading tool 8 and a user based on data pairing the abrading tool 8 and the user as previously discussed. For example, the usage data can include acceleration data from the abrading tool 8 while the abrading tool 8 is checked out by a user associated with the user ID 22. The acceleration data can be associated with the abrading tool 8 and the user. For example, the acceleration data can be associated with the abrading tool 8 for determining whether the abrading tool 8 can require maintenance, while the acceleration data can be associated with the user for determining a cumulative vibration dose for the user.

In response to receiving the usage data, the computing system 4 can perform a usage data routine (66). As noted above, the usage data can include safety data regarding damage, wear and the potential for damage, etc. In some examples, the usage data routine can run and update. Thus, for example, the computing system 4 can identify if the at least one operating parameter falls outside a predetermined operating parameter range, and further can identify the consumable abrasive product has been damaged or is about to be potentially damaged based upon the at least one operating parameter falling outside the predetermined operating parameter range. As discussed above, this data routine can generate a warning, send instructions to the abrading tool or a robotic device configured to operate the abrading tool, prevent use of the abrading tool while the consumable abrasive product is attached to the abrading tool, and store the data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged.

As described above, robots can have difficulty in performing abrading tasks because they lack a human operator's intuitive feel for when work on an area of a workpiece is complete and/or whether a CAP is worn out. However, use of robots to perform abrading tasks can be highly beneficial in some situations, such as when toxic materials are involved, space is constrained, physical access to an area of a workpiece is constrained, work occurs in a hazardous area, and so on. In some instances, the computing system 4 can use the safety, usage and other data for training of robots to perform abrading tasks. For example, the computing system 4 can aggregate usage data from many work sessions to quantify what a worker might intuitively feel about an area of a workpiece being complete or a CAP being worn out. For instance, the computing system 4 can determine (e.g., based on vibration data, electrical current draw data, RPM data, data regarding characteristics of the CAP and workpiece, video information, work duration information, abrading tool movement information, applied pressure information, torque information, electrical resistance measurements, CAP temperature information, and/or other data) when an area of a workpiece is complete. Similar information can be used for determining whether a CAP is worn out. In some examples, computing system 4 can train a machine learning system based on such data to make determinations regarding whether an area of a workpiece is complete and/or whether a CAP is worn out. For instance, usage data can be used as training data for a neural network part of a machine learning routine as discussed below in FIG. 13. Furthermore, the data can be used for manufacturer monitoring of the CAP and/or the abrading tool performance for purposes of product improvement.

In some examples, the usage data indicates how much time or a condition of the abrading tool 8 and/or CAP 10 was in use. A CAP of a particular type can be expected to last a particular number of hours in use. In examples where the usage data includes how much time CAP 10 was in use, the usage data routine can determine whether the CAP 10 is approaching the end of its expected life. Accordingly, based on data, such as data stored in the data storage device 6, the computing system 4 can flag the CAP 10 to be discarded. If a worker subsequently tries to check-out the CAP 10, the computing system 4 can perform an action to warn the worker. Furthermore, in some examples, the computing system 4 can determine based on the remaining time left for CAPs in an inventory whether to order more CAPs.

An abrading tool of a particular type can be expected to last a particular number of hours in use between maintenance or replacement. In examples where the usage data includes how much time abrading tool 8 was in use, the usage data routine can determine whether the abrading tool 8 is approaching the end of its expected operating time between maintenance events or its expected life. Accordingly, based on data, such as data stored in the data storage device 6, the computing device 4 can flag the abrading tool 8 to be removed from service for maintenance, discarded, and/or replaced. If a worker subsequently tries to check-out the abrading tool 8, the computing system 4 can perform an action to warn the worker. Furthermore, in some examples, the computing system 4 can determine based on the remaining time left for abrading tools in an inventory whether to order more abrading tools.

In some examples, the usage data indicates the condition of abrading tool 8 has degraded in performance between maintenance or replacement. For example, an abrading tool that used CAPs at a particular rate or is associated with a particular productivity can change in performance through use or over time. In examples where the usage data includes a condition of the abrading tool 8, the usage data routine can determine whether the abrading tool 8 is approaching the end of its expected operating time between maintenance events or its expected life. Accordingly, based on data, the computing device 4 can flag the abrading tool 8 to be removed from service for maintenance, discarded, and/or replaced.

Furthermore, in the example of FIG. 2, the computing system 4 can receive check-in data (68). Furthermore, in the example of FIG. 2, the computing system 4 can store the check-in data in the data storage device 6 (70). The check-in data can indicate assets checked in to a storage location or checked in at a kiosk or station. Additionally, the check-in data can identify an individual worker who is checking in the assets. Thus, the computing system 4 can be configured to receive an indication that a worker has checked in the abrading tool 8 and/or the CAP 10. Checking in an asset can involve placing the asset in a storage location. The check-in data can include the usage data described elsewhere in this disclosure.

Computing system 4 can receive and store the check-in data in various ways previously discussed in FIG. 1. For example, the computing system 4 can be communicatively coupled to a reader device and a user input device and can recognize the tag and receive data regarding the abrading tool 8, such as from the tag of the abrading tool. The user ID 22 can also be utilized as previously discussed in FIG. 1 according to further examples.

Additionally, in the example of FIG. 2, the computing system 4 can perform a check-in response routine (72). For example, the computing system 4 can determine whether all assets a worker has checked out have been checked back in. Information in such routine can help with inventory management and detecting of theft. For example, if the computing system 4 determines that an inventory of CAPs is running low, the computing system 4 can automatically order more CAPs.

In some examples, such as when the check-in data includes tool identification information, the check-in response routine can include determining a user associated with the abrading tool 8. The computing system 4 can output, in response to determining that the user is associated with abrading tool 8, an indication of the user. In some examples, the check-in response routine can include determining whether the abrading tool 8 is checked in by the user to which the abrading tool 8 is paired.

Furthermore, in the example of FIG. 2, a report generation event can occur at the computing system 4 (74). In one example, the report generation event can comprise an indication of user input to generate the report. In another example, the report generation event can comprise a request from another computing device (e.g., a webpage request, web application programming interface (API) request). In another example, the report generation event can be the expiration of a time interval.

In response to the report generation event, computing system 4 can generate one or more reports based at least on part on the data stored in the data storage device 6 (76). The computing system 4 can generate various types of reports. For example, the computing system 4 can generate a report describing how individual workers use CAPs. For instance, a report can indicate how many CAPs a worker uses, how long a worker typically uses a CAP before it is discarded, how many CAPs were damaged or potentially damaged, worn, etc. by a worker per time spent by the worker using CAPs, how much pressure a worker applies when using an abrading tool, temperatures of CAPs when a worker is using the CAPs, wear states of CAPs before and after a worker uses the CAPs, how much torque an abrading tool applies to CAPs when a worker is using the abrading tool, etc.

In some examples, the computing system 4 can generate a report that provides information for the training a worker or analyzing worker behavior. For instance, the report can indicate that a worker seems to be using excessive or insufficient pressure when using a particular type of CAP or abrading tool. In this instance, use of excessive pressure can lead to added risk of damaging or wear on CAPs, while use of insufficient pressure can result in abrading tasks taking too long. In another example, a report can indicate whether a worker is using different types of CAPs in a correct order. For instance, when smoothing a workpiece, CAPs are typically used in order of decreasing grit size. Reports or raw data on how a worker uses CAPs can be provided to various parties, such as governmental organizations (e.g., for regulatory compliance purposes), manufacturers of CAPs and/or abrading tools (e.g., for research and development purposes), private employers, etc.

In some examples, the computing system 4 can generate a report that aggregates how workers use CAPs. In some examples, the computing system 4 can generate a report regarding worker vibration exposure, other safety and compliance specific criteria.

FIG. 3 is a block diagram illustrating an example implementation of portions of the previously discussed systems and methods on an abrading tool 100. It should be noted that although illustrated as being implemented on the abrading tool 100, the implantation of FIG. 3 can be carried out on other system components such as the CAP and/or workpiece or in a combination of system components as previously discussed.

The abrading tool 100 can be one instance of the abrading tool 8 (FIG. 1). In the example of FIG. 3, the abrading tool 100 comprises a communication unit 102, a microcontroller 104, a memory 106, an input/output (I/O) system 108, a display unit 110, an analog to digital converter (ADC) 112, tool-based sensors 114, a user identification unit 122, and a drive component 124. In the example of FIG. 3, the communication unit 102 comprises a CAP communication unit 115 and an external communication unit 116.

Although shown in the example of FIG. 3 as being part of the same physical unit, the CAP communication unit 115 and the external communication unit 116 can be physically separate. The communication unit 102, microcontroller 104, memory 106, I/O system 108, display unit 110, ADC 112, sensors 114, user identification unit 122, and drive component 124 can be disposed within a physical housing 118 of the abrading tool 100. In other examples, abrading tools can include more, fewer, or different components. The drive component 124 can be configured to move the CAP 120. The drive component 124 can comprise an electrical, pneumatic, or hydraulic motor. The drive component 124 can create vibrations in the abrading tool 100 as the drive component 124 operates, such that the abrading tool 100 can have a measurable vibration level.

The microcontroller 104 can comprise a small computer on a single integrated circuit. In one example, the microcontroller 104 can be configured to implement functionality and/or process instructions for execution within the abrading tool 100. For example, the microcontroller 104 can be capable of processing instructions stored by the memory 106. The microcontroller 104 can include, for example, microprocessors, digital signal processors (DSPs), application specific integrated circuits (ASICs), field-programmable gate array (FPGAs), or equivalent discrete or integrated logic circuitry.

The memory 106 can be configured to store data. For instance, the memory 106 can comprise one or more data storage units configured to store received data, such as data regarding the CAP 120, data regarding the abrading tool 100, data regarding an application specification configuration of the abrading tool 100, or user identification information. In some examples, the memory 106 comprises an Electrically-Erasable Programmable Read Only Memory (EEPROM) non-volatile memory. Consequently, the memory 106 need not be continuously powered to retain stored data. In some examples, the memory 106 can include random access memories (RAM), dynamic random-access memories (DRAM), static random-access memories (SRAM), magnetic hard discs, optical discs, flash memories, forms of electrically programmable memories (EPROM) and/or EEPROM, or other types of data storage unit. Although not shown in the example of FIG. 3, the abrading tool 100 can include an onboard battery to power a calendar and/or clock.

The I/O system 108 can comprise a physical button array, a touchscreen unit, one or more speakers, a siren, and/or other types of devices for interacting with a user. In some examples, the I/O system 108 can include one or more LEDs configured to indicate a vibration level of the abrading tool 100 to a user for local and immediate feedback. In some examples of local feedback, the abrading tool 100 can include components for sensing, comparing, calculating, and providing feedback. For example, the sensors 114 can include a vibration sensor, such as an accelerometer, configured to measure a vibration level, such as acceleration, of the abrading tool. One or more light emitting devices (LED) can be coupled to a housing of the abrading tool 100 and configured to indicate the vibration level of the abrading tool to a user. The microcontroller 104 can be configured to compare the sensed vibration level with a threshold and cause, in response to the vibration level exceeding the threshold, at least one LED of the one or more LEDS to activate.

The microcontroller 104 can be configured to cause the one or more LEDs to activate according to a color or blinking pattern indicative of a condition such as when a vibration threshold is exceeded. In some examples, the LEDs can have various colors indicating various levels, conditions or types of warnings. In some examples, feedback can be more precise or accentuated by combining the LED's color and blinking pattern. The LEDs can be located on a housing of the abrading tool 100, and separately controlled by the microcontroller 104.

In addition to the above, location of the visual feedback on the abrading tool 100, and the selection of optical feedback (e.g., LED, display unit 110) can be conspicuous. For example, the LEDs can be located on a back of a housing of the abrading tool 100, such that a user can view the LEDs while operating the abrading tool 100.

The CAP communication unit 115 can be configured to receive data regarding the CAP 120. The CAP communication unit 115 can enable the abrading tool 100 to communicate with one or more external devices, such as the CAP 120, the computing system 4 (FIG. 1), the mobile device 20 (FIG. 1), or other types of devices. For instance, the CAP communication unit 115 can be configured to receive data regarding the CAP 120 derived from sensors 114. The CAP communication unit 115 can be implemented in various ways. For example, the CAP communication unit 115 can comprise an RFID interface, an NFC interface, optical code reader, or other type of wireless communication interface. Sensors 114 can comprise one or more sensors, such as a temperature sensor, a wear sensor, a crack detection sensor, or another type of sensor. The CAP communication unit 115 can receive data based on measurements of the sensors 114 of the CAP 120.

The user identification unit 122 can be configured to receive user identification information. User identification information comprises data that identifies a user (e.g., a worker) of the abrading tool 100 as previously discussed. The user identification unit 122 can receive the user identification information in various ways also previously discussed in reference to FIGS. 1 and 2. For example, user identification unit 122 can comprise a numerical keypad and the user identification unit 122 can receive the user identification information as PIN. In this example, the user identification unit 122 can be part of the I/O system 108. In some examples, user identification unit 122 comprises a biometric characteristics reader, such as a fingerprint reader, iris or retinal scanner, facial recognition system, voice recognition system, or other system for reading a biometric characteristic of a user. In some examples, the user identification unit 122 can receive the user identification information from a user identification (ID) 126, magnetic stripe dongle, token, or other object storing the user identification information of a worker. In some examples, the user identification unit 122 comprises an RFID or NFC reader.

In some instances, the user identification unit 122 can form part of the communication unit 102, the external communication unit 116, or can be separate from either or both of the communication unit 102 and the external communication unit 116.

The external communication unit 116 can comprise one or more powered or unpowered communications interfaces. For example, the external communication unit 116 can comprise a USB interface, such as a port for a USB hardwire connection, or USB docking station. In some examples, the external communication unit 116 can comprise a Wi-Fi interface, a Bluetooth interface (e.g., a Bluetooth Low Energy (BLE) interface), a mobile data modem (e.g., a 4G LTE modem) or another powered communications interface. In some examples, the external communication unit 116 can comprise an RFID interface, an NFC interface, or another unpowered communications interface. In some examples, the abrading tool 100 can use external communication tool to communicate with the computing system 4 (FIG. 1) as previously described.

In some examples, the communication unit 102 can be configured to receive tag data from NFC tags. For example, the communication unit 102 can comprise an NFC tag reader configured to at least read tag data from NFC tags. Tag data comprises data that is stored on NFC tags and is associated with one or more components of system 2 of FIG. 1. Tag data can include a variety of data stored on NFC tags including, but not limited to: user identification information identifying the user of the abrading tool 100, such as a tag type ID, a user name, or a badge ID of a user ID 126; data regarding the CAP 120, such as the tag type ID, badge ID of a badge of a last user, total runtime of the CAP 120, brand name of the CAP 120, product ID of the CAP 120, manufacturing data of the CAP 120, maximum RPM of the CAP 120, or grit/grade of CAP 120; and data regarding the abrading tool 100, such as tag type ID, part number of the abrading tool 100, and serial number of the abrading tool 100. NFC tags can send data to the NFC tag reader in a variety of ways. For example, an NFC tag can send tag data to the NFC tag reader in response to the harvesting of RF energy emanating from the communication unit 102 that has embedded within the RF signal a command that tells an NFC chip of the NFC tag to respond. In some examples, the communication unit 102 can be configured to send tag data to the microcontroller 104 in response to receiving tag data from an NFC tag, such as an NFC tag on the CAP 120 or the user ID 126.

In some examples, the communication unit 102 can be configured to act as a passive NFC tag for the abrading tool 100. For example, the communication unit 102 can have a passive NFC tag mode that is configured to communicate NFC data to another communication device, such as another NFC reader.

In various examples, the sensors 114 can include various types of sensors located within the housing 118. The sensors 114 are devices that convert real world data (analog) into data that the microcontroller 104 can understand using the ADC 112. For example, the sensors 114 can include a temperature sensor (thermistor, resistive temperature detector, thermocouple, thermoelectric element, combinations thereof, multiples thereof, etc.) that measures the temperature in the vicinity of the abrading tool 100, an accelerometer, an ammeter (i.e., an electrical current meter) that measures an electrical current draw of the abrading tool 100 during use of abrading tool 100, a voltage meter that measures a voltage of an electrical current during use of abrading tool 100, a tachometer that measures rotation of the CAP 120, a timer, a pressure sensor that measures force applied to the abrading tool 100 by a user of the abrading tool 100, a torque sensor that measures torque the abrading tool 100 applies to CAP 120, a vibration sensor that measures vibration generated by the abrading tool 100 during use of abrading tool 100, sensors (e.g., optical sensors) for determining a the wear level of the CAP 120, and so on.

In some examples, a vibration sensor can be implemented as one or more accelerometers. The accelerometer can be coupled to the abrading tool 100, such that accelerometer can receive acceleration stimuli of the drive component 124. The accelerometer can be configured to measure the acceleration stimuli as acceleration data. The acceleration data can describe a vibration level of the abrading tool 100.

The microcontroller 104 can receive data from the CAP communication unit 115, the ADC 112, the external communication unit 116, the user identification unit 122, the communication unit 102, and potentially other components of the abrading tool 100. Additionally, the microcontroller 104 can process received data and output data for display on the display unit 110. For example, the display unit 110 can be configured to display data regarding the CAP 120. For instance, the microcontroller 104 can output the part number of the CAP 120, the grit value for the CAP 120, the max RPM value for the CAP 120, a current wear level of the CAP 120, and the usage time of the CAP 120, other safety or use related information for display on the display unit 110. In this example, the microcontroller 104 can receive data indicating the part number of the CAP 120, grit value for the CAP 120, max RPM value for the CAP 120, current wear level of the CAP 120, and usage time of the CAP 120 from the communication unit 102 and/or the external communication unit 116. Since different CAPs can have different characteristics, the display unit 110 can display different data when different CAPs are attached to the abrading tool 100.

In some examples, the communication unit 102 can be configured to receive data regarding an application specific configuration of the abrading tool 100. For example, the abrading tool 100 can generally operate based on an operating system configuration that defines general purpose inputs and outputs, such as the I/O system 108. To direct operation of the abrading tool 100 to a particular application having particular operating characteristics and conditions, the abrading tool 100 can be initialized with data regarding the application specific configuration that includes parameters configured for the particular operating characteristics and conditions. For example, the communication unit 102 can receive an application configuration file that includes a variety of data and configuration parameters for components of abrading tool 100. The data and configuration parameters can include, but are not limited to, a name of the abrading tool 100, a part number of the abrading tool 100, a serial number of the abrading tool 100, and any other identification or configuration data regarding the abrading tool 100.

In some examples, the data regarding application specific configuration can include at least one configurable parameter of the sensors 114, such as an accelerometer. In this example, the data regarding the application specification configuration can include at least one configurable acceleration parameter such as a minimum acceleration recording threshold, a maximum acceleration recording warning threshold, an accelerometer sampling rate, a hysteresis acceleration threshold. In some examples, the microcontroller 104 can be configured to initialize operation of the abrading tool 100 using at least one configurable acceleration parameter. For example, the memory 106 can include the data regarding application specific configuration.

In some examples, the data regarding the application specific configuration can include at least one configurable parameter of the communication unit 102. For example, the communication unit 102 can include an NFC reader that can operate to read or write to NFC tags and/or act as a passive NFC tag. In this example, the data regarding the application specific configuration can include an NFC mode of the NFC tag reader, a length of time for the communication unit 102 to read/write NFC data from NFC tags, a length of time for the communication unit 102 to act as a passive NFC tag for the abrading tool 100, an address of the NFC tool tag data, and the like.

In some examples, the microcontroller 104 can be configured to monitor the communication unit 102 for tag data from NFC tags. For example, the microcontroller 104 can be configured to receive tag data from the communication unit 102 and maintain an open channel of communication from the communication unit 102. In some examples, the microcontroller 104 can be configured to receive data from the communication unit 102 and determine whether the data is tag data, such as based on a tag type ID. For example, the microcontroller 104 can receive data from an NFC tag and whether the data includes a tag type ID that matches one of several tag type IDs, such as: a tag type ID of the abrading tool 100, identifying the NFC tag as belonging to the abrading tool 100; a tag type ID of the CAP 120, identifying the NFC tag as belonging to the CAP 120; or a tag type ID of the user ID 126, identifying the NFC tag as belonging to the user ID 126.

In another example, in response to the user identification unit 122 receiving user identification information or the CAP communication unit 115 receiving data regarding the CAP 120, the microcontroller 104 can store the user identification information or data regarding the CAP 120 in the memory 106. In some examples, the communication unit 102 can communicate, to one or more external devices (e.g., the CAP 120, the computing system 4 (FIG. 1)) user-device pairing data that associates the abrading tool 100, and a user of user ID 126. In this way, the microcontroller 104 can generate and/or send information associating the user with usage data.

In response to the communication unit 102 receiving tag data, the microcontroller 104 can store the tag data to a data storage device, such as the memory 106. As discussed previously, tag or other data may in some examples only be stored in the memory 106 if the microcontroller 104 identifies if the at least one operating parameter falls outside a predetermined operating parameter range. In some cases, the data is only stored in the memory 106 if the microcontroller 104 identifies the CAP has been damaged or is about to be potentially damaged based upon the at least one operating parameter falling outside the predetermined operating parameter range.

Furthermore, the microcontroller 104 can perform various actions based at least in part on data from the sensors 114. For example, the microcontroller 104 can be configured to perform an action in response to determining, based on the acceleration data, that the abrading tool 100 has exceeded a maximum vibration warning threshold. In this example, performing the action can comprise generating a warning (e.g., lighting a lamp, such as a Light Emitting Diode (LED), on the abrading tool 100), preventing the drive component 124 from moving the CAP 120, saving data regarding the event to the memory 106 and/or other actions.

For example, the sensors 114 can comprise the vibration sensor configured to generate vibration measurements, such as acceleration data, of the abrading tool 100. In this example, the microcontroller 104 can be configured to perform an action in response to determining, based on the vibration measurements generated by the vibration sensor, that a user of the abrading tool 100 has received a vibration dose greater than or equal to a threshold. In this example, the external communication unit 116 can be configured to receive an indication of a vibration dose already received by the user of the abrading tool 100. Furthermore, in this example, the microcontroller 104 can be configured to perform the action in response to determining, based on the vibration measurements generated by the vibration sensors and the indication of the vibration dose already received by the user, that the user has received the vibration dose greater than or equal to the threshold. In this example, performing the actions discussed immediately above.

In some examples, the external communication unit 116 can be configured to send, to an external device (e.g., computing system 4), data based on one or more measurements from the one or more sensors 114. For example, the external communication unit 116 can be configured to send data based on the vibration level measured by the sensors 116 to the external device.

In some examples, the wear sensor of the CAP 120 measures one or more characteristics of the CAP 120 associated with a wear level or likelihood of breakage or other damage of the CAP 120. For instance, the wear sensor can comprise one or more electrical resistance sensors or electrical impedance sensors. As the CAP 120 is used, the thickness of CAP 120 decreases, resulting in a change in electrical resistance and/or impedance between two or more electrodes attached to the CAP 120. Furthermore, an abrupt increase in resistance or impedance can indicate the presence of a crack in the CAP 120. In some examples, CAP 120 comprises a high permeability material in the CAP 120 that is typically lost with wear to the CAP 120. A sensor in the CAP 120 or the abrading tool 100 can sense (e.g., via inductive coupling) the resulting change in permeability (e.g., as a change in inductance). In some examples, the CAP 120 can comprise an annular ring that is eroded as the CAP 120 is used. In such examples, a sensor can measure wear of the CAP 120 based on one or more characteristics of an electrical current applied to the annular ring (e.g., resistance, impedance).

In some examples, the microcontroller 104 can determine a wear level or likelihood of breakage or other damage of the CAP 120 based on data indicating torque required to accelerate the CAP 120. For example, as the CAP 120 wears out, the CAP 120 can lose mass. Thus, the energy required to accelerate the CAP 120 to a certain speed (e.g., RPM level) decreases as the CAP 120 loses mass. Therefore, the energy required to accelerate the CAP 120 to the certain speed can decrease as the CAP 120 wears out. In some examples, the CAP 120 can gain mass as the CAP 120 wears. For instance, the CAP 120 can gain mass as spaces between grit particles can become clogged with abraded material as the CAP 120 wears. Hence, by measuring the torque required to accelerate the CAP 120 to the certain speed, the microcontroller 104 can determine a wear level (and can derive from that a likelihood of breakage/damage for) of the CAP 120. The microcontroller 104 can determine torque be based on a measurement of electrical current. In some examples, the determination of the wear level of the CAP 120 is performed by free spinning the CAP 120 (i.e., without applying the CAP 120 to a workpiece). Determining the wear level of the CAP 120 in this manner can be done before each use of the CAP 120. In some instances, free spinning the CAP prior to use can already be recommended for safety reasons. In some examples, an external device (e.g., the computer system 4) determines the wear level in this manner based on data from the sensors 114 of the abrading tool 100.

In some examples, the CAP communication unit 115 can receive an identifier of the CAP 120 from the CAP 120. The microcontroller 104 can instruct the external communication unit 116 to use the identifier to retrieve data regarding the CAP 120, such as the grit value for the CAP 120, the max RPM value for the CAP 120, current wear level of the CAP 120, and the usage time of the CAP 120. Thus, in this example, the communication unit 102 can receive data identifying the CAP 120. Furthermore, in this example, the communication unit 102 can send, to a remote device (e.g., computing system 4), a request identifying the CAP 120. In this example, the remote device is a device other than the CAP 120. In this example, in response to the request, the communication unit 102 can receive the data regarding the CAP 120 from the remote device.

In some examples, the microcontroller 104 can use the CAP communication unit 115 to write data to the CAP 120. For example, the microcontroller 104 can use the CAP communication unit 115 to write time information (e.g., tool run time, operator run time, CAP run time) to the CAP 120. For instance, the CAP communication unit 115 can be configured to send data to the CAP 120 based on one or more measurements from one or more of the sensors 114. For instance, in some examples, the sensors 114 can include the vibration sensor and the one or more measurements can include a measurement of a vibration level of the abrading tool 100.

Furthermore, in some examples, the microcontroller 104 can use the CAP communication unit 115 to write an RPM history level to the CAP 120 (e.g., a maximum experienced RPM value). The microcontroller 104 can determine the RPM level based on data from a tachometer in the sensors 114. In other words, the sensors 114 can include a tachometer and the one or more measurements can include a measurement of an RPM level of the CAP 120. In this example, the CAP 120 can be damaged if the CAP 120 is used at an RPM greater than a maximum allowed RPM limit. Accordingly, in this example, the microcontroller 104 can use the CAP communication unit 115 to write data to the CAP 120 indicating that the CAP 120 has been used at RPMs greater than the maximum allowed RPM limit and can also indicate how long the CAP 120 was used at RPMs greater than the maximum allowed RPM limit. In this example, an abrading tool or other device can read data indicating that the CAP 120 has been used at an RPM greater than the maximum allowed RPM limit and can generate a warning when a worker subsequently tries to use the CAP 120, even after the CAP 120 has been detached from abrading tool 100 and reattached to abrading tool 100 or another abrading tool. Microcontroller 104 can also determine to save any or all of the above data related to the overspeed event in the memory 106.

Furthermore, the CAP 120 can be damaged if dropped or otherwise subjected to excessive acceleration/deceleration. In many instances, this damage is not visible, but could result in pieces flying off the CAP 120. Accordingly, the microcontroller 104 can receive data on acceleration from one or more accelerometers in the sensors 114. In response to determining that the acceleration data is representative of the abrading tool 100 being dropped while the CAP 120 is attached to the abrading tool 100, microcontroller 104 can use the CAP communication unit 115 to write data to the CAP 120 indicating that the CAP 120 has been dropped. In this example, an abrading tool or other device can generate a warning when a worker subsequently tries to use the CAP 120, even after the CAP 120 has been detached from the abrading tool 100 and reattached to the abrading tool 100 or another abrading tool. In this example, an abrading tool or other device can read data indicating that the CAP 120 has been dropped and generate a warning when a worker subsequently tries to use the CAP 120, even after the CAP 120 has been detached from the abrading tool 100 and reattached to the abrading tool 100 or another abrading tool. Microcontroller 104 can also determine to save any or all of the above data related to the acceleration/deceleration event in the memory 106.

In another example, the microcontroller 104 can be configured to determine, based on data regarding the CAP 120, that the CAP 120 has been damaged, potentially damaged or potentially is about to be damaged based on wear, etc. and cause the abrading tool 100 to perform an action in response to determining the received data indicates the CAP 120 has been damaged, potentially damaged or about to be potentially is about to damaged based on wear, etc. For instance, the data regarding the CAP 120 can indicate whether the CAP 120 is potentially damaged (e.g., the CAP 120 has been dropped, the CAP 120 has been used at an RPM level about the maximum RPM level of CAP 120, a temperature of the CAP 120 has risen above a particular temperature threshold or fallen below a particular temperature threshold, etc.). In this example, microcontroller 104 can generate a warning and/or prevent the drive component 124 of the CAP 120 from moving the CAP 120 in response to determining that the CAP 120 is potentially damaged. Microcontroller 104 can also determine to save any or all of the above data related to the above operation criteria in the memory 106.

In one example, the data regarding CAP 120 can indicate whether the CAP 120 has been damaged by operating the consumable abrasive product at a RPM level greater than a maximum RPM level of the CAP 120. In some examples, the data regarding the CAP 120 can indicate whether CAP 120 has been damaged by CAP 120 being used at a temperature greater than a maximum temperature. In another example, the data regarding the CAP 120 can indicate how much time the CAP 120 has been used and that this has exceeded a threshold time (e.g., a maximum safe usage time, a typical expected lifespan, etc.). In this example, the microcontroller 104 can perform an action (e.g., output warning, prevent movement of CAP 120, save the data regarding such operation criteria to the memory 106) in response to determining a threshold related to operation has been exceeded.

In another example, the received data regarding the CAP 120 can indicate that the CAP 120 is cracked. In some instances, the CAP communication unit 115 receives the indication that the CAP 120 is cracked directly from the CAP 120. In other instances, the external communication unit 116 receives the indication the CAP 120 is cracked. In this example, the microcontroller 104 can perform an action in response to receiving an indication that the CAP 120 is cracked. For instance, the microcontroller 104 can cause abrading tool 100 to generate a warning, cause the drive component 124 not to move the CAP 120 while the CAP 120 is attached to abrading tool 100, save the data regarding the determination of the crack to the memory 106, etc.

In another example, the data regarding the CAP 120 can include product authentication data. In this example, the microcontroller 104 can use the product authentication data to determine whether the CAP 120 is authorized for use with the abrading tool 100. For instance, the CAP 120 can be unauthorized for use with the abrading tool 100 if the CAP 120 is subject to a manufacturer recall, is counterfeit, is registered as stolen, is improperly imported, or is otherwise subject to a condition where the CAP 120 should not be used with the abrading tool 100. In response to determining the CAP 120 is not authorized for use with the abrading tool 100, the microcontroller 104 can output a warning and/or can prevent use of the CAP 120 with the abrading tool 100.

In some examples, the microcontroller 104 can control how or whether a worker uses the abrading tool 100 based on data regarding the CAP 120 (e.g., data received from the CAP 120, data received from the computing system 4 or another device regarding the CAP 120, etc.) and/or data regarding a user of the abrading tool 100. For example, the data regarding CAP 120 can include a maximum RPM level of the CAP 120. In this example, the microcontroller 104 can prevent the abrading tool 100 from rotating CAP 120 at an RPM level greater than the maximum RPM level of the CAP 120. In some examples, the microcontroller 104 can prevent use of the abrading tool 100 with the CAP 120 based on data indicating the CAP 120 is damaged. In some examples, the microcontroller 104 can adjust (e.g., increase or decrease) a tool performance parameter (e.g., speed, torque, etc.) of the abrading tool 100 to prolong a worker's ability to use the abrading tool 100 based on a vibration dose the worker has received. For instance, the microcontroller 104 can increase or decrease a RPM level to reduce vibration.

Furthermore, in some examples, particular types of PPE should be used when using the abrading tool 100 with particular types of CAPs. In some such examples, the microcontroller 104 can control how or whether a worker uses the abrading tool 100 based on whether appropriate PPE is being used. Thus, in this example, the microcontroller 104 can be configured to determine whether a particular type of PPE that is required during use of the abrading tool with CAP 120 is in use. In this example, the microcontroller 104 can be configured to perform the action in response to determining that the particular type of PPE is not in use. For example, the microcontroller 104 can determine that a particular size of debris shield should be used with the CAP 120. In this example, in response to determining that such a debris shield is not properly attached to the abrading tool 100, the microcontroller 104 can prevent use of the abrading tool 100 with the CAP 120.

In some examples, a device (e.g., the microcontroller 104, a computing device of the computer system 4 (FIG. 1)) can determine, based on data regarding the CAP 120 and/or data from the sensors 114, that the abrading tool 100 and/or the CAP 120 requires human attention. For example, the device can determine that human maintenance should be performed on the abrading tool 100, or the like.

FIG. 4 is a diagram of a CAP 150, in accordance with one or more techniques of this disclosure. In the example of FIG. 4, the CAP 150 is presented as a sanding disk or grinding wheel. However, similar examples can be provided with respect to other types of consumable abrasive products. The CAP 150 comprises an abrading surface 151 for abrading a workpiece.

In the example of FIG. 4, the CAP 150 comprises one or more sensors 152, an ADC 154, a communication unit 156, and a data storage unit 158. In other examples, the CAP 150 can include more or fewer components. For instance, in some examples, the sensors 152, ADC 154, and/or data storage unit 158 are not included in the CAP 150. In some examples, the ADC 154 is part of an RFID interface that also comprises the communication unit 156, and, in some instances one or more sensors and/or data storage unit 158. The communication unit 156 can be configured to perform at least one of: sending data to one or more external devices, or receiving data from one or more external devices, such as an abrading tool to which the CAP 150 is attached, a mobile device (e.g., a mobile phone), the computing system 4 (FIG. 1), and so on. In some examples, the communication unit 156 comprises at least one of: a RFID interface or an NFC interface. The data storage unit 158 is configured to store data.

The ADC 154 can be configured to convert analog measurements from the one or more sensors 152 to digital data. For instance, the sensors 152 can comprise a temperature sensor and the ADC 154 can be configured to convert a signal from the analog temperature data into digital data. The data storage unit 158 can be configured to store the digital data. In this example, the digital data can indicate whether a temperature sensed by the temperature sensor has exceeded a threshold. In some cases, the data is only stored such as to the data storage unit 158 if the data exceeds the threshold.

In some examples, the sensors 152 include an impact detection component configured to detect whether the CAP 150 has been subjected to an impact with force sufficient to damage or likely damage the CAP 150. For example, the impact detection component can comprise a brittle electrically-conductive material that breaks when subjected to an impact having force sufficient to damage the CAP 150. In this example, the impact detection component can determine that the CAP 150 has been subjected to an impact with force sufficient to damage the CAP 150 if an electrical current will not flow through the material with an expected resistance or impedance. In this example, the data storage unit 158 can be configured to store data indicating whether the CAP 150 has been subjected to an impact with force sufficient to damage the CAP 150. In some examples, data is only stored such as to the data storage unit 158 if the data indicates impaction with force over the threshold.

Furthermore, in some examples, the sensors 152 can include an excessive RPM detection component configured to detect whether the CAP 150 has been subjected to an RPM level exceeding a threshold sufficient to damage or likely cause damage to the CAP 150. For instance, the excessive RPM detection component can comprise a brittle electrically-conductive material that breaks when subjected to a RPM level exceeding the threshold. In this example, the excessive RPM detection component can determine that the CAP 150 has been subjected to a RPM level exceeding the threshold if an electrical current will not flow through the material with an expected resistance or impedance. In this example, the data storage unit 158 can be configured to store data indicating whether the CAP 150 has been subjected to an RPM level exceeding the threshold sufficient to damage the CAP 150. In some examples, data is only stored such as to the data storage unit 158 if the data indicates overspeed over the threshold.

In some examples, the sensors 152 include one or more wear sensors. A wear sensor can be configured to generate data indicating a wear level of the CAP 150, which can be used to determine a likelihood of potential damage to the CAP 150 in some cases. A wear sensor can comprise a pair of electrodes and circuitry for detecting electrical resistance or impedance. Electrical resistance and/or impedance can change as the CAP 150 thins with use. Hence, changes in electrical resistance and/or impedance can provide a wear level of the CAP 150. Other examples of wear sensors are described elsewhere in this disclosure. In some examples, data is only stored such as to the data storage unit 158 if the data indicates wear level of a sufficient amount such that the likelihood of potential damage to the CAP 150 is above a statistically derived threshold.

In some examples, the communication unit 156 can receive various types of data and can send various types of data. For example, the communication unit 156 can be configured to receive vibration data from an abrading tool (e.g., the abrading tool 8, the abrading tool 100). The abrading tool is detachable from the CAP 150 and can provide motive power to the CAP 150 during a work session. In this example, the vibration data can indicate at least one of: a duration of vibration experienced by a user of the abrading tool during the work session, a frequency of the vibration, and a force of the vibration.

FIG. 5 is a diagram illustrating an example sanding belt 200, in accordance with one or more techniques of this disclosure. The sanding belt 200 is an example of a consumable abrasive product. In the example of FIG. 5, the sanding belt 200 comprises an RFID tag 202 with an antenna 204.

FIG. 6 is a diagram illustrating an example CAP 300 that includes electrodes 302A-302L (collectively, “electrodes 302”) for detecting cracks in the CAP 300, in accordance with one or more techniques of this disclosure. The electrodes 302 can form part of the sensors 152 (FIG. 4). Furthermore, as shown in the example of FIG. 6, the CAP 300 can include a control unit 304, a memory 306, and a communication unit 308.

Failure of a CAP can have serious consequences. For example, the surface of an expensive workpiece can be seriously damaged. In another example, a worker can be injured if the worker is not wearing proper personal protective equipment. The CAP 300 design can help to reduce the risks of damage or injury due to failure of CAP 300.

In the example of FIG. 6, the control unit 304 of CAP 300 can apply an electrical signal to pairs of electrodes (i.e., drive electrodes) while measuring voltage on other pairs (i.e., measurement electrodes). For instance, the control unit 304 can apply an electrical signal across a first pair of electrodes in the plurality of electrodes and measure a voltage across a second pair of electrodes to generate a set of measurements. Each of the electrodes 302 can serve as a drive electrode or a measurement electrode at different times. When a pair of electrodes are serving as drive electrodes, the control unit 304 applies an electrical signal across the pair of electrodes. When a pair of electrodes are acting as measurement electrodes, the control unit 304 uses the electrodes to measure a voltage between the two electrodes. In some examples, the measurement electrodes are the same as the drive electrodes. However, using different electrodes as drive electrodes and measurement electrodes can remove contact impedance from the measurement.

The control unit 304 can repeat the process of applying electrical signals to pairs of drive electrodes for one or more (e.g., a predetermined) number of pairs of electrodes. The control unit 304 can store the resulting measurements as a first dataset in the memory 306. The control unit 304 can comprise a microcontroller or other type of integrated circuit.

Subsequently, the control unit 304 can apply an electrical signal to pairs of electrodes while measuring voltage on other pairs. For instance, the control unit 304 can be configured to apply a second electrical signal across the first pair of electrodes in the plurality of electrodes and measure a voltage across the second pair of electrodes to generate a second set of measurements. The control unit 304 can repeat this process for one or more (e.g., a predetermined) number of pairs of electrodes. The control unit 304 can store the resulting measurements as a second dataset in the memory 306. The control unit 304 can determine, based on a comparison of the first and second datasets, whether the abrasive disk of the CAP 300 contains a crack, such as crack 312. That is, the control unit 304 can be configured to compare a first set of measurements (e.g., the second data set) to a second set of measurements (e.g., the first dataset) to determine whether there is a crack in the CAP 300. The communication unit 308 can be configured such that, in response to the control unit 304 determining there is a crack in the CAP 300, the communication unit 308 sends data to the one or more external devices (e.g., an abrading tool) indicating that there is a crack in the CAP 300.

Cracks or other damage to materials generally appear as changes in impedance (e.g., a real or imaginary component of impedance). The example of FIG. 6 can run either at direct current (DC) or any alternative current (AC) frequency which is realistically feasible, such as 10 Hz to 100 MHz.

There is a wide range of choices for electrode placement, electrical drive signal, choice of measurement electrodes, and algorithms to compare the two datasets and determine whether there is a crack. When a crack is present, the path the electrical current takes between the drive electrodes is disturbed and the measured voltage can be different when the first and second datasets are compared.

In some examples, the first dataset can be generated not from a measurement of the CAP under test but can be a ‘global average’ of many datasets from CAPs known to not contain a crack. The first dataset can also be generated from a simulation or other method. However, measuring a first dataset on each CAP can take into consideration normal manufacturing variation. Non-uniformity of the electrical properties of the CAP can be accounted for, as well as differences in the placement of electrodes.

As shown in the example of FIG. 6, the electrodes 302 are placed on a top surface 310 of the CAP 300. The top surface 310 can face an abrading tool and can be opposite an abrading surface (not shown) of the CAP 300. The electrodes 302 can be placed in any arrangement. However, placement of the electrodes 302 in a ring around an outer perimeter can be advantageous for detecting cracks. In the example of FIG. 6, the CAP 300 has twelve electrodes, but more or fewer electrodes can be used in other examples. For example, the number of electrodes on the CAP 300 can be 16, 24, 32, or another number.

There can be many unique combinations of drive electrode pairs, typically on the order of n*(n−1)/2, where n is the number of electrodes. However, it may not be necessary to test all pairs of electrodes. For instance, it may not be necessary to test pairs of electrodes on opposite sides of the CAP 300. In some examples, pairs of electrodes separated by 3 other electrodes can be tested. For instance, in the example of FIG. 6, the control unit 304 can apply an electrical signal to the electrode pairs 302D and 302H, 302E and 302I, 302F and 302J, and so on. In this example, there are n such pairs for n electrodes.

The electrical signal applied between drive electrodes can be either a current or a voltage. A potential advantage of a current is that contact impedance does not have to be well controlled and the current is identical for all drive pairs. Alternatively, a voltage can be applied, and the current can be measured. The measurement can then be normalized to account for different drive currents. The system can be used with either a DC or AC applied signal. Electronics can be simpler with a DC implementation, but AC can have the added benefit of looking for changes in complex impedance, which cracks often show.

In some examples, the electrodes 302 are manufactured on a ‘sticker’ which is a piece of paper or plastic with an adhesive backing. In other words, the CAP 300 can comprise a sticker that comprises the electrodes 302 and the control unit 304, wherein the sticker adheres to a surface of the CAP 300, such as a surface opposite an abrading surface of the CAP 300. Locations where the electrodes 302 are present can have a conductive adhesive. The measurement electronics (e.g., the control unit 304) can also be on the sticker and can be powered via connections to an abrading tool (e.g., the abrading tool 8 (FIG. 1), the abrading tool 100 (FIG. 3)) through a disk mount. In other words, the control unit 304 can be powered through a connection to an abrading tool through the disk mount 314 of the CAP 300. The communication unit 308 can send a signal to the abrading tool that a crack is present and can prevent the abrading tool from operating. In other words, in response to receiving an indication that a crack is present in the CAP 300, the abrading tool will not operate with the CAP 300. In other examples previously described, in response to receiving an indication that a crack is present in the CAP 300 such data is saved in an electronic storage device.

In addition to the electrodes 302, the applied sticker can also include an inductor for inductive coupling to another antenna in the abrading tool. Thus, power can be provided directly to the sicker from the abrading tool without the need for a physical, wired connection. Additionally, communication can be provided directly from the sticker to the abrading tool without the need for a physical (wired) connection. For instance, the communication unit 308 can comprise an RFID interface and the control unit 304 can be powered through the RFID interface. On a fast-moving abrading tool, not using a physical connection can be advantageous. In such examples, determination of a crack can take place as soon as CAP 300 starts moving.

There can be many ways to detect a crack in the CAP 300 based on the first and second measurements. One way is for control unit 304 to determine a difference between the first and second measurements for a given drive and measurement electrode pair. An increase in resistance can indicate a crack. Another way is to determine a ratio of the first and second measurements. The control unit 304 can determine that a crack is present by finding a statistical outlier among all the measurement ratios.

In some examples, a device separate from the CAP 300 can detect the presence of a crack in the CAP 300. For example, the communication unit 308 can communicate the measurements to another device, such as abrading tool (e.g., abrading tool 8, abrading tool 100), a mobile device (e.g., mobile device 20 (FIG. 1)), a computing system (e.g., computing system 4), or another device or system. In this example, the other device can use the measurements to determine whether there is a crack in the CAP 300.

The electrodes 302 can also be used for determining electrical resistance and/or impedance to determine a wear level of the CAP 300, as described elsewhere in this disclosure.

FIGS. 7 and 7A show an example of a bonded abrasive wheel 400 according to an example of the present application. The bonded abrasive wheel 400 (shown as a depressed-center bonded abrasive wheel) has a depressed central portion 404 encircling a central hub 490 that extends from an abrading surface 424 (also called a front surface) to a back surface 426 (also called an opposing surface). The central hub 490 can comprise a bushing 492, which can be used, for example, for attachment to a power driven tool (not shown). In some examples, the bushing 492 can be constructed so as to minimize interference with the circuits described herein. Thus, for example, the bushing 492 can be comprised of a non-metallic material (e.g., a polymer), for example. In other examples the bushing 492 can be split and/or may not extend entirely through the bonded abrasive wheel 400. An abrasive layer 460 comprises abrasive particles 470 (e.g., crushed but in other examples shaped) retained in binder 475. The abrasive layer 460 optionally further comprises reinforcing material 415 adjacent to the abrading surface 424. The abrasive layer 460 optionally further comprises a secondary reinforcing material 416 adjacent to the back surface 426.

The bonded abrasive wheel 400 has a rotational axis 495 around which the wheel rotates in use, and which is generally perpendicular to the disc of the bonded abrasive wheel.

The layer 460 comprises a curable composition that includes the binder 475 that retains abrasive particles 470. The binder 475 may be inorganic (e.g., vitreous) or organic resin-based, and is typically formed from a respective binder precursor.

FIG. 7A also shows a portion of a circuit 410 comprising an antenna 412 embedded within the bonded abrasive wheel 400 adjacent the back surface 426, thereof. For the circuit 410 configured for NFC, the antenna 412 can be spaced away from either the first grinding surface 424 or the back surface 426 by between 0.1% and 200% percent of the radius of curvature of the antenna. Exemplary constructs of the circuit 410 are further illustrated in FIGS. 7B and 7C and discussed in reference to those FIGURES. As discussed in FIG. 1, the circuit 410 and the other circuits discussed herein can be configured to facilitate communication in various ways to convey or receive data, including data from one or more sensors (e.g., sensors 19)

FIGS. 7B and 7C show an exemplary circuit 400A configured for RFID or NFC communication. The circuit 400A can include an antenna 402A, an integrated circuit (IC) 404A, a capacitor 406A and leads 408A.

As shown the antenna 402A can be operably coupled (electrically connected in a manner to facilitate the movement of electrical current) to the IC 404A via the leads 408A. The capacitor 406A can optionally be utilized, and can be operatively coupled in parallel with the IC 404A to the antenna 402A via the leads 408A. The IC 204 and/or the capacitor 206 may be coupled to the antenna directly without the use of leads 208 in the form of a leadless package, or an unpackaged IC, for example. Although shown as substantially a single loop having a circular substantially constant radius of curvature as described below, in other examples, further loops and other circuit shapes are contemplated including those that are non-circular and do not utilize a radius of curvature or have a varying radius of curvature throughout most/all of their extent.

According to the example of FIGS. 7B and 7C, the antenna 402A can configured to communicate with one or more external devices in the manner previously discussed in reference to FIG. 1. The antenna 402A can include a first end 410A and a second end 412A. The antenna 402A can have a radius of curvature RC about an axis 414A along at least a portion thereof such that the first end 410A can be disposed adjacent to but is spaced from the second end 412A. Such spacing between the first end 410A and the second end 412A can amount to a distance of less than 0.3 inch in the case of the example of FIGS. 2 and 2A. The axis 414A can comprise an axis of symmetry of the antenna 402A according to some examples including the example of FIGS. 7B and 7C. In some examples, the axis 414A can substantially align with the axis 495 (FIGS. 7 and 7A) of the bonded abrasive wheel. However, in other examples the axis can be offset from that of the axis 495.

As shown in FIGS. 7B and 7C, the antenna 402A can comprise a single non-complete loop with the first end 410A spaced a short distance from but interfacing with the second end 412A. According to one example, the antenna 402A has a radius of curvature RC of between about 0.5 inch and about 2 inches and has a width 216 of between about 0.10 inch and about 0.75 inches. The width of the antenna 402A can vary as a ratio of the radius of curvature RC, for example, width up to about 50% of the radius of curvature can be acceptable. A thickness of the antenna 402A can be greater than about 0.001 inches to about 0.01 inches, for example. However, other geometries for the antenna 402A are contemplated and can vary depending upon the application, desired resonant frequency, position of the antenna 402A within the bonded abrasive wheel, the size (e.g., diameter) of the bonded abrasive wheel, and other operational factors. In some cases, it is desirable to have the radius of curvature RC of the antenna 402A be sufficiently larger than depressed central portion 404 (FIG. 8A) of the bonded abrasive wheel.

The antenna 402A according to the example of FIGS. 7B and 7C can comprise a wire or metallic foil such as a copper foil, copper alloy foil, aluminum foil, aluminum alloy foil, alloys thereof, or the like. A diameter of the wire can be between about 5 mils and about 250 mils, for example. The antenna 402A can also be constructed of a composite including a polymer foil in some cases. The antenna 402A can be laminated with several foil layers combined together. For example, an aluminum foil and a polymer film can be heat laminated together. Suitable polymer films include elastomeric polyurethane, polyimide, polysulfide, silicone, co-polyester, or polyether block amide films. In other embodiments, a material is extruded directly onto a metallic foil forming a substrate layer attached to the metallic foil. For example, a polyurethane resin may be extruded onto a copper foil. In other embodiments, a material, such as a urethane, is solvent coated onto a metallic foil. The metallic foil can be patterned using conventional wet etching techniques to produce the antenna 402A. Alternatively, the antenna 402A can be formed through a milling process or through a die cutting process. Each foil may have a thickness in the range of about 0.5 micrometers or about 1 micrometer to about 100 micrometers or to about 200 micrometers.

According to one example, the antenna 402A can be configured to have a resonance frequency of about 13 MHz (e.g., 13.56 MHz to 14.5 MHz) as this is commonly used in NFC. It has been found that, in some embodiments, a desired resonance frequency of a reduced-reactance antenna can be achieved by including one or more stand-alone capacitors (e.g., capacitor 406A) connected in parallel with the antenna and arranged in parallel with IC 404A. The frequency band at about 13.56 MHz is within a range sometimes referred to as a high frequency (HF) band. The circuit 200 of the present description can have resonance frequencies in other bands. Suitable bands include, for example, the high frequency (HF) band from 3-30 MHz and the low frequency (LF) band from 120-150 kHz and the ultra-high frequency (UHF) bands at about 433 MHz, or 865-868 MHz, or 902-928 MHz. Suitable bands also include, for example, other industrial, scientific, and medical (ISM) radio bands such as those having frequencies of about 6.78 MHz, 27.12 MHz, or 40.68 MHz. The antenna 402A can have a quality factor (Q factor) greater than about 35, or greater than about 40, or greater than about 45, or greater than about 50. In some embodiments, the antenna may have a Q factor in the range of about 35 to about 90.

Further details regarding the construct of various circuits that can be used with CAPs discussed herein including the bonded abrasive wheel of FIGS. 7 and 7A can be found in co-owned and co-pending United States Provisional Patent Application, entitled “EMBEDDED ELECTRONIC CIRCUIT IN GRINDING WHEELS AND METHODS OF EMBEDDING”, filed on the even day as the present application, the entire contents of which are incorporated by reference in their entirety.

FIG. 8A is a flowchart illustrating an example system 500 of operation that detects if an operating condition threshold has been breached. The flow chart proceeds from a start 502 by monitoring 504 of various operating conditions discussed previously (revolutions per minute of the abrading tool or the consumable abrasive product, a force applied on one or more of the abrading tool, the consumable abrasive product and the workpiece; impact, a temperature of one or more of the abrading tool, the consumable abrasive product and the workpiece, a duration of operation, crack is detected, etc.). The method 500 can determine at step 506 if an operating parameter falls outside a predetermined operating parameter range. If no such operating parameter is exceeded, for example, the method can return to step 504. However, if the method determines the operating parameter falls outside the predetermined operating parameter range, the method can proceed to step 508. At step 508 the method can determine if the operating parameter that falls outside the predetermined range warrants immediately action (i.e. is immediately actionable).

If the operating parameter falls outside the predetermined range but does not warrant immediate action, then data regarding the operating parameter is written to memory such as to the data storage device at step 510. Examples of conditions/parameters that may be deemed or may not be deemed immediately actionable can be but are not limited to: the type of the consumable abrasive product is improper for the abrading tool, a finish imparted to the workpiece is undesirable, a duration of operation below a certain first threshold period of time, an identity of a tool operator is determined to have changed, a location of the CAP has changed, and other criteria determined by the end user.

If the operating parameter falls outside the predetermined range and does warrant immediate action, then data regarding the operating parameter is written to memory such as to the data storage device as previously discussed at step 512. Examples of conditions/parameters that may or may not be immediately actionable can be but are not limited to: revolutions per minute of the abrading tool or the consumable abrasive product being exceeded, a force applied on one or more of the abrading tool, the consumable abrasive product and the workpiece exceeded; impact limit exceeded, a temperature of one or more of the abrading tool, the consumable abrasive product and the workpiece exceeded, a duration of operation exceeded to a large degree, a crack or defect in the CAP, or the like.

At step 514 if the operating parameter falls outside the predetermined range and does warrant immediate action additional actions can be taken such as generating alerts (sending a text or other notification to the worker or supervisor), sending instructions to the abrading tool or a robotic device configured to operate the abrading tool such as to cease operation and/or locking out the abrading tool to prevent use of the abrading tool with the CAP attached thereto.

FIG. 8B is a flowchart illustrating an example method 600 of operation that detects acceleration data from an accelerometer of a CAP or abrading tool. FIG. 8B is provided as an example and can be described with reference to abrading tool 100 of FIG. 3 and previously discussed method 500 of FIG. 8A. Other examples can be with regard to other data (e.g., force, RPM, etc.) and can omit actions shown in FIG. 8B, can include more actions, can have different action, can include actions in different orders, and so on.

In FIG. 8B, the microcontroller 104 can read a configuration file. For example, the microcontroller 104 can read a configuration file that includes data regarding an application specific configuration of the abrading tool 100 at step 610. The configuration file can include values for configurable parameters, such as configurable acceleration parameters and threshold(s). The microcontroller 104 can read tool data at step 612. For example, the tool data can be stored in the memory 106 of the abrading tool 100, such that the microcontroller 104 can read the tool data from the memory 106. In other examples, the microcontroller 104 can receive the tool data, such as through the communication unit 102.

The microcontroller 104 can monitor acceleration data of an accelerometer of abrading tool 100 by receiving the acceleration data from the accelerometer and determining whether the acceleration data exceeds a maximum acceleration threshold at step 614. If the acceleration exceeds a maximum acceleration threshold, microcontroller 104 can cause abrading tool 100 to save the acceleration data to memory 106 at step 616 according to one example. According to another example, the microcontroller 104 can be configured to continuously monitor and continuously write acceleration data at step 618 such data can be saved to the memory 106 independent of thresholds.

While the microcontroller 104 has not received the indication to write the acceleration data, the microcontroller 104 can determine whether the communication unit 102 is in read/write mode. While the communication unit 102 is in a tag read/write mode at step 620, the microcontroller 104 can monitor the communication unit 102 for tag data from tags at step 622. For example, the communication unit 102 can read badge data from badge tags 626, can read tool data from tool tags 628, and/or can read CAP data from CAP tags 630, etc.

In response to receiving a write/store indication, the microcontroller 104 can write time-stamped acceleration data while the abrading tool 100 is operating at step 632. In some examples, the write indication can be a user input, such as a button indicating that the microcontroller 104 can write acceleration data. In other examples, the write indication can be an automatic indication in response to the communication unit 102 receiving the badge data, tool data, and CAP data and the microcontroller 104 receiving the acceleration data. The microcontroller 104 can continue to monitor the accelerometer of the abrading tool 100 as described in steps 618 and 620 at steps 634, 636 and can save the data to memory 106 as desired if a threshold is determined to be breached.

The microcontroller 104 can continue to write acceleration data while the microcontroller 104 receives acceleration data. In response to cessation of the microcontroller 104 receiving acceleration data, the microcontroller 104 can stop writing the acceleration data at step 638. The microcontroller 104 can output a summary of operation of the abrading tool 100 by writing a runtime of abrading tool 100 at step 640, writing user data of the user of the abrading tool 100 at step 642, and writing CAP data of the CAP 120 coupled to the abrading tool 100 at step 644, for example.

FIG. 9 describes an example flow chart of a system 700 and had aspects thereof previously described in reference to the system of FIG. 1. Thus, the system 700 can have the various components of the system 2 previously described including the data storage device 6, the sensor, communication unit, the CAP, the abrading tool, the workpiece and the computing system 4. However, the system 700 can operate independent of operating parameter threshold(s) and can rather operate on a temporal basis that is further elaborated upon in reference to FIGS. 10 and 11.

According to the flow chart of FIG. 9, the system 700 can start 702 with a timer start 703. The timer can continuously maintain time and date. According to the system 700, the computing system 4 can be configured to receive data from the communication unit regarding the sensor. This data can be indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece. The computing system 4 can continuously store second data in the data storage device, this second data can be based upon the first data.

According to the flowchart of FIG. 9, at 704 in facilitating storage the computing system 4 can continuously gather data as a set or sets (e.g., regarding acceleration, RPM, force, impact, etc.) in the manners previously discussed in reference to FIGS. 1-8B. This is done over a predetermined period of time as discussed below. Operational state and other criteria related to operation can also be determined and checked by the computing system 4. For example, such determination/checks can include but are not limited to: Is this the first time the tool and/or the CAP has been run? How many times has the tool and/or CAP been run? What time intervals are presently in the memory, if any? What is the next time interval? (i.e. when will the next data will need to be stored?) What sensor(s) are present? Are the sensor(s)presently working? Have previous errors or issues been logged?

At 706, the system 700 can determine if a first predetermined time interval has expired such that a next (second) predetermined time interval has been reached. If the next predetermined time interval has not been reached, data continues to be continuously gathered as part of the data set or sets. In between intervals of time, data can be buffered in a transient manner, continuously looping and overwriting. Once a time interval designated has been reached data can be saved more permanently such as in a non-volatile memory.

However, if the next predetermined interval has been reached a second determination is made to ascertain of memory such as in the data storage device 6 is full at 708. If the memory is not full, the computing system 4 writes the data to an open slot X in the data storage device 6 at 710. However, if the memory is determined to be full, the computing system 4 can determine at 712 where the data should be overwritten (e.g., to a slot Y) based on criteria discussed below with regard to FIG. 10. At 714, the computing system 4 can write the data to the determined save location (e.g., to the slot Y).

FIG. 10 shows an example of memory 802 that can be utilized with the systems, and in particular, the data storage devices as previously described herein. As discussed above in FIGS. 1 and 9, according to one example the system can be configured for monitoring one or more of an abrading tool, a consumable abrasive product and a workpiece in a temporal manner. More particularly, the computing system (e.g., the computing system 4) can be configured to receive a first data from the communication unit regarding one or more system sensors. The first data can be indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece. The computing system can continuously store a second data in the data storage device, the second data can be based upon the first data. According to one example, the first data can be continuously gathered by the one or more system sensors.

FIG. 10 shows an example of the memory 802 positioned within or on a containing device 804 (e.g., the data storage device 6, the abrading tool 8, the CAP 10, etc. of FIG. 1). However, as described previously in other examples, the memory 802 can be located at a remote cloud-based location, a memory of the abrading tool, a memory or a robotic device, etc. The second data (indicated as “Previous N seconds” and reference number 806 in FIG. 10) can be saved for a predetermined period of time. Such period of time can comprise, less than 0.1 seconds to 20 seconds of data, for example. Additionally, the second data can be continuously overwritten in a predetermined manner described below.

According to the example of FIG. 10, the memory 802 can save the second data in a quasi-temporal continuous loop. More particularly, the memory 802 can save the second in a quasi-logarithmic continuous loop as shown in FIG. 10. With this quasi-logarithmic continuous loop, the oldest data in the data storage device is not necessarily overwritten and replaced when the second data 806 is stored. FIG. 10 is intended to show the quasi-logarithmic manner where data can be stored somewhat evenly spaced numbers on a log scale, rather than on a linear scale, so that we can efficiently span a longer overall period, maintaining some historical trends by not always overwriting the oldest data when the memory is full. For example, logarithmic spacing for 4 samples taken between 1 minute and 10 minutes could be: 1, 2.2, 4.6, and 10 minutes. These numbers roughly round to the 1, 2, 5, 10 minutes shown in FIG. 10. Thus, an exact formula for time intervals is not contemplated in some examples (including FIG. 10). FIG. 10 is intended to provide only a general template. Some variation to span minutes, hours, and days can be made in conformance with the principles discussed herein and is contemplated. A strict log base 10 format is also not contemplated in all examples. Furthermore, time exactness is not required to implement the proposed technique in all examples (as exhibited by the rounding of FIG. 10—(i.e., 2.2 minutes a 2 minute time was utilized, etc.)). Rather, one of the goals exhibited by FIG. 10 is to provide for a technique(s) that capture data over a non-linear span of time intervals so the gathered data can span a lot of time in the memory, this allows for keeping data from a wider range of times of various interrelated ages.

As shown in both FIGS. 10 and 11, the memory 802 is configured to cyclically organize the second data 806 based upon a time 808 (indicated as “Time Index” in FIG. 11) the second data 806 was stored and associate the second data 806 with further stored data 810 (FIGS. 10 and 11) therein that was previously stored in predetermined time intervals (example intervals of about 1 minute ago, about 2 minutes ago, about 5 minutes ago, about 10 minutes ago, etc.) related to the time the second data 806 was stored. The predetermined time intervals provided in FIG. 10 are exemplary and can differ in other examples. FIG. 11 shows the physical organization and association of the memory 802 in a block structures 811A and 811B where the second data 806 is associated with the further stored data 810 according to the predetermined time intervals. The address <NUM> of each block structure represents the physical location in the memory, generally pre-determined at the time a memory component is manufactured and used to perform read/write operations. The addresses are not necessarily meant to be used sequentially in time, nor overwritten sequentially in time. The storage of a time index 808 associated with each log data 806/810 enables any memory address to store data from any time interval, as needed to maintain a desired distribution of time intervals. As shown in FIG. 10, the predetermined time intervals can comprise at least a first time interval 812 and a second time interval 814. The second time interval 814 can be on an order of magnitude of equal to or greater than ten times that of the first time interval 812. Other orders of magnitude are contemplated and can include greater than or equal to 100 times (the ˜2 hours ago block vs. 812), greater than or equal to 1000 times (the ˜24 hours ago block vs. 812), greater than or equal to 10,000 times (the ˜10 days ago block vs. 812). Indeed, the predetermined time intervals can be spaced in time on a log scale. As time marches on, it may not necessary to continuously update every block to maintain a strict conformance to the pre-determined time intervals, since this could require more power and could induce unnecessary wear on non-volatile memory. Instead, samples can be allowed to drift away from the pre-determined time interval, and the choice of which sample is to be overwritten can be the sample that has drifted far enough from the desired intervals to no longer be deemed as useful as the other samples. Structuring the data as described can be highly desirable in highly memory-constrained systems such as an RFID or NFC tag within the CAP, for example.

Organizing the data as illustrated in FIGS. 9-11 and described herein can allow for greater ease for the computing system 4 in mining the stored data. For instance, the computing system 4 can mine data in the data storage device 6 for data that is then reported to and can receive fed back from appropriate entities, e.g., safety or compliance manager, production foreman, maintenance manager, and so on such a via a text or another alert notification method. In some examples, the computing system 4 can associate the reported data with an urgency level. For instance, reporting that the abrading tool 8 is being operated beyond recommended Rotation Per Minute (RPM) level can be designated as more urgent than reporting that a sanding disk inventory is running low. The RPM reporting can be a safety, compliance, or productivity issue which might need to be reported as soon as possible to the safety officer or shop foreman; low inventory can be reported to a purchasing agent with less urgency.

According to another example, the organizing structure of the data shown in FIGS. 9-11 can be used to monitor the electrical resistance can change over time discussed in reference to FIGS. 1 and 6 in a more efficient manner. As the CAP 10 is used and the electrical resistance changes can be monitored with the gathered an organized data of FIGS. 9-11. Furthermore, crossing a particular threshold can indicate that the CAP 10 is excessively worn or is at a higher likelihood of being about to be potentially damaged.

According to yet another example, the organizing structure of the data shown in FIGS. 9-11 can be used to monitor the condition of abrading tool 8 and/or the CAP 10 for wear and other conditions where performance has degraded between maintenance or replacement. For example, an abrading tool that used CAPs at a particular rate or is associated with a particular productivity can change in performance through use or over time, which can be tracked more efficiently with the data structure and techniques described in FIGS. 9-11. In examples where the usage data includes a condition of the abrading tool 8, a routine/algorithm can determine whether the abrading tool 8 is approaching the end of its expected operating time between maintenance events or approaching its expected life based upon the saved data. Accordingly, based on data, the computing device 4 can flag the abrading tool 8 and/or the CAP 10 to be removed from service for maintenance, discarded, and/or replaced.

FIG. 12 shows a highly schematic exemplary system 900 that includes a robotic device 902 that can be used with an abrading tool 904 and a CAP 906. The abrading tool 904 and the CAP 906 can comprise any of the abrading tools and CAPs previously discussed herein. As illustrated, the robotic device 902 comprises a robot arm 908, force control sensors and devices 910, the abrading tool 904 (e.g., a grinding/polishing tool), a hardware integration device 912, the CAP 906 (e.g., abrasive device(s)), monitoring and feedback devices 914, and a computing system 916. These elements may work together as part of the systems previously described to monitor one or more of the abrading tool 904, the CAP 906 and a workpiece.

Robots such as robotic device 902 can have difficulty in performing abrading tasks because they lack a human operator's intuitive feel for when work on an area of a workpiece is complete and/or whether a CAP is worn out. However, use of robots to perform abrading tasks can be highly beneficial in some situations, such as when toxic materials are involved, space is constrained, physical access to an area of a workpiece is constrained, work occurs in a hazardous area, and so on. In some instances, the computing system 916 can use the safety, usage and other data for training of robots such as robotic device 902 to perform abrading tasks. For example, the computing system 916 can aggregate usage data from many work sessions to quantify what a worker might intuitively feel about an area of a workpiece being complete or the CAP 906 being worn out. For instance, the computing system 916 can determine (e.g., based on vibration data, electrical current draw data, RPM data, data regarding characteristics of the CAP 906 and workpiece, video information, work duration information, abrading tool movement information, applied pressure information, torque information, electrical resistance measurements, CAP temperature information, and/or other data) when an area of a workpiece is complete. Similar information can be used for determining whether the CAP 906 is worn out. In some examples, computing system 916 can train a machine learning system (further shown in FIG. 13) based on such data to make determinations regarding whether an area of a workpiece is complete and/or whether the CAP 906 is worn out. For instance, usage data can be used as training data for a neural network part of a machine learning routine as discussed below in FIG. 13. Furthermore, the data can be used for manufacturer monitoring of the CAP 906 and/or the abrading tool 904 performance for purposes of product improvement.

FIG. 13 shows a sample example of a robotic implemented system 1000 including a learning component and cloud-based process planning and optimization. The flow of data is depicted with arrows in FIG. 13. In the example of FIG. 13, the robotic device 902 has been augmented to further include additional sensors 1002. The abrading tool 904 (FIG. 12) has been provided with sensors and other components discussed previously so as to comprise a smart abrading tool 1004. An ancillary control unit 1006 is provided as part of the system 1000. Furthermore, a cloud computing system 1008 including a database 1010 that is local or maintained in the cloud computing system 1008 and is responsible for executing and maintaining the control policy for the system 1000 including the robotic device 902 including those instructions recommended by a machine learning unit 1012 and maintained by an instruction server 1014 is provided as part of the system 1000.

The ancillary control unit 1006 can take the place of the deterministic code previously residing in a robot controller or similar device and can provide the immediate real-time signals and processing for execution of the robotic device 902 and the smart abrading tool 1004. In this regard, the robotic device 902 can now serve a reactionary role in the system 1000 driven by the ancillary control unit 1006. The database 1010 of the cloud computing system 1000 can serve as a long-term data repository that stores monitoring generated data of processing including state variables, measurements, and resulting performance that can be correlated with identified operating parameter deviations and/or defects to generate instructions (sometimes termed policies) implemented by the instruction server 1014. Additionally, the machine learning unit 1012 can be responsible for continuously improving the operating instructions based on observations (state/sensor data derived from monitoring) and subsequent reward (quality of performance). Online learning can be accomplished by a form of reinforcement learning such as Temporal Difference (TD) Learning, Deep Q Learning, Trust Region Policy Optimization, etc.

In the example of FIG. 13, the robot device 902 can be capable of sufficiently positioning the smart abrading tool 1004 to achieve desired abrading described above. While lower degree of freedom systems could be used in some cases, six degree of freedom serial robot manipulators can be utilized as well. Some examples include, but are not limited to Fanuc's M-20 series, ABB's IRB 1600, or Kuka's KR 60 series. For example, the Kuka KR 60 HA has 6 axes and degrees of freedom, supports a 60 kg payload, and has a 2.033 m reach. Process-specific tooling (i.e., the smart abrading tool 1004) has been covered in extensive detail above.

A robot controller module 1016 can be the robot OEM provided controller for the robotic device 902. The robot controller module 1016 can be responsible for sending motion commands directly to the robotic device 902 and monitoring any operational, safety or other concerns. In practice, the robot controller module 1016 can generally include a robot controller in conjunction with one or more safety programmable logic controllers (PLCs) for cell monitoring. In a sample example, the robot controller module 1016 can be setup to take input from the ancillary control unit 1006 that can provide performance specific information including various of the data (usage, safety, quality, etc.) discussed previously and/or commands. This can happen, depending on the desired implementation, either off-line via program downloads and execution or in real-time via streaming. An example of the offline approach would be a pre-processed robot program in the native robot's language (e.g., RAPID, KRL, Karel, Inform, etc.) that gets run by the robot controller module 1016. On the other hand, example streaming interfaces would be through robot OEM provided sensor interface packages such as Fanuc's Dynamic Path Modification package or Kuka's Robot Sensor Interface. In this real-time example, the ancillary controller 1006 cab (described in further detail below) send on-line, real-time positional offsets to the robot controller module 1016 based on gathered data derived from monitoring.

The ancillary control unit 1006 can serve as the central communication hub between the smart abrading tool 1004, the robotic device 902, other components of the system that can have communication units and/or sensors (e.g., a workpiece 1018 and/or a CAP 1020) and the cloud computing system 1008. The ancillary control unit 1006 can receive monitoring data for the various sensors (from the smart abrading tool 1004, the workpiece 1018, the CAP 1020 and/or sensor(s) 1002) and transmits the resulting policy to the robot controller module 1016 as illustrated in FIG. 13 and can control various devices including the smart abrading tool 1004. As noted above, this transmission can be either online or off-line depending on the particular implementation. The ancillary control unit 1006 can be also responsible for controlling any proprietary hardware such as the force control sensors and devices 910 (FIG. 12), air/servo tools, sensors 1002, and the like.

In one example, the ancillary control unit 1006 can comprise an embedded (industrially hardened) process PC running a real-time/low-latency Linux kernel. Communication to the robot controller module 1016 (via the KUKA. RobotSensorInterface) can be accomplished through UDP protocol. Communication to the various system components can be via the various communication units and modalities discussed previously in reference to FIGS. 1-11.

The robotic device 902 can include any process-specific tooling required for the objective such as force control sensors and devices 910 (FIG. 12), sensor 1002, etc. In general, the robotic device 902 itself may not be dexterous enough or nuanced in force application to adequately apply the correct processing forces. As such, some form of active compliance can often be necessary or desirable. Besides the force control sensors and devices 910, the sensors 1002 can also be desirable as in-situ inspection allows for local hi-fidelity measurements such as of a finish on the workpiece 1018 at process-time along with the ability to acquire feedback mid-process, which may not be achievable with approaches using only pre-inspection and post-inspection. For example, mid-process feedback from various of the sensor previously described in reference to any of the FIGURES herein can be important to a successful learning algorithm. The sensors 1002 can include any of the various sensors previously described and can be mounted on or within the smart abrading tool 1004, the workpiece 1018 and/or the CAP 1020. Additionally, the sensors 1002 can be placed in close proximity to the workplace to gather operation related data including images of objects/components in the workplace.

It is to be recognized that depending on the example, certain acts or events of any of the techniques described herein can be performed in a different sequence, can be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the techniques). Moreover, in certain examples, acts or events can be performed concurrently, e.g., through multi-threaded processing, interrupt processing, or multiple processors, rather than sequentially.

In one or more examples, the functions described can be implemented in hardware, software, firmware, or any combination thereof, located locally or remotely. If implemented in software, the functions can be stored on or transmitted over a computer-readable medium as one or more instructions or code and executed by a hardware-based processing unit. Computer-readable media can include computer-readable storage media, which corresponds to a tangible medium such as data storage media, or communication media including any medium that facilitates transfer of a computer program from one place to another, e.g., according to a communication protocol. In this manner, computer-readable media generally can correspond to (1) tangible computer-readable storage media which is non-transitory or (2) a communication medium such as a signal or carrier wave. Data storage media can be any available media that can be accessed by one or more computers or one or more processors to retrieve instructions, code and/or data structures for implementation of the techniques described in this disclosure. A computer program product can include a computer-readable medium.

By way of example, and not limitation, such computer-readable storage media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage, or other magnetic storage devices, flash memory, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if instructions are transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium.

It should be understood, however, that computer-readable storage media and data storage media do not include connections, carrier waves, signals, or other transitory media, but are instead directed to non-transitory, tangible storage media. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray disc, where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media.

Instructions can be executed by one or more processors, such as one or more digital signal processors (DSPs), general purpose microprocessors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or other equivalent integrated or discrete logic circuitry, as well as any combination of such components. Accordingly, the term “processor,” as used herein can refer to any of the foregoing structures or any other structure suitable for implementation of the techniques described herein. In addition, in some aspects, the functionality described herein can be provided within dedicated hardware and/or software modules. Also, the techniques could be fully implemented in one or more circuits or logic elements.

The techniques of this disclosure can be implemented in a wide variety of devices or apparatuses, including a wireless communication device or wireless handset, a microprocessor, an integrated circuit (IC) or a set of ICs (e.g., a chip set). Various components, modules, or units are described in this disclosure to emphasize functional aspects of devices configured to perform the disclosed techniques, but do not necessarily require realization by different hardware units. Rather, as described above, various units can be combined in a hardware unit or provided by a collection of interoperative hardware units, including one or more processors as described above, in conjunction with suitable software and/or firmware.

The functions, techniques or algorithms described herein may be implemented in software in one example. The software may consist of computer executable instructions stored on computer readable media or computer readable storage device such as one or more non-transitory memories or other type of hardware-based storage devices, either local or networked. Further, such functions correspond to modules, which may be software, hardware, firmware or any combination thereof. Multiple functions may be performed in one or more modules as desired, and the examples described are merely examples. The software may be executed on a digital signal processor, ASIC, microprocessor, or other type of processor operating on a computer system, such as a personal computer, server or other computer system, turning such computer system into a specifically programmed machine

Various examples have been described. These and other examples are within the scope of the following claims.

Claims

1. A system for monitoring one or more of an abrading tool, a consumable abrasive product and a workpiece, the system comprising:

a data storage device;

a sensor;

a communication unit;

a consumable abrasive product that is attachable to and detachable from the abrading tool and configured to abrade the workpiece; a computing system comprising one or more computing devices configured to: receive a first data from the communication unit regarding the sensor, the first data indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece;

identify if the at least one operating parameter falls outside a predetermined operating parameter range; and if the at least one operating parameter falls outside a predetermined operating parameter range, store a second data based upon the first data in the data storage device.

2. The system of claim 1, wherein the first data comprises one or more of safety related data, quality related data and use related data.

3. The system of claim 1, wherein the first data comprises one or more of:

revolutions per minute of the abrading tool or the consumable abrasive product, a type of the abrading tool;

a type of the consumable abrasive product;

a force applied on one or more of the abrading tool, the consumable abrasive product and the workpiece;

a temperature of one or more of the abrading tool, the consumable abrasive product and the workpiece;

a heat flux into or out of one or more of the abrading tool, the consumable abrasive product, and the work piece;

a finish imparted to the workpiece;

a duration of operation;

a type of backing used for the consumable abrasive product;

a type of attachment used to couple the abrading tool to the consumable abrasive product;

an identity of a tool operator;

a location of the system;

a date and time of use; and

an indication the abrading tool is coupled with the consumable abrasive product.

4. The system of claim 1, further comprising a robotic device configured to operate the abrading tool, and wherein the robotic device is configured to change an operation or a parameter based on at least one of the first data and the second data.

5. The system of claim 1, wherein the first data is regarding the consumable abrasive product, and wherein the computing system is configured to identify the consumable abrasive product has been damaged or is about to be potentially damaged based upon the at least one operating parameter falling outside the predetermined operating parameter range.

6. (canceled)

7. The system of claim 5, wherein, in response to receiving data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged, the computing system is configured to perform one or more of: generate a warning, send instructions to the abrading tool or a robotic device configured to operate the abrading tool, prevent use of the abrading tool while the consumable abrasive product is attached to the abrading tool, and store the data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged as the second data.

8. The system of claim 5, wherein the data indicating that the consumable abrasive product has been damaged or is about to be potentially damaged is derived from one or more of a voltage measurement from a crack detection system, the temperature of the consumable abrasive product, the heat flux into or out of the consumable abrasive product, the revolutions per minute of the consumable abrasive product and the force on the consumable abrasive product.

9. The system of claim 1, wherein the sensor or communication unit comprises one or more of:

an electronic identifier and a readout system;

a timer configured to measure elapsed time from a reference time;

a temperature sensor configured to measure the temperature within the system;

an ammeter configured to measure an electrical current draw of the abrading tool during use of the abrading tool;

a tachometer configured to measure rotation of the consumable abrasive product;

a pressure sensor configured to measure force applied to the abrading tool by a user of the abrading tool.

10. The system of claim 1, wherein the data storage device is located at one or more of a remote cloud based location, a device attached to or positioned within the consumable abrasive product, in a memory of the abrading tool, and in a memory of the robotic device configured to operate the abrading tool.

11. (canceled)

12. A system for monitoring one or more of an abrading tool, a consumable abrasive product and a workpiece, the system comprising:

a data storage device;

a sensor;

a communication unit;

a consumable abrasive product that is attachable to and detachable from the abrading tool and configured to abrade the workpiece; and a computing system comprising one or more computing devices configured to: receive a first data from the communication unit regarding the sensor, the first data indicative of at least one operating parameter of one or more of the abrading tool, the consumable abrasive product and the workpiece; and continuously store a second data in the data storage device, wherein the second data is based upon the first data.

13. The system of claim 12, wherein the first data is continuously gathered by the sensor, and wherein the second data is saved for a predetermined length of time and continuously overwritten in a predetermined manner.

14. The system of claim 12, wherein the data storage device is located at one or more of a remote cloud based location, a device attached to or positioned within the consumable abrasive product, in a memory of the abrading tool, and in a memory of the robotic device configured to operate the abrading tool.

15. The system of claim 12, wherein the data storage device is configured such that the second data is saved in a quasi-temporal manner such that an oldest data in the data storage device is not necessarily overwritten and replaced when the second data is stored.

16. The system of claim 12, wherein the data storage device is configured to cyclically organize the second data based upon a time the second data was stored and associate the second data with further stored data therein that was previously stored in predetermined time intervals related to the time the second data was stored.

17. The system of claim 16, wherein the predetermined time intervals comprise at least a first time interval and a second time interval, and the second time interval is on an order of magnitude of equal to or greater than ten times that of the first time interval.

18. The system of claim 16, wherein the predetermined time intervals are spaced in time on a log scale.

19. The system of claim 12, wherein the first data comprises one or more of safety related data, quality related data and use related data.

20. The system of claim 12, wherein the first data comprises one or more of: