Patent Application
20200030936
This disclosure relates to abrading tools and consumable abrasive products.
Abrading tools and associated consumable abrasive products are used in numerous industries. For example, consumable abrasive products are used in the woodworking industries, marine industries, automotive industries, construction industries, and so on. Common abrading tools include orbital sanders, random orbital sanders, belt sanders, angle grinders, die grinders, and other tools for abrading surfaces. Consumable abrasive products may include sanding disks, sanding belts, grinding wheels, burrs, wire wheels, polishing discs/belts, deburring wheels, convolute wheels, unitized wheels, flap discs, flap wheels, cut-off wheels, and other products for physically abrading workpieces. Consumable abrasive products are consumable in the sense that they may be consumed and replaced much more frequently than the abrading tools with which they are used. For instance, a grinding wheel for an angle grinder may only last for a few days of work before needing to be replaced, but the angle grinder itself may last many years.
In general, this disclosure describes techniques related to communication equipped abrading tools and consumable abrasive products. As described herein, communication among abrading tools, consumable abrasive products, and potentially one or more other computing systems may enhance safety, asset security, regulatory compliance, and inventory management.
In one example, this disclosure describes a consumable abrasive product comprising: an abrading surface for abrading a workpiece; a communication unit configured to perform at least one of: sending data to one or more external devices, or receiving data from the one or more external devices; and a data storage unit configured to store the data.
In another example, this disclosure describes an abrading tool comprising: a drive component configured to move a consumable abrasive product; and a communication unit configured to communicate with one or more external devices.
In another example, this disclosure describes a system for managing abrading tools and consumable abrasive products, the system comprising: a database; an abrading tool comprising a communication unit; a consumable abrasive product that is attachable to and detachable from the abrading tool; and a computing system comprising one or more computing devices configured to: receive first data; and store second data in the database, the second data being based on the first data.
In another example, this disclosure describes an abrading tool enhancement kit comprising: a housing shaped for attachment to an abrading tool; and a communication unit embedded in the housing, the communication unit configured to communicate with from one or more external devices.
In another example, this disclosure describes a method for storing acceleration data, comprising: monitoring, by a microcontroller, a communication unit for tag data from Near Field Communication (NFC) tags, the tag data comprising at least one of: (i) user identification information identifying a user of an abrading tool or (i) data regarding a consumable abrasive product attachable to the abrading tool; monitoring, by the microcontroller, an accelerometer coupled to the abrading tool for acceleration data, the acceleration data describing a vibration level of the abrading tool; and storing, by the microcontroller and in response to receiving the acceleration data, the acceleration data to a storage device, wherein the acceleration data is associated with the tag data..
In another example, this disclosure describes a method for storing usage data, comprising: receiving, by a computing system, check-out data that comprises (i) tool identification information of an abrading tool and (ii) user identification information identifying a user of the abrading tool; storing, by the computing system, data pairing the abrading tool and the user based on the check-out data; receiving, by the computing system, usage data regarding the abrading tool; and storing, by the computing system, the usage data, wherein the usage data is associated with the abrading tool and the user based on the data pairing the abrading tool and the user.
The disclosure herein includes but is not limited to the following illustrative Embodiments:
an abrading surface for abrading a workpiece;
a communication unit configured to perform at least one of: sending data to one or more external devices, or receiving data from the one or more external devices; and
a data storage unit configured to store the data.
a temperature sensor; and
an analog to digital converter configured to convert a signal from the temperature sensor into digital data,
wherein the data storage unit is configured to store the digital data.
wherein the data storage unit is configured to store data indicating whether the consumable abrasive product has been subjected to an impact with force sufficient to damage the consumable abrasive product.
wherein the data storage unit is configured to store data indicating whether the consumable abrasive product has been subjected to an RPM level exceeding the threshold sufficient to damage the consumable abrasive product.
a plurality of electrodes; and
a control unit configured to apply an electrical signal across a first pair of electrodes of the plurality of electrodes and measure a voltage across a second pair of electrodes to generate a set of measurements.
compare the first set of measurements to a second set of measurements to determine whether there is a crack in the consumable abrasive product.
an abrading layer;
a tool attachment layer; and
an RFID member sandwiched between the abrading layer and the tool attachment layer.
a drive component configured to move a consumable abrasive product; and
a communication unit configured to communicate with one or more external devices.
the communication unit is configured to receive data regarding the consumable abrasive product, and
the abrading tool comprises a data storage unit configured to store the received data.
determine, based on the data regarding the consumable abrasive product, that the consumable abrasive product has been damaged; and
cause the abrading tool to perform an action in response to determining the received data indicates the consumable abrasive product has been damaged.
the data regarding the consumable abrasive product comprises product authentication data, and
the abrading tool comprises a microcontroller configured to use the product authentication data to determine whether the consumable abrasive product is authorized for use with the abrading tool.
receive, from the consumable abrasive product, data identifying the consumable abrasive product;
send, to the remote device, a request identifying the consumable abrasive product; and
in response to the request, receive the data regarding the consumable abrasive product from the remote device.
one or more sensors; and
wherein the one or more external devices include the consumable abrasive product and the communication unit is configured to send data to the consumable abrasive product based on one or more measurements from the one or more sensors.
one or more sensors; and
wherein the communication unit is configured to send, to the one or more external devices, data based on one or more measurements from the one or more sensors.
the one or more sensors comprise a vibration sensor configured to measure a vibration level of the abrading tool, and
the communication unit is configured to send data based on the vibration level to the one or more external devices.
the one or more sensors comprise one or more of an ammeter that measures an electrical current draw of the abrading tool during use of the abrading tool, a tachometer that measures rotation of the consumable abrasive product, a pressure sensor that measures force applied to the abrading tool by a user of the abrading tool, or a torque sensor that measures torque applied by the abrading tool to the consumable abrasive product, and
the communication unit is configured to send, to the one or more external devices, data based on measurements of at least one of the ammeter, the tachometer, the pressure sensor, or torque sensor.
the abrading tool further comprises a vibration sensor generating vibration measurements of the abrading tool, and
the abrading tool further comprises a microcontroller configured to perform an action in response to determining, based on the vibration measurements generated by the vibration sensor, that a user of the abrading tool has received a vibration dose greater than or equal to a threshold.
the microcontroller is configured to perform the action in response to determining, based on the vibration measurements generated by the vibration sensors and the indication of the vibration dose already received by the user, that the user has received the vibration dose greater than or equal to the threshold.
determine whether a particular type of personal protection equipment that is required during use of the abrading tool with the CAP is in use;
perform the action in response to determining that the particular type of personal protection equipment is not in use.
wherein the communication unit is configured to communicate, to the one or more external devices, user-device pairing data that associates the abrading tool and the user.
an accelerometer coupled to the abrading tool and configured to measure acceleration data describing a vibration level of the abrading tool; and
a microcontroller configured to store, in response to the communication unit receiving the acceleration data, the acceleration data to a storage device, wherein the acceleration data is associated with the tag data, and
wherein the communication unit is further configured to send the acceleration data and the associated tag data to the one or more external devices.
determine, based on the acceleration data and the cumulative vibration dose of the user, a current vibration dose of the user based on the acceleration data and the cumulative vibration dose; and
store the current vibration dose of the user to the storage device.
monitor the pressure sensor for force measurements of the force applied to the abrading tool;
store, in response to receiving the acceleration data, the force measurements to a storage device, wherein the force measurements are associated with the acceleration data;
determine, based on the acceleration data and the force measurements, a value of a safety parameter;
determine whether the value of a safety parameter exceeds a threshold, and cause the abrading tool to output, in response to determining that the value of the safety parameter exceeds the threshold, a safety parameter warning indication.
determine runtime data of the abrading tool based on a start time of receiving the acceleration data and an end time of receiving the acceleration data; and store the runtime data of the abrading tool, wherein the runtime is associated with the tag data.
a vibration sensor configured to measure a vibration level of the abrading tool;
one or more light emitting devices (LED) configured to indicate the vibration level of the abrading tool to a user.
compare the vibration level to a threshold; and
cause, in response to the vibration level exceeding the threshold, at least one LED of the one or more LEDS to activate.
a database;
an abrading tool comprising a communication unit;
a consumable abrasive product that is attachable to and detachable from the abrading tool; and
a computing system comprising one or more computing devices configured to:
receive, from the abrading tool, a request identifying the consumable abrasive product; and
in response to the request, send data regarding the consumable abrasive product to the abrading tool.
receive an indication that a worker has checked out the abrading tool and the consumable abrasive product; and
store, in the database, data pairing the worker with at least one of: the abrading tool or the consumable abrasive product.
determine, in response to receiving the indication that the worker has checked out at least one of the abrading tool or the consumable abrasive product, whether the worker has already received a vibration dose exceeding a threshold; and
perform an action in response to determining that the worker has already received a vibration dose exceeding the threshold.
determine, based on data in the database, a remaining vibration dose that a worker is allowed to receive; and
send third data to the abrading tool, the third data being based on the determined remaining vibration dose.
a housing shaped for attachment to an abrading tool; and
a communication unit embedded in the housing, the communication unit configured to communicate with one or more external devices.
a display screen embedded in the housing; and
control circuitry configured to cause the display screen to display information based on data received from the one or more external devices.
monitoring, by a microcontroller, a communication unit for tag data from Near Field Communication (NFC) tags, the tag data comprising at least one of: (i) user identification information identifying a user of an abrading tool or (i) data regarding a consumable abrasive product attachable to the abrading tool;
monitoring, by the microcontroller, an accelerometer coupled to the abrading tool for acceleration data, the acceleration data describing a vibration level of the abrading tool; and
storing, by the microcontroller and in response to receiving the acceleration data, the acceleration data to a storage device, wherein the acceleration data is associated with the tag data.
receiving, by the microcontroller, an indication of a cumulative vibration dose of the user;
determining, by the microcontroller and based on the acceleration data and the cumulative vibration dose of the user, a current vibration dose of the user based on the acceleration data and the cumulative vibration dose; and
storing, by the microcontroller, the current vibration dose of the user to the storage device.
determining, by the microcontroller, that the current vibration dose exceeds a threshold; and
outputting, by the microcontroller, an indication that the current vibration dose exceeds the threshold.
monitoring, by the microcontroller, the pressure sensor for force measurements of the force applied to the abrading tool;
storing, by the microcontroller and in response to receiving the acceleration data, the force measurements to a storage device, wherein the force measurements are associated with the acceleration data;
determining, by the microcontroller and based on the acceleration data and the force measurements, whether a value of the safety parameter exceeds a threshold; and
outputting, by the communication unit and in response to determining that the value of the safety parameter exceeds the threshold, a safety parameter warning indication.
determining, by the microcontroller, runtime data of the abrading tool based on a start time of receiving the acceleration data and an end time of receiving the acceleration data; and
storing, by the microcontroller, the runtime data of the abrading tool, wherein the runtime is associated with the tag data.
receiving, by a computing system, check-out data that comprises (i) tool identification information of an abrading tool and (ii) user identification information identifying a user of the abrading tool;
storing, by the computing system, data pairing the abrading tool and the user based on the check-out data;
receiving, by the computing system, usage data regarding the abrading tool; and storing, by the computing system, the usage data, wherein the usage data is associated with the abrading tool and the user based on the data pairing the abrading tool and the user.
receiving, by the computing device and after storing the usage data, check-in data that comprises the tool identification information;
determining, by the computing device and in response to receiving the check-in data, that the user is associated with the abrading tool based on the data pairing the abrading tool and the user; and
outputting, by the computing device, an indication of the user.
receiving, by the computing device and after storing the usage data, check-in data that comprises (i) the tool identification information and (ii) the user identification information;
determining, by the computing device, that the abrading tool is associated with the user based on the data pairing the abrading tool and the user; and
storing, by the computing device, data unpairing the abrading tool and the user based on the check-in data.
determining, by the computing device, that the different user is not paired with the abrading tool, based on the data pairing the abrading tool and the user; and
outputting, by the computing device, an indication that the different user is not paired with the abrading tool.
determining, by the computing device and in response to receiving the check-out data, whether the user has already received a vibration dose exceeding a threshold based on the usage data; and
performing, by the computing device, an action in response to determining that the user has already received a vibration dose exceeding the threshold.
The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description, drawings, and Embodiments.
Although use of abrading tools and associated consumable abrasive products are frequently indispensable, abrading tools and associated consumable abrasive products present various challenges for individuals and organizations. For example, vibrations associated with prolonged use of handheld abrading tools are believed to be responsible for causing Hand-Arm Vibration Syndrome (HAYS), a potentially debilitating workplace injury. Accordingly, vibration dosage limits have been adopted to protect workers, such as EN ISO 5349-1 and 5349-2. In another example, inventory of tools, worker information, and consumable abrasive products may not be centrally managed, leading to inconsistent tracking of tool usage. In another example, damaged or worn consumable abrasive products may damage workpieces or cause injury. In another example, workers may use abrading tools improperly, which may result in excessive use of consumable abrasive products, damage to abrading tools or workpieces, injury to workers, and so on. Furthermore, in another example, abrading tools and associated consumable abrasive products are frequently stolen. In still another example, workers frequently develop an intuitive sense of when a workpiece is complete or when a consumable abrasive product is wearing out. However, a robot using an abrading tool may not acquire such an intuitive sense. In another example, consumable abrasive products are consumed and therefore inventory of consumable abrasive products may need to be maintained.
According to aspects of this disclosure, a system includes communication-equipped abrading tools and communication-equipped consumable abrasive products. As described in this disclosure, in some examples, an abrading tool may read information from a consumable abrasive product and may send information to the consumable abrasive product for storage in a memory of the consumable abrasive product. Conversely, in some examples, a consumable abrasive product may send information to an abrading tool, receive data from the abrading tool, and store data based on the received data. Furthermore, in some examples, the abrading tool sends and/or receives data from a computing system that stores and retrieves information from a database. In some examples, the consumable abrasive product sends and/or receives data from a computing system that stores and retrieves information from a database.
As described in detail below, such communication and storage of data may help to address various challenges associated with abrading tools and associated consumable abrasive products. For instance, some examples of this disclosure may enable the collection of vibration dosimetry data for individual workers. Some examples of this disclosure may reduce the chances of using damaged consumable abrasive products. Furthermore, some examples of this disclosure may help to prevent improper use of abrading tools and associated consumable abrasive products. Some examples of this disclosure may reduce the potential of injury. Additionally, some examples of this disclosure may help to prevent theft of abrading tools and associated consumable abrasive products.
Thus, system 2 comprises database 6, an abrading tool 8 comprising a communication unit, a CAP 10 that is attachable and detachable from abrading tool 8, a user ID 22 that includes user identification information, and a computing system 4 comprising one or more computing devices configured to receive first data and store second data in database 6. In this example, the second data may be based on the first data. For instance, the second data may be the same as the first data or determined in various ways using the first data. In some examples, the first data comprises data received from abrading tool 8. In some instances, the first data comprises data based on one or more sensors in abrading tool 8. Furthermore, in some examples, the first data comprises data received from CAP 10. As described elsewhere in this disclosure, the first data may comprise data regarding CAP 10. Additionally, in some examples, the first data may comprise user identification information from user ID 22.
In examples of this disclosure, computing system 4, abrading tool 8, CAP 10, and user ID 22 may communicate various types of data, in various ways, at various times, and in response to various events. For instance, in some examples, CAP 10 may send to abrading tool 8 and/or computing system 4 one or more of: a manufacture data of CAP 10, a maximum rotations per minute (RPM), product authentication data, sensor data (e.g., wear, temperature, pressure, torque) generated during usage, or other types of data regarding CAP 10. In some examples, user ID 22 may send to abrading tool and/or computing system 4 user identification information. In some instances, CAP 10 may communicate data indicating whether CAP 10 has been potentially damaged. In some examples, certain data (e.g., manufacture date, max RPM) may be stored on CAP 10 prior to initial use of CAP 10. In some examples, CAP 10 receives, from abrading tool 8 and/or computing system 4, one or more of CAP usage time, an operator identifier, operator usage time, abrasive wear state, data enabling dosimetry and wear reporting, and so on. In some examples, certain data (e.g., usage time, operator identification) may be generated during use of CAP 10, written to CAP 10, and then subsequently read from CAP 10.
Computing system 4 may comprise one or more computing devices, such as personal computers, server devices, mainframe computers, and other types of devices. Database 6 comprises an organized collection of data. Database 6 may be implemented in various ways. For example, database 6 may comprise one or more relational databases, object-oriented databases, data cubes, and so on. Although
Abrading tool 8 may comprise various types of abrading tools, such as orbital sanders, random orbital sanders, belt sanders, angle grinders, die grinders, floor buffers, reciprocating sanders, file sanders, and other tools for abrading surfaces. CAP 10 may comprise a sanding disk, sanding belt, grinding wheel, burr, wire wheel, polishing discs/belts, deburring wheels, convolute wheels, unitized wheels, flap discs, flap wheels, cut-off wheels, and other product for physically abrading workpieces. While initially separate, a worker may attach CAP 10 to abrading tool 8 prior to work and may detach CAP 10 from abrading tool 8. For example, a worker may attach a sanding disk to a random orbital sander prior to using the random orbital sander on a workpiece. In this example, the worker may detach the sanding disk from the random orbital sander after the worker is done using the random orbital sander on the workpiece.
CAP 10 and abrading tool 8 may communicate in various ways. For example, CAP 10 may comprise a communication unit, such as a Radio Frequency Identifier (RFID) or Near Field Communication (NFC) interface (i.e., tag). In some examples, abrading tool 8 may comprise a communication unit, such as an RFID or NFC reader, configured to read data from and/or write data to the RFID or NFC interface of CAP 10 when CAP 10 is brought sufficiently close to abrading tool 8. Thus, in this example, CAP 10 and abrading tool 8 may communicate without WiFi or Bluetooth infrastructure. In some examples, the communication unit of CAP 10 may use energy harvesting techniques to derive power needed for communication, sensing, data storage, and other operations from a source external to CAP 10, such as abrading toll 8. In some examples, CAP 10 comprises an optical code. The optical code may comprise a machine-readable representation of data, such as a barcode or Quick Response (QR) code. Abrading tool 8 or another device may receive data from CAP 10 by reading the optical code.
Furthermore, CAP 10 and computing system 4 may communicate in various ways. For example, CAP 10 may comprise a communication unit, such as an RFID or NFC tag. In this example, a tag reading device, such as a fixed location device or wand, may read data from the communication unit of CAP 10. The tag reading device may send the data to computing system 4 via a communications network. In another example, a mobile device 20 (such as a worker's mobile phone) may read data from the communication unit of CAP 10 and send the data to computing system 4 via a communications network. In some examples, mobile device 20 may perform some or all of the functionality described in this disclosure with respect to computing system 4. In general, a communication network may include the Internet, a cellular data network, a WiFi network, and/or another type of communication networks.
User ID 22 and abrading tool 8 may communicate in various ways. For example, user ID 22 may comprise a communication unit, such as a Radio Frequency Identifier (RFID) or Near Field Communication (NFC) interface (i.e., tag). In some examples, abrading tool 8 may comprise a communication unit, such as an RFID or NFC reader, configured to read data from and/or write data to the RFID or NFC interface of user ID 22 when user ID 22 is brought sufficiently close to abrading tool 8. Thus, in this example, CAP 10 and abrading tool 8 may communicate without WiFi or Bluetooth infrastructure. In some examples, the communication unit of user ID 22 may use energy harvesting techniques to derive power needed for communication, sensing, data storage, and other operations from a source external to user ID 22, such as abrading tool 8. In some examples, user ID 22 comprises an optical code. The optical code may comprise a machine-readable representation of data, such as a barcode or Quick Response (QR) code. Abrading tool 8 or another device may receive data from user ID 22 by reading the optical code.
Furthermore, user ID 22 and computing system 4 may communicate in various ways. For example, user ID 22 may comprise a communication unit, such as an RFID or NFC tag. In this example, a tag reading device, such as a fixed location device or wand, may read data from the communication unit of user ID 22. The tag reading device may send the data to computing system 4 via a communications network. In another example, a mobile device 20 (such as a worker's mobile phone) may read data from the communication unit of user ID 22 and send the data to computing system 4 via a communications network. In yet another example, mobile device 20 may comprise user ID 22 and may send the data to computing system 4 via a communications network. In some examples, mobile device 20 may perform some or all of the functionality described in this disclosure with respect to computing system 4. In general, a communication network may include the Internet, a cellular data network, a WiFi network, and/or another type of communication networks.
Abrading tool 8 and computing system 4 may communicate in various ways. For example, abrading tool 8 may comprise a communication unit, such as an RFID or NFC interface (e.g., an RFID or NFC tag). In this example, a tag reading device, such as a fixed location device or wand, may read data from the communication unit of abrading tool 8 and send the data to computing system 4 via a communications network. In some examples, abrading tool 8 may comprise a wireless network interface, such as a WiFi interface, Bluetooth interface, cellular data network interface (e.g., a 4G LTE interface), and/or another type of wireless network interface. In such examples, abrading tool 8 may use the wireless network interface to send and/or receive data from computing system 4. In some examples, abrading tool 8 may comprise a wire-based communication interface, such as a Universal Serial Bus (USB) interface. In such examples, abrading tool 8 may use the wire-based communications interface to send and/or receive data from computing system 4. For instance, abrading tool 8 may use a USB connection with another device, such as mobile device 20, that is configured to communicate with computing system 4. In this example, abrading tool 8 may communicate with computing system 4 while connected to the other device. In some examples, abrading tool 8 may comprise an internal communication bus, such as a serial peripheral interface (SPI) bus or I2C bus, such as shown in
Furthermore, in some examples, abrading tool 8 communicates with computing system 4 via hub wireless hardware. The hub wireless hardware may comprise a device located at a worksite to which multiple assets (e.g., tools, personal protection equipment, consumable products, etc.) communicate. In this example, the hub wireless hardware may communicate via another network (e.g., the internet) to computing system 4.
In some examples, abrading tool 8 may communicate with computing system 4 via mobile device 20. For instance, abrading tool 8 may comprise a communication unit, such as an RFID or NFC tag, Bluetooth interface, or other short-range wireless communication interface. In this example, mobile device 20 may relay data between computing system 4 and abrading tool 8.
In some examples, abrading tool 8 does not communicate directly with CAP 10. For instance, abrading tool 8 may send data to computing system 4 and computing system 4, in response, may send data to CAP 10. Similarly, CAP 10 may send data to computing system 4 and computing system 4, in response, may send data to abrading tool 8. In some examples, mobile device 20 may read data from CAP 10 and, in response, send data to abrading tool 8. Similarly, abrading tool 8 may send data to mobile device 20 and mobile device 20 may send the data to CAP 10.
In some examples, communication between abrading tool 8 and computing system 4 occurs asynchronously. For instance, data from computing system 4 may be stored at an intermediary device (e.g., mobile device 20, wireless hub hardware, an RFID or NFC reader, etc.) until a communication link between abrading tool 8 and the intermediary device is established. When the communication link is established, the intermediary device transmits the data to abrading tool 8. Additionally, in some examples, abrading tool 8 may generate and store data for transmission to computing system 4. Subsequently, in this example, when a communication link between abrading tool 8 and intermediary device is established, abrading tool 8 may send the data to the intermediary device for transmission to computing system 4. A similar asynchronous communication style may be used for communication between CAP 10 and computing system 4.
In some examples, abrading tool 8, CAP 10, and user ID 22 may communicate with computing system 4 in a similar way. For example, abrading tool 8, CAP 10, and user ID 22 may comprise a communication unit, such as an RFID or NFC tag, while computing system 4 may include or be communicatively coupled, such as through a USB cable, to a tag reading device, such as an RFID or NFC tag reader. In this example, the tag reading device, such as a fixed location device or wand, may read data from the communication unit of abrading tool 8, CAP 10, and/or user ID 22. The tag reading device may send the data to computing system 4 via a communications network. In another example, a mobile device 20 (such as a worker's mobile phone) may read data from the communication unit of abrading tool 8, CAP 10, and/or user ID 22 and send the data to computing system 4 via a communications network. In general, a communication network may include the Internet, a cellular data network, a WiFi network, and/or another type of communication networks.
In some examples, computing system 4 may mine data stored in database 6. For instance, computing system 4 may mine data in database 6 for data that is then reported and fed back to appropriate entities, e.g., safety or compliance manager, production foreman, maintenance manager, and so on. In some examples, computing system 4 may associate the reported data with an urgency level. For instance, reporting that abrading tool 8 is being operated beyond recommended Rotation Per Minute (RPM) level may be more urgent than reporting that a sanding disk inventory is running low. The RPM reporting may be a safety, compliance, or productivity issue which might need to be reported as soon as possible to a safety officer or shop foreman; low inventory can be reported to a purchasing agent with less urgency.
Additionally, computing system 4 may mine and/or analyze data in database 6 for information on productivity, security, inventory, safety, or other topics. For example, computing system 4 may generate various types of reports on these topics. Productivity: reporting on tool RPM, runtime, force, etc., basically how the tool and abrasive is being used. Security: has abrading tool 8 disappeared? Inventory: is the site running low on a specific product, such as CAPs? Computing system 4 may automatically place orders. Safety: is PPE being used correctly? Is a worker using the proper abrading tool? Is the worker using an abrading tool properly?
Examples of this disclosure may be used separately or in combination. Some examples of the disclosure may omit computing system 4, database 6, mobile device 20, and any of abrading tool 8, CAP 10, and/or user ID 22. Examples of this disclosure may be configured in any operable configuration. For example, while computing system 4 and database 6 have been described as separate units, either or both of computing system 4 may be coupled to or part of any of abrading tool 8, mobile device 20, or an external device, such as a local server or remote server.
As shown in the example of
In response to receiving the check-out data, computing system 4 may store the check-out data (or data determined based on the check-out data) to database 6 (52). The check-out data may indicate assets checked out from a storage location, including asset identification information such as an asset serial number, a type of asset, and other information regarding the asset. Assets may include an abrading tool (e.g., abrading tool 8), a CAP (e.g., CAP 10), personal protective equipment
(PPE), and so on. Additionally, the check-out data may include user identification information that identifies an individual who is checking out the assets and associates usage data of abrading tool 8 with the user during a period that abrading tool 8 is checked out and operated. Checking out an asset may involve removing the asset from a storage location or checking out the asset at a kiosk or station. Thus, computing system 4 may receive an indication that a worker has checked out abrading tool 8 and/or CAP 10 and may store, in database 6, data pairing the worker with at least one of: abrading tool 8 or CAP 10.
Computing system 4 may receive the check-out data in various ways. For example, a reader device may be situated at an exit of the storage location. When a worker passes by the reader device, the reader device receives data from an identification badge of the worker and data from assets carried past the reader device. In some examples, abrading tools, CAPs, PPEs, identification badges, and other assets comprise RFID tags and the reader device comprises an RFID reader. In other examples, abrading tools, CAPs, PPEs, identification badges, and other assets may comprise NFC tags. In other examples, other communication technologies may be used.
Computing system 4 may store the check-out data in various ways. For example, computing system 4 may be communicatively coupled to a reader device and a user input device. A user may bring a tag of abrading tool 8 in close proximity to the reader device. Computing system 4 may recognize the tag and receive data regarding abrading tool 8, such as data from the tag of abrading tool 8 or data from database 6 based on data from the tag of abrading tool 8. The user may bring a tag of user ID 22 in close proximity to the reader device. Computing system 4 may recognize the tag and receive user identification information, such as information from the tag of user ID 22 or information from database 6 based on information from the tag of user ID 22. A user, such as the user checking out abrading tool 8 or a supervisor managing abrading tool inventory, may operate the user input device, such as by pressing a button, to send an indication to computing system 4 to pair abrading tool 8 and user ID 22. In response to receiving the pairing indication, computing system 4 may store data pairing abrading tool 8 and user ID 22. In some examples, computing system 4 may centrally store the data pairing abrading tool 8 and user ID 22 by sending the data pairing abrading tool 8 and user ID 2 to one or more external devices, such as database 6. Other components communicatively coupled to computing device 4 and/or database 6 may access the pairing data, such that an inventory of abrading tools and users may be centrally maintained, accessed, and associated with usage data of any one of abrading tool 8, CAP 10, and user ID 22.
Furthermore, computing system 4 may perform a check-out response routine in response to receiving the check-out data (54). In some examples, the check-out response routine may determine whether the worker has all of the appropriate PPE for abrading tool 8. For instance, the check-out response routine may determine whether the worker has safety glasses, gloves, etc. Computing system 4 may also be configured to provide information related to the appropriate PPE, such as a location of the PPE. Thus, computing system 4 may be configured to determine, in response to receiving the indication that the worker has checked out at least one of abrading tool 8 or CAP 10, that the worker has also checked out personal protection equipment appropriate for use with abrading tool 8 and/or CAP 10. Furthermore, in some examples, computing system 4 may determine, based on the remaining quantity of personal protection equipment in an inventory, whether to order more personal protection equipment and display, in response to determining that more PPE should be ordered, a link to purchase additional PPE.
In some examples, the check-out response routine may determine whether the worker is allowed or qualified to check-out the assets. In some examples, the check-out response routine may determine whether a checked-out CAP is compatible with the checked-out abrading tool. In some examples, the check-out response routine may include determining whether abrading tool 8 is checked by a worker. For example, computing system 4 may receive check-out data regarding an abrading tool that is currently paired with another user. Computing system 4 may look up the check-out data for the abrading tool, determine that the abrading tool is checked out by another user, and send an indication, such as a warning, that the abrading tool is currently checked out or may display data, such as data pairing the abrading tool with the current user, on a display device that identifies the current user.
In some examples, the check-out response routine may perform one or more actions (e.g., generate a warning, instruct abrading tool 8 not to allow a worker to use abrading tool 8 with CAP 10, etc.) if any of the assets checked out are damaged or excessively worn. For instance, the check-out response routine may perform one or more action in response to determining CAP 10 is cracked, has been used at too high a RPM level, been subjected to excessively high temperatures, is worn out, and so on. In some examples, a warning may be audible (e.g., an alarm) and/or visible ((e.g., lighting a lamp, such as a Light Emitting Diode (LED), on an abrading tool or other device), sending a message, or performing another action to alert a person.
In some examples, the check-out response routine may include determining whether the worker has already received a vibration dose exceeding a limit. If so, the check-out response routine may perform an action, such as outputting a warning or instructing abrading tool 8 not to allow the worker to use abrading tool 8 with CAP 10. In other words, computing system 4 may determine, in response to receiving the indication that the worker has checked out at least one of abrading tool 8 or CAP 10, whether the worker has already received a vibration dose exceeding a threshold. In this example, computing system 4 may perform an action in response to determining that the worker has already received a vibration dose exceeding the threshold. For example, if a maximum vibration dosage level (e.g., vibration dose value (VDV)) for the worker is 9.1 m/s1.75 per day, and the worker's vibration dosage level for the day is already 9.1 m/s1.75 or greater, the check-out response routine may generate a warning. That is, computing system 4 may send instructions to a device (e.g., abrading tool 8, mobile device 20, etc.) to activate a warning indicator, such as a visible and/or audible alarm. The warning may be directed to the worker, a supervisor, or another person. In this way, someone may be warned that the worker should not use abrading tool 8 with CAP 10, or that the worker should be using any vibration inducing equipment for a period of time. In some examples, the threshold and the warnings may be user configurable. In some examples, the check-out response routine may send instructions to abrading tool 8 to prevent the worker from using abrading tool 8 with CAP 10.
In some examples, the check-out response routine may include determining whether the worker is likely to receive more than a maximum allowed vibration dosage level for the current day by using the abrading tool and CAP, the check-out response routine may perform an action, such as generating a warning. For example, if a maximum vibration dosage level for the worker is 9.1 m/s1.75 per day and the worker's vibration dosage level for the day is already 8.0 m/s1.75, the check-out response routine may generate a warning.
A device (e.g., a device of computing system 4, abrading tool 8) may generate a warning in various ways. For example, computing system 4 may send a text message to a mobile device of a user (e.g., worker, supervisor, or another person). In another example, the device (e.g., a device of computing system 4) may transmit instructions to the reader device or abrading tool 8 to output an audible and/or visible warning.
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A device, such as a device of computing system 4, abrading tool 8, or another device, may determine the usage limit in various ways. For example, the device may determine, based on data stored in database 6, a worker's vibration dosage level so far for the current day. The device may then subtract the worker's vibration dosage level so far for the current day from a threshold level (e.g., a maximum allowable vibration dosage level for the current day). The resulting value may be the usage limit. Thus, the device may determine, based on data in database 6, a remaining vibration dose that a worker is allowed to receive and send data to the abrading tool, the data being based on the determined remaining vibration dose. In this example, the data may indicate at least one of: the remaining vibration dose, or an amount of use time corresponding to the remaining vibration dose. In this example, the device may determine, based on data in database 6 indicating a vibration dose already received by the worker during a time period (e.g., 1 day, week, hour, etc.), the remaining vibration dose that the worker is allowed to receive in the time period.
In some examples, the threshold level is user configurable (e.g., by a compliance officer), and in some instances, may be tailored to specific individual workers or classes of workers based on characteristics (e.g., age, body geometry, previous injuries, etc.) of individual workers or classes of workers. In some examples, there are multiple threshold levels. For instance, there may be a “warning” threshold level, such as may be indicated by a yellow LED, and a “final” threshold level, such as may be indicated by a red LED. When the “warning” threshold level is reached, a warning may be generated, but a worker is not yet required to stop work. In this example, at the “final” threshold level, the worker may be required to stop work using the abrading tool and CAP.
In some examples, the usage limit may be based on a “points” system corresponding to limits on vibration/acceleration. The points system may be used to quantify acceleration exposure. For example, in the European Union, ISO5349-1 defines how to use an acceleration points system. Vibration data, such as acceleration data, may be recorded in the time domain. Time slices of the acceleration data may be transformed to the frequency domain to generate acceleration frequency data. A frequency weighting curve may be applied to the acceleration frequency data. A time an operator is exposed to these weighted frequencies may be recorded and summed. Points may be assigned based on frequency and time exposure to the frequency. This points system may quantify the operator exposure to acceleration energy in frequency bands, and these acceleration points may be accumulated during the shift.
In some examples, points associated with a user may be monitored in real-time. For example, points may be tracked and accumulated throughout a shift of an operator of the tool. In some examples, computing system 4 or abrading tool 8 may determine a projected points accumulation for shift end. For example, computing system 4 or abrading tool 8 may estimate end of shift accumulation by the most recent rate of points per time (e.g., represented as dP/dt). While dP/dt may vary significantly, a sum of points to date in the shift plus the recent work time average dP/dt may provide useful information as to the expected points at the end of the shift. In some examples, a remaining vibration dose may be an estimate based on a rate of vibration dose, such as rate of points per time, and a cumulative vibration dose, such as cumulative points.
Storage of the acceleration data (acceleration vs time, frequency, or points) may be local, such as on abrading tool 8, or remote, such as uploaded to computing system 4, smart phone 20, database 6, or cloud. The acceleration data may be presented to an operator, compliance officer, or other interested party to help maintain an operator and tool within threshold limits or provide information as to product performance. Feedback may be local and immediate (e.g. on the tool to the operator), or delayed (e.g. uploaded in real-time, or periodically) to computing system 4, smart phone 20, data base 6 or cloud and presented to an operator, compliance officer, or other interested party. For example, abrading tool 8 may output an indication of a current or remaining vibration dose, such as a point accumulation or projection, to the operator through an LCD display or LED feedback. As another example, computing system 4 may output an indication of a current or remaining vibration dose, such as a point accumulation or projection, to a compliance officer, safety officer, or other interested party through a display on computing system 4 or smart phone 20.
In another example, the device may determine, based on data stored in database 6 or generated by abrading tool 8, a worker's vibration dosage level based on a safety parameter that incorporates other factors related to worker safety. For example, during operation of abrading tool 8, a vibration level of abrading tool 8 may be modified through a higher application of downward force. However, the physiological effect on the user may be greater than indicated by the vibration level. A safety parameter may account for other variables, such as downward force, when determining a particular vibration dosage level that a worker may receive before exceeding a threshold. In some examples, the safety parameter may be based on real-time sensor feedback of data related to operation of abrading tool 8. For example, a pressure sensor on abrading tool 8 may measure a downward force that may be used in conjunction with vibration or acceleration data to determine a safety parameter. In some examples, the safety parameter may be based on past feedback for a particular user. For example, a particular user may have an average applied downward force determined by previous use of abrading tool 8 or testing with abrading tool 8. The average downward force may be used in conjunction with vibration or acceleration data to determine the safety parameter.
In another example, CAP 10 may store data regarding whether CAP 10 has potentially been damaged or excessively worn (e.g., from excessive heat, excessive RPM, drops, excessive use time, cracked, etc.). In this example, as part of the tool/CAP coupling routine (or at another event, such as check-out), computing system 4 may determine whether CAP 10 can be safely used with abrading tool 8. In this example, if CAP 10 cannot be safely used with abrading tool 8, computing system 4 may send instructions to abrading tool 8 to output a warning, prevent use, or perform some other action. Thus, in this example, in response to receiving data indicating that CAP 10 has been potentially damaged or excessively worn, computing system 4 may be configured to send instructions to abrading tool 8 to instruct abrading tool 8 to perform an action, such as generating a warning or preventing use of abrading tool 8 while CAP 10 is attached to abrading tool 8. In some examples, CAP 10 may comprise a thermometer that measures a temperature of CAP 10 and the data indicating whether CAP 10 has been potentially damaged may comprise data indicating whether the temperature of CAP 10 has exceeded a threshold. In some examples, the data indicating whether CAP 10 has been potentially damaged comprises at least one of: data indicating whether CAP 10 has been subject to an impact of sufficient force to damage CAP 10 or data indicating whether CAP 10 has been used at an RPM level exceeding a maximum allowable RPM level for CAP 10. In some examples, the data indicating whether CAP 10 is excessively worn comprise data indicating an electrical resistance between electrodes mounted on CAP 10. In this example, the electrical resistance may change over time as CAP 10 is used and the electrical resistance crossing a particular threshold may indicate that CAP 10 is excessively worn.
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In some examples, computing system 4 may receive usage data in real-time from abrading tool 8. Real-time receipt of usage data may include any receipt of usage data during or immediately after generation or storage of the usage data. For example, abrading tool 8 may continuously send usage data regarding abrading tool 8 to computing system 4 as abrading tool 8 stores the usage data to memory. As another example, abrading tool 8 may locally store the usage data on abrading tool 8 and send the usage data to computing system 4 periodically before operation of abrading tool 8 is complete.
In some examples, the stored usage data may be associated with abrading tool 8 and a user based on data pairing abrading tool 8 and the user. For example, the usage data may include acceleration data from abrading tool 8 while abrading tool 8 is checked out by a user associated with user ID 22. The acceleration data may be associated with abrading tool 8 and the user. For example, the acceleration data may be associated with abrading tool 8 for determining whether abrading tool 8 may require maintenance, while the acceleration data may be associated with the user for determining a cumulative vibration dose for the user.
In some examples, usage data may include data received from devices paired to a user of abrading tool 8. For example, a user may be monitored for various physiological responses with respect to operation of abrading tool 8, such as heart rate. A heart rate monitor functionally coupled to the user may record data of the user's heart rate as the user operates abrading tool 8. The heart rate data may be received by computing system 4 and associated with the user specifically or with users of abrading tool 8 generically. For example, the user may be monitored for changes in physiological responses to abrading tool 8 and receive a particular condition for operation of abrading tool 8, such as a vibration limit, usage limit, or the like. As another example, the physiological response to abrading tool 8 may be associated with vibration data of abrading tool 8. Other physiological responses may include, for example, changes in force applied to abrading tool 8 by a user, changes in operating time of abrading tool 8 by the user, and any other operational data of abrading tool 8 that may be related to physiological parameters of the user.
In response to receiving the usage data, computing system 4 may perform a usage data routine (66). As noted above, the usage data may include vibration data. In some examples, the usage data routine may update a worker's vibration dosage level based on the vibration data in the usage data. Furthermore, in some examples, the usage data routine may generate a warning if the worker's vibration dosage level has exceeded or is approaching a maximum allowable vibration dosage level threshold. The warning may be directed to the worker, a supervisor, or another individual.
In some examples, the usage data routine may update physiological responses of a user to abrading tool 8 based on the usage data. Computing system 4 may use the physiological response to, for example, improve operation of abrading tool 8 or change a behavior or operating practice of workers with respect to operation of abrading tool 8 to change the physiological response.
As described above, robots may have difficulty in performing abrading tasks because they lack a human operator's intuitive feel for when work on an area of a workpiece is complete and/or whether a CAP is worn out. However, use of robots to perform abrading tasks may be highly beneficial in some situations, such as when toxic materials are involved, space is constrained, physical access to an area of a workpiece is constrained, work occurs in a hazardous area, and so on. In some instances, computing system 4 may use usage data for training of robots to perform abrading tasks. For example, computing system 4 may aggregate usage data from many work sessions to quantify what a worker might intuitively feel about an area of a workpiece being complete or a CAP being worn out. For instance, computing system 4 may determine (e.g., based on vibration data, electrical current draw data, RPM data, data regarding characteristics of the CAP and workpiece, video information, work duration information, abrading tool movement information, applied pressure information, torque information, electrical resistance measurements, CAP temperature information, and/or other data) when an area of a workpiece is complete. Similar information can be used for determining whether a CAP is worn out. In some examples, computing system 4 may train a machine learning system based on such data to make determinations regarding whether an area of a workpiece is complete and/or whether a CAP is worn out. For instance, usage data may be used as training data for a neural network. Furthermore, the usage data may be used for manufacturer monitoring of CAP and/or abrading tool performance for purposes of product improvement.
In some examples, the usage data indicates how much time CAP 10 was in use. A CAP of a particular type can be expected to last a particular number of hours in use. In examples where the usage data includes how much time CAP 10 was in use, the usage data routine may determine whether CAP 10 is approaching the end of its expected life. Accordingly, based on data stored in database 6, computing system 4 may flag CAP 10 to be discarded. If a worker subsequently tries to check-out CAP 10, computing system 4 may perform an action to warn the worker. Furthermore, in some examples, computing system 4 may determine based on the remaining time left for CAPs in an inventory whether to order more CAPs.
In some examples, the usage data indicates how much time abrading tool 8 was in use. An abrading tool of a particular type may be expected to last a particular number of hours in use between maintenance or replacement. In examples where the usage data includes how much time abrading tool 8 was in use, the usage data routine may determine whether abrading tool 8 is approaching the end of its expected operating time between maintenance events or its expected life. Accordingly, based on data stored in database 6, computing device 4 may flag abrading tool 8 to be removed from service for maintenance, discarded, and/or replaced. If a worker subsequently tries to check-out abrading tool 8, computing system 4 may perform an action to warn the worker. Furthermore, in some examples, computing system 4 may determine based on the remaining time left for abrading tools in an inventory whether to order more abrading tools.
In some examples, the usage data indicates a condition of abrading tool 8. An abrading tool of a particular type may be expected to degrade in operation between maintenance or replacement. For example, an abrading tool that used CAPs at a particular rate or is associated with a particular productivity may change in performance through use or over time. In examples where the usage data includes a condition of abrading tool 8, the usage data routine may determine whether abrading tool 8 is approaching the end of its expected operating time between maintenance events or its expected life. Accordingly, based on data stored in database 6, computing device 4 may flag abrading tool 8 to be removed from service for maintenance, discarded, and/or replaced. If a worker subsequently tries to check-out abrading tool 8, computing system 4 may perform an action to warn the worker. Furthermore, in some examples, computing system 4 may determine based on the condition of abrading tools in an inventory whether to order more abrading tools.
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Computing system 4 may receive the check-in data in various ways. For example, a reader device may be situated at an entrance to a storage location. When a worker passes by the reader device, the reader device receives data from an identification badge of the worker and data from assets carried past the reader device.
Computing system 4 may store the check-in data in various ways. For example, computing system 4 may be communicatively coupled to a reader device and a user input device. A user may bring a tag of abrading tool 8 in close proximity to the reader device. Computing system 4 may recognize the tag and receive data regarding abrading tool 8, such as from the tag of abrading tool 8 or database 6 based on data from the tag of abrading tool 8. The user may bring a tag of user ID 22 in close proximity to the reader device. Computing system 4 may recognize the tag and receive user identification information, such as from the tag of user ID 22 or from database 6 based on data from the tag of user ID 22. A user, such as the user checking out abrading tool 8 or a supervisor managing abrading tool inventory, may operate the user input device, such as by pressing a button, to send an indication to computing system 4 to unpair abrading tool 8 and user ID 22. Computing system 4 may determine that abrading tool 4 is associated with the user of user ID 22 based on the data pairing abrading tool 8 and the user. In response to receiving the unpairing indication and determining that abrading tool 8 is associated with the user, computing system 4 may store data unpairing abrading tool 8 and the user. In some examples, computing device 4 may the send data unpairing abrading tool 8 and user ID 22 to one or more external devices, such as database 6, so that the one or more external devices no longer associate abrading tool 8 with the user.
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In some examples, such as when the check-in data includes tool identification information, the check-in response routine may include determining a user associated with abrading tool 8. For example, computing system 4 may determine, in response to receiving the check-in data, that the user is associated with abrading tool 8 based on the data pairing abrading tool 8 and the user. Computing system 4 may output, in response to determining that the user is associated with abrading tool 8, an indication of the user.
In some examples, the check-in response routine may include determining whether abrading tool 8 is checked in by the user to which abrading tool 8 is paired. For example, computing system 4 may receive check-in data that includes user identification information of a different user than is associated with abrading tool 8. Computing system 4 may look up the check-in data for the abrading tool, determine that the abrading tool is checked out by another user, and output an indication, such as a warning, that the abrading tool is currently checked out or may display data, such as data pairing the abrading tool with the current user, on a display device that identifies the current user.
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In response to the report generation event, computing system 4 may generate one or more reports based at least on part on data stored in database 6 (76). Computing system 4 may generate various types of reports. For example, computing system 4 may generate a report describing how individual workers use CAPs. For instance, a report may indicate how many CAPs a worker uses, how long a worker typically uses a CAP before it is discarded, how many CAPs were damaged by a worker per time spent by the worker using CAPs, how much pressure a worker applies when using an abrading tool, temperatures of CAPs when a worker is using the CAPs, wear states of CAPs before and after a worker uses the CAPs, how much torque an abrading tool applies to CAPs when a worker is using the abrading tool, and so on.
In some examples, computing system 4 may generate a report that provides information for training a worker or analyzing worker behavior. For instance, the report may indicate that a worker seems to be using excessive or insufficient pressure when using a particular type of CAP or abrading tool. In this instance, use of excessive pressure may lead to added risk of damaging or wear on CAPs, while use of insufficient pressure may result in abrading tasks taking too long. In another example, a report may indicate whether a worker is using different types of CAPs in a correct order. For instance, when smoothing a workpiece, CAPs are typically used in order of decreasing grit size. Reports or raw data on how a worker uses CAPs may be provided to various parties, such as governmental organizations (e.g., for regulatory compliance purposes), manufacturers of CAPs and/or abrading tools (e.g., for research and development purposes), private employers, and so on.
In some examples, computing system 4 may generate a report that aggregates how workers use CAPs. For instance, a report may indicate how much time workers typically use a CAP before the CAP is discarded, how frequently CAPs are damaged, how much pressure workers typically apply while using a particular type of CAP with an abrading tool, how much torque abrading tools apply to a particular type of CAP, and other information. Reports or raw data aggregating how workers use CAPs may be provided to various parties, such as governmental organizations (e.g., for regulatory compliance purposes), manufacturers of CAPs and/or abrading tools (e.g., for research and development purposes), private employers, and so on.
In some examples, computing system 4 may generate a report regarding worker vibration exposure. For instance, the report may identify individual workers who have been exposed to excessive vibration, when the workers were exposed to excessive vibration, levels of excessive vibration experienced by workers, and other information regarding vibration exposure for individual workers. In some instances, the report may aggregate information about vibration exposure across workers (e.g., to surface information about how frequently various sets workers in an organization are exposed to excessive vibration). Reports on vibration may be used for a variety of purposes, such as compliance with governmental regulations limiting vibration exposure, epidemiological research, product research and development, and so on.
Microcontroller 104 may comprise a small computer on a single integrated circuit. In one example, microcontroller 104 is configured to implement functionality and/or process instructions for execution within abrading tool 100. For example, microcontroller 104 may be capable of processing instructions stored by memory 106. Microcontroller 104 may include, for example, microprocessors, digital signal processors (DSPs), application specific integrated circuits (ASICs), field-programmable gate array (FPGAs), or equivalent discrete or integrated logic circuitry.
Memory 106 may be configured to store data. For instance, memory 106 may comprise one or more data storage units configured to store received data, such as data regarding CAP 120, data regarding abrading tool 100, data regarding an application specification configuration of abrading tool 100, or user identification information. In some examples, memory 106 comprises an Electrically-Erasable Programmable Read Only Memory (EEPROM) non-volatile memory. Consequently, memory 106 need not be continuously powered to retain stored data. In some examples, memory 106 may include random access memories (RAM), dynamic random access memories (DRAM), static random access memories (SRAM), magnetic hard discs, optical discs, flash memories, forms of electrically programmable memories (EPROM) and/or EEPROM, or other types of data storage unit. Although not shown in the example of
I/O system 108 may comprise a physical button array, a touchscreen unit, one or more speakers, a siren, and/or other types of devices for interacting with a user. In some examples, I/O system 108 may include one or more LEDs configured to indicate a vibration level of abrading tool 100 to a user for local and immediate feedback. In some examples of local feedback, abrading tool 100 may include components for sensing, comparing, calculating, and providing feedback. For example, sensors 114 may include a vibration sensor, such as an accelerometer, configured to measure a vibration level, such as acceleration, of the abrading tool. One or more light emitting devices (LED) may be coupled to a housing of abrading tool 100 and configured to indicate the vibration level of the abrading tool to a user. Microcontroller 104 may be configured to compare the sensed vibration level with a threshold and cause, in response to the vibration level exceeding the threshold, at least one LED of the one or more LEDS to activate.
Microcontroller 104 may be configured to cause the one or more LEDs to activate according to a color or blinking pattern when a vibration threshold is exceeded. In some examples, the LEDs may have various colors indicating various vibration levels and conditions. For example, a green LED may indicate operation within a normal operating range; a yellow LED may indicate that a first, less severe acceleration threshold is exceeded; and a red light may indicate that a second, more sever acceleration threshold is exceeded. Additionally or alternatively, the LEDs may be configured to activate at various blinking patterns. For example, a blinking green LED may indicate operation below a minimum operating threshold; a solid green LED may indicate operation within the normal operating range; a blinking yellow LED may indicate that a first, less severe acceleration threshold is exceeded; and a blinking red LED may indicate that a second, more sever acceleration threshold is exceeded. The LEDs may be located on a housing of abrading tool 100, and separately controlled by microcontroller 104 by monitoring acceleration and comparing the acceleration to threshold acceleration values, which may be read from a configuration file.
In some examples, feedback may be more precise or accentuated by combining the LED's color and blinking pattern. For example, a slowly blinking LED may indicate that an acceleration threshold has been slightly exceeded, while a rapidly blinking LED may indicate that the acceleration threshold has been greatly exceeded. Additionally, these the LED colors and blinking patterns may be combined to further customize feedback. For example, a rate at which the blinking occurs can also be used as feedback to the operator, database and monitoring systems. Both acceleration thresholds (e.g., minimum operating threshold, first high threshold, second high threshold, etc.) and blinking rates may be stored in a configuration file in, for example, memory 106.
In addition to the above, location of the visual feedback on abrading tool 100, and the selection of optical feedback (e.g., LED, display unit 110) may be conspicuous. For example, the LEDs may be located on a back of a housing of abrading tool 100, such that a user may view the LEDs while operating abrading tool 100.
CAP communication unit 115 may be configured to receive data regarding CAP 120. CAP communication unit 115 may enable abrading tool 100 to communicate with one or more external devices, such as a CAP 120, computing system 4 (
User identification unit 122 may be configured to receive user identification information. User identification information comprises data that identifies a user (e.g., a worker) of abrading tool 100. User identification unit 122 may receive the user identification information in various ways. For example, user identification unit 122 may comprise a numerical keypad and user identification unit 122 may receive the user identification information as PIN. In this example, user identification unit 122 may be part of I/O system 108. In some examples, user identification unit 122 comprises a biometric characteristics reader, such as a fingerprint reader, iris or retinal scanner, facial recognition system, voice recognition system, or other system for reading a biometric characteristic of a user. In some examples, user identification unit 122 may receive the user identification information from a user identification (ID) 126, dongle, token, or other object storing the user identification information of a worker. In some examples, user identification unit 122 comprises an RFID or NFC reader. In some examples, user identification unit 122 may comprise a magnetic stripe reader through which a user of abrading tool 100 swipes his or her identification badge. In some examples, user identification unit 122 may comprise a chip reader. In some examples, user identification unit 122 comprises a housing that defines a slot into which an identification badge is inserted. In some such examples, microcontroller 104 may prevent use of abrading tool 100 unless an appropriate identification badge is inserted into the slot.
In some instances, user identification unit 122 may form part of communication unit 102, external communication unit 116, or may be separate from either or both of communication unit 102 and external communication unit 116. For example, user identification unit 122 may be part of communication unit 102, such that communication unit 102 may be configured to receive user identification information identifying a user of abrading tool 100.
External communication unit 116 may comprise one or more powered or unpowered communications interfaces. For example, external communication unit 116 may comprise a USB interface, such as a port for a USB hardwire connection, or USB docking station. In some examples, external communication unit 116 may comprise a WiFi interface, a Bluetooth interface (e.g., a Bluetooth Low Energy (BLE) interface), a mobile data modem (e.g., a 4G LTE modem) or another powered communications interface. In some examples, external communication unit 116 may comprise an RFID interface, an NFC interface, or another unpowered communications interface. In some examples, abrading tool 100 may use external communication tool to communicate with computing system 4 (
In some examples, communication unit 102 may be configured to receive tag data from NFC tags. For example, communication unit 102 may comprise an NFC tag reader configured to at least read tag data from NFC tags. Tag data comprises data that is stored on NFC tags and is associated with one or more components of system 2 of
In some examples, communication unit 102 may be configured to act as a passive NFC tag for abrading tool 100. For example, communication unit 102 may have a passive NFC tag mode that is configured to communicate NFC data to another communication device, such as another NFC reader.
In various examples, sensors 114 may include various types of sensors located within housing 118. Sensors 114 are devices that converts real world data (analog) into data that microcontroller 104 can understand using ADC 112. For example, sensors 114 may include an accelerometer, an ammeter (i.e., an electrical current meter) that measures an electrical current draw of abrading tool 100 during use of abrading tool 100, a voltage meter that measures a voltage of an electrical current during use of abrading tool 100, a tachometer that measures rotation of CAP 120, a timer, a pressure sensor that measures force applied to abrading tool 100 by a user of abrading tool 100, a torque sensor that measures torque abrading tool 100 applies to CAP 120, a vibration sensor that measures vibration generated by abrading tool 100 during use of abrading tool 100, sensors (e.g., optical sensors) for determining a wear level of CAP 120, and so on.
In some examples, a vibration sensor may be implemented as one or more accelerometers. An accelerometer may be coupled to abrading tool 100, such that accelerometer may receive acceleration stimuli of drive component 124. The accelerometer may be configured to measure the acceleration stimuli as acceleration data. The acceleration data may describe a vibration level of abrading tool 100.
Microcontroller 104 may receive data from CAP communication unit 115, ADC 112, external communication unit 116, user identification unit 122, communication unit 102, and potentially other components of abrading tool 100. Additionally, microcontroller 104 may process received data and output data for display on display unit 110. For example, display unit 110 may be configured to display data regarding CAP 120. For instance, microcontroller 104 may output the part number of CAP 120, the grit value for CAP 120, the max RPM value for CAP 120, a current wear level of CAP 120, and the usage time of CAP 120 for display on display unit 110. In this example, microcontroller 104 may receive data indicating the part number of CAP 120, grit value for CAP 120, max RPM value for CAP 120, current wear level of CAP 120, and usage time of CAP 120 from communication unit 102 and/or external communication unit 116. Since different CAPs may have different characteristics, display unit 110 may display different data when different CAPs are attached to abrading tool 100.
In some examples, communication unit 102 is configured to receive data regarding an application specific configuration of abrading tool 100. For example, abrading tool 100 may generally operate based on an operating system configuration that defines general purpose inputs and outputs, such as I/O system 108. To direct operation of abrading tool 100 to a particular application having particular operating characteristics and conditions, abrading tool 100 may be initialized with data regarding the application specific configuration that includes parameters configured for the particular operating characteristics and conditions. For example, communication unit 102 may receive an application configuration file that includes a variety of data and configuration parameters for components of abrading tool 100. The data and configuration parameters may include, but are not limited to, a name of abrading tool 100, a part number of abrading tool 100, a serial number of abrading tool 100, and any other identification or configuration data regarding abrading tool 100.
In some examples, the data regarding application specific configuration may include at least one configurable parameter of sensors 114, such as an accelerometer. For example, sensors 114 may include an accelerometer. In this example, the data regarding the application specification configuration may include at least one configurable acceleration parameter such as a minimum acceleration recording threshold, a maximum acceleration recording warning threshold, an accelerometer sampling rate, a hysteresis acceleration threshold. In some examples, microcontroller 104 may be configured to initialize operation of abrading tool 100 using at least one configurable acceleration parameter. For example, memory 106 may include the data regarding application specific configuration.
In some examples, the data regarding the application specific configuration may include at least one configurable parameter of communication unit 102. For example, communication unit 102 may include an NFC reader that may operate to read or write to NFC tags and/or act as a passive NFC tag. In this example, the data regarding the application specific configuration may include an NFC mode of the NFC tag reader, a length of time for communication unit 102 to read/write NFC data from NFC tags, a length of time for communication unit 102 to act as a passive NFC tag for abrading tool 100, an address of NFC tool tag data, and the like.
In some examples, microcontroller 104 may be configured to monitor communication unit 102 for tag data from NFC tags. For example, microcontroller 104 may be configured to receive tag data from communication unit 102 and maintain an open channel of communication from communication unit 102. In some examples, microcontroller 104 may be configured to receive data from communication unit 102 and determine whether the data is tag data, such as based on a tag type ID. For example, microcontroller 104 may receive data from an NFC tag and whether the data includes a tag type ID that matches one of several tag type IDs, such as: a tag type ID of abrading tool 100, identifying the NFC tag as belonging to abrading tool 100; a tag type ID of CAP 120, identifying the NFC tag as belonging to CAP 120; or a tag type ID of user ID 126, identifying the NFC tag as belonging to user ID 126.
In response to communication unit 102 receiving tag data, microcontroller 104 may store the tag data to a storage device, such as memory 106. For example, in response to user identification unit 122 receiving user identification information or CAP communication unit 115 receiving data regarding CAP 120, microcontroller 104 may store the user identification information or data regarding CAP 120 in memory 106. In some examples, communication unit 102 may communicate, to one or more external devices (e.g., CAP 120, computing system 4 (
In some examples, microcontroller 104 may perform various actions based at least in part on data from sensors 114. For example, microcontroller 104 may be configured to perform an action in response to determining, based on the acceleration data, that abrading tool 100 has exceeded a maximum vibration warning threshold. In this example, performing the action may comprise generating a warning (e.g., lighting a lamp, such as a Light Emitting Diode (LED), on abrading tool 100), preventing drive component 124 from moving CAP 120, and/or other actions.
In some examples, sensors 114 may comprise a vibration sensor configured to generate vibration measurements, such as acceleration data, of abrading tool 100. In this example, microcontroller 104 may be configured to perform an action in response to determining, based on the vibration measurements generated by the vibration sensor, that a user of abrading tool 100 has received a vibration dose greater than or equal to a threshold. In this example, external communication unit 116 may be configured to receive an indication of a vibration dose already received by the user of abrading tool 100. Furthermore, in this example, microcontroller 104 may be configured to perform the action in response to determining, based on the vibration measurements generated by the vibration sensors and the indication of the vibration dose already received by the user, that the user has received the vibration dose greater than or equal to the threshold. In this example, performing the action may comprise generating a warning (e.g., lighting a lamp, such as a Light Emitting Diode (LED), on abrading tool 100), preventing drive component 124 from moving CAP 120, and/or other actions.
In some examples, sensors 114 may comprise an accelerometer as a vibration sensor that generates acceleration measurements. In this example, microcontroller 104 may be configured to monitor the accelerometer for acceleration data. For example, microcontroller 104 may be configured to receive acceleration data from the accelerometer and maintain an open channel of communication from accelerometer 104. Microcontroller 104 may be configured to store, in response to receiving the acceleration data, the acceleration data to a storage device, such as memory 106. In some examples, microcontroller 104 may be configured to filter the received acceleration data from the accelerometer before storing the acceleration data. For example, microcontroller may receive the acceleration data from the accelerometer and compare the acceleration data to a minimum acceleration recording threshold. If a value of the acceleration data, such as an amplitude, exceeds the minimum acceleration recording threshold, microcontroller 104 may store the acceleration data.
In some examples, external communication unit 116 may be configured to send, to an external device (e.g., computing system 4), data based on one or more measurements from one or more sensors 114. For example, sensors 114 may comprise a vibration sensor configured to measure a vibration level of abrading tool 100. In this example, external communication unit 116 may be configured to send data based on the vibration level to the external device. In some examples, sensors 114 comprise one or more of an ammeter that measures an electrical current draw of abrading tool 100 during use of abrading tool 100, a tachometer that measures rotation of CAP 120, a pressure sensor that measures force applied to abrading tool 100 by a user of abrading tool 100, or a torque sensor that measures torque applied by abrading tool 100 to CAP 120. In such examples, external communication unit 116 may be configured to send, to the external device, data based on measurements of at least one of the ammeter, the tachometer, the pressure sensor, torque sensor, or wear sensor.
In some examples, a wear sensor of CAP 120 measures one or more characteristics of CAP 120 associated with a wear level of CAP 120. For instance, the wear sensor may comprise one or more electrical resistance sensors or electrical impedance sensors. As CAP 120 is used, the thickness of CAP 120 decreases, resulting in a change in electrical resistance and/or impedance between two or more electrodes attached to CAP 120. Furthermore, an abrupt increase in resistance or impedance may indicate the presence of a crack in CAP 120. In some examples, CAP 120 comprises a high permeability material in CAP 120 that is typically lost with wear to CAP 120. A sensor in CAP 120 or abrading tool 100 may sense (e.g., via inductive coupling) the resulting change in permeability (e.g., as a change in inductance). In some examples, CAP 120 may comprise an annular ring that is eroded as CAP 120 is used. In such examples, a sensor may measure wear of CAP 120 based on one or more characteristics of an electrical current applied to the annular ring (e.g., resistance, impedance).
In some examples, microcontroller 104 may determine a wear level of CAP 120 based on data indicating torque required to accelerate CAP 120. For example, as CAP 120 wears out, CAP 120 may lose mass. Thus, the energy required to accelerate CAP 120 to a certain speed (e.g., RPM level) decreases as CAP 120 loses mass. Therefore, the energy required to accelerate CAP 120 to the certain speed may decrease as CAP 120 wears out. In some examples, CAP 120 may gain mass as CAP 120 wears. For instance, CAP 120 may gain mass as spaces between grit particles may become clogged with abraded material as CAP 120 wears. Hence, by measuring the torque required to accelerate CAP 120 to the certain speed, microcontroller 104 may determine a wear level of CAP 120. Microcontroller 104 may determine torque be based on a measurement of electrical current. In some examples, the determination of the wear level of CAP 120 is performed by free spinning CAP 120 (i.e., without applying CAP 120 to a workpiece). Determining the wear level of CAP 120 in this manner may be done before each use of CAP 120. In some instances, free spinning a CAP prior to use may already be recommended for safety reasons. In some examples, an external device (e.g., computer system 4) determines the wear level in this manner based on data from sensors 114 of abrading tool 100.
In some examples, CAP communication unit 115 may receive an identifier of CAP 120 from CAP 120. Microcontroller 104 may instruct external communication unit 116 to use the identifier to retrieve data regarding CAP 120, such as the grit value for CAP 120, the max RPM value for CAP 120, current wear level of CAP 120, and the usage time of CAP 120. Thus, in this example, communication unit 102 may receive, from CAP 120, data identifying CAP 120. Furthermore, in this example, communication unit 102 may send, to a remote device (e.g., computing system 4), a request identifying CAP 120. In this example, the remote device is a device other than CAP 120. In this example, in response to the request, communication unit 102 may receive the data regarding CAP 120 from the remote device.
In some examples, microcontroller 104 may output worker-specific information for display on display unit 110. For example, microcontroller 104 may output worker vibration dosage information for display on display unit 110. In some examples, microcontroller 104 may output a current measure of a current vibration level for display on display unit 110. In some examples, microcontroller 104 may output, and update, on display unit 110 an indication of a remaining vibration dose allowed for a worker and/or a remaining usage time permitted to the worker given the worker's previous and ongoing vibration dose. In some examples, microcontroller 104 may output, for display on display unit 110 or in another manner, an indication (e.g., on display unit 110) that a worker should switch to a finer grit abrasive to prolong work time given the worker's vibration dose.
In some examples, microcontroller 104 may use CAP communication unit 115 to write data to CAP 120. For example, microcontroller 104 may use CAP communication unit 115 to write time information (e.g., tool run time, operator run time, CAP run time) to CAP 120. For instance, CAP communication unit 115 may be configured to send data to CAP 120 based on one or more measurements from one or more of sensors 114. For instance, in some examples, sensors 114 may include a vibration sensor and the one or more measurements may include a measurement of a vibration level of abrading tool 100.
Furthermore, in some examples, microcontroller 104 may use CAP communication unit 115 to write an RPM history level to CAP 120 (e.g., a maximum experienced RPM value). Microcontroller 104 may determine the RPM level based on data from a tachometer in sensors 114. In other words, sensors 114 may include a tachometer and the one or more measurements may include a measurement of an RPM level of CAP 120. In this example, CAP 120 may be damaged if CAP 120 is used at an RPM greater than a maximum allowed RPM limit. Accordingly, in this example, microcontroller 104 may use CAP communication unit 115 to write data to CAP 120 indicating that CAP 120 has been used at RPMs greater than the maximum allowed RPM limit, and may also indicate how long CAP 120 was used at RPMs greater than the maximum allowed RPM limit. In this example, an abrading tool or other device may read data indicating that CAP 120 has been used at an RPM greater than the maximum allowed RPM limit and may generate a warning when a worker subsequently tries to use CAP 120, even after CAP 120 has been detached from abrading tool 100 and reattached to abrading tool 100 or another abrading tool.
Furthermore, CAP 120 may be damaged if dropped or otherwise subjected to excessive acceleration/deceleration. In many instances, this damage is not visible, but could result in pieces flying off CAP 120. Accordingly, microcontroller 104 may receive data on acceleration from one or more accelerometers in sensors 114. In response to determining that the acceleration data is representative of abrading tool 100 being dropped while CAP 120 is attached to abrading tool 100, microcontroller 104 may use CAP communication unit 115 to write data to CAP 120 indicating that CAP 120 has been dropped. In this example, an abrading tool or other device may generate a warning when a worker subsequently tries to use CAP 120, even after CAP 120 has been detached from abrading tool 100 and reattached to abrading tool 100 or another abrading tool. In this example, an abrading tool or other device may read data indicating that CAP 120 has been dropped and generate a warning when a worker subsequently tries to use CAP 120, even after CAP 120 has been detached from abrading tool 100 and reattached to abrading tool 100 or another abrading tool.
In another example, microcontroller 104 may be configured to determine, based on data regarding CAP 120, that CAP 120 has been damaged and cause abrading tool 100 to perform an action in response to determining the received data indicates CAP 120 has been damaged. For instance, the data regarding CAP 120 may indicate whether CAP 120 is potentially damaged (e.g., CAP 120 has been dropped, CAP 120 has been used at an RPM level about the maximum RPM level of CAP 120, a temperature of CAP 120 has risen above a particular temperature threshold or fallen below a particular temperature threshold, etc.). In this example, microcontroller 104 may generate a warning and/or prevent drive component 124 of CAP 120 from moving CAP 120 in response to determining that CAP 120 is potentially damaged. Thus, in one example, the data regarding CAP 120 may indicate whether CAP 120 has been damaged by operating the consumable abrasive product at a RPM level greater than a maximum RPM level of CAP 120. In some examples, the data regarding CAP 120 may indicate whether CAP 120 has been damaged by CAP 120 being used at a temperature greater than a maximum temperature. In another example, the data regarding CAP 120 may indicate how time CAP 120 has been used and a threshold time (e.g., a maximum safe usage time, a typical expected lifespan, etc.). In this example, microcontroller 104 may perform an action (e.g., output warning, prevent movement of CAP 120) in response to determining that the amount of time CAP 120 has been used exceeds the threshold time.
In another example, the received data regarding CAP 120 may indicate that CAP 120 is cracked. In some instances, CAP communication unit 115 receives the indication that CAP 120 is cracked directly from CAP 120. In other instances, external communication unit 116 receives the indication the CAP 120 is cracked. In this example, microcontroller 104 may perform an action in response to receiving an indication that CAP 120 is cracked. For instance, microcontroller 104 may cause abrading tool 100 to generate a warning or microcontroller 104 may cause drive component 124 not to move CAP 120 while CAP 120 is attached to abrading tool 100.
In another example, the data regarding CAP 120 may include product authentication data. In this example, microcontroller 104 may use the product authentication data to determine whether CAP 120 is authorized for use with abrading tool 100. For instance, CAP 120 may be unauthorized for use with abrading tool 100 if CAP 120 is subject to a manufacturer recall, is counterfeit, is registered as stolen, is improperly imported, or is otherwise subject to a condition where CAP 120 should not be used with abrading tool 100. In response to determining CAP 120 is not authorized for use with abrading tool 100, microcontroller 104 may output a warning and/or may prevent use of CAP 120 with abrading tool 100.
In some examples, microcontroller 104 may control how or whether a worker uses abrading tool 100 based on data regarding CAP 120 (e.g., data received from CAP 120, data received from computing system 4 or another device regarding CAP 120, etc.) and/or data regarding a user of abrading tool 100. For example, the data regarding CAP 120 may include a maximum RPM level of CAP 120. In this example, microcontroller 104 may prevent abrading tool 100 from rotating CAP 120 at an RPM level greater than the maximum RPM level of CAP 120. In some examples, microcontroller 104 may prevent use of abrading tool 100 with CAP 120 based on data indicating CAP 120 is damaged. In some examples, microcontroller 104 may adjust (e.g., increase or decrease) a tool performance parameter (e.g., speed, torque, etc.) of abrading tool 100 to prolong a worker's ability to use abrading tool 100 based on a vibration dose the worker has received. For instance, microcontroller 104 may increase or decrease a RPM level to reduce vibration.
Furthermore, in some examples, particular types of PPE should be used when using abrading tool 100 with particular types of CAPs. In some such examples, microcontroller 104 may control how or whether a worker uses abrading tool 100 based on whether appropriate PPE is being used. Thus, in this example, microcontroller 104 may be configured to determine whether a particular type of PPE that is required during use of the abrading tool with CAP 120 is in use. In this example, microcontroller 104 may be configured to perform the action in response to determining that the particular type of PPE is not in use. For example, microcontroller 104 may determine that a particular size of debris shield should be used with CAP 120. In this example, in response to determining that such a debris shield is not properly attached to abrading tool 100, microcontroller 104 may prevent use of abrading tool 100 with CAP 120.
In some examples, a device (e.g., microcontroller 104, a computing device of computer system 4 (
In the example of
ADC 154 is configured to convert analog measurements from one or more sensors 152 to digital data. For instance, sensors 152 may comprise a temperature sensor and ADC 154 is configured to convert a signal from the analog temperature data into digital data. Data storage unit 158 may be configured to store the digital data. In this example, the digital data may indicate whether a temperature sensed by the temperature sensor has exceeded a threshold.
In some examples, sensors 152 include an impact detection component configured to detect whether CAP 150 has been subjected to an impact with force sufficient to damage CAP 150. For example, the impact detection component may comprise a brittle electrically-conductive material that breaks when subjected to an impact having force sufficient to damage CAP 150. In this example, the impact detection component may determine that CAP 150 has been subjected to an impact with force sufficient to damage CAP 150 if an electrical current will not flow through the material with an expected resistance or impedance. In this example, data storage unit 158 may be configured to store data indicating whether CAP 150 has been subjected to an impact with force sufficient to damage CAP 150.
Furthermore, in some examples, sensors 152 may include an excessive RPM detection component configured to detect whether CAP 150 has been subjected to an RPM level exceeding a threshold sufficient to damage CAP 150. For instance, the excessive RPM detection component may comprise a brittle electrically-conductive material that breaks when subjected to a RPM level exceeding the threshold. In this example, the excessive RPM detection component may determine that CAP 150 has been subjected to a RPM level exceeding the threshold if an electrical current will not flow through the material with an expected resistance or impedance. In this example, data storage unit 158 may be configured to store data indicating whether CAP 150 has been subjected to an RPM level exceeding the threshold sufficient to damage CAP 150.
In some examples, sensors 152 include one or more wear sensors. A wear sensor may be configured to generate data indicating a wear level of CAP 150. A wear sensor may comprise a pair of electrodes and circuitry for detecting electrical resistance or impedance. Electrical resistance and/or impedance may change as CAP 150 thins with use. Hence, changes in electrical resistance and/or impedance may provide a wear level of CAP 150. Other examples of wear sensors are described elsewhere in this disclosure.
In some examples, communication unit 156 may receive various types of data and may send various types of data. For example, communication unit 156 may be configured to receive vibration data from an abrading tool (e.g., abrading tool 8, abrading tool 100). The abrading tool is detachable from CAP 150 and may provide motive power to CAP 150 during a work session. In this example, the vibration data may indicate at least one of: a duration of vibration experienced by a user of the abrading tool during the work session, a frequency of the vibration, and a force of the vibration.
Failure of a CAP may have serious consequences. For example, the surface of an expensive workpiece may be seriously damaged. In another example, a worker may be injured if the worker is not wearing proper personal protective equipment. CAP 300 may help to reduce the risks of damage or injury due to failure of CAP 300.
In the example of
Control unit 304 may repeat the process of applying electrical signals to pairs of drive electrodes for one or more (e.g., a predetermined) number of pairs of electrodes. Control unit 304 may store the resulting measurements as a first dataset in a memory 306. Control unit 304 may comprise a microcontroller or other type of integrated circuit.
Subsequently, control unit 304 may apply an electrical signal to pairs of electrodes while measuring voltage on other pairs. For instance, control unit 304 may be configured to apply a second electrical signal across the first pair of electrodes in the plurality of electrodes and measure a voltage across the second pair of electrodes to generate a second set of measurements. Control unit 304 may repeat this process for one or more (e.g., a predetermined) number of pairs of electrodes. Control unit 304 may store the resulting measurements as a second dataset in memory 306. Control unit 304 may determine, based on a comparison of the first and second datasets, whether the abrasive disk of CAP 300 contains a crack, such as crack 312. That is, control unit 304 may be configured to compare a first set of measurements (e.g., the second data set) to a second set of measurements (e.g., the first dataset) to determine whether there is a crack in CAP 300. Communication unit 308 is configured such that, in response to control unit 304 determining there is a crack in CAP 300, communication unit 308 sends data to the one or more external devices (e.g., an abrading tool) indicating that there is a crack in CAP 300.
Cracks or other damage to materials generally appear as changes in impedance (e.g., a real or imaginary component of impedance). Example of
There is a wide range of choices for electrode placement, electrical drive signal, choice of measurement electrodes, and algorithms to compare the two datasets and determine whether there is a crack. When a crack is present, the path the electrical current takes between the drive electrodes is disturbed and the measured voltage may be different when the first and second datasets are compared.
In some examples, the first dataset may be generated not from a measurement of the CAP under test, but may be a ‘global average’ of many datasets from CAPs known to not contain a crack. The first dataset may also be generated from a simulation or other method. However, measuring a first dataset on each CAP may take into consideration normal manufacturing variation. Non-uniformity of the electrical properties of the CAP can be accounted for, as well as differences in the placement of electrodes.
As shown in the example of
There may be many unique combinations of drive electrode pairs, typically on the order of n*(n-1)/2, where n is the number of electrodes. However, it may not be necessary to test all pairs of electrodes. For instance, it may not be necessary to test pairs of electrodes on opposite sides of CAP 300. In some examples, pairs of electrodes separated by 3 other electrodes may be tested. For instance, in the example of
The electrical signal applied between drive electrodes can be either a current or a voltage. A potential advantage of a current is that contact impedance does not have to be well controlled and the current is identical for all drive pairs. Alternatively, a voltage can be applied and the current can be measured. The measurement can then be normalized to account for different drive currents. The system can be used with either a DC or AC applied signal. Electronics may be simpler with a DC implementation but AC may have the added benefit of looking for changes in complex impedance, which cracks often show.
In some examples, electrodes 302 are manufactured on a ‘sticker’ which is a piece of paper or plastic with an adhesive backing. In other words, CAP 300 may comprise a sticker that comprises electrodes 302 and control unit 304, wherein the sticker adheres to a surface of CAP 300, such as a surface opposite an abrading surface of CAP 300. Locations where electrodes 302 are present may have a conductive adhesive. The measurement electronics (e.g., control unit 304) may also be on the sticker, and may be powered via connections to an abrading tool (e.g., abrading tool 8 (
In addition to electrodes 302, the applied sticker may also include an inductor for inductive coupling to another antenna in the abrading tool. Thus, power may be provided directly to the sicker from the abrading tool without the need for a physical, wired connection. Additionally, communication may be provided directly from the sticker to the abrading tool without the need for a physical (wired) connection. For instance, communication unit 308 may comprise an RFID interface and control unit 304 may be powered through the RFID interface. On a fast-moving abrading tool, not using a physical connection may be advantageous. In such examples, determination of a crack may take place as soon as CAP 300 starts moving.
There may be many ways to detect a crack in CAP 300 based on the first and second measurements. One way is for control unit 304 to determine a difference between the first and second measurements for a given drive and measurement electrode pair. An increase in resistance may indicate a crack. Another way is to determine a ratio of the first and second measurements. Control unit 304 may determine that a crack is present by finding a statistical outlier among all the measurement ratios. In some examples, a device separate from CAP 300 may detect the presence of a crack in CAP 300. For example, communication unit 308 may communicate the measurements to another device, such as abrading tool (e.g., abrading tool 8, abrading tool 100), a mobile device (e.g., mobile device 20 (
Electrodes 302 may also be used for determining electrical resistance and/or impedance to determine a wear level of CAP 300, as described elsewhere in this disclosure.
Control unit 304 may compare the first and second datasets to determine whether there are any cracks in CAP 300 (354). In response to determining that there is a crack in CAP 300 (“YES” branch of 356), control unit 304 may configure communication unit 308 to send data to one or more external devices indicating that CAP 300 is cracked (358). On the other hand, when there is no crack in CAP 300 (“NO” branch of 356), control unit 304 may generate a new second dataset when CAP 300 is next used (352).
Furthermore, in the example of
In the example of
Enhancement component 524 includes components for communicating with a communication-equipped CAP. In some examples, enhancement component 524 includes components for communicating with an external network or device, such as mobile device 20 or computing system 4. Additionally, as shown in the example of
Thus, in the example of
The “RFID Click” accessory board has two main ICs:
CR95HF 13.56 Mhz contactless transceiver IC
PIC16F468A microcontroller unit (MCU)
In the example of
In some examples, the “RFID Click” board, the rectangular antenna of the CR95HF transceiver may be removed, as shown in
In some examples, an application of a mobile device (such as mobile device 20 of
In some examples, more than one RFID tag or sensor is embedded in a communication- equipped CAP and RFID antennas may not be coaxial with an antenna of a reader. This scenario is possible if there are multiple sensors embedded in the communication-equipped CAP, such as a temperature, wear or pressure sensor and these are not in one single RFID chip. For instance, temperature sensors, and potentially simple ohmmeters are now often integrated into an RFID chip and share the same antenna. However, other sensors are not currently integrated into an RFID chip.
A random orbital sander permits coaxial alignment reader and appropriately positioned RFID tag antennas, or at least maintaining of RFID tag antennas within the electromagnetic field of the smart power tool reader. This is also true with many other applications, including, floor buffer/sanders, reciprocating sanders, and other tools. Although not rotation, the motion of the reciprocating sander does not remove the reader electromagnetic field from a properly placed RFID tag. Belt type sanders may not permit RFID tags to be under constant power from a reader. Rather, the RFID tag repeatedly passes into and out of the reader electromagnetic field. These sanders move the belt around at least two pulleys over which the belt is mounted.
In some examples, a reader of a file sander is disposed in an arm of the file sander with substantially the same electronics and software as used in a random orbital sander, as described elsewhere in this disclosure. The electromagnetic field of the reader is normal to the antenna of the tag. The orientation of antenna 764 may require a reader antenna to be oriented at a right angle to an arm of a file sander. Thus, an antenna of a communication unit of the file sander may be located in an arm of the file sander.
In some instances, discussion above with respect to RFID may apply to other communications technologies, such as NFC.
As shown in the example of
Microcontroller 104 may monitor a communication unit, such as communication unit 102, for tag data from NFC tags (902). In some examples, the tag data may include at least one of: (i) user identification information identifying a user of abrading tool 100, such as shown in
Microcontroller 104 may monitor the accelerometer for acceleration data (904). For example, microcontroller 104 may receive acceleration data from the accelerometer and maintain an open channel of communication from accelerometer 104.
In response to the communication unit receiving the acceleration data, microcontroller 104 may store the acceleration data to a storage device (906). In some examples, microcontroller 104 may optionally filter the received acceleration data from the accelerometer before storing the acceleration data. This filter may also be the H(s) filter described in ISO5349-1. This filtering may be done in the tool, or external computing device (smart phone, computer, database or cloud). For example, microcontroller may receive the acceleration data from the accelerometer and compare the acceleration data to a minimum, maximum, or intermediate acceleration recording thresholds that have been set in the tool config file, database or cloud. If a value of the acceleration data, such as an amplitude, falls below the minimum acceleration recording threshold, microcontroller 104 may optionally store the acceleration data, or turn on an indicator. The stored acceleration data may be associated with the tag data, such as user identification information identifying a user of abrading tool 100, such as shown in
Microcontroller 104 may perform various actions using the acceleration data. In some examples, microcontroller 104 may cause communication unit 102 to send the acceleration data and the associated tag data to the one or more external devices (908). In some examples, microcontroller 104 may output the acceleration data to the one or more external devices in response to cessation of microcontroller 104 receiving the acceleration data.
In some examples, the acceleration data output by microcontroller 104 includes a summary of the acceleration data. For example, the summary of the acceleration data may include at least one of a user identification (ID) from the user identification information, a consumable abrasive product type from the data regarding the consumable abrasive product, a tool type from data regarding the abrading tool, and a time of operation of the abrading tool, such as a starting and stopping time of recording the acceleration data. In some examples, microcontroller 104 may output, in response to an acceleration value of the acceleration data exceeding the maximum acceleration warning threshold, a warning indication. In some examples, microcontroller 104 outputs the acceleration data in real-time, such as continuously or periodically.
In some examples, microcontroller 104 receives an indication of a cumulative vibration dose of the user and determines, based on the acceleration data and the cumulative vibration dose of the user, a current vibration dose of the user based on the acceleration data and the cumulative vibration dose. For example, microcontroller 104 may receive information on productivity, security, inventory, safety, or other topics based on data mined and/or analyzed by a computing system, such as computing system 4 of
In some examples, such as examples in which the abrading tool includes a pressure sensor that measures force applied to the abrading tool by the user of the abrading tool, microcontroller 104 may monitor the pressure sensor for force measurements of the force applied to abrading tool 100. In response to receiving the acceleration data, microcontroller 104 may store the force measurements to a storage device and associate the force measurements with the acceleration data. Microcontroller 104 may determine, based on the acceleration data and the force measurements, whether a value of the safety parameter exceeds a threshold. In some examples, in response to determining that the value of the safety parameter exceeds the threshold, microcontroller 104 may cause communication unit 102 to output a safety parameter warning indication. In some examples, in response to determining that the value of the safety parameter exceeds the threshold, microcontroller 104 may cause I/O system 106 to output a safety parameter warning indication, such as a color or blinking pattern of one or more LEDs. For example, I/O system 106 may include one or more LEDS having various colors and/or various blinking patterns configured to indicate that the value of the safety parameter exceeds the threshold.
In some examples, microcontroller 104 determines runtime data of the abrading tool based on a start time of receiving the acceleration data and an end time of receiving the acceleration data. Runtime data may include an amount of time that the abrading tool is operated, and may be indicated by an amount of time that the acceleration data is stored. Microcontroller 104 may store the runtime data of the abrading tool. The runtime may be associated with the tag data. For example, the tag data, such as shown in
Microcontroller 104 may read a configuration file, such as
Microcontroller 104 may monitor acceleration data of an accelerometer of abrading tool 100 by receiving the acceleration data from the accelerometer and determining whether the acceleration data exceeds a maximum acceleration threshold (914). If the acceleration exceeds a maximum acceleration threshold, microcontroller 104 may cause abrading tool 100 to output an acceleration indication (916). The microcontroller 104 may monitor and continuously write acceleration data (918) independent of thresholds.
While microcontroller 104 has not received the indication to write the acceleration data, microcontroller 104 may determine whether communication unit 102 is in read/write mode. While communication unit 102 is in a tag read/write mode (920), microcontroller 104 may monitor communication unit 102 for tag data from tags (922). For example, communication unit 102 may read badge data from badge tags (926), may read tool data from tool tags (928), or may read CAP data from CAP tags (930).
In response to receiving a write indication, microcontroller 104 may write time-stamped acceleration data while abrading tool 100 is operating (932). In some examples, the write indication may be a user input, such as a button indicating that microcontroller 104 may write acceleration data. In other examples, the write indication may be an automatic indication in response to communication unit 102 receiving the badge data, tool data, and CAP data and microcontroller 104 receiving the acceleration data. Microcontroller 104 may continue to monitor the accelerometer of abrading tool 100 as described in steps 918 and 920 above (934, 936).
Microcontroller 104 may continue to write acceleration data while microcontroller 104 receives acceleration data. In response to cessation of microcontroller 104 receiving acceleration data, microcontroller 104 may stop writing acceleration data (938). Microcontroller 104 may output a summary of operation of abrading tool 100 by writing a runtime of abrading tool 100 (940), writing user data of the user of abrading tool 100 (942), and writing CAP data of CAP 120 coupled to abrading tool 100 (944).
If the type ID of the tag is 01, the control board may determine the tag to be a badge tag (1080). The control board may set BadgeFound to “TRUE” and display “badge in”. The control board may read the operator name and ID data from the tag and write the data into a data file header to identify acceleration data with the operator. The control board may display the operator name and ID and prompt the operator to “attach abrasive”. If a tag escape button is activated, the control board may display “exit badge”.
If the type ID of the tag is 02, the control board may determine the tag to be a tool tag (1082). The control board may set ToolFound to “TRUE” and display “Tool fnd”. The control board may display “badge in”. If a tag escape button is activated, the control board may display “exit tool”.
If the type ID of the tag is 03, the control board may determine the tag to be a consumable abrasive product tag (1084). The control board may set CtagFound to “TRUE”. If the badge has not been found or the tool has been found, the control board may prompt the operator to scan “badge frst”. If the badge has been found, the control board may prompt the user to “Attach <CR><LF>abrasive”. The control board may read the C-tag data, write the C-tag data to the data file header to identify, and display the C-tag data. If a tag escape button is activated, the control board may display “exit abr”.
If the type ID of the tag is not found, the control board may assign a default (1086). The control board may display “no tag fnd”. In a tag escape button is activated, the control board may display “exit dfalt”.
It is to be recognized that depending on the example, certain acts or events of any of the techniques described herein can be performed in a different sequence, may be added, merged, or left out altogether (e.g., not all described acts or events are necessary for the practice of the techniques). Moreover, in certain examples, acts or events may be performed concurrently, e.g., through multi-threaded processing, interrupt processing, or multiple processors, rather than sequentially.
In one or more examples, the functions described may be implemented in hardware, software, firmware, or any combination thereof, located locally or remotely. If implemented in software, the functions may be stored on or transmitted over a computer-readable medium as one or more instructions or code, and executed by a hardware-based processing unit. Computer-readable media may include computer-readable storage media, which corresponds to a tangible medium such as data storage media, or communication media including any medium that facilitates transfer of a computer program from one place to another, e.g., according to a communication protocol. In this manner, computer-readable media generally may correspond to (1) tangible computer-readable storage media which is non-transitory or (2) a communication medium such as a signal or carrier wave. Data storage media may be any available media that can be accessed by one or more computers or one or more processors to retrieve instructions, code and/or data structures for implementation of the techniques described in this disclosure. A computer program product may include a computer-readable medium.
By way of example, and not limitation, such computer-readable storage media can comprise RAM, ROM, EEPROM, CD-ROM or other optical disk storage, magnetic disk storage, or other magnetic storage devices, flash memory, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer. Also, any connection is properly termed a computer-readable medium. For example, if instructions are transmitted from a website, server, or other remote source using a coaxial cable, fiber optic cable, twisted pair, digital subscriber line (DSL), or wireless technologies such as infrared, radio, and microwave, then the coaxial cable, fiber optic cable, twisted pair, DSL, or wireless technologies such as infrared, radio, and microwave are included in the definition of medium.
It should be understood, however, that computer-readable storage media and data storage media do not include connections, carrier waves, signals, or other transitory media, but are instead directed to non-transitory, tangible storage media. Disk and disc, as used herein, includes compact disc (CD), laser disc, optical disc, digital versatile disc (DVD), floppy disk and Blu-ray disc, where disks usually reproduce data magnetically, while discs reproduce data optically with lasers. Combinations of the above should also be included within the scope of computer-readable media.
Instructions may be executed by one or more processors, such as one or more digital signal processors (DSPs), general purpose microprocessors, application specific integrated circuits (ASICs), field programmable gate arrays (FPGAs), or other equivalent integrated or discrete logic circuitry, as well as any combination of such components. Accordingly, the term “processor,” as used herein may refer to any of the foregoing structures or any other structure suitable for implementation of the techniques described herein. In addition, in some aspects, the functionality described herein may be provided within dedicated hardware and/or software modules. Also, the techniques could be fully implemented in one or more circuits or logic elements.
techniques of this disclosure may be implemented in a wide variety of devices or apparatuses, including a wireless communication device or wireless handset, a microprocessor, an integrated circuit (IC) or a set of ICs (e.g., a chip set). Various components, modules, or units are described in this disclosure to emphasize functional aspects of devices configured to perform the disclosed techniques, but do not necessarily require realization by different hardware units. Rather, as described above, various units may be combined in a hardware unit or provided by a collection of interoperative hardware units, including one or more processors as described above, in conjunction with suitable software and/or firmware.
Various examples have been described. These and other examples are within the scope of the following claims.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US2018/020176 | 2/28/2018 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62464618 | Feb 2017 | US | |
| 62471125 | Mar 2017 | US |
