U.S. patent application number 16/530867 was filed with the patent office on 2020-02-06 for abrasive article including a wear detection sensor.
The applicant listed for this patent is SAINT-GOBAIN ABRASIFS, SAINT-GOBAIN ABRASIVES, INC.. Invention is credited to Karen CONLEY, Thierry DESIRE, Remi J. GOULET, Robin Chandras JAYARAM, Yeshwanth NARENDAR, Sethumadhavan RAVICHANDRAN, Brian RUTKIEWICZ, Vivek SINGH, Rajappa TADEPALLI, Arunvel THANGAMANI.
Application Number | 20200039027 16/530867 |
Document ID | / |
Family ID | 69228199 |
Filed Date | 2020-02-06 |
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United States Patent
Application |
20200039027 |
Kind Code |
A1 |
GOULET; Remi J. ; et
al. |
February 6, 2020 |
ABRASIVE ARTICLE INCLUDING A WEAR DETECTION SENSOR
Abstract
An abrasive article can include a wear detection sensor embedded
within the abrasive body or extending along an exterior surface of
the abrasive body. The wear detection sensor can include at least
one conductive lead and be designed to create one or more wear
signals corresponding to the wear stage of the abrasive body. The
at least one conductive lead can be coupled to a logic device,
which may control the wear detection sensor and register the wear
signal(s).
Inventors: |
GOULET; Remi J.;
(Sturbridge, MA) ; SINGH; Vivek; (Boston, MA)
; RAVICHANDRAN; Sethumadhavan; (Shrewsbury, MA) ;
DESIRE; Thierry; (Cambridge, MA) ; CONLEY; Karen;
(Amesbury, MA) ; JAYARAM; Robin Chandras;
(Thiruvananthapuram, IN) ; THANGAMANI; Arunvel;
(Chennai, IN) ; NARENDAR; Yeshwanth; (Westford,
MA) ; RUTKIEWICZ; Brian; (Worcester, MA) ;
TADEPALLI; Rajappa; (Northborough, MA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
SAINT-GOBAIN ABRASIVES, INC.
SAINT-GOBAIN ABRASIFS |
Worcester
Conflans-Sainte-Honorine |
MA |
US
FR |
|
|
Family ID: |
69228199 |
Appl. No.: |
16/530867 |
Filed: |
August 2, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62713685 |
Aug 2, 2018 |
|
|
|
62822717 |
Mar 22, 2019 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B24D 5/02 20130101; B24B
49/10 20130101; B24B 49/14 20130101; B24D 7/04 20130101 |
International
Class: |
B24B 49/10 20060101
B24B049/10; B24D 7/04 20060101 B24D007/04 |
Claims
1. An abrasive article comprising: an abrasive body including
abrasive particles contained within a bond material; and a wear
detection sensor configured to detect a change in dimension of the
abrasive body, wherein at least a portion of the wear detection
sensor is coupled to and extending along at least a portion of the
abrasive body.
2. The abrasive article of claim 1, wherein the wear detection
sensor comprises at least one electronic device including at least
one antenna.
3. The abrasive article of claim 2, wherein the antenna extends
over a greater surface area of the abrasive body compared to an
electronic element coupled to the antenna.
4. The abrasive article of claim 2, wherein the antenna is arranged
in a loop, in a serpentine shape, or a combination thereof.
5. The abrasive article of claim 2, wherein the electronic device
comprises an electronic element, wherein the electronic element is
positioned within a non-abrasive portion of the abrasive body, and
wherein at least a portion of the at least one antenna is
positioned in an abrasive portion of the abrasive body.
6. The abrasive article of claim 5, wherein the electronic element
comprises a chip, an integrated circuit, a logic, a
microcontroller, a transponder, a transceiver, a passive element, a
resistor, a capacitor, a memory, or any combination thereof.
7. The abrasive article of claim 2, wherein the antenna is at least
partially embedded in the abrasive body.
8. The abrasive article of claim 1, wherein the wear detection
sensor comprises a plurality of antennas, wherein the plurality of
antennas extend different lengths compared to each other toward a
material removal surface of the abrasive body.
9. The abrasive article of claim 1, wherein the wear detection
sensor comprises an electronic device and a package encapsulating
the electronic device.
10. The abrasive article of claim 1, wherein the wear detection
sensor comprises a plurality of antennas, wherein: at least one of
the plurality of antennas is positioned within an exterior
circumferential region of the abrasive body; at least one of the
plurality of the antennas comprises a flared body, wherein a width
of the flared body increases as a length of the antenna extends; at
least one of the plurality of antennas extends in a radial
direction, an axial direction, or a combination thereof, from a
center region toward a material removal surface of the abrasive
body; at least one of the plurality of antennas comprises a
terminal end aligned with the material removal surface; or any
combination thereof.
11. The abrasive article of claim 1, wherein the wear detection
sensor comprises at least one electronic device coupled to an
electrical component, wherein the electrical component comprises a
lead, a capacitor, a resistor, an inductor, a loop circuit, or a
combination thereof, wherein the capacitor comprises a first
capacitance plate positioned in an interior circumferential region
of the abrasive body and a second capacitance plate positioned in
an exterior circumferential region of the abrasive body.
12. The abrasive article of claim 1, wherein the wear detection
sensor comprises a first electronic device and a second electronic
device extending in parallel along a portion of the abrasive body,
wherein the first and second electronic devices are spaced apart
from one another and staggered such that a first terminal end of
the first electronic device is closer to a material removal surface
compared to a second terminal end of the second electronic device,
wherein the first terminal end is distal to a center region of the
abrasive body compared to a third terminal end of the first
electronic device, and the second terminal end is distal to the
center region of the abrasive body compared to a fourth terminal
end of the second electronic device.
13. The abrasive article of claim 1, wherein the wear detection
sensor comprises a plurality of components coupled to one another,
wherein the plurality of components comprises a sensing circuit, a
microcontroller, a transceiver, an antenna, or any combination
thereof, wherein the sensing circuit comprises a magnetometer, such
as a 3-axis magnetometer, a temperature and/or humidity sensor,
3-axis accelerometer, a capacitive input interface, or any
combination thereof.
14. A system for detecting wear in an abrasive article, comprising:
the abrasive article of claim 1; and a data receiving unit
configured to receive data generated by the wear detection
sensor.
15. The abrasive article of claim 1, wherein the wear detection
sensor comprises a communication device for wireless communication
with an external controller.
16. An abrasive article comprising: an abrasive body comprising;
abrasive particles contained within a bond material; a wear
detection sensor comprising at least one lead in contact with the
abrasive body; and at least one logic device in communication with
the at least one conductive lead.
17. The abrasive article of claim 16, wherein the at least one
logic device is coupled to a hub, wherein the hub is coupled to the
abrasive body, and wherein the wear sensor comprises a protection
layer overlying the at least one logic device.
18. The abrasive article of claim 16, wherein the protection layer
comprises a material including polydimethylsiloxane (PDMS),
polyethylene naphthalate (PEN), polyimide, polyether ether ketone
(PEEK), or any combination thereof.
19. The abrasive article of claim 16, wherein the wear sensor
comprises a heat resistant coating overlying at least a portion of
the at least one lead.
20. The abrasive article of claim 16, wherein the wear detection
sensor includes a plurality of conductive leads extending in
parallel along a portion of an exterior surface of the abrasive
body, wherein the plurality of leads have different lengths
compared to each other.
Description
CROSS-REFERENCE TO RELATED APPLICATION(S)
[0001] This application claims priority under 35 U.S.C. .sctn.
119(e) to U.S. Provisional Patent Application No. 62/713,685, filed
Aug. 2, 2018, entitled "ABRASIVE ARTICLE INCLUDING A WEAR DETECTION
SENSOR," by Remi J. GOULET et al., and this application claims
priority under 35 U.S.C. .sctn. 119(e) to U.S. Provisional Patent
Application No. 62/822,717, filed Mar. 22, 2019, entitled "ABRASIVE
ARTICLE INCLUDING A WEAR DETECTION SENSOR," by Remi J. GOULET et
al., which are both assigned to the current assignee hereof and
incorporated by reference herein in their entireties.
BACKGROUND
Field of the Disclosure
[0002] The following is directed to an abrasive article, and
particularly, to an abrasive article including a wear detection
sensor.
Description of the Related Art
[0003] Fixed abrasive articles can be used in various material
removal operations and are often subjected to long time grinding
processes, for example, during the grinding of railroad tracks. In
order to optimize the grinding process and to determine a needed
replacement of an abrasive article, it is important to observe the
wear stage of the abrasive body, which can require time-consuming
operation stops. For example, rail grinding can only be conducted
in time periods when the trains are not running. These time periods
can be of short duration and need to be efficiently used, such that
a major part of the time is spend on the grinding operation and not
on time-consuming replacement of abrasive wheels. The amount of
abrasive material left on each wheel is typically manually measured
prior to the grinding to identify the wheels that may be fully worn
during the next run. These measurements are also time consuming and
any needed replacement is handled conservatively by the operator,
to avoid changing of the wheels during the open grinding time
period.
[0004] There exists a demand to continuously observe the wear stage
of an abrasive article without interrupting the grinding
process.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] The present disclosure may be better understood, and its
numerous features and advantages made apparent to those skilled in
the art by referencing the accompanying drawings.
[0006] FIG. 1 includes a side-view illustration of an abrasive
article according to one embodiment.
[0007] FIG. 2 includes a cross-sectional illustration of an
abrasive article according to one embodiment.
[0008] FIG. 3 includes a side view illustration of an abrasive
article according to one embodiment.
[0009] FIG. 4A includes an illustration of a section of an abrasive
body before use including portions of the wear detection sensor
according to one embodiment.
[0010] FIG. 4B includes an illustration of a section of an abrasive
body during a material removing operation including portions of the
wear detection sensor according to one embodiment.
[0011] FIG. 5A includes an illustration of one lead of a wear
detection sensor according to one embodiment.
[0012] FIG. 5B includes an illustration of one lead of a wear
detection sensor according to another embodiment.
[0013] FIG. 6 includes an illustration of one lead helically wound
around an abrasive body according to one embodiment.
[0014] FIG. 7 includes an illustration of a plan view of an
abrasive article including a wear detection sensor according to an
embodiment.
[0015] FIG. 8 includes an illustration of a plan view of an
abrasive article including a detection sensor according to another
embodiment.
[0016] FIG. 9A includes an illustration of a wear detection sensor
according to an embodiment.
[0017] FIG. 9B includes an illustration of a wear detection sensor
according to another embodiment.
[0018] FIG. 9C includes an illustration of a portion of a wear
sensor attached to a mounting plate according to an embodiment.
[0019] FIG. 9D includes an illustration of a plot of time vs. loop
state for a wear sensor.
[0020] FIG. 9E includes an illustration of another plot of time vs.
loop state for a wear sensor.
[0021] FIG. 10 includes an illustration of a cross-sectional view
of a portion of an abrasive article according to an embodiment.
[0022] FIG. 11 includes an illustration of a plan view of an
abrasive article including a detection sensor according to another
embodiment.
[0023] FIG. 12 includes an illustration of a plan view of an
abrasive article including a detection sensor according to another
embodiment.
[0024] FIG. 13 includes an illustration of a plan view of an
abrasive article including a detection sensor according to another
embodiment.
[0025] FIG. 14 includes an illustration of a plan view of an
abrasive article including a detection sensor according to another
embodiment.
[0026] FIG. 15 includes an illustration of a section of an abrasive
body according to an embodiment.
[0027] FIG. 16A includes an illustration of a plan view of an
abrasive article including a detection sensor according to another
embodiment.
[0028] FIG. 16B includes a plot of diameter vs. reflected
power.
[0029] FIG. 17A includes an illustration of a section of an
abrasive body according to an embodiment.
[0030] FIG. 17B includes an illustration of a section of another
abrasive body according to an embodiment.
[0031] FIG. 18 includes an illustration of a wear detection system
according to an embodiment.
[0032] FIG. 19A includes a plot of reflected power vs. time of an
abrasive article according to an embodiment.
[0033] FIG. 19B includes a plot of reflected power vs. time of
another abrasive article according to an embodiment.
[0034] FIG. 20 includes an illustration of an exemplary wear
sensor.
[0035] FIG. 21 includes an illustration of components of an
exemplary reader.
DETAILED DESCRIPTION
[0036] The following description in combination with the figures is
provided to assist in understanding the teachings provided herein.
The following disclosure will focus on specific implementations and
embodiments of the teachings. This focus is provided to assist in
describing the teachings and should not be interpreted as a
limitation on the scope or applicability of the teachings. However,
other teachings can certainly be used in this application.
[0037] As used herein, the terms "comprises," "comprising,"
"includes," "including," "has," "having" or any other variation
thereof, are intended to cover a non-exclusive inclusion. For
example, a method, article, or apparatus that comprises a list of
features is not necessarily limited only to those features but may
include other features not expressly listed or inherent to such
method, article, or apparatus. Further, unless expressly stated to
the contrary, "or" refers to an inclusive-or and not to an
exclusive-or. For example, a condition A or B is satisfied by any
one of the following: A is true (or present) and B is false (or not
present), A is false (or not present) and B is true (or present),
and both A and B are true (or present).
[0038] Also, the use of "a" or "an" is employed to describe
elements and components described herein. This is done merely for
convenience and to give a general sense of the scope of the
invention. This description should be read to include one or at
least one and the singular also includes the plural, or vice versa,
unless it is clear that it is meant otherwise. For example, when a
single item is described herein, more than one item may be used in
place of a single item. Similarly, where more than one item is
described herein, a single item may be substituted for that more
than one item.
[0039] Unless otherwise defined, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. The
materials, methods, and examples are illustrative only and not
intended to be limiting. To the extent that certain details
regarding specific materials and processing acts are not described,
such details may include conventional approaches, which may be
found in reference books and other sources within the manufacturing
arts.
[0040] Embodiments disclosed herein are directed to an abrasive
article including an abrasive body of abrasive particles within a
bond material. The abrasive article can include a wear detection
sensor configured for detecting a change in a dimension of the
abrasive body, wherein at least a portion of the wear detection
sensor is coupled to and extending along at least a portion of the
abrasive body. As used herein, the phrase "coupled to and extending
along at least a portion of the abrasive body" means that at least
a portion of the wear detection sensor can be contained at an
exterior surface of the body, or being partially embedded in the
abrasive body, or being totally embedded in the body of the
abrasive article.
[0041] In one embodiment, the wear detection sensor can include at
least one lead. The at least one lead can include an electrically
conductive structure.
[0042] In one aspect, the lead can include a pair of conductive
wires connected together at their ends (i.e., terminal end or lead
tip), which can create an electrically conductive loop.
[0043] In another aspect, the lead can be a thin elongated
conductive plate or wire adapted to change resistance corresponding
to a length of the elongated plate or wire. With increasing wear of
the abrasive body, the length of the lead becomes shorter, and the
measured change in resistance of the lead with decreasing length of
the lead may correspond to the wear of the abrasive body.
[0044] In yet another aspect, the lead can be an electric circuit
including two wires connected by a plurality of resistors. The
resistors are positioned in parallel to each other at different
locations along a length direction of the two wires (i.e., a
resistive ladder). As resistors get destroyed during the wear of
the abrasive body, the equivalent resistance of the circuit
increases and the measured increase in resistance of the circuit
can correspond to the state of the wear of the abrasive body.
[0045] The at least one lead of the wear detection sensor can be
partially embedded in the abrasive body, completely embedded in the
abrasive body, or extend along an exterior surface of the abrasive
body.
[0046] As used herein, the term at least one lead is also called
plurality of leads if the wear detection sensor contains more than
one lead.
[0047] In one aspect, the at least one lead of the wear detection
sensor can extend along a portion of the exterior surface of the
abrasive body. In another aspect, a majority or the leads of the
plurality of leads can extend along a portion of the exterior
surface of the abrasive body. In a particular aspect, each lead of
the plurality of leads may extend along a portion of the exterior
surface of the abrasive body.
[0048] In a further embodiment, at least one lead of the plurality
of leads can be embedded within the abrasive body. In a particular
embodiment, all of the leads of the plurality of leads may be
embedded within the abrasive body.
[0049] In one aspect, the wear detection sensor can have a first
portion, e.g., a logic device, and a second portion, e.g., a
plurality of leads, wherein the first portion can be coupled to a
hub and the second portion can be coupled to the abrasive body. In
another aspect, the first portion of the wear detection sensor can
be coupled to the abrasive body and the second portion may be
coupled to the hub. In another aspect, both the plurality of leads
and the logic device can be coupled to the abrasive body.
[0050] FIG. 1 includes an illustration of an abrasive article 100
according to one embodiment.
[0051] The abrasive article (100) can be an abrasive wheel, wherein
the abrasive body (102) is coupled to a hub (103). The abrasive
body can include a bonded abrasive material, including abrasive
particles contained in a three-dimensional matrix of bond material.
The abrasive body (102) may optionally include some porosity as a
distinct phase from the abrasive particles and bond material. A
wear detection sensor can be coupled to the abrasive article (100),
such as the abrasive body (102) and/or hub (103) in form of a
plurality of leads (104) and a logic device (105). The plurality of
leads (104) of the wear detection sensor can be coupled to a
portion of the exterior surface of the abrasive body (102). The
plurality of leads 104 can extend from the logic device (105) in
axial direction (x) of the abrasive body (102) towards the material
removing surface (107).
[0052] In another embodiment of an abrasive article illustrated in
FIG. 2, the plurality of leads (204) of the wear detection sensor
can extend from the logic device (205) in a radial direction (z) of
the abrasive body (202), the radial direction (z) being orthogonal
to the axial direction (x). FIG. 2 shows a crosscut of an abrasive
wheel including an abrasive body (202) attached to a hub (203),
wherein all leads of the wear detection sensor (204) can be
completely embedded in the abrasive body (202) and point towards
the material removal surface (207). The logic device (205) can
further optionally include a communication device (e.g.,
transceiver) (206) for communication with an external controller
(not shown).
[0053] FIG. 3 illustrates a side view of an abrasive wheel (300) of
the present disclosure. In this embodiment, the plurality of leads
of the wear detection sensor (304) can extend along a portion of
the exterior surface (308) of the abrasive body. The plurality of
leads (304) may be connected to a logic device (305), and the logic
device (305) can be coupled to a hub (303). The plurality of leads
(304) may extend in a radial direction (z) to the outer material
removal surface (307).
[0054] The amount of leads of the wear detection sensor can be at
least one lead and may have no specific upper limit. The amount of
leads can depend on the thickness of the abrasive body subjected to
a material removing process, such as grinding, cutting, or
polishing, and in which increments of the wear of the abrasive body
should be observed. In one embodiment, the wear detection sensor
can include at least one lead, such as at least two leads, at least
three leads or at least four leads, at least five leads, at least
seven leads, or at least nine leads. In another embodiment, the
wear detection sensor can include not more than 100 leads, such as
not more than 80 leads, not more than 60 leads, not more than 50
leads, not more than 30 leads, not more than 20 leads, not more
than 15 leads, or not more than 10 leads. The amount of leads in
the wear detection sensor can be a value within a range including
any of the minimum and maximum values noted above.
[0055] The plurality of leads of the wear detection sensor may have
different lengths compared to each other. In one embodiment, all
the leads can extend parallel to each other from a logic device for
different depths into the volume of the abrasive body. In one
aspect, each of the leads of the plurality of leads can include a
terminal end, and each of the terminal ends can be located at a
different position relative to each other. For example, each of the
terminal ends may be embedded at different depths within the
abrasive body relative to each other.
[0056] In another embodiment, the plurality of leads may extend
from the logic device at an angle to each other along the abrasive
body. In a further embodiment, the plurality of leads may not be
directly coupled to the logic device but can have a connective
structure between the logic device and the plurality of leads.
[0057] In one embodiment, each lead can reach with its terminal end
up to a defined distance .DELTA.DT from the original material
removing surface of the abrasive body, wherein the terminal ends of
the leads can be embedded in the abrasive body or extend along an
exterior surface of the abrasive body. FIG. 4A illustrates a
section of an abrasive body, wherein all leads of the wear
detection sensor (404) may be embedded in the abrasive body (402)
and the terminal end of each lead can have a defined distance
.DELTA.DT1, .DELTA.DT2, .DELTA.DT3, and .DELTA.DT4, from the
original material removing surface of the abrasive body (407).
Under original material removing surface of the abrasive body (407)
should be understood herein the exterior surface of the abrasive
body before it is subjected to grinding or cutting of a work piece.
In FIG. 4A, the plurality of leads extends in axial direction (x)
towards the original material removal surface (407).
[0058] During a material removing operation, the abrasive body of
the present disclosure can be subjected to wear, such that portions
of the abrasive body may be removed from the original material
removing surface. FIG. 4B illustrates a stage of an abrasive
article 401 wherein a portion of the abrasive body has been removed
from the original outer material removing surface during a material
removing operation of a work piece (410), and the terminal end of
the longest lead of the plurality of leads (404) has reached the
actual material removing surface (409) of the abrasive body
(402).
[0059] When the terminal end of a lead reaches the actual material
removing surface (409) of the abrasive body (402), the connection
between the two wires which conduct current through the lead can be
destroyed, thereby opening the electric circuit, and the current
between the pair of wires of the lead cannot flow anymore. The open
circuit of the broken wire loop can be detected by the logic device
and understood herein as a broken lead. From the amount of broken
leads detected by the logic device, a calculation can be made about
the wear of the abrasive body.
[0060] In another aspect, the plurality of leads can be connected
together within one electric circuit, wherein a broken wire loop
can cause a change of the total voltage through the complete
electric circuit if the total amount of supplied current is
remained constant. The amount of change in voltage can be measured
as a wear signal by the logic device connected to the plurality of
leads and can allow to make conclusions about the wear stage of the
abrasive body, such as how much of the abrasive body has been
removed from the original outer material removing surface (307) and
the remaining life time.
[0061] By knowing the position of the terminal ends of the leads
within the abrasive body or along the exterior surface of the
abrasive body from the original material removal surface of the
abrasive body, the wear stage of the abrasive body during working
operation can be calculated by the logic device. In one embodiment,
the distance .DELTA.DT of a terminal end of a lead of the plurality
of leads from the original removal surface of the abrasive body can
be at least 100 microns, such as at least 150 microns, at least 200
microns, at least 500 microns, at least 1000 microns, at least 5000
microns, or at least 10000 microns. In another aspect, the distance
.DELTA.DT may be not be greater than 1.5 meters, such as not
greater than 1.3 meters, or not greater than 1.0 meter, or not
greater than 0.8 meter, or not greater than 0.5 meter, or not
greater than 0.3 meter, or not greater than 0.1 meter, or not
greater than 0.05 meter, or not greater than 0.01 meter. The
distance .DELTA.DT can be a value within a range including any of
the minimum and maximum values noted above.
[0062] In a further embodiment, a distance .DELTA.DI between two
terminal lead ends to each other in a direction orthogonal to the
material removal surface of the abrasive body can be at least 100
microns, such as at least 200 microns, at least 300 microns, or at
least 500 microns, or at least 1000 microns, or at least 5000
microns. In another aspect, the distance between two terminal lead
ends may be not greater than 1.5 meters, such as not greater than
1.2 meters, or not greater than 1.0 meter, or not greater than 0.8
meter, or not greater than 0.5 meter, or not greater than 0.3
meter, or not greater than 0.1 meter, or not greater than 0.05
meter. The distance .DELTA.DI can be a value within a range
including any of the minimum and maximum values noted above.
[0063] In the embodiment wherein each lead of the wear detection
sensor is a single wire or elongated plate, the wear detection
sensor can be designed that the area of the lead (e.g., the length
of the lead) correlates with a certain resistance, wherein the
change in resistance with decreasing length of the lead (by
increasing wear) can be converted to information about the wear of
the abrasive body.
[0064] In one embodiment, the total length of the at least one lead
of the wear detection sensor can be at least 100 microns, such as
at least 200 microns, or at least 500 microns, or at least 1000
microns, or at least 1 cm, or at least 5 cm. In another aspect, the
total length of the at least one lead may be not greater than 10
meters, such as not greater than 8 meters, or not greater than 5
meters, or not greater than 3 meters, or not greater than 2 meters,
or not greater than 1.5 meters, or not greater than 1.0 meter, or
not greater than 0.8 meter, or not greater than 0.5 meter, or not
greater than 0.3 meter, or not greater than 0.2 meter, or not
greater than 0.1 meter, or not greater than 0.05 meter, or not
greater than 0.01 meter. The total length of the at least one lead
can be a value within a range including any of the minimum and
maximum values noted above.
[0065] The at least one conductive lead of the wear detection
sensor can be in communication with at least one logic device. In
one embodiment, the logic device can be a microcontroller
configured to detect a change in the states of the wear detection
sensor. The logic device can optionally include a communication
device, for example, a transceiver, for communication with an
external controller.
[0066] In one aspect, the at least one lead of the wear detection
sensor can be detected by the logic device being in an active state
when a current is flowing through the lead, and being in an
inactive state when no or a smaller amount of current is flowing
through the lead because the lead is damaged. The interruption or
reduction of the current flow in the inactive stage of the lead can
create a wear signal. Accordingly, by detecting the wear signals
and controlling and measuring the current flowing through the
plurality of leads, the wear stage of the abrasive body can be
analyzed without interrupting the material removing process.
[0067] The wear signal created by the wear detection sensor can be
transmitted by a communication device to an external controller,
e.g., a portable control unit in the hand of an operator, or a
fixed unit implemented on the machine on which the wheels are
mounted. The transmission of the wear signal can be via an
electrical connection, for example, to the spindle on which the
wheel is mounted, or as a wireless signal. In one aspect, the logic
device can include a transceiver, e.g., an RFID transceiver, for
sending the wear signals to an external controller which may
oversee and control the grinding process. Other options for
wireless sending the wear signal can be via Wi-Fi or Bluetooth or
other wireless protocols. The wear signals can be stored as local
data storage on a logic board (e.g., SD card or flash memory). The
external controller can be a part of the logic device or an
independent unit. In a further aspect, light indicators can be used
to signal that a wheel needs to be replaced or still has a long
life time.
[0068] The electrical power needed for operating the wear detection
sensor can be provided from a battery, or from a direct electrical
connection from a machine or train. The wear detection sensor can
also be remotely powered using RF energy or powered by an energy
harvesting system, for instance a system producing electrical
energy from vibration.
[0069] The material of the at least one conductive lead can be a
metal or metal alloy. Non-limiting examples of lead materials can
be copper, aluminum, silver, or stainless steel.
[0070] In one embodiment, particularly when the lead has the
structure of a wire loop or of a resistive ladder, each lead may be
further surrounded or embedded by a protective material. FIG. 5A
illustrates an embodiment of one lead (500), which can include a
pair of wires (501) connected together by forming a lead end (502)
and forming a loop, wherein the wire may be surrounded by a lead
protecting material (503).
[0071] FIG. 5B illustrates a lead having the structure of a
resistive ladder, wherein two wires (504) are connected by a
plurality of resistors (505) placed parallel to each other at
different positions along a length direction of the two wires
(504). The whole electric circuit is embedded in a protective
material (503).
[0072] The lead protecting material can be a material which may
protect the wire of the lead during manufacturing of the abrasive
article, but can be easily destroyed by the forces during the
material removal operation of the abrasive article when it reaches
the actual outer material removing surface of the abrasive body.
Non-limiting examples of lead-protecting materials can be, e.g., a
polyimide, a polyurethane, or a polyolefin. The lead protecting
material can also serve as an insulator preventing shorting of the
electric circuit, for example, in an embodiment wherein the
abrasive body is electrically conductive. In one aspect, at least
one wire loop can be directly applied on the exterior surface of
the abrasive body and embedded within a protective polymer, e.g., a
polyimide. Similarly, if the lead is designed for measuring the
change in resistance, the wire or elongated plate can be directly
applied on the exterior surface of the abrasive body and embedded
within a protective polymeric material.
[0073] In another embodiment, the leads of the wear protection
sensor may not include a wire protecting material.
[0074] In yet a further embodiment, the at least one lead can have
a spiral form and be wound around an external surface of the
abrasive body, as illustrated in FIG. 6. This embodiment may apply
for a lead which can change resistance according to its size
reduction during wear of the abrasive body. FIG. 6 shows an
abrasive body in form of a wheel (602) fixed on a hub (603),
wherein the lead (604) is in form of a wire and wound helically
around the abrasive body (602) in axial direction (x). In one
aspect, the abrasive body can be covered by a reinforcement fiber
glass mat (not shown) and the lead can be weaved into the mat or
the lead can directly replace some of the threads of the fiber
glass mat.
[0075] In another embodiment, the wear detection sensor can include
at least one electronic device. In an aspect, the electronic device
can include an electronic element. The electronic element can
include, for example, a chip, an integrated circuit, logic, a
transponder, a transceiver, a passive element, such as a resistor,
a capacitor, a memory, or the like, or any combination thereof. In
another aspect, the electronic device can include an antenna
directly coupled to the electronic element. In a particular aspect,
the electronic device can include a chip, an integrated circuit,
data transponder, a radio frequency based tag or sensor with or
without chip, an electronic tag, electronic memory, a sensor, an
analog to digital converter, a transmitter, a receiver, a
transceiver, a modulator circuit, a multiplexer, an antenna, a
near-field communication device, a power source, a display (e.g.,
LCD or OLED screen), optical devices (e.g., LEDs), global
positioning system (GPS) or device, fixed or programmable logic, or
any combination thereof. In some instances, the electronic device
may optionally include a substrate, a power source, or both. In a
further aspect, the electronic device can be wired or wireless.
[0076] A more particular example of the electronic device can
include a tag or sensor, such as a radio-frequency identification
(RFID) tag or sensor, a near field communication tag or sensor, or
a combination thereof. In an aspect, the electronic device can
include a RFID tag. In some instances, the RFID tag can be
inactive, and may be powered by a reader device for the RFID tag.
In another instance, the RFID tag can be active, including for
example, a power supply, such as a battery or inductive capacitive
tank circuit.
[0077] In another aspect, the electronic device can include a
near-field communication device. A near field communication device
can be any device capable of transmitting information via
electromagnetic radiation within a certain defined radius of the
device, typically less than 20 meters.
[0078] In a particular aspect, the electronic device can include a
dual frequency tag. A dual frequency tag can facilitate readability
in multiple frequencies. For instance, the electronic device can
include a near-field communication device and an RFID tag. In a
further instance, the electronic device can include a dual
frequency chip attached to an RFID antenna and an NFC antenna.
[0079] In a further aspect, the electronic device can include a
transceiver. A transceiver can be a device that can receive
information and/or transmit information. Unlike passive RFID tags
or passive near-field communication devices, which are generally
read-only devices that store information for a read operation, a
transceiver can actively transmit information without having to
conduct an active read operation. Moreover, the transceiver may be
capable of transmitting information over various select
frequencies, which may improve the communication capabilities of
the electronic device with a variety of systems that are intended
for receiving and/or storing the information.
[0080] In an aspect, the electronic device can be attached to at
least a portion of the abrasive body. For example, the electronic
device can be attached to a portion of a surface of the abrasive
body, such as to a major surface, a peripheral surface, or a
combination thereof. In a further aspect, the electronic device can
be in contact with the abrasive body. In another aspect, the
electronic device can be partially embedded in the abrasive body.
In a further aspect, the electronic device can be fully embedded
within the abrasive body.
[0081] In some implementations, the electronic device can be
adapted to detect wear of the abrasive article, such as a dimension
change of the abrasive body. In other implementations, the
electronic device may be combined with another component to
facilitate wear detection.
[0082] FIG. 7 includes an illustration of a plan view of an
abrasive article 700 including an abrasive body 701 and a wear
detection sensor 702. The body 701 can include a center hole 713.
In some instances, the abrasive body 701 can include an interior
circumferential region 704 that abuts the center hole 703 and an
exterior circumferential region 705 that is outside of the interior
circumference region 705. The interior circumferential region can
include an interior circumferential diameter D.sub.I, and the
abrasive body can include an outer diameter D.sub.O that may also
be referred to as an exterior circumferential region diameter in
this disclosure.
[0083] In an embodiment, wear of the abrasive article can include a
dimension change including reduction in the outer diameter D.sub.O.
For instance, a peripheral surface of the abrasive body may be the
material removing surface in contact with a work piece. Material
loss on the material removing surface can cause a reduction in the
outer diameter D.sub.O. In certain applications, when the outer
diameter D.sub.O is reduced to approximately the size of the inner
diameter D.sub.I, the abrasive article may not be suitable for
further use. In another embodiment, a major surface of the abrasive
body can be the material removing surface.
[0084] The wear detection sensor 702 can include an electronic
device 710 including an electronic element 712, such as an
integrated circuit, coupled to an antenna 714. In some
implementations, the electronic device 710 can include an
integrated circuit and may not include an antenna. The electronic
device 710 can be placed within the interior circumferential region
704 or within the exterior circumferential region 705 or extending
along a portion of the interior circumferential region 704 and a
portion of the exterior circumferential region 705. In a particular
instance, the electronic device 710 can be placed within the
interior circumferential region 704, as illustrated.
[0085] The wear detections sensor 702 can further include an
electrical component coupled to the electronic device 710. The
electrical component can include a passive element, such as a
capacitor, a resistor, an inductor, or combination thereof. In a
particular instance, the electrical component can include a first
capacitance plate 718 and a second capacitance plate 720. The first
and second capacitance plates 718 and 720 can be coupled to the
electronic device 710, such as by wires 716.
[0086] The first capacitance plate 718 and the second capacitance
plate 720 can be spaced apart and may be placed in parallel to each
other. In some instances, the first capacitance plate 718 can be
placed in the interior circumferential region 704 and the second
capacitance plate 720 can be placed in the exterior circumferential
region 705.
[0087] In an exemplary material removing operation, wear of the
abrasive article may result in removal of a portion of or the
entire second capacitance plate 720, which can cause the electric
field strength in the capacitor plates to change. The electronic
device 710 can detect the change and generate a wear signal.
[0088] In other instances, the electrical component can include a
resistor, inductor, or a combination thereof. In an exemplary
material removing operation, a portion of the resistor, inductor,
or both may be removed, which may cause the current or magnetic
filed to change, which can lead to generation of a wear signal.
[0089] The wear signal can be received by a data-receiving device
and the operator may be warned of the wear condition of the
abrasive article.
[0090] In an embodiment, a data-receiving device can include a
reader, an interrogator, or another device that can receive, read,
store, and/or edit data. In some instances, the data-receiving
device can read data stored in the electronic device, and the
electronic device may not function to transmit data. In another
embodiment, the data-receiving device can transmit data from the
electronic device to another device, system, a database, or the
like. In particular embodiment, the data-receiving device can
include a RFID reader or interrogator, an NFC reader, a mobile
phone, or a combination thereof.
[0091] As illustrated in FIG. 7, the wear detection sensor 702 can
be positioned over a major surface of the abrasive body 701. In
another embodiment, at least a portion of the wear detection sensor
702 can be attached to a portion of the major surface, peripheral
surface, or both. For example, the electronic device, the
electrical component, the wire, or any combination thereof, may be
directly cold pressed, warm pressed, or hot pressed onto a surface
of the abrasive body. In another example, at least a portion of the
wear detection sensor may be disposed on a surface of the abrasive
body during a forming process of the abrasive body, and co-cured
with the abrasive body. In a further instance, at least a portion
of the wear detection sensor may be attached to the surface by
heat, radiation, glues, adhesives, in a mechanical manner, or any
combination thereof.
[0092] In an embodiment, the wear detection sensor 702 can be in
contact with a portion of the abrasive body 701. For example, the
wear detection sensor 702 can be in direct contact with the bond
material, abrasive particles, another component of the abrasive
body 701, or the combination thereof. In another embodiment, the
wear detection sensor 702 can be partially embedded or entirely
embedded within the abrasive body. In some instances, a portion of
the abrasive body may be removed to create a space (e.g., a slot)
inside the abrasive body to receive the wear detection sensor, and
heat, pressure, adhesives, glue, or any combination thereof, may be
used to attach the wear detection sensor to at least a portion of
the body. In some other instance, the wear detection sensor may be
embedded in a mixture for forming the abrasive body during the
forming process. The mixture can include the bond material,
abrasive articles, and optionally additives. In a particular
example, the mixture and the wear detection sensor can be placed in
a mold, wherein the wear detection sensor can be partially or fully
embedded in the mixture. The abrasive body can then be formed by
subjecting the mixture to pressure, heat, irradiation, other known
processes for forming an abrasive body, or a combination
thereof.
[0093] As illustrated, at least a portion of the electrical
component, such as the first and second capacitance plates 718 and
720, can be placed on a major surface of the abrasive body 701. In
a particular instance, a portion of the electrical component, such
as at least one of the capacitance plates 718 and 720, can be
attached to a portion of the abrasive body. In another particular
instance, the first and second capacitance plates 718 and 720 can
be attached to a portion of a major surface, a peripheral surface,
or both. In a more particular instance, at least one of the first
and second capacitance plates 718 and 720 can be in contact with a
portion of the abrasive body including the bond material, abrasive
particles, another component, or any combination thereof.
[0094] In some implementations, at least one of the capacitance
plates 718 and 720 can be partially or fully embedded in the
abrasive body 701. For instance, the first capacitance plate 718
can be placed on a major surface or a peripheral surface, and the
second capacitance plate can be partially or fully embedded in the
abrasive body 701. In another instance, the second capacitance
plate 720 can be placed on a major surface or a peripheral surface,
while the first capacitance plate 718 can be partially or fully
embedded in the abrasive body 701. In another instance, both the
first and second capacitance plates 718 and 720 can be partially or
fully embedded in the abrasive body 701.
[0095] In another embodiment, the wear detection sensor can include
a loop circuit coupled to the electronic device. FIG. 8 includes an
illustration of a plan view of another exemplary abrasive wheel 800
including an abrasive body 801. The abrasive article 800 includes a
wear detection sensor 802 including an electronic device 810 placed
on a major surface 803. The electronic device 810 can include an
electronic element, and optionally, an antenna 814 coupled to the
electronic element 812. The wear detection sensor 802 can include a
loop circuit. In some applications, the loop circuit can include a
wire loop 820 coupled to the electronic device 810. For instance,
the wire can be resistive. The wire loop can be directly connected
to the electronic element 812, such as an integrated circuit.
Alternatively, the wire loop can be coupled to the electronic
element 812 by the antenna 814.
[0096] In another application, the loop circuit can include a
passive element, such as a capacitor, a resistor, an inductor, or a
combination thereof. In a particular application, the loop circuit
can include a capacitive loop circuit including at least one
capacitor. In another particular application, the loop circuit can
include at least one resistor. In another particular instance, the
loop circuit can include a plurality of capacitive loop circuits,
where capacitors are placed in parallel connected by a wire.
[0097] FIG. 9A includes an illustration of a wear detection sensor
900 including an electronic device 901 coupled to a loop circuit
902. The electronic device 901 can include an electronic element
905, such as a transponder, integrated circuit, or the like, and
antenna 903 coupled to the electronic element 905. The loop circuit
902 can include a plurality of capacitors 911, 912, and 913 placed
in parallel. In another instance, at least one or all of 911, 912,
and 913 can include a resistor.
[0098] In an embodiment, the wear detection sensor 802 or 900 may
be placed on a major surface 803, a peripheral surface (not
illustrated), or a combination thereof, of the abrasive body 801.
In an aspect, the length L.sub.L of the loop circuit 820 or 902 can
extend along a portion of the major surface, the peripheral
surface, or both. In another aspect, the length L.sub.L of the loop
circuit 820 or 902 can extend in a radial direction, an axial
direction, or a combination thereof, of the abrasive body 801. In
another instance, the length L.sub.L of the loop circuit 820 or 902
can extend toward the material removing surface to facilitate wear
detection.
[0099] In a further embodiment, at least a portion of the wear
detection sensor 802 or 900 can be embedded in the abrasive body
801. In an aspect, the loop circuit 820 or 902, the electronic
device 810 or 901, or both can be partially embedded in the
abrasive body. In another aspect, the loop circuit 820 or 902, the
electronic device 810 or 901, or both can be fully embedded in the
abrasive body.
[0100] In another embodiment, the wear detection sensor 802 or 900
can be placed in a certain position that can facilitate
determination of the wear level. For example, in a material removal
operation, a first portion of the wear detection sensor can be
removed and a first wear signal can be generated, when wear of the
abrasive body reaches a first level. The first wear signal can be
an indicator of a first wear level. The first wear level may be a
relatively low wear level, such as 20%, 30%, or 40%. As the
operation continues, a second portion of the wear detection sensor
may be removed and a second wear signal is generated, when a second
wear level is reached. The second wear signal can be an indicator
of a second wear level. The second wear level may be a relatively
higher wear level, such as 705, 80%, or 90%. The second wear signal
can be interpreted as a warning of the upcoming end-of-life of the
abrasive article.
[0101] Referring to FIG. 8, the loop circuit 820 can extend in the
radial direction toward the peripheral surface. The peripheral
surface can be the material removing surface. The wear detection
sensor 810 may be positioned such that in a material removal
operation, a certain length of the circuit loop 820 or 902 can be
removed to cause the circuit loop to break, as wear of the abrasive
body reaches a certain level. The electronic device can sense the
broken circuit loop and generate a wear signal. A data-receiving
device can receive the wear signal and interpret it as an indicator
that the certain wear level, such as a certain low level wear, is
reached. As the operation continues, a portion of the electronic
device 810, such as at least a portion of the electronic element
812, antenna 814, or both, may be removed, which may turn the
electronic device into an inactive state, and the data-receiving
device may receive a wear signal indicating a higher level of wear
is reached. A wear signal can include a change in a signal, such as
a change in response time, signal strength, reflected energy,
disappearance of existing signal, or any combination thereof. In
certain instances, as the electronic device becomes inactive, the
data-receiving device may stop receiving any signal or response
from the electronic device.
[0102] In some instances, the electronic device 810 may be damaged
gradually during an operation of the abrasive article 800, and the
received signal strength indicator on the data-receiving device may
be used to determine the level of wear, as the electronic device
810 may send a progressively weaker signal until the electronic
device 810 turns inactive. The value of the received signal
strength indicator can be measured, calculated, or both by the
data-receiving device to determine the level of wear.
[0103] FIG. 9B includes an illustration of another example of the
wear detection sensor 950 including a wire loop 951 coupled to an
electronic device 952. In an embodiment, the wire loop 951 can
include one or more wire loops, such as 1 loop, 2 loops, 3 loops, 5
loops, or more. The electronic device 952 can include an integrated
circuit 954 and an antenna 953. In a particular embodiment, the
electronic device 952 can include an RFID chip or integrated
circuit. The electronic device 952 may further include additional
components 955, such as a chip, another integrated circuit, a logic
device, a transponder, a transceiver, a passive element, or the
like, or any combination thereof. In some implementations, the wear
detection sensor 950 can be printed and include a substrate 956.
The substrate 956 can include a flexible material, such as an
organic material, and more particularly, a flexible material. A
more particular example of the substrate 956 can include PET,
polyimide, or another material that can be used to make flexible
electronics.
[0104] In certain implementations, the wear detection sensor 950
can be placed abut an outer surface, such as the peripheral
surface, of the abrasive body of an abrasive article. For example,
the wear detection sensor 950 can be placed around at least a
portion of the peripheral surface of the abrasive body, and a
non-abrasive portion, such as a layer of fiber, can be wound over
the wear detection sensor 950 and at least a portion or the entire
outer peripheral surface of the abrasive body.
[0105] FIG. 9C includes an illustration of a top view of a mounting
plate (or a hub) 981 attached with an electronic assembly 982
including an electronic device 983 contained within a package 985.
The package 985 and the stool spokes 988 can help protect the
electronic device 983 from sparks and heat generated during a
grinding operation. In an embodiment, the package 985 can include a
protecting material that can be resistant to high temperatures and
function as a heat shield. In another embodiment, the package 985
can include a polymer. A particular example of the polymer can
include a high performance polymer, such as polyether ether ketone
(PEEK) or the like or a combination thereof. Alternatively, the
electronics device 983 may be completely covered by a protecting
material in lieu of the package and separated from the outer
environment.
[0106] The electronic device 983 can be part of a wear sensor that
further includes wire loops attached to the electronic device 983.
In a particular embodiment, the electronic device 983 can include a
microcontroller, and the wire loops can be attached to the
microcontroller. The wire loops can also be attached to a
peripheral surface of the abrasive body that is attached to the
mounting plate 981. The peripheral surface can be the inner or
outer peripheral surface. In an implementation, a coating may be
applied to the wire loops to facilitate attachment of the wire
loops to the peripheral surface and provide protection against heat
and sparks. In an embodiment, the coating can include an adhesive.
In another embodiment, the coating can be heat resistant. In
particular instances, the coating can include a heat resistant
adhesive, which may facilitate improved performance of the wear
sensor. An exemplary adhesive can include epoxy, acrylates,
silicone rubber, or the like. In a particular embodiment, the
coating can include steel epoxy.
[0107] In some instances, signal transmission from the electronic
device 983 during a grinding operation can be wireless. For
example, wheel wear information can be sent via Wi-Fi, Bluetooth,
or a combination thereof, to a receiving device, such as a mobile
phone, a hand held device, a computer, or the like. The transmitted
data can include state and change of state of the wire loops. For
instance, data may be in the format in which "0" represents closed
loop (e.g., no detectable wear of the wire loop), and "1"
represents open loop (broken loop). State and/or change of state of
wear loops can be used to determine the level of wear of the
abrasive tool. FIGS. 9D and 9E include graphs illustrating data
transmitted by a wear sensor including wire loops attached to the
electronic device 983, indicating state of different wire loops in
a grinding operation. As illustrated, the wire loop #2 is closed
and has no state change, while the state of the wire loop #4
changes from 0 to 1 indicating the wire loop is broken during the
grinding operation and some level of wear of the grinding tool. As
grinding continues, the wire loop#2 can be broken at a later time
to indicate a higher level of wear of the grinding tool.
[0108] FIG. 10 includes an illustration of a cross section of a
portion of an abrasive article 1000 including a body 1001. The body
1001 can include a first major surface 1002 opposite a second major
surface 1003, and a peripheral surface 1004 extending between the
first and second major surfaces 1002 and 1003. In some instances,
the body 1001 can include an abrasive portion 1020 and a
non-abrasive portion 1022. The peripheral surface 1004 can be the
material removing surface of the abrasive article 1000.
[0109] The wear detection sensor 1005 can be at least partially
embedded in the body 1101, including an electronic device including
an electronic element 1008 and an antenna 1006 coupled to the
electronic element 1008. The electronic element 1008 may be placed
within the non-abrasive portion 1022. In some instances, a portion
of the electronic element 1008 may be placed in the abrasive
portion 1020. The antenna 1006 is placed in the abrasive portion
1020, and in some instances, a portion of the antenna may be placed
in the non-abrasive portion. The terminal end 1014 of the antenna
1006 can be aligned with the peripheral surface 1004.
[0110] The antenna 1006 can extend toward the peripheral surface
1004. For instance, the antenna 1006 can extend in the radial
direction along a portion of the body. In another instance, the
antenna 1006 can extend over an entire radial distance of the
abrasive portion.
[0111] In some instances, the wear detection sensor can include a
package that contains at least a portion of the electronic element
1008 and the antenna 1006. For instance, the package can separate
the electronic element 1008 and/or the antenna 1006 from a
surrounding environment. In another instance, the package can
separate the electronic element 1008 and/or the antenna 1006 from
the composition of the body 1001, such as abrasive particles, the
bond material, and other components.
[0112] The package may include, such as a protective layer 1010, a
substrate 1012, or both. A portion of the protective layer 1010 may
extend above the major surface 1003. Alternatively, the protective
layer 1010 can be beneath the major surface 1003 or at the same
plane as the major surface 1003. In an aspect, the protective layer
1010 may include a material that can protect the electronic element
1008 and/or antenna 1006 from an outer environment condition,
including such as moisture, coolant, or the like. An exemplary
protective material can include polydimethylsiloxane (PDMS),
polyethylene naphthalate (PEN), polyimide, polyether ether ketone
(PEEK), or any combination thereof.
[0113] In some instances, certain coolant is used in material
removal operations, and exposing an electronic device to the
coolant can cause degradation of the electronic device. The
protective layer 1010 or the entire package can be applied to
protect the electronic device from the coolant and extend service
life of the electronic device. The protective layer can also be
applied to protect the electronic device from moisture, harsh
temperatures, or other conditions that may damage the electronic
device.
[0114] In an aspect, the substrate 1012 can include a similar or
different material as the protective layer 1010. In a particular
instance, the package may encapsulate the electronic device.
[0115] The wear detection sensor 1005 can survive multiple material
removal operations, and serve as an indicator that high level of
wear is reached when the abrasive article 1000 is retired. For
instance, the remaining length of the electronic element 1008 can
be an indicator that the interior circumference is reached at the
time the abrasive article 1000 is replaced.
[0116] In an embodiment, the wear detection sensor can include an
electronic device including an antenna directly and electrically
connected to an electronic element. In another embodiment, the wear
detection sensor can include a plurality of electronic devices,
wherein at least one of the electronic devices can include an
antenna directly and electrically connected to an electronic
element. In still another embodiment, the wear detection sensor can
include a plurality of electronic devices, wherein at least some or
each of the electronic devices can include an antenna directly and
electrically connected to an electronic element. In some
implementations, the antenna can include a thin film antenna.
[0117] In an aspect, the antenna can extend along a portion of the
abrasive body. For instance, the antenna can extend along a portion
of a major surface, a peripheral surface, or both, toward a
material removing surface of the abrasive body. In another aspect,
the antenna can extend in a radial direction, an axial direction,
or combination thereof of the abrasive body. In a further aspect,
the antenna may be partially or fully embedded in the abrasive
body.
[0118] In an aspect, the electronic device can include at least 1
antenna, at least 2 antennas, at least 3 antennas, or at least 4
antennas, wherein each antenna is directly and electrically
connected to an electronic element. In an aspect, at least some of
the antennas may extend a different distance along the abrasive
body. In another aspect, each of the antennas can extend a
different distance along the abrasive body.
[0119] FIG. 11 includes an illustration of a plan view of an
abrasive article 1100 including a body 1101 including an interior
circumferential region 1103 and an exterior circumferential region
1102. The wear detection sensor 1104 can include an electronic
device including an electronic element 1105 and a plurality of
antennas 1106 to 1109 coupled to the electronic element 1105. The
electronic element 1105 can be placed within the interior
circumferential region 1103. In another instance, the electronic
element 1105 may be placed in the exterior circumferential region
1102. In some particular implementations, the electronic element
1105 can include an integrated circuit, a transponder, or a
combination thereof.
[0120] The antennas 1106 to 1109 can be spaced apart from one
another. As illustrated, the antennas 1106 to 1109 can extend such
that the lengths of the antennas are in parallel to one another. In
another instance, at least some of the antennas 1106 to 1109 can be
placed such that the lengths may extend at an angle to each other.
For example, the angle can include an acute angle, an obtuse angle,
a right angle, or a combination thereof.
[0121] The antennas 1106 to 1109 can extend along a portion toward
a material removing surface (e.g., the peripheral surface) of the
abrasive body. In an aspect, one of the antennas can extend a
different distance compared to one of the other antennas. In
another aspect, all the antennas can extend a different distance
along the abrasive body.
[0122] In a further aspect, at least some of the antennas 1106 to
1109 can include different lengths compared to one another. In a
particular aspect, each of the antennas 1106 to 1009 can include a
different length. For example, a relative difference in length
between the antennas can be at least 5%, at least 10%, at least
15%, at least 17%, at least 20%, at least 30%, at least 40%, or at
least 50%. In another aspect, a relative difference in length
between the antennas can be at most 80%, at most 70%, at most 60%,
at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%.
Moreover, the relative difference in length between the antennas
can be in the range including any of the minimum and maximum
percentages noted herein.
[0123] As illustrated, the antennas 1109 can be placed within the
interior circumferential region 1103. The other antennas 1106 to
1108 can extend from a position within the interior circumferential
region 1103 into the exterior circumferential region 1102 for a
different distance.
[0124] The antennas 1106 to 1109 can be spaced apart from the
centerline 1111 of the abrasive body 1101 by a distance
.delta.d.sub.C. As illustrated, .delta.d.sub.C is the vertical
distance from a terminal end of the antenna (e.g., 1106) to the
centerline 1111, wherein the terminal end is the one that is closer
to the centerline 1111. For example, a relative difference in
distance .delta.d.sub.C between at least some of or all of the
antennas 1106 to 1109 can be at least 2%, at least 5%, at least
10%, at least 15%, or at least 20%. In another instance, a relative
difference in distance .delta.d.sub.C can be at most 40%, at most
35%, at most 20%, at most 15%, or at most 10%. Moreover, the
relative difference in .delta.d.sub.C can be in the range including
any of the minimum and maximum percentages noted herein.
[0125] The other terminal end of each antenna can be spaced apart
from the outer circumference of the abrasive body 1101 by a
distance .delta.d.sub.O. The distance is the linear extension from
the terminal end of the antenna (e.g., 1106) to the outer
circumference. The distance .delta.d.sub.O between the antennas
1106 to 1109 may be different. For example, a relative difference
in distance .delta.d.sub.O between at least some of or all of the
antennas 1106 to 1109 can be at least 2%, at least 5%, at least 8%,
at least 10%, or at least 15%. In another instance, a relative
difference in distance .delta.d.sub.O can be at most 45%, at most
40%, at most 35%, at most 30%, or at most 25%. Moreover, the
relative difference in .delta.d.sub.O can be in the range including
any of the minimum and maximum percentages noted herein.
[0126] In an exemplary material removal operation of the abrasive
article 1100, the longest antenna 1107 may come into contact with
the actual material removing surface (e.g., the peripheral surface)
and a portion of the antenna 1107 may be removed. As wear of the
abrasive article progresses, portions of antennas 1108, 1106, and
1104 may be removed. As the sizes of the antennas reduce, the
response energy from the electronic device decreases. The
data-receiving device can sense the changes in received signals and
the operator can be warned of wear. In some instances, the
data-receiving device may calculate the changes in response energy
and calculate to indicate the level of wear.
[0127] In an embodiment, the wear detection sensor can include an
electronic device including an electronic element and an antenna,
wherein the antenna can include a greater surface area than the
electronic element. For example, the electronic device can include
a plurality of antennas coupled to an electronic element, wherein
at least one, some, or each of the antennas can have a surface
greater than a surface area of the electronic element.
[0128] In another instance, the wear detection sensor can include a
plurality of electronic devices, wherein at least one of the
electronic devices can include an antenna coupled to an electronic
element, wherein the antenna can have a surface area bigger than
the electronic element. In a particular instance, some or each of
the plurality of electronic devices can include an antenna coupled
to an electronic element, wherein the antenna can have a surface
area bigger than the electronic element. In another particular
instance, one or more of the plurality of electronic devices can
include a plurality of antennas coupled to an electronic element,
wherein at least one or more of the plurality of antennas can have
a bigger surface area than the electronic element. In a more
particular instance, all of the antennas can have a surface arear
greater than the electronic elements they are coupled to.
[0129] In an embodiment, the electronic device can be positioned at
a non-abrasive portion, an abrasive portion, or both, of the body
of the abrasive article. In some instances, the antenna can be
coupled to an electronic element can be positioned at a
non-abrasive portion of the body of the abrasive article. As used
herein, non-abrasive portion is intended to refer to a portion of
an abrasive article body that is essentially free of an abrasive
particle. The non-abrasive portion may or may not include a bond
material. Abrasive portion is intended to refer to a portion of an
abrasive article body that includes a bond matrix and abrasive
particles contained in the bond matrix. The abrasive body is
intended to refer to a bonded body including a bond matrix and
abrasive particles distributed through the bond matrix, wherein the
bonded body is essentially free of a non-abrasive portion.
[0130] In an embodiment, the wear detection sensor can include an
antenna including a flared body. In some instances, the wear
detection sensor can include a plurality of antennas, wherein one
or more of the antennas can include a flared body. FIG. 12 includes
an illustration of a plan view of an abrasive article 1200
including an abrasive body 1201 including an interior
circumferential region 1214 and an exterior circumferential region
1215. In some instances, the body can include a center region 1213.
The center region may include a flange region or a hub.
[0131] A wear detection sensor 1203 can include the first
electronic device 1204 including an electronic element 1205 placed
in the center region 1213 and an antenna 1207. The second
electronic device 1208 includes an electronic element 1209
positioned in the interior circumferential region 1214 and an
antenna 1211. In another instance, the first and second electronic
elements 1205 and 1209 can be placed out side of the center region
1213. In still another instance, both of the first and second
electronic elements 1209 and 1205 can be placed in the interior
circumferential region 1214. In yet another instance, one of the
first and second electronic elements 1205 and 1209 can be placed in
the interior circumferential region 1214 and the other can be
placed in the exterior circumferential region 1215. In a particular
instance, none of the electronic elements is placed in the exterior
circumferential region 1215. In another particular instance, at
most one of the electronic elements can be placed in the center
region 1213. In a more particular instance, at least some of the
electronic elements are placed in different regions including the
center region 1213, the interior circumferential region 1214, and
the exterior circumferential region 1215.
[0132] The antennas 1207 and 1211 can be spaced apart from one
another in the circumferential direction, in the radial direction,
in the axial direction, or any combination thereof, of the abrasive
body 1201. The antennas 1207 and 1211 can extend in the radial
direction, axial direction, or a combination thereof along a
portion of the abrasive body. The antennas 1207 can extend from a
location in the center region 1213, across the entire radial
distance of the interior circumferential region 1214, and into the
exterior circumferential region 1215. The terminal end of the
antenna 1207 can be spaced apart from or aligned with the outer
circumference or the material removing surface (e.g., peripheral
surface) of the abrasive body. As illustrated, one of the terminal
ends of the secondary antenna 1207 can reach the outer
circumference or the material removing surface.
[0133] The antenna 1211 can extend from a location in the interior
circumferential region 1214 into the exterior circumferential
region 1215. At least one of the antenna 1211 can have a terminal
end that can reach the outer circumference.
[0134] As illustrated, each of the secondary antennas 1207 and 1211
can include a flared body. The width of the body can increase as
the secondary antennas 1207 and 1211 extend toward the outer
circumference or peripheral surface. For instance, the width W at
the terminal end of the secondary antenna 1207 or 1211 that is
closer to the outer circumference of the body 1201 can be greatest
compared to a width of another portion of the antenna.
[0135] In some instances, the antenna 1207 or 1211 or both can be
attached to a major surface of the abrasive body 1201. For
instance, the antenna 1207 or 1211 or both can extend along a
portion of a major surface of the abrasive body. In another
instance, a portion of the antenna 1207 or 1211 or both can be
exposed to an outer environment. For instance, the secondary
antenna 1207 or 1211 or both can be partially embedded in the
abrasive body 1201. In another instance, the antenna 1207 or 1211
or both can include a portion protruding outside of a surface
portion of an interior circumferential region 1214 of the abrasive
body 1201.
[0136] In other instances, the antenna 1207 or 1211 can extend over
a greater surface area of the abrasive body compared to the
electronic device 1204 or 1205, while in a shape other than a
flared body. For instance, the antenna 1207 and/or 1211 can be in a
shape including a triangle, a rectangle, a square, or an irregular
shape. The antenna 1207 and 1211 can be in the same or different
shape.
[0137] In another instance, any or each of the antennas 1207 and
1211 can extend over a certain surface area of the abrasive body
that can facilitate improved data transmission and/or continuous
powering the electronic devices 1204 and/or 1208. For instance, any
or each of the antennas 1207 and 1211 can extend over at least 1/20
of the surface area of a major surface or a peripheral surface of
the abrasive body 1201, such as at least 2/20, at least 3/20, at
least 4/20, or at least 5/20 of the surface area of a major surface
or a peripheral surface of the abrasive body 1201. In another
instance, any or each of the antennas 1207 and 1211 can extend over
at most 10/20 of the surface area of a major surface or a
peripheral surface of the abrasive body 1201, such as at most 9/20,
at most 8/20, at most 7/20, at most 6/20, at most 5/20, at most
4/20, or at most 3/20 of the surface area of a major surface or a
peripheral surface of the abrasive body 1201. Moreover, any or each
of the antennas 1207 and 1211 can extend over a surface area
including any of the minimum and maximum values noted herein.
[0138] FIG. 13 includes an illustration of a plan view of an
abrasive article 1300 including an abrasive body 1301. The abrasive
body 1301 can include an interior circumferential region 1302 and
an exterior circumferential region 1303. In some instances, the
abrasive body 1301 can include a center region 1310.
[0139] The wear detection sensor 1304 can include a first
electronic device including an electronic element 1305 coupled to
an antenna 1306, and a second electronic device including an
electronic element 1307 coupled to an antenna 1308.
[0140] The antennas 1307 and 1308 can include a curved portion that
can extend in the circumferential direction of the abrasive body
1301. In a particular instance, the antennas 1307 and 1308 can
include a length that can extend in the circumferential direction.
In a further instance, the antenna 1307, 1308, or both can extend
in a circumferential direction, an axial direction, a radial
direction, or any combination thereof. In another instance, the
antenna 1307 and 1308 can have the same or different length.
[0141] In another instance, the antenna 1306, 1308, or both can
extend for a certain length along a portion of the abrasive body
1301. In an aspect, the antenna 1307, 1308, or both can extend
along a portion of a major surface, peripheral surface, or a
combination thereof. In another aspect, one or each of the antennas
1307 and 1308 can extend for a certain length that can facilitate
improved data transmission and/or continuous powering. For
instance, one or each of the antennas 1307 and 1308 can extend for
at least 1/10 of the outer circumference of the abrasive body 1301,
such as at least 2/10, at least 3/10, at least 4/10, at least 5/10,
at least 6/10, or at least 7/10 of the outer circumference of the
abrasive body 1301. In another instance, one or each of the
antennas 1307 and 1308 can extend for at most 9/10, of the outer
circumference of the abrasive body 1301, such as at most 8/10, at
most 7/10, at most 6/10, at most 5/10, or at most 4/10 of the outer
circumference of the abrasive body 1301. Moreover, one or each of
the antennas 1307 and 1308 can extend for a length in a range
including any of the minimum and maximum values noted herein.
[0142] In another instance, any or each of the antennas 1306 and
1308 can extend over a certain surface area of the abrasive body
that can facilitate improved data transmission and/or continuous
powering the electronic devices 1305 and/or 1307. For instance, any
or each of the antennas 1306 and 1308 can extend over at least 1/20
of the surface area of a major surface or a peripheral surface of
the abrasive body 1301, such as at least 2/20, at least 3/20, at
least 4/20, or at least 5/20 of the surface area of a major surface
or a peripheral surface of the abrasive body 1301. In another
instance, any or each of the antennas 1306 and 1308 can extend over
at most 10/20 of the surface area of a major surface or a
peripheral surface of the abrasive body 1201, such as at most 9/20,
at most 8/20, at most 7/20, at most 6/20, at most 5/20, at most
4/20, or at most 3/20 of the surface area of a major surface or a
peripheral surface of the abrasive body 1301. Moreover, any or each
of the antennas 1306 and 1308 can extend over a surface area
including any of the minimum and maximum values noted herein.
[0143] As illustrated, each of the antennas 1306 and 1308 can have
an arc shape. The antennas 1306 and 1308 can extend toward each
other and be spaced apart in the radial direction, the axial
direction, the circumferential direction, or a combination
thereof.
[0144] The antennas 1306 and 1308 can extend along a portion of the
interior circumferential region 1302, a portion of the exterior
circumferential region 1303, or both. In some instances, the
antennas 1306 and 1308 and the electronic devices 1305 and 1306 may
be placed outside of the center region 1310. In another instance,
one of the electronic devices 1307 and 1305 may be placed in the
center circumferential region 1310 or the exterior circumferential
region 1303.
[0145] In some instances, one or each of the antennas 1306 and 1308
can extend along a portion of a major surface of the abrasive body.
In a particular instance, one or each of the antennas 1306 and 1308
can be attached to a major surface of the abrasive body. In another
instance, one or each of the antennas 1306 and 1308 is at least
partially embedded in the abrasive body. In a further instance, at
least one or each of the antennas 1306 and 1308 can include a
portion exposed to an outer environment. In a particular instance,
at least one or each of the antennas 1306 and 1308 can include a
portion protruding outside of a surface portion of the interior
circumferential region 1302.
[0146] In another embodiment, the wear detection sensor can include
a certain number of an electronic device that can facilitate
improved response of the electronic device to a data-receiving
device. For instance, the wear detection sensor can include at
least 1 electronic device, such as at least 2, at least 3, at least
5, at least 6, or at least 7 electronic devices. In a further
embodiment, the wear detection sensor can include at most 45
electronic devices, at most 40, at most 35, at most 30, at most 25,
at most 20, at most 15, at most 12, at most 10, at most 9, or at
most 8 electronic devices. Moreover, the number of the electronic
devices can be in the range including any of the minimum and
maximum values noted herein. For instance, the wear detection
sensor can include 1 to 45 electronic devices.
[0147] In an aspect, the wear detection sensor can include a
plurality of electronic devices that are spaced apart from one
another in the radial direction, the axial direction, the
circumferential direction, or a combination thereof. In another
aspect, at least some of the plurality of electronic devices may be
placed in an angle to one another. In another aspect, some of the
electronic devices may be aligned in the radial direction. In still
another aspect, some of the electronic devices may be in parallel.
In a further aspect, the plurality of electronic devices can extend
toward a material removing surface of the abrasive body.
[0148] FIG. 14 includes an illustration of a plan view of an
abrasive article 1400 including an abrasive body 1401 and a wear
detection sensor including a plurality of electronic devices 1402
extending along a portion of the abrasive body 1401. The plurality
of electronic devices 1402 can include the same or different
electronic devices including any of the electronic devices noted in
embodiments of this disclosure. In a particular instance, the
plurality of electronic devices 1402 can include a RFID tag or
sensor, an NFID tag or sensor, or any combination thereof.
[0149] In some instances, one or more of the electronic devices
1402 can extend along a portion of major surface, a peripheral
surface, or a combination thereof, of the abrasive body 1401. In
another instance, one or more or each of the electronic devices
1402 can be partially embedded or fully embedded in the abrasive
body.
[0150] The abrasive body 1401 can include an interior
circumferential region 1404 and an exterior circumferential region
1403. The plurality of electronic devices 1402 can be placed in the
exterior circumferential region 1403. In some instances, one or
more of the electronic devices 1402 may be placed in the interior
circumferential region 1404. In a further instance, one or more of
the electronic devices 1402 may extend along a portion of the
interior circumferential region 1404 and a portion of the exterior
circumferential region 1403. In another instance, one or more of
the electronic devices 1402 can include a terminal end that is
aligned with a material removal surface of the abrasive body
1401.
[0151] At least some of the electronic devices 1402 can include an
electronic element 1410 and antenna 1411. The electronic element
1410 can be positioned within the interior circumferential region
1405.
[0152] During an operation of the abrasive 1400, one or more of the
electronic devices may contact the material removing surface, and a
portion of the electronic device may be removed. The damaged
electronic device or devices may reflect reduced power in response
to a data-receiving device or not respond when turn inactive. The
reduction in reflected energy can be sensed and may be calculated
by the data-receiving device such that the operator can be warned
of the wear condition of the abrasive article 1400 and determine
when the abrasive article 1400 must be replaced.
[0153] FIG. 15 includes an illustration of a plan view of a portion
of an abrasive body 1500 of another abrasive article. The abrasive
body 1500 can include an inner circumference 1501 defining a center
hole of the abrasive body 1500 and an outer circumference 1502. In
some instances, the outer circumference can define the material
removing surface. In some instances, the abrasive body can include
a major surface 1503. In other instances, the abrasive body can
include a peripheral surface 1503.
[0154] A wear detection sensor including a plurality of electronic
devices can include a first electronic device 1504 and a second
electronic device 1505. The first and second electronic devices
1504 and 1505 can be staggered and placed in parallel to each
other. The first and second electronic devices 1504 and 1505 can
extend along a portion of the abrasive body 1500 and be spaced
apart from one another in the radial direction, the axial
direction, the circumferential direction, or a combination thereof.
In some instances, the first and second electronic devices 1504 and
1505 can extend along the surface 1503. In another instance, the
first and second electronic devices 1504 and 1505 can extend in the
radial direction, in the axial direction, or a combination thereof,
toward a material removing surface. In a further instance, one or
each of the electronic devices 1504 and 1505 can be partially or
fully embedded in the abrasive body 1500.
[0155] The first electronic device 1504 can include a first length
L.sub.1 extending between the terminal ends 1510 and 1511, wherein
the terminal end 1511 is closer to the inner circumference 1501
compared to the terminal end 1511, and the terminal end 1512 can be
closer to the outer circumference 1502 compared to the terminal end
1511.
[0156] The second electronic device 1505 can include a second
length L.sub.2 extending between the terminal ends 1513 and 1514,
wherein the terminal end 1513 is closer to the inner circumference
1501 compared to the terminal end 1514, and the terminal 1514 can
be closer to the outer circumference 1502 compared to the terminal
end 1513. The lengths, L.sub.1 and L.sub.2, can the same or
different.
[0157] In an aspect, the distance .delta.d.sub.I1 from the terminal
end 1511 to the inner circumference 1501 can be greater than the
distance .delta.d.sub.I2 between the terminal end 1513 to the inner
circumference 1501. For instance, a relative difference between
.delta.d.sub.I1 and .delta.d.sub.I2 can be at least at least 2%, at
least 5%, at least 10%, at least 12%, at least 15%, at least 20%,
at least 30%, at least 40%, or at least 50%. In another instance, a
relative difference between .delta.d.sub.I1 and .delta.d.sub.I2 can
be at most 80%, at most 70%, at most 60%, at most 50%, at most 45%,
at most 40%, at most 35%, or at most 30%. Moreover, the relative
difference .delta.d.sub.I1 and .delta.d.sub.I2 can be in the range
including any of the minimum and maximum percentages noted
herein.
[0158] In another aspect, the distance .delta.d.sub.O2 between the
terminal end 1514 to the outer circumference 1502 can be greater
than the distance .delta.d.sub.O1 from the terminal end 1512 to the
outer circumference 1502. For instance, a relative difference
between .delta.d.sub.O1 and .delta.d.sub.O2 can be at least at
least 2%, at least 5%, at least 10%, at least 12%, at least 15%, at
least 20%, at least 30%, at least 40%, or at least 50%. In another
instance, a relative difference between .delta.d.sub.O1 and
.delta.d.sub.O2 can be at most 80%, at most 70%, at most 60%, at
most 50%, at most 45%, at most 40%, at most 35%, or at most 30%.
Moreover, the relative difference .delta.d.sub.O1 and
.delta.d.sub.O2 can be in the range including any of the minimum
and maximum percentages noted herein.
[0159] In an exemplary operation of the abrasive article, the first
electronic device 1504 may be damaged sooner than the second
abrasive device 1505, which may cause a change of signal received
by a data-receiving device. For instance, when wear reaches the
position 1507 of the first electronic device 1504, the first
electronic device 1504 may be damaged and turns inactive (e.g., not
functional), while the second electronic device 1505 can remain
functional. The signal change, such as a change in strength or
intensity of the signal may be measured and/or calculated by the
data-receiving device, and the data-receiving device can send a
wear warning to the operator. In a particular aspect, the
electronic devices 1504 and 1505 can be positioned such that when
wear reaches a certain position, such as 1507, of the first
electronic device, the wear level can be determined. For instance,
the electronic devices 1504 and 1505 can be positioned such that
when the position 1507 is reached, the wear level can be 50%. As
the operation continues, the position 1506 may be reached and the
second electronic device may be damaged. A further change to the
signal received by the data-receiving device may be utilized to
send another warning of the wear level, such as 80% wear, to warn
the operator of the upcoming end-of-life of the abrasive
article.
[0160] In some exemplary forming processes, an abrasive body
precursor may be subjected to a heating cycle of 20 to 30 hours to
form a finally formed abrasive body. In some instances, the
electronic devices, such as 1504 and 1505, may be subjected to the
same heating cycle. In those instances, the electronic devices 1504
and 1505 may include a protection layer to facilitate improved heat
resistance of the electronic devices and/or coupling of the
electronic devices to the abrasive body. The protection layer can
cover at least a portion of the electronic device, and in
particular instances, the protection layer can encapsulate the
entire electronic device. In an aspect, the protection layer can
include a heat resistance material. In another aspect, the
protection layer can include the lead protecting material described
in embodiments of this disclosure. In a particular aspect, the
protection layer can include a polyimide film.
[0161] In other instances, the electronic devices, such as 1504 and
1505, may be coupled to the abrasive body after the heating cycle
is completed. In an exemplary implement, an opening may be formed
in the wheel mounting plate and/or the abrasive body to accommodate
the electronic devices using, such as a snap-fit configuration. The
electronic devices can be secured to the mounting plate and/or an
outer surface of the abrasive body. In a particular instance, a
coating can be applied over the electronic devices, and may be also
over at least a portion of the mounting plate and/or a portion of
the outer surface of the abrasive body. The coating may help to
secure the electronic devices and/or protect the electronic devices
from the outer environment. An exemplary coating can include
epoxy.
[0162] In another instance, the electronic devices, such as 1504
and 1505, may include components that can be attached to the
abrasive body separately. For example, the electronic device can
include a two-piece tag including antenna and integrated circuit,
such as an RFID circuit. The antenna can be attached to the
abrasive body prior to the heating cycle, and the integrated
circuit can be attached after the heating cycle. In a particular
implement, an opening can be formed on the mounting plate that is
attached to an abrasive body precursor, and an antenna can be
attached near the cutout of the mounting plate to an outer surface
of the abrasive body precursor, such as the peripheral surface. In
some instances, a non-abrasive portion, such as a layer of fiber,
can be wound over the antenna and at least a portion of the
peripheral surface. After the heating cycle, the antenna may be
bonded to the abrasive body and/or the non-abrasive portion, and
the integrated circuit can be placed into the opening in the
mounting plate via snap-fit configuration and attached to the
antenna. In a particular instance, the antenna can be a dipole
antenna. In another particular instance, the dipole antenna can be
formed using a conductive material, including for example, a metal
wire, such as a copper wire, conductive ink. In another particular
instance, the dipole antenna can include a thin film, such as a
thin metal foil, and in a more particular instance, the dipole
antenna can include a thin copper foil tape. In another particular
instance, the electronic device can include a printed integrated
circuit on a flexible substrate (e.g., a PCB), and the antenna can
be attached to the integrated circuit.
[0163] FIG. 16A includes an illustration of an abrasive article
1600 including a body 1601. The wear detection sensor can include
an electronic device including an electronic element 1605 and an
antenna 1606. The electronic element 1605 can be positioned within
the interior circumferential region 1602 of the abrasive body, and
the antenna 1606 can extend along a portion of the interior
circumferential region 1602 and a portion of the exterior
circumferential region 1603 toward the material removing surface,
i.e., the peripheral surface.
[0164] In a material removal operation utilizing the abrasive
article 1600, as the outer diameter D.sub.O reduces, the size of
the antenna 1606 may start to reduce. The reduction of the size of
the antenna can cause energy reflected by the antenna to reduce.
Referring to FIG. 16B, as the wheel diameter D.sub.O decreases,
reduction in reflected energy increases. The outer diameter D.sub.O
is a function of the reduction in energy reflected by the antenna.
Wear of the abrasive article can be determined based on the
reduction of the reflected energy.
[0165] FIG. 17A includes an illustration of a cross section of an
abrasive article 1701 including a body 1702 and wear detection
sensor 1703 fully embedded in the abrasive body 1702. The body can
include a center hole 1705, an interior circumferential region
1706, and an exterior circumferential region 1707. The boundary
between the interior and exterior regions is indicated by a dotted
line.
[0166] The wear detection sensor 1703 can include an electronic
element 1709 positioned within the interior circumferential region
1706, and an antenna 1708 extending in a serpentine shape toward
the material removing surface 1704. In another instance, the
antenna can be arranged in a shape of a loop or multiple loops.
Such shapes of the antenna or the like may facilitate improved wear
detection. For example, during a material removal process, multiple
portions of the antenna may be removed at the same wear level of
the abrasive body, which can increase the amount of data generated
by the electronic device. In certain instances, data can be
compared and used to verify wear level of the abrasive body.
[0167] In some implementations, the antenna may be arranged such
that a portion of the antenna can protrude outside of the major
surface of the abrasive body. As illustrated in FIG. 17B, the
abrasive article 1710 can include a body 1712 and wear detection
sensor 1713 embedded in the abrasive body 1712. The wear detection
sensor 1713 can include an electronic element 1719 and an antenna
1718, wherein a portion 1720 of the antenna 1718 is raised above
the major surface 1714. The raised portion 1720 is abut the
interior circumferential region 1716 and can be visible when viewed
from the major surface 1714, which can allow visual observation of
wear of the abrasive body and help to confirm wear level detected
by a data-receiving device. For instance, that the size of the
raised portion 1720 starts to reduce can be an indicator of the
upcoming end-of-life. In another instance, that the raised portion
1720 disappears can be an indicator that the abrasive article 1710
must be replaced.
[0168] The abrasive particles contained within the bond material of
the abrasive article can include an oxide, a carbide, a nitride, a
boride, an oxynitride, an oxyboride, diamond, or any combination
thereof. In a certain aspect, the abrasive particles can include a
superabrasive material, for example, cubic boron nitride or
diamond.
[0169] In one embodiment, the average particles size of the
abrasive particles (D50) can be at least 0.1 microns or at least
0.5 microns or at least 1 micron or at least 2 microns or at least
5 microns or at least 8 microns. In another embodiment, the average
particle size of the abrasive particles may be not greater than
6000 microns, such as not greater than 5000 microns, or not greater
than 3000 microns, or not greater than 2000 microns, or not greater
than 1500 microns, or not greater than 1000 microns, or not greater
than 900 microns, or not greater than 800 microns, or not greater
than 500 microns, or not greater than 300 microns. The average
particles size of the abrasive particles can be a value within a
range including any of the minimum and maximum values noted
above.
[0170] The bond material of the abrasive article of the present
disclosure may have a particular bond chemistry that may facilitate
improved manufacturing and performance of the abrasive article. The
bond material can be an inorganic material, an organic material, or
a combination thereof. The bond material can have a certain
porosity or be free porosity. In one embodiment, the bond material
can be an inorganic material, such as a metal, a metal alloy, a
ceramic, a glass, a ceramic, a cermet, or any combination thereof.
The bond material may have at least one of a monocrystalline phase,
a polycrystalline phase, amorphous phase, or any combination
thereof. In yet a further aspect, the bond material can include an
oxide, a boride, a nitride, a carbide, or any combination
thereof.
[0171] In another embodiment, the bond material may be an organic
material, such as a natural material, a synthetic material, a
polymer, a resin, an epoxy, a thermoset, a thermoplastic, an
elastomer, or any combination thereof. In a certain embodiment, the
organic material can include a phenolic resin, an epoxy resin, a
polyester resin, a polyurethane, a polyester, a polyimide, a
polybenzimidazole, an aromatic polyamide, a modified phenolic resin
(such as: epoxy modified and rubber modified resin, or phenolic
resin blended with plasticizers) or any combination thereof.
[0172] The present disclosure is further directed to a system for
detecting wear in an abrasive article. The system can comprise an
abrasive body including abrasive particles within a bond material
and a wear detection system coupled to the abrasive body. The wear
detection system can comprise a wear detection sensor including at
least one lead configured to change states between an active state
and an inactive state; and at least one logic device coupled to the
wear detection sensor and configured to detect a change in states
of the at least one lead and generate a wear signal based on the
change in states. In one aspect, the wear signal can correspond to
a voltage increase measured across an electric circuit of the at
least one lead.
[0173] In another embodiment, a system for detecting wear in an
abrasive article can include any of the abrasive articles described
in embodiments herein, and a data receiving unit configured to
receive data, such as a wear signal, generated by the wear
detection sensor. In an aspect, the data receiving unit can be
further configured to transmit the data, to provide energy to the
wear detection sensor, to send a signal to the wear detection
sensor and to receive a response from the wear detection sensor, or
a combination thereof. In a particular aspect, the electronic
device, the antenna, or the electronic element can be powered by
the data receiving unit in a wireless manner. In another aspect,
the data receiving unit can include a data-receiving device, a data
base, a system, or a combination thereof. An exemplary
data-receiving device can include a reader, an interrogator, a cell
phone, a computer, a data base, or a combination thereof.
[0174] In a further instance, the system can include an additional
antenna, wherein the antenna may not be coupled to an electronic
device. In a particular instance, the antenna can help to boost a
signal generated by the wear detection sensor, the data receiving
unit, or both.
[0175] FIG. 18 includes an illustration of an exemplary system for
detecting wear in an abrasive article 1803 including a wear
detection sensor 1804. The abrasive article 1803 is installed in a
grinding machine including a metallic cage 1801 and utilized in a
material removal process. The metallic cage 1801 can include an
opening, and a booster antenna 1805 is placed in the opening. The
system can further include a data receiving unit including an edge
reception antenna 1806, an edge computing processor 1807, or a
combination thereof. In some instances, the edge computing process
may be connected to cloud or the like.
[0176] The metallic cage can have an adverse effect on signal
transmission. With the aid of the booster antenna 1805, signal
generated by the wear detection sensor 1804, such as wear signal or
reflected energy or another signal, may be amplified and/or
transmitted by the booster antenna, and received by the edge
reception antenna 1806 and the processor 1807.
[0177] The present disclosure is further directed to a method of
detecting the wear of an abrasive article. In one embodiment, the
method of detecting the wear of an abrasive article can include
conducting a material removing process with an abrasive article.
The abrasive article can comprise an abrasive body having abrasive
particles contained within a bond material, and may have a wear
detection sensor embedded in at least a portion of the abrasive
body or the wear detection sensor can extend along an exterior
surface of the abrasive body. During the material removing process,
the abrasive article can be worn and material of the abrasive body
being removed, which can be detected by a wear signal generated by
the wear detection sensor. The wear signal can be based on removing
at least a portion of the wear detection sensor. As described
above, the wear detection sensor can include at least one lead, and
the wear signal may correspond to an inactive state of one lead of
the at least one lead by interrupting a current flow through the
lead.
[0178] In another embodiment, the method of detecting the wear of
an abrasive article can include removing at least a portion of a
wear detection sensor attached to at least a portion of the
abrasive body and generating a wear signal based on removing at
least a portion of the wear detection sensor. In an aspect,
removing at least a portion of the wear detection sensor can
include removing a portion of an antenna. In a further aspect,
reduction in the length or surface area or a combination thereof of
an antenna can result in generation of a wear signal. In a further
aspect, the wear signal can be received and interpreted as an
indicator of a wear level by a data-receiving device.
[0179] In another aspect, removing at least a portion of the wear
detection sensor can include removing a first portion of a first
electronic device and removing a second portion of a second
electronic device. In a further aspect, a first wear signal can be
generated based on removing the first portion, and a second wear
signal can be generated based on removing the second portion. In
still another aspect, the first and second wear signals may be
compared by the data-receiving unit to determine wear level of the
abrasive article. In yet another aspect, portions of additional
electronic devices may be removed, such as a third portion or more,
and additional wear signal can be generated and used for
confirmation of the wear level.
[0180] In another embodiment, the method of detecting the wear of
an abrasive article can include improving response of a wear
detection sensor. In certain implementations, an abrasive article
can be installed on a grinding machine including a metallic cage.
Only a portion of the abrasive article may be exposed to an outside
environment in a grinding operation. As the metallic cage can have
an adverse effect on signal transmission of the wear detection
sensor, signal can only be transmitted when the wear detection
sensor is exposed to the outside environment. For instance, a
data-receiving device can only receive energy reflected by the
electronic devices when the wear detection sensor is exposed, which
may result in a low data output frequency by the data receiving
device. As illustrated in FIG. 19A, when the wear detection sensor
includes one electronic device, the reflected energy can be
received at intervals. Increasing the number of electronic devices
can help shorten the intervals, and in certain instances, allow the
reflected energy to be received continuously. In a particular
aspect, the wear detection sensor can include at least 2, at least
4, or more electronic devices to improve response of the wear
detection sensor to the data-receiving device. In another aspect,
the method of detecting the wear of an abrasive article can include
improving frequency of data output by a data-receiving device. As
illustrated in FIG. 19B, when the wear detection sensor includes 4
electronic devices, the reflected energy can be detected at much
shorter intervals, compared to the wear detection sensor having one
electronic device.
[0181] Further embodiments are drawn to methods of detecting
vibration, acoustic, rotation per minute, cracks, and/or other
operation conditions of the abrasive article. The wear detection
sensor noted in the embodiments herein can be suitable for the
detection. For instance, certain operation conditions, such as a
crack, vibration, and acoustic, can affect resistance or impedance
of an electrical field, which can be detected by the wear detection
sensor and cause a signal change. In some instances, one or more
additional components, such as another electronic device, logic
element, passive element, lead, antenna, or the like, can be
coupled to the wear detection sensor to facilitate detection of
operation conditions of the abrasive article.
[0182] FIG. 20 includes an illustration of a particular example of
a wear sensor 2000 according to an embodiment. The wear sensor 2000
can include a sensing circuit 2001, a microcontroller 2002, an RFID
transceiver 2003, and an antenna 2004. In an embodiment, the
sensing circuit 2001 can convert the magnetic field into equivalent
digital electric output (current/voltage). Alternatively, the wear
sensor 2000 can include an analog-to-digital converter for
converting the sensing signal. In another embodiment, the wear
sensor 2000 can include an additional component, such as a passive
element. For instance, the wear sensor 2000 may include a memory
for storage of data. In an embodiment, the wear sensor 2000 may be
contained in a package or printed or attached to a substrate.
[0183] The microcontroller 2002 can receive signals from the
sensing circuit 2001 and transmit related data to the RFID
transceiver 2003 and/or an outside communication unit. The
microcontroller 2002 may perform certain operations, such as
determining wear level based on the sensing signal received from
the sensing circuit, and/or sending data related to the wear level
to the RFID transceiver 2003. In some instances, the data sent from
the microcontroller 2002 may include sensing signals, the wear
level, and/or additional information, such as instructions to
adjust grinding/cutting parameters and/or to terminate the current
grinding/cutting operation, indications of a proper
grinding/cutting operation, or the like, or any combination
thereof. The microcontroller may also store data on the transceiver
2003 or a memory, and the data may be referenced for next operation
using the abrasive tool. Additionally, or optionally, the
microcontroller 2002 may receive data from the RFID transceiver
2003 and transmit the data to the sensing circuit 2001.
[0184] The antenna 2004 can be directional or non-directional. The
antenna 2004 can function to receive and/or transmit signal and/or
data to an outside communication unit. The sensing circuit 2000 may
be battery powered, powered by wires, or wirelessly powered through
the antenna 2004, Wi-Fi, Bluetooth, or any combination thereof.
[0185] An exemplary sensing circuit can include a magnetometer,
such as a 3-axis magnetometer, a temperature and/or humidity
sensor, 3-axis accelerometer, a capacitive input interface, or the
like, or any combination thereof.
[0186] A magnetometer can sense the surrounding magnetic field and
convert into digital electric output. In applications involving a
ferrous workpiece, the inherent magnetic field of the workpiece can
be a source of field variations for the magnetometer. The
magnetometer can sense proximity of a workpiece to the abrasive
tool. In some applications, the magnetometer may function as a
counter indicating the number of grind that has been performed on a
single workpiece as changes of the dimension of the workpiece can
cause changes to the magnetic field. In other applications, wear of
the abrasive tool can be detected and indicated by an abrupt change
to magnetic field. In some instances, interference with grinding by
a foreign object may be detected due to interference with magnetic
field. Inappropriate tilting of the workpiece can cause shift of
the magnetic field and be sensed by the magnetometer.
[0187] A temperature and/or humidity sensor can sense surrounding
environmental temperature and/or humidity and in some instances can
convert the signal into equivalent digital electric output. In some
instances, temperature and/or humidity sensor can be based on
capacitive sensing and may not be affected by magnetic field of a
ferrous environment. In some instances, temperature and/or humidity
sensor can sense the presence of coolant on a workpiece,
inappropriate applications of coolant, or any combination thereof
due to effect of coolant on capacity.
[0188] 3-axis accelerometer can be based on an MEMS accelerometer
sensing acceleration in 3 axes. A 3-axis accelerometer can sense
vibrations and angular acceleration of the abrasive tool and may
convert sensing signals into equivalent digital electric output. In
some instances, acoustics data may be obtained by detecting surface
acoustic waves. In other instances, 3-axis accelerometer may sense
wheel rpm by calculating the number of repeated cycles of
grinding.
[0189] In some instances, the wear sensor can further include
capacitive plates or wires when a capacitive input interface is
used as a sensing circuit. The capacitive plates or wires may be
external to the components illustrated in FIG. 20. The capacitive
plates or wires can sense variations in density of the abrasive
body, such as material loss or a crack of the abrasive body.
Changes in capacity may be sensed by the capacitive input interface
and converted into equivalent digital electric output.
[0190] FIG. 21 includes an illustration of components of a radio
frequency reader 2100 including a radio frequency unit (e.g.,
transceiver) 2106. The radio frequency unit 2106 can generate radio
frequency signals and receive reflected signals and data from a
wear sensor, such as the wear sensor 2000. The up convertor 2107
and down convertor 2108 can adjust and match frequencies between
control unit 2102 and radio frequency signals. The DAC unit 2104
and ADC unit 2105 are analog/digital convertors. Control unit 2102
can control all the data acquisition such that the same antenna may
be used as a transmitter and receiver. The Wi-Fi/Blue tooth unit
2101 can facilitate communication with an external server,
visualization device, cloud, or any combination thereof. The reader
2100 may be powered by the power unit 2103. In other
implementations, the reader 2100 may include one or more additional
component or fewer components than illustrated.
[0191] The abrasive article described in embodiments herein can be
employed in various material removal operations wherein it is
desirable to observe the wear stage of the abrasive body during the
material removing process. Non-limiting examples can include, but
are not limited to, bonded abrasives, which may come in various
grades, structures, and shapes. In one particular embodiment, the
abrasive article can include a bonded abrasive grinding wheel. More
specifically, the abrasive article may be a grinding wheel
configured to be attached to a portion of a railroad car or other
object configured to grind railroad tracks.
[0192] It will be appreciated that the abrasive article of the
present disclosure may have any suitable size and shape as known in
the art.
[0193] Many different aspects and embodiments are possible. Some of
those aspects and embodiments are described herein. After reading
this specification, skilled artisans will appreciate that those
aspects and embodiments are only illustrative and do not limit the
scope of the present invention. Embodiments may be in accordance
with any one or more of the embodiments as listed below.
Embodiments
[0194] Embodiment 1. An abrasive article comprising: an abrasive
body including abrasive particles contained within a bond material;
and a wear detection sensor configured to detect a change in
dimension of the abrasive body, wherein at least a portion of the
wear detection sensor is coupled to and extending along at least a
portion of the abrasive body.
[0195] Embodiment 2. An abrasive article comprising: an abrasive
body comprising; abrasive particles contained within a bond
material; a wear detection sensor comprising at least one lead in
contact with the abrasive body; and at least one logic device in
communication with the at least one conductive lead.
[0196] Embodiment 3. The abrasive article of Embodiments 1 or 2,
wherein at least a portion of the wear detection sensor extends
along an exterior surface of the abrasive body.
[0197] Embodiment 4. The abrasive article of any one of Embodiments
1 and 2, wherein a first portion of the wear detection sensor is
coupled to a portion of the abrasive body and a second portion of
the wear detection sensor is coupled to a hub, wherein the hub is
coupled to the abrasive body.
[0198] Embodiment 5. The abrasive article of Embodiment 4, wherein
the first portion includes at least one lead and the second portion
includes a logic device.
[0199] Embodiment 6. The abrasive article of Embodiment 4, wherein
the first portion includes a logic device and the second portion
includes at least one lead extending from the logic device.
[0200] Embodiment 7. The abrasive article of any one of Embodiments
1 and 2, wherein at least a portion of the wear detection sensor is
embedded in the abrasive body.
[0201] Embodiment 8. The abrasive article of Embodiment 7, wherein
the portion of the wear detection sensor embedded in the abrasive
body extends for a depth into a volume of the abrasive body towards
a material removing surface of the abrasive body.
[0202] Embodiment 9. The abrasive article of Embodiment 8, wherein
the portion of the wear detection sensor embedded in the abrasive
body includes at least one lead extending from a logic device.
[0203] Embodiment 10. The abrasive article of Embodiment 9, wherein
the logic device is coupled to an exterior surface of the abrasive
body.
[0204] Embodiment 11. The abrasive article of Embodiment 10,
wherein the logic device is coupled to a hub, and the hub is
coupled to the abrasive body.
[0205] Embodiment 12. The abrasive article of Embodiment 10,
wherein the portion of the wear detection sensor includes a
plurality of leads extending parallel to each other for different
depths into the volume of the abrasive body.
[0206] Embodiment 13. The abrasive article of Embodiment 2, wherein
the logic device and the wear detection sensor are coupled to an
exterior surface of the abrasive body.
[0207] Embodiment 14. The abrasive article of Embodiment 1, wherein
the wear detection sensor comprises at least one lead in contact
with the abrasive body.
[0208] Embodiment 15. The abrasive article of any one of
Embodiments 2 and 14, wherein the wear detection sensor comprises a
plurality of leads.
[0209] Embodiment 16. The abrasive article of Embodiment 15,
wherein at least one lead of the plurality of leads extends along a
portion of the exterior surface of the abrasive body.
[0210] Embodiment 17. The abrasive article of Embodiment 15,
wherein a majority of the leads of the plurality of leads extend
along a portion of the exterior surface of the abrasive body.
[0211] Embodiment 18. The abrasive article of Embodiment 15,
wherein each of the leads of the plurality of leads extend along a
portion of the exterior surface of the abrasive body.
[0212] Embodiment 19. The abrasive article of Embodiment 15,
wherein the plurality of leads have different lengths compared to
each other.
[0213] Embodiment 20. The abrasive article of Embodiment 14,
wherein at least one of the leads of the plurality of leads is
embedded within the abrasive body.
[0214] Embodiment 21. The abrasive article of Embodiment 20,
wherein all of the leads of the plurality of leads are embedded
within the abrasive body.
[0215] Embodiment 22. The abrasive article of Embodiment 20,
wherein at least two of the leads of the plurality of leads have
terminal ends spaced apart from each other.
[0216] Embodiment 23. The abrasive article of Embodiment 22,
wherein each of the leads of the plurality of leads comprise
terminal ends, and wherein each of the terminal ends are spaced
apart from each other.
[0217] Embodiment 24. The abrasive article of Embodiment 23,
wherein each of the terminal ends are located at different
positions relative to each other.
[0218] Embodiment 25. The abrasive article of Embodiment 23,
wherein each of the terminal ends are embedded at different depths
within the abrasive body relative to each other.
[0219] Embodiment 26. The abrasive article of any one of
Embodiments 2 and 14, wherein the at least one lead is partially
embedded within the abrasive body.
[0220] Embodiment 27. The abrasive article of any one of
Embodiments 2 and 14, wherein the at least one lead is embedded
within the abrasive body.
[0221] Embodiment 28. The abrasive article of Embodiments 2 or 14,
wherein the at least one lead includes an elongated plate or wire
adapted to change resistance corresponding to a length of the
elongated plate or wire.
[0222] Embodiment 29. The abrasive article of Embodiments 2 or 14,
wherein the at least one lead comprises an electric circuit
including two wires connected by a plurality of resistors, wherein
the resistors are positioned in parallel to each other at different
locations along a length direction of the two wires.
[0223] Embodiment 30. The abrasive article of Embodiments 2 or 14,
wherein the at least one lead comprises a metal or metal alloy.
[0224] Embodiment 31. The abrasive article of Embodiment 1, further
comprising a logic device in communication with the wear detection
sensor.
[0225] Embodiment 32. The abrasive article of any one of
Embodiments 2, 14, or 31, wherein the logic device comprises a
microcontroller configured to detect a change in states of the wear
detection sensor.
[0226] Embodiment 33. The abrasive article of any one of
Embodiments 2, 14, or 31, wherein the wear detection sensor
comprises at least one lead configured to change states between an
active state and an inactive state, and wherein the logic device
comprises a microcontroller configured to detect a change in states
of the at least one lead.
[0227] Embodiment 34. The abrasive article of any one of
Embodiments 2, 14, or 31, wherein the wear detection sensor
comprises a plurality of leads, each of the leads of the plurality
of leads having terminal ends at different positions, and wherein
during use the terminal ends of the leads are adapted to be worn
and change states from an active state to an inactive state upon
being worn.
[0228] Embodiment 35. The abrasive article of Embodiments 2, 14, or
31, wherein a distance .DELTA.DT orthogonal from an original outer
material removing surface of the abrasive body to a terminal end of
the at least one lead is at least 100 micron, such as at least 200
microns, or at least 300 microns, or at least 500 microns, or at
least 800 microns, or at least 900 microns, or at least 1000
microns, or at least 5000 microns, and not greater than 1.5 meters,
such as not greater than 1.3 meters, or not greater than 1.0 meter,
or not greater than 0.8 meter, or not greater than 0.5 meter or not
greater than 0.3 meter, or not greater than 0.1 meter, or not
greater than 0.05 meter, or not greater than 0.01 meter.
[0229] Embodiment 36. The abrasive article of Embodiments 2, 14, or
31, wherein a distance .DELTA.DI between two terminal lead ends to
each other in a thickness direction of the abrasive body is at
least 50 microns, such as at least 100 microns, at least 250
microns, at least 500 microns, or at least 1000 microns, and not
greater than 1.5 meters, such as not greater than 1.2 meters, or
not greater than 1 meter, or not greater than 0.8 meter, or not
greater than 0.5 meter, or not greater than 0.3 meter, or not
greater than 0.2 meter, or not greater than 0.1 meter, or not
greater than 0.05 meter, or not greater than 0.01 meter.
[0230] Embodiment 37. The abrasive article of Embodiments 2, 14, or
31, wherein a total length of the at least one lead is at least 100
microns, such as at least 200 microns, or at least 500 microns, or
at least 1000 microns, or at least 10,000 microns, or at least
50,000 microns, and not greater than 10 meters, such as not greater
than 8 meters, not greater than 5 meters, not greater than 3
meters, not greater than 2 meters, not greater than 1.5 meters, not
greater than 1.2 meters, not greater than 1.0 meter, not greater
than 0.8 meter, not greater than 0.5 meter, not greater than 0.3
meter, not greater than 0.2 meter, not greater than 0.1 meter, not
greater than 0.05 meter, or not greater than 0.01 meter.
[0231] Embodiment 38. The abrasive article of Embodiments 2, 14, or
31, wherein each of the at least one lead comprises an electric
circuit.
[0232] Embodiment 39. The abrasive article of Embodiments 2, 14, or
31, wherein the at least lead is a plurality of leads, and the
plurality of leads is combined within one electric circuit.
[0233] Embodiment 40. The abrasive article of Embodiments 2, 14, or
31, wherein the at least one lead comprises at least two leads, or
at least 3 leads, at least 5 leads, at least 7 leads, or at least 9
leads.
[0234] Embodiment 41. The abrasive article of Embodiments 2, 14, or
31, wherein the at least one lead comprises not more than 100
leads, such as not more than 80 leads, not more than 60 leads, not
more than 50 leads, not more than 30 leads, not more than 20 leads,
not more than 15 leads, or not more than 10 leads.
[0235] Embodiment 42. The abrasive article of Embodiments 2, 14, or
31, wherein the logic device further includes a communication
device for wireless communication with an external controller.
[0236] Embodiment 43. The abrasive article of Embodiment 42,
wherein the communication device is a transceiver.
[0237] Embodiment 44. The abrasive article of Embodiment 43,
wherein the communication device is an RFID transceiver.
[0238] Embodiment 45. A system for detecting wear in an abrasive
article comprising: an abrasive body comprising abrasive particles
contained within a bond material; a wear detection system coupled
to the abrasive body, wherein the wear detection system comprises:
a wear detection sensor including at least one lead configured to
change states between an active state and an inactive state; and at
least one logic device coupled to the wear detection sensor and
configured to detect a change in states of the at least one lead
and generate a wear signal based on the change in states.
[0239] Embodiment 46. The system of Embodiment 45, wherein the wear
signal corresponds to a voltage change measured across an electric
circuit of the at least one lead.
[0240] Embodiment 47. The system of Embodiment 45, wherein each
lead of the at least one lead has an independent electric circuit,
and the inactive state of the at least one lead corresponds to an
interrupted electric circuit.
[0241] Embodiment 48. A system for detecting wear in an abrasive
article comprising: an abrasive body comprising abrasive particles
contained within a bond material; a wear detection system coupled
to the abrasive body, wherein the wear detection system comprises:
a wear detection sensor including at least one lead configured to
change resistance during wear of the abrasive body; and at least
one logic device coupled to the wear detection sensor and
configured to measure the resistance of the at least one lead and
to generate a wear signal based on a change of the measured
resistance.
[0242] Embodiment 49. The system of Embodiment 48, wherein the at
least one lead is an elongated plate or wire adapted to change
resistance corresponding to a length of the elongated plate or
wire.
[0243] Embodiment 50. The system of Embodiment 48, wherein the at
least one lead wherein the at least one lead comprises an electric
circuit including two wires connected by a plurality of resistors,
wherein the resistors are positioned in parallel to each other at
different locations along a length distance of the two wires.
[0244] Embodiment 51. A method for detecting wear in an abrasive
article comprising: conducting a material removal process with an
abrasive body comprising abrasive particles contained within a bond
material; removing at least a portion of a wear detection sensor
embedded in at least a portion of the abrasive body; and generating
a wear signal based on removing at least a portion of the wear
detection sensor.
[0245] Embodiment 52. The method of Embodiment 51, wherein the wear
detection sensor includes at least one lead configured to change
states between an active state and an inactive state.
[0246] Embodiment 53. The method of Embodiment 51, wherein the wear
signal is generated by removing at least a portion of the at least
one lead and changing said lead states from active state to
inactive state.
[0247] Embodiment 54. The method of Embodiment 51, wherein the wear
signal corresponds to a voltage change measured across an electric
circuit of the at least one lead.
[0248] Embodiment 55. The method of Embodiment 51, wherein the wear
signal corresponds to a measured resistance change of the at least
one lead.
[0249] Embodiment 56. The method of Embodiment 51, wherein the at
least one lead is an elongated plate or wire and the resistance
change corresponds to a decrease in length of the elongated plate
or wire during wear of the abrasive body.
[0250] Embodiment 57. The method of Embodiment 51, wherein the at
least one lead comprises an electric circuit including two wires
connected by a plurality of resistors, wherein the resistors are
positioned in parallel to each other at different locations along a
length direction of the two wires, and a change in total resistance
of the circuit corresponds to an amount of destroyed resistors
during wear of the abrasive body.
[0251] Embodiment 58. An abrasive article comprising:
[0252] an abrasive body including:
[0253] abrasive particles contained within a bond material; and
[0254] a wear detection sensor coupled to the abrasive body,
[0255] wherein the wear detection sensor is configured to detect a
change in a dimension of the abrasive body; and
[0256] wherein the wear detection sensor comprises at least one
electronic device.
[0257] Embodiment 59. The abrasive article of 58, wherein at least
a portion of the wear detection sensor is in direct contact with a
portion of the abrasive body.
[0258] Embodiment 60. The abrasive article of Embodiment 58 or 59,
wherein the at least one electronic device comprises an
antenna.
[0259] Embodiment 61. The abrasive article of Embodiment any one of
Embodiments 58 to 60, wherein the wear detection sensor comprises
at least one, at least 2, at least 4, or at least 6 antennas.
[0260] Embodiment 62. The abrasive article of any one of
Embodiments 58 to 61, wherein the electronic device is attached to
a major surface of the abrasive body, a peripheral surface of the
abrasive body, or a combination thereof.
[0261] Embodiment 63. The abrasive article of any one of
Embodiments 58 to 61, wherein the electronic device is at least
partially embedded in the abrasive body.
[0262] Embodiment 64. The abrasive article of any one of
Embodiments 58 to 61, wherein the electronic device is completely
embedded within the abrasive body.
[0263] Embodiment 65. The abrasive article of any one of
Embodiments 58 to 64, wherein the wear detection sensor comprises
an electrical component coupled to the at least one electronic
device, wherein the electrical component comprises a capacitor, a
resistor, an inductor, or a combination thereof.
[0264] Embodiment 66. The abrasive article of Embodiment 65,
wherein the electrical component comprises a first capacitance
plate, and a second capacitance plate that is spaced apart from the
first capacitance plate.
[0265] Embodiment 67. The abrasive article of Embodiments 65 or 66,
wherein the abrasive body comprises an interior circumferential
region and an exterior circumferential region, wherein the first
capacitance plate is positioned in the interior circumferential
region, and the second capacitance plate is positioned in the
exterior circumferential region.
[0266] Embodiment 68. The abrasive article of any one of
Embodiments 65 to 67, wherein the electrical component is attached
to a portion of the abrasive body or at least partially embedded in
the abrasive body.
[0267] Embodiment 69. The abrasive article of any one of
Embodiments 65 to 68, wherein at least one of the first and second
capacitance plates is attached to a major surface of the abrasive
body, a peripheral surface of the abrasive body, or a combination
thereof.
[0268] Embodiment 70. The abrasive article of any one of
Embodiments 65 to 69, wherein both the first and second capacitance
plates are attached to a major surface or a peripheral surface of
the abrasive body.
[0269] Embodiment 71. The abrasive article of any one of
Embodiments 65 to 69, wherein the first capacitance plate is
attached to a major surface or peripheral surface of the abrasive
body, and wherein the second capacitance plate is at least
partially embedded within the abrasive body.
[0270] Embodiment 72. The abrasive article of any one of
Embodiments 65 to 68, wherein both the first and second capacitance
plates are at least partially embedded in the abrasive body.
[0271] Embodiment 73. The abrasive article of any one of
Embodiments 65 to 68, wherein both the first and second capacitance
plates are fully embedded within the abrasive body.
[0272] Embodiment 74. The abrasive article of any one of
Embodiments 58 to 73, wherein the wear detection sensor comprises a
loop circuit.
[0273] Embodiment 75. The abrasive article of Embodiment 74,
wherein the loop circuit comprises a resistive wire loop coupled to
the at least one electronic device.
[0274] Embodiment 76. The abrasive article of Embodiments 74 or 75,
wherein the wear detection sensor comprises a loop circuit
comprising the electrical component.
[0275] Embodiment 77. The abrasive article of any one of
Embodiments 74 to 76, wherein the loop circuit further comprises a
resistive element.
[0276] Embodiment 78. The abrasive article of Embodiment 77,
wherein the resistive element comprises resistor, a resistive wire,
or a combination thereof.
[0277] Embodiment 79. The abrasive article of any one of
Embodiments 74 to 78, wherein the loop circuit comprises a
plurality of capacitors, a plurality of resistors, a plurality of
inductors, or a combination thereof.
[0278] Embodiment 80. The abrasive article of any one of
Embodiments 58 to 64, wherein the at least one electronic device
comprising an electronic element and an antenna directly and
electrically connected to the electronic element, wherein the
electronic element comprises a chip, an integrated circuit, logic,
a transponder, a transceiver, a memory, a passive element, or any
combination thereof.
[0279] Embodiment 81. The abrasive article of Embodiment 80,
wherein the wear detection sensor comprises a plurality of
electronic devices including the at least one the electronic
devices.
[0280] Embodiment 82. The abrasive article of Embodiments 80 or 81,
wherein the wear detection sensor comprises a plurality of
electronic devices, wherein at least some of the electronic devices
comprise an antenna.
[0281] Embodiment 83. The abrasive article of any one of
Embodiments 80 to 82, wherein the wear detection sensor comprises a
plurality of electronic devices, wherein each one of the electronic
devices comprises an antenna.
[0282] Embodiment 84. The abrasive article of any one of
Embodiments 80 to 83, wherein the wear detection sensor comprises
an electronic device comprising at least 1, at least 2, at least 3,
or at least 4 antennas directly and electrically coupled to an
electronic element.
[0283] Embodiment 85. The abrasive article of any one of
Embodiments 80 to 84, wherein the antenna comprises a thin film
antenna.
[0284] Embodiment 86. The abrasive article of any one of
Embodiments 80 to 85, wherein the antenna includes a surface area
that is greater than a surface area of the electronic element.
[0285] Embodiment 87. The abrasive article of any one of
Embodiments 80 to 87, wherein the antenna extends over a greater
surface area of the abrasive body compared to the electronic
element.
[0286] Embodiment 88. The abrasive article of any one of
Embodiments 80 to 87, wherein the antenna is directly and
electrically coupled to the integrated circuit.
[0287] Embodiment 89. The abrasive article of any one of
Embodiments 86 to 88, wherein the electronic device including the
antenna is coupled to a non-abrasive portion of the abrasive
article.
[0288] Embodiment 90. The abrasive article of any one of
Embodiments 80 to 89, wherein the antenna extends along a portion
of a major surface, a peripheral surface, or both, toward a
material removing surface of the abrasive body.
[0289] Embodiment 91. The abrasive article of any one of
Embodiments 80 to 90, wherein the antenna is at least partially
embedded or fully embedded in the abrasive body.
[0290] Embodiment 92. The abrasive article of any one of
Embodiments 80 to 91, wherein the antenna extends in a radial
direction, an axial direction, a circumferential direction, or
combination thereof of the abrasive body.
[0291] Embodiment 93. The abrasive article of any one of
Embodiments 80 to 92, wherein the antenna is arranged in a loop, in
a serpentine shape, or a combination thereof.
[0292] Embodiment 94. The abrasive article of any one of
Embodiments 80 to 93, wherein the electronic element is positioned
within an interior circumferential region of the abrasive body,
wherein the electronic element includes an integrated element,
wherein the integrated element is positioned within the interior
circumferential region.
[0293] Embodiment 95. The abrasive article of any one of
Embodiments 80 to 94, wherein the electronic element is positioned
within a non-abrasive portion of the abrasive body, wherein the
antenna is positioned in an abrasive portion of the abrasive
body.
[0294] Embodiment 96. The abrasive article of any one of
Embodiments 80 to 95, wherein the wear detection sensor comprises a
package containing at least a portion of the electronic element,
the antenna, or a combination thereof.
[0295] Embodiment 97. The abrasive article of Embodiment 96,
wherein the package comprises a protective layer.
[0296] Embodiment 98. The abrasive article of Embodiment 97,
wherein the protective layer comprises a material including
polydimethylsiloxane (PDMS), polyethylene naphthalate (PEN),
polyimide, polyether ether ketone (PEEK), or any combination
thereof.
[0297] Embodiment 99. The abrasive article of Embodiment 98 or 99,
wherein the protective layer encapsulates the electronic element
and the antenna.
[0298] Embodiment 100. The abrasive article of any one of
Embodiments 80 to 99, wherein the wear detection sensor comprises a
plurality of antennas, wherein the plurality of antennas have a
different length compared to each other.
[0299] Embodiment 101. The abrasive article of Embodiment 100,
wherein a relative difference in length between the plurality of
antennas can be at least 5%, at least 10%, at least 15%, at least
17%, at least 20%, at least 30%, at least 40%, or at least 50%.
[0300] Embodiment 102. The abrasive article of Embodiment 100 or
101, wherein a relative difference in length between the plurality
of antennas can be at most 80%, at most 70%, at most 60%, at most
50%, at most 45%, at most 40%, at most 35%, or at most 30%.
[0301] Embodiment 103. The abrasive article of Embodiment 102,
wherein the plurality of antennas extend a different distance along
the abrasive body toward a material removing surface.
[0302] Embodiment 104. The abrasive article of any one of
Embodiments 100 to 103, wherein at least one of the antennas is
positioned within an interior circumferential region of the
abrasive body.
[0303] Embodiment 105. The abrasive article of any one of
Embodiments 100 to 104, wherein at least one of the antennas
extends from an interior circumferential region into an exterior
circumferential region.
[0304] Embodiment 106. The abrasive article of any one of
Embodiments 100 to 105, wherein at least one of the antennas is
positioned within an exterior circumferential region of the
abrasive body.
[0305] Embodiment 107. The abrasive article of any one of
Embodiments 80 to 106, wherein wear detection sensor comprises a
plurality of antennas, wherein at least one of the antennas
comprises a flared body.
[0306] Embodiment 108. The abrasive article of Embodiment 107,
wherein each of the plurality of antennas comprises a flared
body.
[0307] Embodiment 109. The abrasive article of Embodiment 107 or
108, wherein at least one of the plurality of antennas extends in a
radial direction, an axial direction, or a combination thereof,
from a center region toward a material removing surface of the
abrasive body, wherein a width of the flared body increases as the
antenna extends from the center region to the material removal
surface of the abrasive body.
[0308] Embodiment 110. The abrasive article of any one of
Embodiments 107 to 108, wherein at least one of the plurality of
antennas extends in the radial direction, an axial direction, or a
combination there, across at least a portion of the center region
and across at least a portion of an interior circumferential region
of the abrasive body.
[0309] Embodiment 111. The abrasive article of any one of
Embodiments 107 to 110, wherein at least one of the plurality of
antennas extends from the center region, across the interior
circumferential region, and into an exterior region of the abrasive
body.
[0310] Embodiment 112. The abrasive article of Embodiment 111,
wherein the at least one of the plurality of secondary antennas
comprises a terminal end aligned with the material removal
surface.
[0311] Embodiment 113. The abrasive article of Embodiment 111 or
112, wherein each of the plurality of antennas extends across a
portion of the interior circumferential region and into an exterior
region of the abrasive body.
[0312] Embodiment 114. The abrasive article of any one of
Embodiments 111 to 113, wherein at least one of the plurality of
antennas comprises at least a portion exposed to an outer
environment.
[0313] Embodiment 115. The abrasive article of any one of
Embodiments 111 to 114, wherein at least one of the plurality of
antennas is partially embedded in the abrasive body
[0314] Embodiment 116. The abrasive article of any one of
Embodiments 111 to 115, wherein each of the antennas is partially
embedded in the abrasive body.
[0315] Embodiment 117. The abrasive article of any one of
Embodiments 111 to 116, wherein at least one of the antennas
comprises a portion protruding outside of a surface portion of an
interior circumferential region of the abrasive body.
[0316] Embodiment 118. The abrasive article of any one of
Embodiments 111 to 117, wherein at least one of the antennas
extends along a portion of a major surface of the abrasive
body.
[0317] Embodiment 119. The abrasive article of any one of
Embodiments 111 to 118, wherein each of the antennas extends along
a portion of a major surface of the abrasive body.
[0318] Embodiment 120. The abrasive article of any one of
Embodiments 80 to 118, wherein the wear detection sensor comprises
a plurality of antennas, wherein one or more of the plurality of
antennas comprises a body including a curved portion.
[0319] Embodiment 121. The abrasive article of Embodiment 119 or
120, wherein at least one of the plurality of antennas has a curved
body, wherein at least a portion of the curved body extends in a
circumferential direction of the abrasive body.
[0320] Embodiment 122. The abrasive article of any one of
Embodiments 119 to 120, wherein at least one of the plurality of
antennas has a length extending in a circumferential direction.
[0321] Embodiment 123. The abrasive article of any one of
Embodiment 119 to 122, wherein each one of the antennas has a
length extending in a circumferential direction of the abrasive
body.
[0322] Embodiment 124. The abrasive article of any one of
Embodiments 119 to 122, wherein one or more of the antennas extend
in a radial direction, circumferential direction, axial direction,
or a combination thereof.
[0323] Embodiment 125. The abrasive article of any one of
Embodiments 119 to 124, wherein the wear detection sensor can
include a first and second antennas extending from a same
electronic device in an opposite direction.
[0324] Embodiment 126. The abrasive article of any one of
Embodiments 119 to 125, wherein one or each of the antennas extend
along a portion of the interior circumferential region, a portion
of the exterior circumferential region, or combination thereof.
[0325] Embodiment 127. The abrasive article of any one of
Embodiments 119 to 126, wherein each of the antennas is positioned
outside of a center area of the abrasive body.
[0326] Embodiment 128. The abrasive article of any one of
Embodiments 119 to 127, wherein at least one of the electronic
elements are positioned outside of a center area of the abrasive
body.
[0327] Embodiment 129. The abrasive article of any one of
Embodiments 119 to 128, wherein each of the electronic elements is
positioned outside of a center area of the abrasive body.
[0328] Embodiment 130. The abrasive article of any one of
Embodiment 119 to 129, wherein at least one of the antennas extends
along a portion of a major surface of the abrasive body.
[0329] Embodiment 131. The abrasive article of any one of the
Embodiments 119 to 130, wherein the at least one of the antennas is
attached to a major surface of the abrasive body.
[0330] Embodiment 132. The abrasive article of any one of
Embodiments 119 to 131, wherein each one of the antennas extends
along a portion of a major surface of the abrasive body
[0331] Embodiment 133. The abrasive article of any one of
Embodiments 119 to 132, wherein each one of the antennas is
attached to a major surface of the abrasive body.
[0332] Embodiment 134. The abrasive article of any one of
Embodiments 119 to 133, wherein at least one of the antennas is at
least partially embedded in the abrasive body.
[0333] Embodiment 135. The abrasive article of any one of
Embodiments 119 to 134, wherein each of the antennas is at least
partially embedded in the abrasive body.
[0334] Embodiment 136. The abrasive article of any one of
Embodiments 119 to 135, wherein at least one of the antennas
comprises a portion exposed to an outer environment.
[0335] Embodiment 137. The abrasive article of any one of
Embodiments 119 to 136, wherein at least one of the antennas
comprises a portion protruding outside of a surface portion of an
interior circumferential region.
[0336] Embodiment 138. The abrasive article of any one of
Embodiments 119 to 137, wherein each antenna comprises a portion
protruding outside of a surface portion of an interior
circumferential region.
[0337] Embodiment 139. The abrasive article of any one of
Embodiments 119 to 138, wherein the antennas have different lengths
compared to each other.
[0338] Embodiment 140. The abrasive article of any one of
Embodiments 58 to 60, wherein the wear detection sensor comprises a
plurality of electronic devices.
[0339] Embodiment 141. The abrasive article of Embodiment 140,
wherein the wear detection sensor comprises at least 2 electronic
devices, at least 3, at least 5, at least 6, or at least 8
electronic devices, wherein each of the electronic devices extend
along a portion of the abrasive body toward a material removing
surface of the abrasive body.
[0340] Embodiment 142. The abrasive article of Embodiment 141,
wherein at least one of the electronic devices extend in a radial
direction, an axial direction, or a combination thereof of the
abrasive body.
[0341] Embodiment 143. The abrasive article of Embodiments 141 or
142, wherein an electronic element of at least one of the
electronic devices is positioned in the interior circumferential
region of the abrasive body.
[0342] Embodiment 144. The abrasive article of Embodiment 143,
wherein the electronic element includes an integrated circuit,
wherein the integrated circuit is positioned in the interior
circumferential region.
[0343] Embodiment 145. The abrasive article of Embodiments 141 to
144, wherein at least one of the electronic devices has a terminal
end that is aligned with a material removal surface of the abrasive
body.
[0344] Embodiment 146. The abrasive article of Embodiment 145,
wherein the wear detection sensor comprises a first electronic
device and a second electronic device, wherein the first and second
electronic devices are placed spaced apart from one another and
extend along a portion of the abrasive body.
[0345] Embodiment 147. The abrasive article of Embodiment 146,
wherein the first electronic device is positioned closer to the
material removing surface compared to the second electronic
device.
[0346] Embodiment 148. The abrasive article of Embodiments 146 or
147, wherein the second electronic device is positioned closer to
an inner circumference of the abrasive body compared to the first
electronic device.
[0347] Embodiment 149. The abrasive article of any one of
Embodiments 146 to 148, wherein the first electronic device
comprises a first length extending from a first terminal end to a
second terminal end of the first body toward an outer
circumference, and wherein the second electronic device comprises a
second length extending from a third terminal end to a fourth
terminal end toward the outer circumference, wherein the first
terminal end is closer to an inner circumference compared to the
third terminal end, and the second terminal end is father away from
the outer circumference compared to the fourth terminal end.
[0348] Embodiment 150. The abrasive article of Embodiment 149,
wherein the first length and the second length extend in a radial
or an axial direction of the abrasive body.
[0349] Embodiment 151. The abrasive article of Embodiments 149 or
150, wherein the first electronic device is in parallel to the
second electronic device.
[0350] Embodiment 152. The abrasive article of any one of
Embodiments 149 to 151, wherein the first and second electronic
devices are staggered.
[0351] Embodiment 153. The abrasive article of any one of
Embodiments 149 to 152, wherein a distance .delta.d.sub.I1 between
the first terminal end and the inner circumference is greater than
a distance .delta.d.sub.I2 between the third terminal end to the
inner circumference, wherein a relative difference between
.delta.d.sub.I1 and .delta.d.sub.I2 is at least at least 2%, at
least 5%, at least 10%, at least 12%, at least 15%, at least 20%,
at least 30%, at least 40%, or at least 50%.
[0352] Embodiment 154. The abrasive article of Embodiment 153,
wherein the relative difference between .delta.d.sub.I1 and
.delta.d.sub.I2 is most 80%, at most 70%, at most 60%, at most 50%,
at most 45%, at most 40%, at most 35%, or at most 30%.
[0353] Embodiment 155. The abrasive article of any one of
Embodiments 149 to 154, wherein a distance .delta.d.sub.O2 between
the fourth terminal end and the outer circumference is greater than
a distance .delta.d.sub.O1 from the second terminal end to the
outer circumference, wherein a relative difference between
.delta.d.sub.O1 and .delta.d.sub.O2 is at least at least 2%, at
least 5%, at least 10%, at least 12%, at least 15%, at least 20%,
at least 30%, at least 40%, or at least 50%.
[0354] Embodiment 156. The abrasive article of Embodiment 155,
wherein the relative difference between .delta.d.sub.O1 and
.delta.d.sub.O2 is at most 80%, at most 70%, at most 60%, at most
50%, at most 45%, at most 40%, at most 35%, or at most 30%.
[0355] Embodiment 157. The abrasive article of any one of
Embodiments 58 to 156, wherein the wear detection sensor comprises
an electronic device, wherein the device comprises a chip, an
integrated circuit, data transponder, a radio frequency based tag
or sensor with or without chip, an electronic tag, electronic
memory, a sensor, an analog to digital converter, a transmitter, a
receiver, a transceiver, a modulator circuit, a multiplexer, an
antenna, a near-field communication device, a power source, a
display (e.g., LCD or OLED screen), optical devices (e.g., LEDs),
global positioning system (GPS) or device, fixed or programmable
logic, or any combination thereof.
[0356] Embodiment 158. The abrasive article of any one of
Embodiments 58 to 157, wherein the wear detection sensor comprises
an electronic device comprising a radio-frequency identification
tag or sensor, a near field communication tag or sensor, or a
combination thereof.
[0357] Embodiment 159. The abrasive article of any one of
Embodiments 58 to 158, wherein the wear detection sensor comprises
a plurality of electronic devices, wherein at least one of the
electronic devices is placed in an interior circumferential region
of the abrasive body.
[0358] Embodiment 160. The abrasive article of Embodiments 159,
wherein each of the electronic devices is placed outside of an
exterior circumferential region of the abrasive body.
[0359] Embodiment 161. The abrasive article of Embodiments 159 or
160, wherein each of the electronic devices is placed outside of a
center area of the abrasive body.
[0360] Embodiment 162. The abrasive article of Embodiments 160 or
161, wherein at least one of the electronic devices is placed in a
center area of the abrasive body
[0361] Embodiment 163. The abrasive article of any one of
Embodiments 58 to 162, wherein the wear detection sensor comprises
a plurality of electronic devices comprising a plurality of
integrated circuits.
[0362] Embodiment 164. A system for detecting wear in an abrasive
article, comprising:
[0363] the abrasive article of any one of Embodiments 58 to 163;
and
[0364] a data receiving unit configured to receive data generated
by the wear detection sensor.
[0365] Embodiment 165. The system of Embodiment 164, wherein the
data receiving unit is further configured to transmit the data.
[0366] Embodiment 166. The system of Embodiment 164 or 165, wherein
the data receiving unit is configured to provide energy to the wear
detection sensor.
[0367] Embodiment 167. The system of Embodiment 166, wherein the
wear detection sensor comprises an antenna and an electronic
element, wherein the antenna, electronic element, or both is
powered by the data receiving unit in a wireless manner.
[0368] Embodiment 168. The system of any one of Embodiments 164 to
167, wherein the data receiving unit is configured to send a signal
to the wear detection sensor and to receive a response from the
wear detection sensor.
[0369] Embodiment 169. The system of any one of Embodiments 164 to
168, further comprising an antenna, wherein the antenna is not
coupled to the wear detection sensor.
[0370] Embodiment 170. The system of any one of Embodiments 164 to
169, wherein the antenna is configured to boost a signal generated
by the wear detection sensor, the data receiving unit, or both.
[0371] Embodiment 171. The system of any one of Embodiments 164 to
170, wherein the data receiving unit comprises a reader, an
interrogator, a cell phone, a computer, a data base, or a
combination thereof.
[0372] Embodiment 172. The method of Embodiment 51, wherein
removing at least a portion of the wear detection sensor comprises
removing a portion of an antenna.
[0373] Embodiment 173. The method of Embodiments 51 or 172, wherein
generating a wear signal is based on reduction of a surface area, a
length, or a combination thereof, of an antenna.
[0374] Embodiment 174. The method of any one of Embodiments 51 and
172 to 173, generating wear signal comprises generating a first
wear signal based on removing at least a first portion of the wear
detection sensor, and generating a second wear signal based on
removing at least a second portion of the wear detection
sensor.
[0375] Embodiment 175. The method of Embodiment 174, further
comprising comparing the first wear signal and the second wear
signal to determine wear of the abrasive body.
[0376] Embodiment 176. The method of Embodiments 174 or 175,
wherein the wear detection sensor comprises a plurality of
electronic devices, wherein the first portion of the wear detection
sensor comprises a first portion of a first electronic device, and
the second portion of the wear detection sensor comprises a second
portion of a second electronic device.
[0377] Embodiment 177. The method of Embodiment 51, wherein the
portion of the wear detection sensor comprises a portion of an
antenna.
[0378] Embodiment 178. The method of Embodiment 177, wherein the
wear signal comprises a reduction in energy reflected by the
antenna, wherein a dimension of the abrasive body is a function of
the reduction.
[0379] Embodiment 179. The method of Embodiment 178, further
comprising determining a first dimension of the abrasive body based
on a first wear signal, and a second dimension of the abrasive body
based on a second wear signal.
[0380] Embodiment 180. The method of Embodiment 179, further
comprising comparing the first and second dimension and determining
wear of the abrasive body.
EXAMPLES
[0381] Example 1. Manufacturing an abrasive wheel for grinding
railroad tracks including a wear detection sensor.
[0382] An abrasive body of a grinding wheel is formed and pressed.
Before applying an external fiber winding to the wheel, a plurality
of five leads is attached to the exterior surface of the wheel by
gluing such that the leads extend in axial direction x towards the
outer grinding surface of the wheel, as also illustrated in FIG. 1.
After an exterior fiber winding and a hub is applied to the wheel,
a logic device in form of a microcontroller is connected via
electric wiring to the leads and mounted on an inner diameter of
the abrasive body of wheel. The logic device contains an RFID chip
for wireless sending data related to the wear stage of the abrasive
body to an external control device which is handled by an
operator.
[0383] Example 2. Wheel operation during rail grinding.
[0384] A plurality of abrasive wheels manufactured as described in
Example 1 is mounted on a railtrack grinder. During the grinding
operation, leads of the wear detection sensor in each wheel get
broken according to the wear of the abrasive body. The exact wear
of each wheel is measured by the amount of broken leads, which
corresponds to the amount of leads changing from active stage to
inactive stage (closed circuit to open circuit), and is registered
by the logic device. Based on the amount of broken leads, the logic
device of each wheel is calculating a single number of the
remaining abrasive wheel life in % and transmitting this number
with an RFID chip to the control device. The control device is
collecting the data of each wheel attached to the rail grinder and
is indicating during grinding operation by blinking of red colored
light bulbs when a specific wheel needs to be replaced.
[0385] The foregoing embodiments are directed to bonded abrasive
products, and particularly grinding wheels, which represent a
departure from the state-of-the-art.
[0386] Benefits, other advantages, and solutions to problems have
been described above with regard to specific embodiments. However,
the benefits, advantages, solutions to problems, and any feature(s)
that may cause any benefit, advantage, or solution to occur or
become more pronounced are not to be construed as a critical,
required, or essential feature of any or all the claims. Reference
herein to a material including one or more components may be
interpreted to include at least one embodiment wherein the material
consists essentially of the one or more components identified. The
term "consisting essentially" will be interpreted to include a
composition including those materials identified and excluding all
other materials except in minority contents (e.g., impurity
contents), which do not significantly alter the properties of the
material. Additionally, or in the alternative, in certain
non-limiting embodiments, any of the compositions identified herein
may be essentially free of materials that are not expressly
disclosed. The embodiments herein include range of contents for
certain components within a material, and it will be appreciated
that the contents of the components within a given material total
100%. The specification and illustrations of the embodiments
described herein are intended to provide a general understanding of
the structure of the various embodiments. The specification and
illustrations are not intended to serve as an exhaustive and
comprehensive description of all of the elements and features of
apparatus and systems that use the structures or methods described
herein. Separate embodiments may also be provided in combination in
a single embodiment, and conversely, various features t