JP7465377B2 - Abrasive article including a wear detection sensor - Patent Application 20070123633 - Google Patents

Description

The following relates to abrasive articles, and more specifically to abrasive articles that include wear detection sensors.

Fixed abrasive articles can be used in various material removal operations and are often subjected to lengthy grinding processes, for example during the grinding of railroad tracks. It is important to observe the wear stage of the abrasive body in order to optimize the grinding process and to determine the required replacement of the abrasive article, which may require time-consuming operation shutdowns. For example, grinding of railroad tracks can only be performed during times when trains are not running. These times are short and may need to be used efficiently, so that most of the time is spent on the grinding operation and not on time-consuming replacement of the abrasive wheels. The amount of abrasive material remaining on each wheel is typically measured manually before grinding to identify wheels that are likely to be completely worn out during the next operation. These measurements are also time-consuming, leading operators to address any required replacements conservatively and avoid changing wheels during open grinding times.

There is a need to continuously monitor the wear stage of the abrasive article without interrupting the grinding process.

The present disclosure may be better understood, and its numerous features and advantages made apparent to those skilled in the art, by referencing the accompanying drawings.

1 includes a side view of an abrasive article, according to one embodiment. 1 includes a cross-sectional view of an abrasive article according to one embodiment. 1 includes a side view of an abrasive article, according to one embodiment. 1 includes a cross-sectional view of an abrasive body prior to use, including a portion of a wear detection sensor, according to one embodiment. 1 includes a cross-sectional view of an abrasive body during a material removal operation, including a portion of a wear detection sensor, according to one embodiment. 1 includes a diagram of one lead of a wear detection sensor according to one embodiment. 11 includes a diagram of one lead of a wear detection sensor according to another embodiment. 1 includes a diagram of one lead spirally wrapped around an abrasive body, according to one embodiment. 1 includes a top view of an abrasive article including a wear detection sensor according to an embodiment. 1 includes a top view of an abrasive article including a detection sensor according to another embodiment. 1 includes a diagram of a wear detection sensor according to an embodiment. 4 includes a diagram of a wear detection sensor according to another embodiment. 1 includes a diagram of a portion of a wear sensor attached to a mounting plate, according to an embodiment. 1 includes a plot of wear sensor time versus loop status. 1 includes another plot of wear sensor time versus loop status. 1 includes a cross-sectional view of a portion of an abrasive article, according to an embodiment. 1 includes a top view of an abrasive article including a detection sensor according to another embodiment. 1 includes a top view of an abrasive article including a detection sensor according to another embodiment. 1 includes a top view of an abrasive article including a detection sensor according to another embodiment. 1 includes a top view of an abrasive article including a detection sensor according to another embodiment. 1 includes a cross-sectional view of an abrasive body according to an embodiment. 1 includes a top view of an abrasive article including a detection sensor according to another embodiment. A plot of diameter versus reflectivity is included. 1 includes a cross-sectional view of an abrasive body according to an embodiment. 1 includes a cross-sectional view of another abrasive body, according to an embodiment. 1 includes a diagram of a wear detection system according to an embodiment. 1 includes a plot of reflectivity versus time for an abrasive article, according to an embodiment. 1 includes a plot of reflectivity versus time for another abrasive article, according to an embodiment. 1 includes a diagram of an exemplary wear sensor. 1 includes a diagram of components of an exemplary reader.

The following description in combination with the drawings is provided to aid in understanding the teachings provided herein. The following disclosure will focus on specific implementations and embodiments of the present teachings. This focus is provided to help explain the present teachings and should not be construed as a limitation on the scope or applicability of the present teachings. However, other teachings may be used in the present application.

As used herein, the terms "comprises," "comprising," "includes," "including," "has," "having," or any other variations thereof, are intended to include non-exclusive inclusions. For example, a method, article, or apparatus that comprises a list of features is not necessarily limited to only those features, but may include other features not expressly listed or inherent in such method, article, or apparatus. Furthermore, unless expressly stated otherwise, "or" refers to an inclusive "or," not an exclusive "or." For example, a condition A or B is satisfied by any one of the following: A is true (or exists) and B is false (or does not exist), A is false (or does not exist) and B is true (or exists), and both A and B are true (or exist).

Additionally, the use of "a" or "an" is used to describe elements and components described herein. This is done merely for convenience and to give a general sense of the scope of the invention. This description should be read to include the singular forms including one or at least one and also the plural, or vice versa, unless it is clear that something else is meant. For example, where a single item is described herein, the plural may be used in place of the single item. Similarly, where multiple items are described herein, the single may be used in place of the multiple items.

Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Materials, methods, and examples are illustrative only and are not intended to be limiting. Unless certain details regarding specific materials and processing acts are described, such details may include conventional techniques found in the literature and other sources within the manufacturing arts.

Embodiments disclosed herein relate to an abrasive article comprising an abrasive body of abrasive particles in an adhesive material. The abrasive article may include a wear detection sensor configured to detect a change in a dimension of the abrasive body, at least a portion of the wear detection sensor being coupled to and extending along at least a portion of the abrasive body. As used herein, the phrase "coupled to and extending along at least a portion of the abrasive body" means that at least a portion of the wear detection sensor may be included on an outer surface of the body, or may be partially embedded in the abrasive body, or may be entirely embedded in the body of the abrasive article.

In one embodiment, the wear detection sensor may include at least one lead. The at least one lead may include a conductive structure.

In one aspect, the lead may include a pair of conductive wires connected together at their ends (i.e., the termini or lead tips), which may create a conductive loop.

In another aspect, the lead may be a thin, elongated conductive plate or wire adapted to change resistance in response to the length of the elongated plate or wire. As wear of the abrasive body increases, the length of the lead decreases, and the change in measured lead resistance as the lead length decreases may correspond to wear of the abrasive body.

In yet another aspect, the lead can be an electrical circuit including two wires connected by a number of resistors. The resistors are positioned parallel to one another at different locations along the length of the two wires (i.e., a resistor ladder). As resistors break down during wear of the abrasive body, the equivalent resistance of the circuit increases, and the measured increase in resistance of the circuit can correspond to a state of wear of the abrasive body.

At least one lead of the wear detection sensor may be partially embedded in the abrasive body, completely embedded in the abrasive body, or extend along the outer surface of the abrasive body.

As used herein, the term at least one lead is also referred to as multiple leads when the wear detection sensor includes two or more leads.

In one aspect, at least one lead of the wear detection sensor may extend along a portion of the outer surface of the abrasive body. In another aspect, a majority or a lead of the plurality of leads may extend along a portion of the outer surface of the abrasive body. In certain aspects, each lead of the plurality of leads may extend along a portion of the outer surface of the abrasive body.

In further embodiments, at least one lead of the plurality of leads may be embedded within the abrasive body. In certain embodiments, all of the leads of the plurality of leads may be embedded within the abrasive body.

In one aspect, the wear detection sensor may have a first portion, e.g., a logic device, and a second portion, e.g., a plurality of leads, and the first portion may be coupled to the hub and the second portion may be coupled to the abrasive body. In another aspect, the first portion of the wear detection sensor may be coupled to the abrasive body and the second portion may be coupled to the hub. In another aspect, both the plurality of leads and the logic device may be coupled to the abrasive body.

Figure 1 includes a diagram of an abrasive article 100 according to one embodiment.

The abrasive article (100) may be an abrasive wheel, with the abrasive body (102) coupled to the hub (103). The abrasive body may include a bonded abrasive material, including abrasive particles contained in a three-dimensional matrix of the bonded material. The abrasive body (102) may optionally include some porosity as an inherent phase from the abrasive particles and the bonded material. A wear detection sensor may be coupled to the abrasive article (100), such as the abrasive body (102) and/or the hub (103), in the form of a plurality of leads (104) and a logic device (105). The plurality of leads (104) of the wear detection sensor may be coupled to a portion of the outer surface of the abrasive body (102). The plurality of leads 104 may extend from the logic device (105) in the axial direction (x) of the abrasive body (102) toward the material removal surface (107).

In another embodiment of the abrasive article shown in FIG. 2, the wear detection sensor's multiple leads (204) may extend from the logic device (205) in a radial direction (z) of the abrasive body (202), which is perpendicular to the axial direction (x). FIG. 2 shows a crosscut of an abrasive wheel including an abrasive body (202) attached to a hub (203), in which all the leads of the wear detection sensor (204) may be fully embedded in the abrasive body (202) and directed toward the material removal surface (207). The logic device (205) may optionally further include a communication device (e.g., a transceiver) (206) for communication with an external controller (not shown).

Figure 3 shows a side view of the polishing wheel (300) of the present disclosure. In this embodiment, the leads of the wear detection sensor (304) may extend along a portion of the outer surface (308) of the polishing body. The leads (304) may be connected to a logic device (305), which may be connected to the hub (303). The leads (304) may extend radially (z) to the outer material removal surface (307).

The amount of leads in the wear detection sensor may be at least one lead, and may not have a specific upper limit. The amount of leads may depend on the thickness of the abrasive body that is subjected to a material removal process, such as grinding, cutting, or polishing, where increased wear of the abrasive body should be observed. In one embodiment, the wear detection sensor may include at least one lead, for example, at least two leads, at least three leads, or at least four leads, at least five leads, at least seven leads, or at least nine leads. In another embodiment, the wear detection sensor may include 100 or less leads, for example, 80 or less leads, 60 or less leads, 50 or less leads, 30 or less leads, 20 or less leads, 15 or less leads, or 10 or less leads. The amount of leads in the wear detection sensor may be a value within a range including any of the minimum and maximum values mentioned above.

The multiple leads of the wear detection sensor may have different lengths relative to one another. In one embodiment, all of the leads may extend parallel to one another from the logic device to different depths into the volume of the abrasive body. In one aspect, each of the multiple leads may include a terminal end, and each of the terminal ends may be located at a different position relative to one another. For example, each of the terminal ends may be embedded at a different depth within the abrasive body relative to one another.

In another embodiment, the leads may extend from the logic device at angles to one another along the abrasive body. In a further embodiment, the leads may not be directly coupled to the logic device, but may have a connection structure between the logic device and the leads.

In one embodiment, each lead may reach at its end a specified distance ΔDT from the original material removal surface of the abrasive body, and the end of the lead may be embedded in the abrasive body or extend along the outer surface of the abrasive body. FIG. 4A shows a cross section of an abrasive body, where all the leads of the wear detection sensor (404) may be embedded in the abrasive body (402), and the end of each lead may have a specified distance ΔDT1, ΔDT2, ΔDT3, and ΔDT4 from the original material removal surface of the abrasive body (407). It should be understood here that below the original material removal surface of the abrasive body (407) should be the outer surface of the abrasive body before it is subjected to grinding or cutting of the workpiece. In FIG. 4A, the multiple leads extend in an axial direction (x) toward the original material removal surface (407).

During a material removal operation, the abrasive body of the present disclosure may be subjected to wear and portions of the abrasive body may be removed from the original material removal surface. FIG. 4B shows a stage of the abrasive article 401 where a portion of the abrasive body has been removed from the original outer material removal surface during a material removal operation of the workpiece (410) and the end of the longest of the multiple leads (404) has reached the actual material removal surface (409) of the abrasive body (402).

When the end of the lead reaches the actual material removal surface (409) of the abrasive body (402), the connection between the two wires that carry the current through the lead may be broken, thereby opening the electrical circuit and current between the pair of wires of the lead may no longer flow. The open circuit of the broken wire loop may be detected by a logic device, known herein as a broken lead. From the amount of broken lead detected by the logic device, a calculation may be made about the wear of the abrasive body.

In another aspect, the multiple leads may be connected together in an electrical circuit, and a broken wire loop may cause a change in the total voltage through the complete electrical circuit if the total amount of supply current remains constant. The amount of change in voltage may be measured as a wear signal by a logic device connected to the multiple leads, and may allow conclusions to be made about the wear stage of the abrasive body, such as how much of the abrasive body has been removed from the original outer material removal surface (307) and the remaining life.

By knowing the location of the ends of the leads within the abrasive body or along the outer surface of the abrasive body from the original material removal surface of the abrasive body, the wear stage of the abrasive body during the work operation can be calculated by the logic device. In one embodiment, the distance ΔDT of the ends of the leads of the leads from the original removal surface of the abrasive body can be at least 100 microns, e.g., at least 150 microns, at least 200 microns, at least 500 microns, at least 1000 microns, at least 5000 microns, or at least 10000 microns. In another aspect, the distance ΔDT can be 1.5 meters or less, e.g., 1.3 meters or less, or 1.0 meters or less, or 0.8 meters or less, or 0.5 meters or less, or 0.3 meters or less, or 0.1 meters or less, or 0.05 meters or less, or 0.01 meters or less. The distance ΔDT can be a value within a range including any of the minimum and maximum values mentioned above.

In further embodiments, the distance ΔDI between the two lead ends in a direction perpendicular to the material removal surface of the abrasive body may be at least 100 microns, e.g., at least 200 microns, at least 300 microns, or at least 500 microns, or at least 1000 microns, or at least 5000 microns. In another aspect, the distance between the two lead ends may be 1.5 meters or less, e.g., 1.2 meters or less, or 1.0 meters or less, or 0.8 meters or less, or 0.5 meters or less, or 0.3 meters or less, or 0.1 meters or less, or 0.05 meters or less. The distance ΔDI may be a value within a range including any of the minimum and maximum values described above.

In embodiments in which each lead of the wear detection sensor is a single wire or elongated plate, the wear detection sensor can be designed such that the area of the lead (e.g., the length of the lead) correlates with a certain resistance, and the change in resistance with decreasing lead length (due to increasing wear) can be translated into information about the wear of the abrasive body.

In one embodiment, the total length of at least one lead of the wear detection sensor may be at least 100 microns, e.g., at least 200 microns, or at least 500 microns, or at least 1000 microns, or at least 1 cm, or at least 5 cm. In another aspect, the total length of at least one lead may be 10 meters or less, e.g., 8 meters or less, or 5 meters or less, or 3 meters or less, or 2 meters or less, or 1.5 meters or less, or 1.0 meters or less, or 0.8 meters or less, or 0.5 meters or less, or 0.3 meters or less, or 0.2 meters or less, or 0.1 meters or less, or 0.05 meters or less, or 0.01 meters or less. The total length of at least one lead may be within a range including any of the minimum and maximum values described above.

At least one conductive lead of the wear detection sensor may be in communication with at least one logic device. In one embodiment, the logic device may be a microcontroller configured to detect changes in the state of the wear detection sensor. The logic device may optionally include a communication device, e.g., a transceiver for communicating with an external controller.

In one aspect, at least one lead of the wear detection sensor can be detected by a logic device that is in an active state when current flows through the lead, and in an inactive state when no current or a small amount of current flows through the lead because the lead is damaged. A wear signal can be created by interrupting or reducing the current during the inactive phase of the lead. Thus, by detecting the wear signal and controlling and measuring the current flowing through the multiple leads, the wear phase of the abrasive body can be analyzed without interrupting the material removal process.

The wear signal created by the wear detection sensor can be transmitted by the communication device to an external controller, for example a portable control unit owned by the operator or a fixed unit mounted on the machine on which the wheel is mounted. The transmission of the wear signal can be done, for example, via an electrical connection to the spindle on which the wheel is mounted or as a wireless signal. In one aspect, the logic device can include a transceiver, for example an RFID transceiver, for transmitting the wear signal to an external controller that can monitor and control the grinding process. Other options for wireless transmission of the wear signal can be via Wi-Fi or Bluetooth or other wireless protocols. The wear signal can be stored on the logic board (e.g. SD card or flash memory) as a local data storage. The external controller can be part of the logic device or a separate unit. In a further aspect, a light indicator can be used to indicate that the wheel needs to be replaced or that it still has a long life left.

The power required to operate the wear detection sensor can be provided from a battery or from a direct electrical connection from the machine or train. The wear detection sensor can also be powered remotely using RF energy or by an energy harvesting system, e.g. a system that generates electrical energy from vibrations.

The material of the at least one conductive lead may be a metal or metal alloy. Non-limiting examples of lead materials may include copper, aluminum, silver, or stainless steel.

In one embodiment, each lead may be further surrounded or embedded in a protective material, especially if the lead has a wire loop or resistor ladder configuration. FIG. 5A shows an embodiment of a single lead (500) that may include a pair of wires (501) connected together by forming a loop at the leading end (502), and the wires may be surrounded by a lead protective material (503).

Figure 5B shows a lead with a resistor ladder configuration, where two wires (502) are connected by multiple resistors (505) arranged parallel to each other at different positions along the length of the two wires (502). The entire electrical circuit is embedded in a protective material (503).

The lead protection material may be a material that may protect the wires of the lead during the manufacture of the abrasive article, but may be easily destroyed by forces during the material removal operation of the abrasive article when reaching the actual outer material removal surface of the abrasive body. Non-limiting examples of lead protection materials may be, for example, polyimide, polyurethane, or polyolefin. The lead protection material may also act as an insulator to prevent shorting of an electrical circuit, for example, in embodiments where the abrasive body is conductive. In one aspect, at least one wire loop may be applied directly to the outer surface of the abrasive body and embedded in a protective polymer, for example, polyimide. Similarly, if the lead is designed to measure a change in resistance, a wire or elongated plate may be applied directly to the outer surface of the abrasive body and embedded in a protective polymer material.

In another embodiment, the wear protection sensor leads may not include wire protection material.

In yet a further embodiment, at least one reed may have a spiral shape and be wound around the outer surface of the abrasive body, as shown in Figure 6. This embodiment may be applied for a reed that may change resistance according to its size reduction during wear of the abrasive body. Figure 6 shows an abrasive body in the form of a wheel (602) fixed to a hub (603), with a reed (604)
are in the form of wires and are spirally wrapped in the axial direction (x) around the abrasive body (602). In one aspect, the abrasive body may be covered by a reinforcing fiberglass mat (not shown) and the reeds may be woven into the mat or the reeds may directly replace some of the threads of the fiberglass mat.

In another embodiment, the wear detection sensor may include at least one electronic device. In some aspects, the electronic device may include an electronic element. The electronic element may include, for example, a chip, an integrated circuit, logic, a transponder, a transceiver, a passive element such as a resistor, a capacitor, a memory, or the like, or any combination thereof. In another aspect, the electronic device may include an antenna directly coupled to the electronic element. In certain aspects, the electronic device may include a chip, an integrated circuit, a data transponder, a radio frequency based tag or sensor with or without a chip, an electronic tag, an electronic memory, a sensor, an analog-to-digital converter, a transmitter, a receiver, a transceiver, a modulator circuit, a multiplexer, an antenna, a near-field communication device, a power source, a display (e.g., an LCD or OLED screen), an optical device (e.g., an LED), a global positioning system (GPS) or device, fixed or programmable logic, or any combination thereof. In some cases, the electronic device may optionally include a substrate, a power source, or both. In further aspects, the electronic device may be wired or wireless.

More specific examples of electronic devices may include tags or sensors, such as radio frequency identification (RFID) tags or sensors, near field communication tags or sensors, or combinations thereof. In certain aspects, the electronic device may include an RFID tag. In some cases, the RFID tag may be inactive and may be powered by a reader device for the RFID tag. In other cases, the RFID tag may be active and include a power supply, such as, for example, a battery or an inductive-capacitive tank circuit.

In another aspect, the electronic device may include a short-range communication device. A short-range communication device may be any device capable of transmitting information via electromagnetic radiation within a certain defined radius of the device, typically less than 20 meters.

In certain aspects, the electronic device may include a dual frequency tag. The dual frequency tag may facilitate readability at multiple frequencies. By way of example, the electronic device may include a near field communication device and an RFID tag. In further instances, the electronic device may include a dual frequency chip attached to an RFID antenna and an NFC antenna.

In a further aspect, the electronic device may include a transceiver. A transceiver may be a device that can receive information and/or transmit information. Unlike passive RFID tags or passive near-field communication devices, which are generally read-only devices that store information for a read operation, a transceiver can actively transmit information without having to perform an active read operation. Additionally, the transceiver may be capable of transmitting information on a variety of selected frequencies, which may improve the electronic device's communication capabilities with a wide variety of systems intended to receive and/or store information.

In some aspects, the electronic device may be attached to at least a portion of the abrasive body. For example, the electronic device may be attached to a portion of a surface of the abrasive body, such as a major surface, a periphery, or a combination thereof. In further aspects, the electronic device may be in contact with the abrasive body. In another aspect, the electronic device may be partially embedded in the abrasive body. In further aspects, the electronic device may be entirely embedded within the abrasive body.

In some implementations, the electronic device may be adapted to detect wear of the abrasive article, such as dimensional changes in the abrasive body. In other implementations, the electronic device may be combined with another component to facilitate wear detection.

7 includes a top view of an abrasive article 700 including an abrasive body 701 and a wear detection sensor 702. The body 701 may include a center hole 703. In some cases, the abrasive body 701 may include an inner circumferential region 704 abutting the center hole 703 and an outer circumferential region 705 outside the inner circumferential region 705. The inner circumferential region may include an inner circumferential diameter DI, and the abrasive body may include an outer diameter DO, which may also be referred to in this disclosure as the outer circumferential region diameter.

In some embodiments, wear of the abrasive article may include a dimensional change, including a reduction in the outer diameter DO. As an example, the peripheral surface of the abrasive body may be a material removal surface in contact with the workpiece. Material loss on the material removal surface may cause a reduction in the outer diameter DO. In certain applications, when the outer diameter DO reduces to approximately the size of the inner diameter DI, the abrasive article may not be suitable for further use. In another embodiment, the major surface of the abrasive body may be a material removal surface.

The wear detection sensor 702 may include an electronic device 710 including an electronic element 712, such as an integrated circuit, coupled to an antenna 714. In some implementations, the electronic device 710 may include an integrated circuit and not include an antenna. The electronic device 710 may be disposed within the inner circumferential region 704 or the outer circumferential region 705, or may extend along a portion of the inner circumferential region 704 and a portion of the outer circumferential region 705. In certain cases, the electronic device 710 may be disposed within the inner circumferential region 704, as shown.

The wear detection sensor 702 may further include an electrical component coupled to the electronic device 710. The electrical component may include a passive element, such as a capacitor, a resistor, an inductor, or a combination thereof. In certain cases, the electrical component may include a first capacitive plate 718 and a second capacitive plate 720. The first and second capacitive plates 718 and 720 may be coupled to the electronic device 710 by a wire 716 or the like.

The first capacitive plate 718 and the second capacitive plate 720 may be spaced apart and disposed parallel to one another. In some cases, the first capacitive plate 718 may be disposed at the inner circumferential region 704 and the second capacitive plate 720 may be disposed at the outer circumferential region 705.

In an exemplary material removal operation, wear of the abrasive article may result in removal of a portion of the entire second capacitive plate 720, which may change the electric field strength at the capacitor plate. The electronic device 710 may detect the change and generate a wear signal.

In other cases, the electrical components may include resistors, inductors, or combinations thereof. In an exemplary material removal operation, a portion of a resistor, inductor, or both may be removed, which may change a current or a magnetic field, resulting in the generation of a wear signal.

The wear signal can be received by a data receiving device and an operator can be alerted to the wear condition of the abrasive article.

In some embodiments, the data receiving device may be a reader, interrogator, or another device that may receive, read, and/or edit data. In some cases, the data receiving device may read data stored on an electronic device, and the electronic device may not function to transmit the data. In another embodiment, the data receiving device may transmit data from the electronic device to another device, system, database, etc. In certain embodiments, the data receiving device may include an RFID reader or interrogator, an NFC reader, a mobile phone, or a combination thereof.

As shown in FIG. 7, the wear detection sensor 702 may be positioned on the main surface of the abrasive body 701. In another embodiment, at least a portion of the wear detection sensor 702 may be attached to a portion of the main surface, the peripheral surface, or both. For example, an electronic device, an electrical component, a wire, or any combination thereof may be cold-pressed, warm-pressed, or hot-pressed directly onto the surface of the abrasive body. In another example, at least a portion of the wear detection sensor may be aligned to the surface of the abrasive body during the formation process of the abrasive body and co-cured to the abrasive body. In further instances, at least a portion of the wear detection sensor may be attached to the surface by heat, radiation, glue, adhesive, mechanical methods, or any combination thereof.

In some embodiments, the wear detection sensor 702 may contact a portion of the abrasive body 701. For example, the wear detection sensor 702 may directly contact the adhesive material, the abrasive particles, another component of the abrasive body 701, or a combination thereof. In other embodiments, the wear detection sensor 702 may be partially embedded or entirely embedded within the abrasive body. In some cases, a portion of the abrasive body may be removed to create a space (e.g., a slot) within the abrasive body to receive the wear detection sensor, and the wear detection sensor may be attached to at least a portion of the body using heat, pressure, adhesive, glue, or any combination thereof. In some other cases, the wear detection sensor may be embedded in a mixture for forming the abrasive body during a forming process. The mixture may include an adhesive material, an abrasive article, and optionally an adhesive. In certain examples, the mixture and the wear detection sensor may be placed in a mold, and the wear detection sensor may be partially or entirely embedded in the mixture. The abrasive body may then be formed by subjecting the mixture to pressure, heat, irradiation, other known processes for forming an abrasive body, or a combination thereof.

As shown, at least a portion of the electrical components, such as the first and second capacitive plates 718 and 720, may be disposed on a major surface of the abrasive body 701. In certain cases, a portion of the electrical components, such as at least one of the capacitive plates 718 and 720, may be attached to a portion of the abrasive body. In other certain cases, the first and second capacitive plates 718 and 720 may be attached to a portion of the major surface, the peripheral surface, or both. In more particular cases, at least one of the first and second capacitive plates 718 and 720 may contact a portion of the abrasive body that includes an adhesive material, an abrasive particle, another component, or any combination thereof.

In some implementations, at least one of the capacitive plates 718 and 720 may be partially or entirely embedded in the polishing body 701. As an example, the first capacitive plate 718 may be disposed on a major surface or a peripheral surface, and the second capacitive plate may be partially or entirely embedded in the polishing body 701. In another case, the second capacitive plate 720 may be disposed on a major surface or a peripheral surface, while the first capacitive plate 718 may be partially or entirely embedded in the polishing body 701. In another case, both the first and second capacitive plates 718 and 720 may be partially or entirely embedded in the polishing body 701.

In another embodiment, the wear detection sensor may include a loop circuit coupled to an electronic device. Figure 8 includes a plan view of another exemplary abrasive wheel 800 including an abrasive body 801. The abrasive article 800 includes a wear detection sensor 802 including an electronic device 810 disposed on a major surface 803. The electronic device 810 may include an electronic element and, optionally, an antenna 814 coupled to the electronic element 812. The wear detection sensor 802 may include a loop circuit. In some applications, the loop circuit may include a wire loop 820 coupled to the electronic device 810. By way of example, the wire may be resistive. The wire loop is directly connected to the electronic element 812, such as an integrated circuit. Alternatively, the wire loop may be coupled to the electronic element 812 by an antenna 814.

In other applications, the loop circuit may include passive elements such as a capacitor, a resistor, an inductor, or a combination thereof. In certain applications, the loop circuit may include a capacitive loop circuit including at least one capacitor. In other specific applications, the loop circuit may include at least one resistor. In other specific cases, the loop circuit may include multiple capacitive loop circuits, with the capacitors arranged in parallel connected by wires.

FIG. 9A includes a diagram of a wear detection sensor 900 including an electronic device 901 coupled to a loop circuit 902. The electronic device 901 may include an electronic element 905, such as a transponder, an integrated circuit, etc., and an antenna 903 coupled to the electronic element 905. The loop circuit 902 may include multiple capacitors 911, 912, and 913 arranged in parallel. In another case, at least one or all of 911, 912, and 913 may include resistors.

In some embodiments, the wear detection sensor 802 or 900 may be located on the major surface 803, the peripheral surface (not shown), or a combination thereof of the abrasive body 801. In some aspects, the length LL of the loop circuit 820 or 902 may extend along a portion of the major surface, the peripheral surface, or both. In other aspects, the length LL of the loop circuit 820 or 902 may extend radially, axially, or a combination thereof of the abrasive body 801. In other cases, the length LL of the loop circuit 820 or 902 may extend toward the material removal surface to facilitate wear detection.

In further embodiments, at least a portion of the wear detection sensor 802 or 900 may be embedded in the abrasive body 801. In one aspect, the loop circuit 820 or 902, the electronic device 810 or 901, or both may be partially embedded in the abrasive body. In another aspect, the loop circuit 820 or 902, the electronic device 810 or 901, or both may be entirely embedded in the abrasive body.

In another embodiment, the wear detection sensor 802 or 900 may be placed at a certain location that may facilitate the determination of the wear level. For example, in a material removal operation, a first portion of the wear detection sensor may be removed and a first wear signal may be generated when the wear of the abrasive body reaches a first level. The first wear signal may be an indicator of a first wear level. The first wear level may be a relatively low wear level, such as 20%, 30%, or 40%. As the operation continues, a second portion of the wear detection sensor may be removed and a second wear signal may be generated when a second wear level is reached. The second wear signal may be an indicator of a second wear level. The second wear level may be a relatively higher wear level, such as 705, 80%, or 90%. The second wear signal may be interpreted as a warning of the approaching end of life of the abrasive article.

With reference to FIG. 8 , the loop circuit 820 may extend radially toward the circumferential surface. The circumferential surface may be a material removal surface. The wear detection sensor 810 may be positioned such that in a material removal operation, when a certain length of the circuit loop 820 or 902 is removed and wear of the abrasive body reaches a certain level, the circuit loop may break. The electronic device may sense the broken circuit loop and generate a wear signal. The data receiving device may receive the wear signal and interpret it as an indicator that a certain wear level has been reached, such as a certain low-level wear. As the operation continues, a portion of the electronic device 810, such as at least a portion of the electronic element 812, the antenna 814, or both, may be removed, which may cause the electronic device to become inactive, and the data receiving device may receive a wear signal indicating that a higher wear level has been reached. The wear signal may include a change in the signal, such as a change in response time, signal strength, reflected energy, loss of an existing signal, or any combination thereof. In certain cases, when the electronic device becomes inactive, the data receiving device may stop receiving any signals or responses from the electronic device.

In some cases, the received signal strength indicator on the data receiving device may be used to determine the wear level because the electronic device 810 may gradually wear out during operation of the abrasive article 800, causing the electronic device 810 to transmit weaker and weaker signals until the electronic device 810 becomes inactive. The value of the received signal strength indicator may be measured, calculated, or both, by the data receiving device to determine the wear level.

9B includes a diagram of another example of a wear detection sensor 950 including a wire loop 951 coupled to an electronic device 952. In an embodiment, the wire loop 951 may include one or more wire loops, such as one loop, two loops, three loops, five loops, or more. The electronic device 952 may include an integrated circuit 954 and an antenna 953. In a particular embodiment, the electronic device 952 may include an RFID chip or an integrated circuit. The electronic device 952 may further include additional components 955, such as a chip, another integrated circuit, a logic device, a transponder, a transceiver, a passive element, or the like, or any combination thereof. In some implementations, the wear detection sensor 950 may be printed and include a substrate 956. The substrate 956 may include a flexible material, such as an organic material, more specifically, a flexible material. More particular examples of the substrate 956 may include PET, polyimide, or another material that can be used to create flexible electronics.

In certain implementations, the wear detection sensor 950 can be positioned against an outer surface, such as a peripheral surface, of the abrasive body of the abrasive article. For example, the wear detection sensor 950 can be positioned around at least a portion of the peripheral surface of the abrasive body, and a non-abrasive portion, such as a layer of fiber, can be wrapped over the wear detection sensor 950 and at least a portion or the entire outer peripheral surface of the abrasive body.

9C includes a top view of a mounting plate (or hub) 981 attached to an electronic assembly 982 that includes an electronic device 983 contained within a package 985. The package 985 and stool spokes 988 can help protect the electronic device 983 from sparks and heat generated during the grinding operation. In an embodiment, the package 985 can include a protective material that can be resistant to high temperatures and can act as a heat shield. In another embodiment, the package 985 can include a polymer. Specific examples of polymers can include high performance polymers such as polyetheretherketone (PEEK), and the like, or combinations thereof. Alternatively, the electronic device 983 can be completely protected and isolated from the outside environment by a protective material instead of a package.

The electronic device 983 may be part of a wear sensor that further includes a wire loop attached to the electronic device 983. In certain embodiments, the electronic device 983 may include a microcontroller, and the wire loop may be attached to the microcontroller. The wire loop may also be attached to a peripheral surface of the abrasive body that is attached to the mounting plate 981. The peripheral surface may be an inner or outer peripheral surface. In certain implementations, a coating may be applied to the wire loop to facilitate attachment of the wire loop to the peripheral surface and provide protection against heat and sparks. In certain embodiments, the coating may include an adhesive. In another embodiment, the coating may be heat resistant. In certain cases, the coating may include a heat resistant adhesive, which may facilitate improved performance of the wear sensor. Exemplary adhesives may include epoxies, acrylates, silicone rubbers, and the like. In certain embodiments, the coating may include steel epoxy.

In some instances, signal transmission from electronic device 983 during the grinding operation may be wireless. For example, wheel wear information may be transmitted via Wi-Fi, Bluetooth, or a combination thereof to a receiving device such as a cell phone, handheld device, computer, etc. The transmitted data may include the state and change in state of the wire loop. As an example, the data may be in a format where a "0" represents a closed loop (e.g., no detectable wire loop wear) and a "1" represents an open loop (damaged loop). The state and/or change in state of the wear loop may be used to determine the wear level of the grinding tool. FIGS. 9D and 9E include graphs showing data transmitted by a wear sensor including a wire loop attached to electronic device 983, displaying the state of different wire loops in the grinding operation. As shown, wire loop number 2 is closed and has no state change, while the state of wire loop number 4 changes from 0 to 1, indicating that the wire loop is damaged during the grinding operation and some level of wear of the grinding tool. As grinding continues, wire loop number 2 later breaks off, indicating a higher level of wear on the grinding tool.

10 includes a cross-sectional view of a portion of an abrasive article 1000 including a body 1001. The body 1001 may include a first major surface 1002 opposite a second major surface 1003 and a peripheral surface 1004 extending between the first and second major surfaces 1002 and 1003. In some cases, the body 1001 may include an abrasive portion 1020 and a non-abrasive portion 1022. The peripheral surface 1004 may be a material removal surface of the abrasive article 1000.

The wear detection sensor 1005 may be at least partially embedded in the body 1101 and includes an electronic device including an electronic element 1008 and an antenna 1006 coupled to the electronic element 1008. The electronic element 1008 may be disposed in the non-polished portion 1022. In some cases, a portion of the electronic element 1008 may be disposed in the polished portion 1020. The antenna 1006 may be disposed in the polished portion 1020 and in some cases, a portion of the antenna may be disposed in the non-polished portion. The end 1014 of the antenna 1006 may be aligned with the surrounding surface 1004.

The antenna 1006 may extend toward the peripheral surface 1004. As an example, the antenna 1006 may extend radially along a portion of the body. In another instance, the antenna 1006 may extend the entire radial distance of the polishing portion.

In some cases, the wear detection sensor may include a package that includes at least a portion of the electronic element 1008 and the antenna 1006. By way of example, the package may separate the electronic element 1008 and/or the antenna 1006 from the surrounding environment. In other cases, the package may separate the electronic element 1008 and/or the antenna 1006 from the composition of the body 1001, such as abrasive particles, adhesive materials, and other components.

The package may include a protective layer 1010, a substrate 1012, or both, etc. A portion of the protective layer 1010 may extend above the major surface 1003. Alternatively, the protective layer 1010 may be below or in the same plane as the major surface 1003. In an aspect, the protective layer 1010 may include a material that may protect the electronic elements 1008 and/or the antenna 1006 from external environmental conditions, including moisture, coolants, etc. Exemplary protective materials may include polydimethylsiloxane (PDMS), polyethylene naphthalate (PEN), polyimide, polyether ether ketone (PEEK), or any combination thereof.

In some cases, certain coolants are used in material removal operations and exposing the electronic device to the coolant can cause degradation of the electronic device. A protective layer 1010 or the entire package can be applied to protect the electronic device from the coolant and extend the useful life of the electronic device. A protective layer can also be applied to protect the electronic device from moisture, extreme temperatures, or other conditions that can damage the electronic device.

In some aspects, the substrate 1012 may include a similar or different material to the protective layer 1010. In certain cases, the package may encapsulate the electronic device.

The wear detection sensor 1005 can survive multiple material removal operations and serve as an indicator that a high wear level has been reached when the abrasive article 1000 will no longer function. As an example, the remaining length of the electronic element 1008 can be an indicator that the inner circumference has been reached when it is time to replace the abrasive article 1000.

In some embodiments, the wear detection sensor may include an electronic device including an antenna directly and electrically connected to the electronic element. In another embodiment, the wear detection sensor may include a plurality of electronic devices, at least one of which may include an antenna directly and electrically connected to the electronic element. In yet another embodiment, the wear detection sensor may include a plurality of electronic devices, at least some or each of which may include an antenna directly and electrically connected to the electronic element. In some implementations, the antenna may include a thin film antenna.

In some aspects, the antenna may extend along a portion of the abrasive body. By way of example, the antenna may extend along a portion of the major surface, the peripheral surface, or both of the abrasive body toward the material removal surface. In another aspect, the antenna may extend radially, axially, or a combination thereof, of the abrasive body. In further aspects, the antenna may be partially or entirely embedded in the abrasive body.

In some aspects, the electronic device may include at least one antenna, at least two antennas, at least three antennas, or at least four antennas, each antenna directly and electrically connected to an electronic element. In some aspects, at least some of the antennas may extend different distances along the abrasive body. In other aspects, each of the antennas may extend different distances along the abrasive body.

FIG. 11 includes a plan view of an abrasive article 1100 including a body 1101 including an inner circumferential region 1103 and an outer circumferential region 1102. The wear detection sensor 1104 may include an electronic device including an electronic element 1105 and multiple antennas 1106-1109 coupled to the electronic element 1105. The electronic element 1105 may be disposed within the inner circumferential region 1103. In another case, the electronic element 1105 may be disposed in the outer circumferential region 1102. In some particular implementations, the electronic element 1105 may include an integrated circuit, a transponder, or a combination thereof.

The antennas 1106-1109 may be spaced apart from one another. As shown, the antennas 1106-1109 may extend such that their lengths are parallel to one another. In another case, at least some of the antennas 1106-1109 may be positioned such that their lengths extend at an angle to one another. For example, the angles may include acute angles, obtuse angles, right angles, or combinations thereof.

The antennas 1106-1109 can extend along a portion of the abrasive body toward the material removal surface (e.g., the peripheral surface). In some aspects, one of the antennas can extend a different distance compared to one of the other antennas. In other aspects, all of the antennas can extend a different distance along the abrasive body.

In further aspects, at least some of the antennas 1106-1109 may include different lengths compared to one another. In certain aspects, each of the antennas 1106-1009 may include different lengths. For example, the relative difference in length between the antennas may be at least 5%, at least 10%, at least 15%, at least 17%, at least 20%, at least 30%, at least 40%, or at least 50%. In other aspects, the relative difference in length between the antennas may be at most 80%, at most 70%, at most 60%, at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%. Additionally, the relative difference in length between the antennas may be within a range that includes any of the minimum and maximum percentages described herein.

As shown, antenna 1109 may be positioned within inner circumferential region 1103. The other antennas 1106-1108 may extend different distances from positions within inner circumferential region 1103 into outer circumferential region 1102.

The antennas 1106-1109 may be spaced apart from the centerline 1111 of the abrasive body 1101 by a distance δdC. As shown, δdC is the perpendicular distance from an end of an antenna (e.g., 1106) to the centerline 1111, with the end being the end closer to the centerline 1111. For example, the relative difference in distance δdC between at least some or all of the antennas 1106-1109 may be at least 2%, at least 5%, at least 10%, at least 15%, or at least 20%. In other cases, the relative difference in distance δdC may be at most 40%, at most 35%, at most 20%, at most 15%, or at most 10%. Additionally, the relative difference in δdC may be within a range that includes any of the minimum and maximum percentages described herein.

The other end of each antenna may be spaced a distance δdO from the outer periphery of the abrasive body 1101. The distance is the linear extension from the end of the antenna (e.g., 1106) to the outer periphery. The distance δdO between the antennas 1106-1109 may be different. For example, the relative difference in the distance δdO between at least some or all of the antennas 1106-1109 may be at least 2%, at least 5%, at least 8%, at least 10%, or at least 15%. In other cases, the relative difference in the distance δdO may be at most 45%, at most 40%, at most 35%, at most 30%, or at most 25%. Furthermore, the relative difference in δdO may be within a range that includes any of the minimum and maximum percentages described herein.

In an exemplary material removal operation of the abrasive article 1100, the longest antenna 1107 may contact the actual material removal surface (e.g., the surrounding surface) and a portion of the antenna 1107 may be removed. As wear of the abrasive article progresses, portions of antennas 1108, 1106, and 1104 may be removed. As the antennas decrease in size, the response energy from the electronic device decreases. The data receiving device may sense the change in the received signal and the operator may be alerted to the wear. In some instances, the data receiving device may calculate the change in response energy and calculate to indicate the wear level.

In some embodiments, the wear detection sensor may include an electronic device including an electronic element and an antenna, where the antenna may include a surface area that is greater than the electronic element. For example, the electronic device may include multiple antennas coupled to the electronic element, where at least one, some, or each of the antennas may have a surface that is greater than the surface area of the electronic element.

In another case, the wear detection sensor may include a plurality of electronic devices, at least one of which may include an antenna coupled to the electronic element, and the antenna may have a larger surface area than the electronic element. In a particular case, some or each of the plurality of electronic devices may include an antenna coupled to the electronic element, and the antenna may have a larger surface area than the electronic element. In another particular case, one or more of the plurality of electronic devices may include a plurality of antennas coupled to the electronic element, and at least one or more of the plurality of antennas may have a larger surface area than the electronic element. In a more particular case, all of the antennas may have a larger surface area than the electronic element to which the antenna is coupled.

In some embodiments, the electronic device may be located on the non-abrasive portion of the body of the abrasive article, the abrasive portion, or both. In some cases, the antenna may be coupled to the electronic element and located on the non-abrasive portion of the body of the abrasive article. As used herein, non-abrasive portion is intended to refer to a portion of the abrasive article body that is essentially free of abrasive particles. The non-abrasive portion may or may not include an adhesive material. Abrasive portion is intended to refer to a portion of the abrasive article body that includes an adhesive matrix and abrasive particles contained in the adhesive matrix. Abrasive body is intended to refer to an adhesive body that includes an adhesive matrix and abrasive particles dispersed in the adhesive matrix, the adhesive body being essentially free of non-abrasive portions.

In some embodiments, the wear detection sensor may include an antenna that includes a flared body. In some cases, the wear detection sensor may include multiple antennas, one or more of which may include a flared body. FIG. 12 includes a top view of an abrasive article 1200 that includes an abrasive body 1201 that includes an inner circumferential region 1214 and an outer circumferential region 1215. In some cases, the body may include a central region 1213. The central region may include a flange region or a hub.

The wear detection sensor 1203 may include a first electronic device 1204 including an electronic element 1205 disposed in a central region 1213 and an antenna 1207. The second electronic device 1208 includes an electronic element 1209 positioned in an inner circumferential region 1214 and an antenna 1211. In another case, the first and second electronic elements 1205 and 1209 may be disposed outside the central region 1213. In yet another case, both the first and second electronic elements 1209 and 1205 may be disposed in the inner circumferential region 1214. In yet another case, one of the first and second electronic elements 1205 and 1209 may be disposed in the inner circumferential region 1214 and the other may be disposed in the outer circumferential region 1215. In a particular case, neither of the electronic elements is disposed in the outer circumferential region 1215. In another particular case, at most one of the electronic elements may be disposed in the central region 1213. In more particular cases, at least some of the electronic elements are disposed in different regions, including a central region 1213, an inner circumferential region 1214, and an outer circumferential region 1215.

The antennas 1207 and 1211 may be spaced apart from one another in a circumferential, radial, axial, or any combination thereof, direction of the abrasive body 1201. The antennas 1207 and 1211 may extend radially, axially, or any combination thereof along a portion of the abrasive body. The antenna 1207 may extend from a location in the central region 1213, over the entire radial distance of the inner circumferential region 1214, and into the outer circumferential region 1215. The ends of the antenna 1207 may be spaced apart from or aligned with the outer periphery or material removal surface (e.g., the peripheral surface) of the abrasive body. As shown, one of the ends of the secondary antenna 1207 may reach the outer periphery or material removal surface.

The antennas 1211 may extend from a location in the inner circumferential region 1214 into the outer circumferential region 1215. At least one of the antennas 1211 may have a terminal end that may reach the outer periphery.

As shown, each of the secondary antennas 1207 and 1211 may include a flared body. The width of the body may increase as the secondary antennas 1207 and 1211 extend toward the periphery or peripheral surface. By way of example, the width W of the end of the secondary antenna 1207 or 1211 closer to the periphery of the body 1201 may be greatest compared to the width of another portion of the antenna.

In some cases, the antenna 1207 or 1211, or both, may be attached to a major surface of the polishing body 1201. By way of example, the antenna 1207 or 1211, or both, may extend along a portion of the major surface of the polishing body. In other cases, a portion of the antenna 1207 or 1211, or both, may be exposed to the outside environment. By way of example, the secondary antenna 1207 or 1211, or both, may be partially embedded in the polishing body 1201. In other cases, the antenna 1207 or 1211, or both, may include a portion that protrudes outside of a surface portion of the inner circumferential region 1214 of the polishing body 1201.

In other cases, antenna 1207 or 1211 may extend over a larger surface area of the polishing body compared to electronic device 1204 or 1205, but be a shape other than a flared body. By way of example, antenna 1207 and/or 1211 may be shaped to include a triangle, rectangle, square, or irregular shape. Antennas 1207 and 1211 may be the same or different shapes.

In another case, either or each of antennas 1207 and 1211 may extend over a certain surface area of the polishing body, which may facilitate improved data transmission and/or continuous power supply to electronic devices 1204 and/or 1208. By way of example, either or each of antennas 1207 and 1211 may extend over at least 1/20 of the surface area of the major or peripheral surface of polishing body 1201, e.g., at least 2/20, at least 3/20, at least 4/20, or at least 5/20 of the surface area of the major or peripheral surface of polishing body 1201. In another example, either or each of antennas 1207 and 1211 may extend over at most 10/20 of the surface area of the major or peripheral surface of abrasive body 1201, e.g., at most 9/20, at most 8/20, at most 7/20, at most 6/20, at most 5/20, at most 4/20, or at most 3/20 of the surface area of the major or peripheral surface of abrasive body 1201. Additionally, either or each of antennas 1207 and 1211 may extend over a surface area that includes any of the minimum and maximum values set forth herein.

FIG. 13 includes a top view of an abrasive article 1300 that includes an abrasive body 1301. The abrasive body 1301 can include an inner circumferential region 1302 and an outer circumferential region 1303. In some cases, the abrasive body 1301 can include a central region 1310.

The wear detection sensor 1304 may include a first electronic device including an electronic element 1305 coupled to an antenna 1306 and a second electronic device including an electronic element 1307 coupled to an antenna 1308.

The antennas 1306 and 1308 may include curved portions that may extend circumferentially around the abrasive body 1301. In certain cases, the antennas 1306 and 1308 may include lengths that may extend circumferentially. In further cases, the antennas 1307, 1308, or both, may extend circumferentially, axially, radially, or any combination thereof. In other cases, the antennas 1306 and 1308 may have the same or different lengths.

In another instance, the antennas 1306, 1308, or both, may extend a certain length along a portion of the polishing body 1301. In an aspect, the antennas 1307, 1308, or both, may extend along a portion of the main surface, the peripheral surface, or a combination thereof. In another aspect, one or each of the antennas 1306 and 1308 may extend a certain length that may facilitate improved data transmission and/or continuous power supply. By way of example, one or each of the antennas 1306 and 1308 may extend at least 1/10 of the circumference of the polishing body 1301, e.g., at least 2/10, at least 3/10, at least 4/10, at least 5/10, at least 6/10, or at least 7/10 of the circumference of the polishing body 1301. In other cases, one or each of antennas 1306 and 1308 may extend up to 9/10 of the circumference of abrasive body 1301, e.g., up to 8/10, up to 7/10, up to 6/10, up to 5/10, or up to 4/10 of the circumference of abrasive body 1301. Additionally, one or each of antennas 1306 and 1308 may extend a length range that includes any of the minimum and maximum values stated herein.

In another case, either or each of antennas 1306 and 1308 may extend over a certain surface area of the polishing body, which may facilitate improved data transmission and/or continuous power supply to electronic devices 1305 and/or 1307. By way of example, either or each of antennas 1306 and 1308 may extend over at least 1/20 of the surface area of the major or peripheral surface of polishing body 1301, e.g., at least 2/20, at least 3/20, at least 4/20, or at least 5/20 of the surface area of the major or peripheral surface of polishing body 1301. In another example, either or each of antennas 1306 and 1308 may extend over up to 10/20 of the surface area of the major or peripheral surface of abrasive body 1201, e.g., up to 9/20, up to 8/20, up to 7/20, up to 6/20, up to 5/20, up to 4/20, or up to 3/20 of the surface area of the major or peripheral surface of abrasive body 1301. Additionally, either or each of antennas 1306 and 1308 may extend over a surface area that includes any of the minimum and maximum values set forth herein.

As shown, each of the antennas 1306 and 1308 may have an arc shape. The antennas 1306 and 1308 may extend toward one another and may be spaced apart radially, axially, circumferentially, or a combination thereof.

Antennas 1306 and 1308 may extend along a portion of inner circumferential region 1302, a portion of outer circumferential region 1303, or both. In some cases, antennas 1306 and 1308 and electronic devices 1305 and 1307 may be disposed outside of central region 1310. In other cases, one of electronic devices 1307 and 1305 may be disposed in central circumferential region 1310 or outer circumferential region 1303.

In some cases, one or each of the antennas 1306 and 1308 may extend along a portion of the major surface of the abrasive body. In certain cases, one or each of the antennas 1306 and 1308 may be attached to the major surface of the abrasive body. In other cases, one or each of the antennas 1306 and 1308 may be at least partially embedded in the abrasive body. In further cases, at least one or each of the antennas 1306 and 1308 may include a portion exposed to the outside environment. In certain cases, at least one or each of the antennas 1306 and 1308 may include a portion that protrudes outside of the surface portion of the inner circumferential region 1302.

In another embodiment, the wear detection sensor may include a certain number of electronic devices that may facilitate improved response of the electronic device to the data receiving device. As an example, the wear detection sensor may include at least one electronic device, for example, at least two, at least three, at least five, at least six, or at least seven electronic devices. In further embodiments, the wear detection sensor may include up to 45 electronic devices, up to 40, up to 35, up to 30, up to 25, up to 20, up to 15, up to 12, up to 10, up to 9, or up to 8 electronic devices. Furthermore, the number of electronic devices may be within a range including any of the minimum and maximum values stated herein. As an example, the wear detection sensor may include 1 to 45 electronic devices.

In one aspect, the wear detection sensor may include a plurality of electronic devices spaced apart from one another radially, axially, circumferentially, or a combination thereof. In another aspect, at least some of the plurality of electronic devices may be disposed at an angle to one another. In another aspect, some of the electronic devices may be radially aligned. In yet another aspect, some of the electronic devices may be parallel. In a further aspect, the plurality of electronic devices may extend toward the material removal surface of the abrasive body.

14 includes a top view of an abrasive article 1400 including an abrasive body 1401 and a wear detection sensor including a plurality of electronic devices 1402 extending along a portion of the abrasive body 1401. The plurality of electronic devices 1402 may include the same or different electronic devices, including any of the electronic devices described in the embodiments of this disclosure. In certain cases, the plurality of electronic devices 1402 may include RFID tags or sensors, NFID tags or sensors, or any combination thereof.

In some cases, one or more of the electronic devices 1402 may extend along a portion of a major surface, a peripheral surface, or a combination thereof, of the polishing body 1401. In other cases, one or more or each of the electronic devices 1402 may be partially embedded or entirely embedded in the polishing body.

The polishing body 1401 may include an inner circumferential region 1404 and an outer circumferential region 1403. A plurality of electronic devices 1402 may be disposed in the outer circumferential region 1403. In some cases, one or more of the electronic devices 1402 may be disposed in the inner circumferential region 1404. In further cases, one or more of the electronic devices 1402 may extend along a portion of the inner circumferential region 1404 and a portion of the outer circumferential region 1403. In another case, one or more of the electronic devices 1402 may include an end that is aligned with the material removal surface of the polishing body 1401.

At least some of the electronic devices 1402 may include an electronic element 1410 and an antenna 1411. The electronic element 1410 may be positioned within the inner circumferential region 1405.

During operation of the abrasive 1400, one or more of the electronic devices may contact the material removal surface and a portion of the electronic device may be removed. A damaged electronic device or devices may reflect reduced power in response to the data receiving device or may not respond when inactive. The reduction in reflected energy may be sensed and calculated by the data receiving device, allowing an operator to be alerted to the wear condition of the abrasive article 1400 and determine when the abrasive article 1400 should be replaced.

15 includes a plan view of a portion of an abrasive body 1500 of another abrasive article. The abrasive body 1500 can include an inner periphery 1501 that defines a center hole of the abrasive body 1500, and an outer periphery 1502. In some cases, the outer periphery can define a material removal surface. In some cases, the abrasive body can include a major surface 1503. In other cases, the abrasive body can include a peripheral surface 1503.

A wear detection sensor including multiple electronic devices may include a first electronic device 1504 and a second electronic device 1505. The first and second electronic devices 1504 and 1505 may be staggered and arranged parallel to one another. The first and second electronic devices 1504 and 1505 may extend along a portion of the polishing body 1500 and may be spaced apart from one another in a radial, axial, circumferential, or combination thereof. In some cases, the first and second electronic devices 1504 and 1505 may extend along the surface 1503. In other cases, the first and second electronic devices 1504 and 1505 may extend toward the material removal surface in a radial, axial, or combination thereof. In further cases, one or each of the electronic devices 1504 and 1505 may be partially or entirely embedded in the polishing body 1500.

The first electronic device 1504 may include a first length L1 extending between end 1512 and end 1511, with end 1511 being closer to the inner periphery 1501 compared to end 1512 and end 1512 being closer to the outer periphery 1502 compared to end 1511.

The second electronic device 1505 may include a second length L2 extending between end 1513 and end 1514, with end 1513 closer to inner periphery 1501 compared to end 1514, and end 1514 closer to outer periphery 1502 compared to end 1513. The lengths, L1 and L2, may be the same or different.

In some aspects, the distance δdI1 from the end 1511 to the inner periphery 1501 can be greater than the distance δdI2 from the end 1513 to the inner periphery 1501. By way of example, the relative difference between δdI1 and δdI2 can be at least 2%, at least 5%, at least 10%, at least 12%, at least 15%, at least 20%, at least 30%, at least 40%, or at least 50%. In other cases, the relative difference between δdI1 and δdI2 can be at most 80%, at most 70%, at most 60%, at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%. Additionally, the relative differences δdI1 and δdI2 can be within a range that includes any of the minimum and maximum percentages described herein.

In another aspect, the distance δdO2 from the end 1514 to the periphery 1502 can be greater than the distance δdO1 from the end 1512 to the periphery 1502. By way of example, the relative difference between δdO1 and δdO2 can be at least 2%, at least 5%, at least 10%, at least 12%, at least 15%, at least 20%, at least 30%, at least 40%, or at least 50%. In another instance, the relative difference between δdO1 and δdO2 can be at most 80%, at most 70%, at most 60%, at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%. Additionally, the relative differences δdO1 and δdO2 can be within a range that includes any of the minimum and maximum percentages described herein.

In an exemplary operation of the abrasive article, the first electronic device 1504 may be damaged faster than the second polishing device 1505, which may cause a change in the signal received by the data receiving device. As an example, when wear reaches the location 1507 of the first electronic device 1504, the first electronic device 1504 may be damaged and become inactive (e.g., non-functional), while the second electronic device 1505 may remain functional. The signal change, such as the strength or intensity of the signal, may be measured and/or calculated by the data receiving device, which may send a wear warning to the operator. In certain aspects, the electronic devices 1504 and 1505 may be connected to each other when wear reaches the location 1507 of the first electronic device.
The electronic devices 1502 and 1503 may be positioned such that when a certain position, such as 80% wear, is reached, the wear level can be determined. By way of example, electronic devices 1504 and 1505 may be positioned such that when position 1507 is reached the wear level may be 50%. As operation continues, position 1506 may be reached and the second electronic device may be damaged. Further changes to the signal received by the data receiving device may be used to send a warning of another wear level, such as 80% wear, to alert the operator of the approaching end of life of the abrasive article.

In some exemplary formation processes, the abrasive body precursor may be subjected to a 20-30 hour heating cycle to form the final formed abrasive body. In some cases, electronic devices such as 1504 and 1505 may be subjected to the same heating cycle. In these cases, electronic devices 1504 and 1505 may include a protective layer to promote heat resistance of the electronic device and/or improve coupling of the electronic device to the abrasive body. The protective layer may cover at least a portion of the electronic device, and in certain cases, the protective layer may encapsulate the entire electronic device. In certain aspects, the protective layer may include a heat resistant material. In another aspect, the protective layer may include a lead protection material as described in embodiments of the present disclosure. In certain aspects, the protective layer may include a polyimide film.

In other cases, electronic devices such as 1504 and 1505 may be coupled to the polishing body after completion of the heating cycle. In an exemplary implementation, an opening may be formed in the wheel mounting plate and/or polishing body to accommodate the electronic device using a snap-fit arrangement or the like. The electronic device may be secured to an outer surface of the mounting plate and/or polishing body. In certain cases, a coating may be applied over the electronic device and may also be applied over at least a portion of the mounting plate and/or a portion of the outer surface of the polishing body. The coating may help secure the electronic device and/or protect the electronic device from the outside environment. An exemplary coating may include an epoxy.

In another case, the electronic device, such as 1504 and 1505, may include components that can be separately attached to the polishing body. For example, the electronic device may include a two-piece tag that includes an antenna and an integrated circuit, such as an RFID circuit. The antenna may be attached to the polishing body before the heating cycle, and the integrated circuit may be attached after the heating cycle. In a particular implementation, an opening may be formed in a mounting plate that is attached to the polishing body precursor, and the antenna may be attached near a cutout in the mounting plate to an outer surface of the polishing body precursor, such as the peripheral surface. In some cases, a non-abrasive portion, such as a layer of fiber, may be wrapped over the antenna and at least a portion of the peripheral surface. After the heating cycle, the antenna may be attached to the polishing body and/or the non-abrasive portion, and the integrated circuit may be placed in the opening of the mounting plate via a snap-fit configuration and attached to the antenna. In a particular case, the antenna may be a dipole antenna. In another particular case, the dipole antenna may be formed using conductive materials, including, for example, metal wire, such as copper wire, conductive ink. In another particular case, the dipole antenna may include a thin film, such as a thin metal foil, and in a more particular case, the dipole antenna may include a thin copper foil tape. In another particular case, the electronic device may include a printed integrated circuit on a flexible substrate (e.g., PCB) and the antenna may be attached to the integrated circuit.

16A includes a diagram of an abrasive article 1600 including a body 1601. The wear detection sensor may include an electronic device including an electronic element 1605 and an antenna 1606. The electronic element 1605 may be positioned within an inner circumferential region 1602 of the abrasive body, and the antenna 1606 may extend along a portion of the inner circumferential region 1602 and a portion of the outer circumferential region 1603 toward the material removal surface, i.e., the peripheral surface.

In a material removal operation utilizing the abrasive article 1600, as the outer diameter DO decreases, the size of the antenna 1606 may begin to decrease. The reduction in the size of the antenna may reduce the energy reflected by the antenna. With reference to FIG. 16B, as the wheel diameter DO decreases, the reduction in reflected energy increases. The outer diameter DO is a function of the reduction in energy reflected by the antenna. Wear of the abrasive article can be determined based on the reduction in reflected energy.

FIG. 17A includes a cross-sectional view of an abrasive article 1701 including a body 1702 and a wear detection sensor 1703 embedded entirely within the abrasive body 1702. The body may include a center hole 1705, an inner circumferential region 1706, and an outer circumferential region 1707. The boundary between the inner and outer regions is indicated by a dotted line.

The wear detection sensor 1703 may include an electronic element 1709 positioned within the inner circumferential region 1706 and an antenna 1708 extending in a serpentine shape toward the material removal surface 1704. In another case, the antenna may be arranged in the shape of a loop or multiple loops. Such antenna shapes and the like may facilitate improved wear detection. For example, during the material removal process, multiple portions of the antenna may be removed at the same wear level of the abrasive body, which may increase the amount of data generated by the electronic device. In certain cases, the data may be compared and used to verify the wear level of the abrasive body.

In some implementations, the antenna may be arranged such that a portion of the antenna may protrude from the exterior of the major surface of the abrasive body. As shown in FIG. 17B, the abrasive article 1701 may include a body 1702 and a wear detection sensor 1713 embedded in the abrasive body 1702. The wear detection sensor 1713 may include an electronic element 1709 and an antenna 1718, with a portion 1720 of the antenna 1718 raised above the major surface 1714. The raised portion 1720 abuts the inner circumferential region 1716 and is visible when viewed from the major surface 1714, which allows for visual observation of the wear of the abrasive body and may help confirm the wear level detected by the data receiving device. As an example, the size of the raised portion 1720 may begin to decrease, which may be an indicator of approaching end of life. In another instance, the disappearance of the raised portion 1720 may be an indicator that the abrasive article 1701 should be replaced.

The abrasive particles contained within the bond material of the abrasive article may include oxides, carbides, nitrides, borides, oxynitrides, oxyborides, diamond, or any combination thereof. In certain aspects, the abrasive particles may include a superabrasive material, such as cubic boron nitride or diamond.

In one embodiment, the average particle size (D50) of the abrasive particles may be at least 0.1 microns, or at least 0.5 microns, or at least 1 micron, or at least 2 microns, or at least 5 microns, or at least 8 microns. In another embodiment, the average particle size of the abrasive particles may be 6000 microns or less, e.g., 5000 microns or less, or 3000 microns or less, or 2000 microns or less, or 1500 microns or less, or 1000 microns or less, or 900 microns or less, or 800 microns or less, or 500 microns or less, or 300 microns or less. The average particle size of the abrasive particles may be within a range including any of the minimum and maximum values set forth above.

The adhesive material of the abrasive article of the present disclosure may have a specific adhesive chemistry that may facilitate the manufacture and performance improvement of the abrasive article. The adhesive material may be an inorganic material, an organic material, or a combination thereof. The adhesive material may have a certain porosity or free porosity. In an embodiment, the adhesive material may be an inorganic material, such as a metal, a metal alloy, a ceramic, a glass, a ceramic, a cermet, or any combination thereof. The adhesive material may have at least one of a single crystal phase, a polycrystalline phase, an amorphous phase, or any combination thereof. In yet a further aspect, the adhesive material may include an oxide, a boride, a nitride, a carbide, or any combination thereof.

In another embodiment, the adhesive material may be an organic material such as a natural material, a synthetic material, a polymer, a resin, an epoxy, a thermoset, a thermoplastic, an elastomer, or any combination thereof. In certain embodiments, the organic material may include phenolic resins, epoxy resins, polyester resins, polyurethanes, polyesters, polyimides, polybenzimidazoles, aromatic polyamides, modified phenolic resins (epoxy-modified and rubber-modified resins, or phenolic resins blended with plasticizers), or any combination thereof.

The present disclosure further relates to a system for detecting wear in an abrasive article. The system may include an abrasive body including abrasive particles in a bonding material and a wear detection system coupled to the abrasive body. The wear detection system may include a wear detection sensor including at least one lead configured to change state between an active state and an inactive state, and at least one logic device coupled to the wear detection sensor and configured to detect the change in state of the at least one lead and generate a wear signal based on the change in state. In one aspect, the wear signal may correspond to a voltage increase measured across an electrical circuit of the at least one lead.

In another embodiment, a system for detecting wear in an abrasive article may include any of the abrasive articles described in the embodiments herein and a data receiving unit configured to receive data, such as a wear signal generated by a wear detection sensor. In certain aspects, the data receiving unit may be further configured to transmit data, provide energy to the wear detection sensor, transmit a signal to the wear detection sensor, and receive a response from the wear detection sensor, or a combination thereof. In certain aspects, the electronic device, antenna, or electronic element may be powered by the data receiving unit in a wireless manner. In another aspect, the data receiving unit may include a data receiving device, a database, a system, or a combination thereof. Exemplary data receiving devices may include a reader, an interrogator, a mobile phone, a computer, a database, or a combination thereof.

In further cases, the system may include additional antennas, which may not be coupled to the electronic device. In certain cases, the antennas may serve to boost signals generated by the wear detection sensor, the data receiving unit, or both.

FIG. 18 includes a diagram of an exemplary system for detecting wear in an abrasive article 1803 including a wear detection sensor 1804. The abrasive article 1803 is mounted in a grinding machine including a metal cage 1801 and utilized in a material removal process. The metal cage 1801 may include an opening and a booster antenna 1805 is disposed in the opening. The system may further include a data receiving unit including an edge receiving antenna 1806, an edge calculation processor 1807, or a combination thereof. In some instances, the edge calculation process may be connected to a cloud or the like.

The metal cage may adversely affect signal transmission. With the aid of the booster antenna 1805, the signal generated by the wear detection sensor 1804, such as a wear signal or reflected energy or another signal, may be amplified and/or transmitted by the booster antenna and received by the edge receiving antenna 1806 and the processor 1807.

The present disclosure further relates to a method for detecting wear of an abrasive article. In one embodiment, the method for detecting wear of an abrasive article may include performing a material removal process on the abrasive article. The abrasive article may include an abrasive body having abrasive particles contained within an adhesive material, and may have a wear detection sensor embedded in at least a portion of the abrasive body, or the wear detection sensor may extend along an outer surface of the abrasive body. During the material removal process, the abrasive article may wear and material of the abrasive body is removed, which may be detected by a wear signal generated by the wear detection sensor. The wear signal may be based on the removal of at least a portion of the wear detection sensor. As described above, the wear detection sensor may include at least one lead, and the wear signal may correspond to an inactive state of one of the at least one lead by interrupting a current through the lead.

In another embodiment, a method of detecting wear in an abrasive article may include removing at least a portion of a wear detection sensor attached to at least a portion of the abrasive body and generating a wear signal based on the removal of at least a portion of the wear detection sensor. In one aspect, removing at least a portion of the wear detection sensor may include removing a portion of an antenna. In a further aspect, a reduction in the length or surface area of the antenna or a combination thereof may result in the generation of the wear signal. In a further aspect, the wear signal may be received and interpreted by a data receiving device as an indicator of the wear level.

In another aspect, removing at least a portion of the wear detection sensor may include removing a first portion of the first electronic device and removing a second portion of the second electronic device. In a further aspect, a first wear signal may be generated based on the removal of the first portion and a second wear signal may be generated based on the removal of the second portion. In yet another aspect, the first and second wear signals may be compared by a data receiving unit to determine the wear level of the abrasive article. In yet another aspect, additional portions of the electronic device, such as a third portion or more, may be removed and additional wear signals may be generated and used to ascertain the wear level.

In another embodiment, the method of detecting wear of an abrasive article may include improving the response of a wear detection sensor. In one particular implementation, the abrasive article may be placed in a grinding machine that includes a metal cage. Only a portion of the abrasive article may be exposed to the external environment in the grinding operation. The metal cage may adversely affect the signal transmission of the wear detection sensor, so that the signal may be transmitted only when the wear detection sensor is exposed to the external environment. As an example, the data receiving device may receive energy reflected by the electronic device only when the wear detection sensor is exposed, which may result in a low data output frequency by the data receiving device. As shown in FIG. 19A, if the wear detection sensor includes one electronic device, the reflected energy may be received at intervals. Increasing the number of electronic devices may help to shorten the intervals, and in certain cases, it may be possible to receive the reflected energy continuously. In certain aspects, the wear detection sensor may include at least two, at least four, or more electronic devices to improve the response of the wear detection sensor to the data receiving device. In another aspect, the method of detecting wear of an abrasive article may include improving the frequency of the data output by the data receiving device. As shown in FIG. 19B, when a wear detection sensor includes four electronic devices, reflected energy can be detected at shorter intervals compared to a wear detection sensor having one electronic device.

Further embodiments are directed to methods of detecting vibration, sound, revolutions per minute, cracks, and/or other operating conditions of the abrasive article. The wear detection sensor described in the embodiments herein may be suitable for detection. By way of example, certain operating conditions such as cracks, vibrations, and sound that can be detected by the wear detection sensor may affect the resistance or impedance of the electric field, causing a signal change. In some cases, one or more additional components, such as another electronic device, a logic element, a passive element, a lead, an antenna, etc., may be coupled to the wear detection sensor to facilitate detection of the operating conditions of the abrasive article.

20 includes a diagram of a particular example of a wear sensor 2000, according to an embodiment. The wear sensor 2000 may include a sensing circuit 2001, a microcontroller 2002, an RFID transceiver 2003, and an antenna 2004. In an embodiment, the sensing circuit 2001 may convert a magnetic field into an equivalent digital electrical output (current/voltage). Alternatively, the wear sensor 2000 may include an analog-to-digital converter for converting the sensing signal. In another embodiment, the wear sensor 2000 may include additional components, such as passive elements. By way of example, the wear sensor 2000 may include a memory for storage of data. In an embodiment, the wear sensor 2000 may be included in a package that is printed or attached to a substrate.

The microcontroller 2002 may receive signals from the sensing circuit 2001 and transmit relevant data to the RFID transceiver 2003 and/or the external communication unit. The microcontroller 2002 may perform certain operations, such as determining the wear level based on the sensing signal received from the sensing circuit and/or transmitting data related to the wear level to the RFID transceiver 2003. In some cases, the data transmitted from the microcontroller 2002 may include additional information, such as the sensing signal, the wear level, and/or instructions to adjust the grinding/cutting parameters and/or to terminate the current grinding/cutting operation, an indication of the appropriate grinding/cutting operation, etc., or any combination thereof. The microcontroller may also store the data in the transceiver 2003 or memory, and the data may be referenced for the next operation using the polishing tool. Additionally or optionally, the microcontroller 2002 may receive data from the RFID transceiver 2003 and transmit the data to the sensing circuit 2001.

The antenna 2004 may be directional or omnidirectional. The antenna 2004 may function to receive and/or transmit signals and/or data to an external communication unit. The sensing circuit 2000 may be battery powered, wire powered, or wirelessly powered through the antenna 2004, Wi-Fi, Bluetooth, or any combination thereof.

Exemplary sensing circuitry may include a magnetometer, such as a three-axis magnetometer, a temperature and/or humidity sensor, a three-axis accelerometer, a capacitive input interface, or the like, or any combination thereof.

The magnetometer may sense the ambient magnetic field and convert it to a digital electrical output. In applications involving ferrous workpieces, the inherent magnetic field of the workpiece may be the source of magnetic field fluctuations for the magnetometer. The magnetometer may sense the proximity of the workpiece to the grinding tool. In some applications, the magnetometer may function as a counter indicating the number of cuts performed on a single workpiece, as changes in the dimensions of the workpiece may cause changes to the magnetic field. In other applications, wear on the grinding tool may be detected and indicated by sudden changes to the magnetic field. In some cases, interruption of the grinding by foreign objects may be detected by disturbance of the magnetic field. Improper tilting of the workpiece causes a shift in the magnetic field that may be sensed by the magnetometer.

The temperature and/or humidity sensor may sense the ambient environmental temperature and/or humidity and in some cases may convert the signal into an equivalent digital electrical output. In some cases, the temperature and/or humidity sensor may be based on capacitive sensing and may not be affected by the magnetic fields of a ferrous environment. In some cases, the temperature and/or humidity sensor may sense the presence of coolant on the workpiece, improper application of coolant, or any combination thereof, due to the effect on the volume of the coolant.

The three-axis accelerometer may be based on a MEMS accelerometer that senses acceleration in three axes. The three-axis accelerometer may sense vibration and angular acceleration of the polishing tool and convert the sensed signal into an equivalent digital electrical output. In some cases, acoustic data may be obtained by detecting surface acoustic waves. In other cases, the three-axis accelerometer may sense wheel rpm by calculating the number of repeated grinding cycles.

In some cases, the wear sensor may further include a capacitive plate or wire when using a capacitive input interface as the sensing circuit. The capacitive plate or wire may be external to the components shown in FIG. 20. The capacitive plate or wire may sense variations in density of the abrasive body, such as material loss or cracks in the abrasive body. The change in capacitance may be sensed by the capacitive input interface and converted to an equivalent digital electrical output.

21 includes a diagram of components of a radio frequency reader 2100, including a radio frequency unit (e.g., transceiver) 2106. The radio frequency unit 2106 may generate radio frequency signals and receive reflected signals and data from a wear sensor, such as the wear sensor 2000. The up-converter 2107 and down-converter 2108 may tune and match frequencies between the control unit 2102 and the radio frequency signals. The DAC unit 2104 and ADC unit 2106 are analog-to-digital converters. The control unit 2102 may control all data collection and may use the same antenna as a transmitter and receiver. The Wi-Fi/Blue?tooth unit 2101 may facilitate communication with an external server, visualization device, cloud, or any combination thereof. The reader 2100 may be powered by a power unit 2103. In other implementations, the reader 2100 may include one or more additional components or fewer components than shown.

The abrasive articles described in the embodiments herein can be employed in a variety of material removal operations where it is desirable to observe the wear stage of the abrasive body during the material removal process. Non-limiting examples include, but are not limited to, bonded abrasives, which can come in a variety of grades, configurations, and shapes. In one particular embodiment, the abrasive article can include a bonded abrasive grinding wheel. More specifically, the abrasive article can be an abrasive wheel configured to be attached to a portion of a vehicle or other object configured to grind railroad tracks.

It will be understood that the abrasive articles of the present disclosure may have any suitable size and shape known in the art.

Many different aspects and embodiments are possible. Some of these aspects and embodiments are described herein. After reading this specification, one of ordinary skill in the art will understand that these aspects and embodiments are merely exemplary and do not limit the scope of the invention. An embodiment may follow any one or more of the embodiments listed below.

EMBODIMENTS EMBODIMENT 1. An abrasive article comprising an abrasive body including abrasive particles contained within an adhesive material, and a wear detection sensor configured to detect a change in a dimension of the abrasive body, wherein at least a portion of the wear detection sensor is coupled to and extends along at least a portion of the abrasive body.
Embodiment 2. An abrasive article comprising an abrasive body comprising abrasive particles contained within an adhesive material, a wear detection sensor comprising at least one lead in contact with the abrasive body, and at least one logic device in communication with the at least one conductive lead.
Embodiment 3. The abrasive article of embodiment 1 or 2, wherein at least a portion of the wear detection sensor extends along an outer surface of the abrasive body.
Embodiment 4. The abrasive article according to any one of embodiments 1 and 2, wherein a first portion of the wear detection sensor is coupled to a portion of the abrasive body, a second portion of the wear detection sensor is coupled to the hub, and the hub is coupled to the abrasive body.
Embodiment 5. The abrasive article of embodiment 4, wherein the first portion comprises at least one lead and the second portion comprises a logic device.
Embodiment 6. The abrasive article of embodiment 4, wherein the first portion includes a logic device and the second portion includes at least one lead extending from the logic device.
Embodiment 7. The abrasive article of any one of embodiments 1 and 2, wherein at least a portion of the wear detection sensor is embedded in the abrasive body.
Embodiment 8. The abrasive article of embodiment 7, wherein the portion of the wear detection sensor embedded in the abrasive body extends deep into the volume of the abrasive body toward the material removal surface of the abrasive body.
Embodiment 9. The abrasive article of embodiment 8, wherein the portion of the wear detection sensor embedded in the abrasive body includes at least one lead extending from the logic device.
Embodiment 10. The abrasive article of embodiment 9, wherein the logic device is coupled to an exterior surface of the abrasive body.
Embodiment 11. The abrasive article of embodiment 10, wherein the logic device is coupled to a hub, and the hub is coupled to the abrasive body.
Embodiment 12. The abrasive article of embodiment 10, wherein the portion of the wear detection sensor comprises a plurality of nodes extending parallel to one another at different depths into the volume of the abrasive body.
Embodiment 13. The abrasive article of embodiment 2, wherein the logic device and the wear detection sensor are coupled to an exterior surface of the abrasive body.
Embodiment 14. The abrasive article of embodiment 1, wherein the wear detection sensor comprises at least one reed in contact with the abrasive body.
Embodiment 15. The abrasive article of any one of embodiments 2 and 14, wherein the wear detection sensor comprises a plurality of leads.
Embodiment 16. The abrasive article of embodiment 15, wherein at least one lead of the plurality of leads extends along a portion of the exterior surface of the abrasive body.
Embodiment 17. The abrasive article of embodiment 15, wherein a majority of the plurality of leads extend along a portion of the exterior surface of the abrasive body.
Embodiment 18. The abrasive article of embodiment 15, wherein each of the leads of the plurality of leads extends along a portion of the outer surface of the abrasive body.
Embodiment 19. The abrasive article of embodiment 15, wherein the multiple reeds have different lengths compared to one another.
Embodiment 20. The abrasive article of embodiment 14, wherein at least one of the leads of the plurality of leads is embedded within the abrasive body.
Embodiment 21. The abrasive article of embodiment 20, wherein all of the leads of the plurality of leads are embedded within the abrasive body.
Embodiment 22. The abrasive article of embodiment 20, wherein at least two of the leads of the plurality of leads have ends spaced apart from one another.
Embodiment 23. The abrasive article of embodiment 22, wherein each of the leads of the plurality of leads comprises an end, each of the ends being spaced apart from one another.
Embodiment 24. The abrasive article of embodiment 23, wherein each of the ends is located at a different position relative to one another.
Embodiment 25. The abrasive article of embodiment 23, wherein each of the ends is embedded at a different depth within the abrasive body relative to one another.
Embodiment 26. The abrasive article of any one of embodiments 2 and 14, wherein at least one lead is partially embedded within the abrasive body.
Embodiment 27. The abrasive article of any one of embodiments 2 and 14, wherein at least one lead is embedded within the abrasive body.
Embodiment 28. The abrasive article of embodiment 2 or 14, wherein at least one lead comprises an elongated plate or wire adapted to vary in resistance with the length of the elongated plate or wire.
Embodiment 29. The abrasive article of embodiment 2 or 14, wherein at least one lead comprises an electrical circuit including two wires connected by a plurality of resistors, the resistors being positioned parallel to one another at different locations along the length of the two wires.
Embodiment 30. The abrasive article of embodiment 2 or 14, wherein at least one lead comprises a metal or metal alloy.
Embodiment 31. The abrasive article of embodiment 1, further comprising a logic device in communication with the wear detection sensor.
Embodiment 32. The abrasive article of any one of embodiments 2, 14, or 31, wherein the logic device comprises a microcontroller configured to detect a change in state of the wear detection sensor.
Embodiment 33. The abrasive article of any one of embodiments 2, 14, or 31, wherein the wear detection sensor comprises at least one lead configured to change state between an active state and an inactive state, and the logic device comprises a microcontroller configured to detect the change in state of the at least one lead.
Embodiment 34. The abrasive article of any one of embodiments 2, 14, or 31, wherein the wear detection sensor comprises a plurality of leads, each of the leads having a terminal end at a different location, and during use, the terminal ends of the leads are adapted to be worn and change state from an active state to an inactive state upon wear.
Embodiment 35. The abrasive article of embodiment 2, 14, or 31, wherein the distance ΔDT perpendicular to the original outer material removal surface of the abrasive body to the end of at least one lead is at least 100 microns, e.g., at least 200 microns, or at least 300 microns, or at least 500 microns, or at least 800 microns, or at least 900 microns, or at least 1000 microns, or at least 5000 microns, and 1.5 meters or less, e.g., 1.3 meters or less, or 1.0 meters or less, or 0.8 meters or less, or 0.5 meters or less, or 0.3 meters or less, or 0.1 meters or less, or 0.05 meters or less, or 0.01 meters or less.
Embodiment 36. The abrasive article of embodiment 2, 14, or 31, wherein the distance ΔDI between the two terminal lead ends relative to each other in the thickness direction of the abrasive body is at least 50 microns, for example, at least 100 microns, at least 250 microns, at least 500 microns, or at least 1000 microns, and 1.5 meters or less, for example, 1.2 meters or less, or 1 meter or less, or 0.8 meters or less, or 0.5 meters or less, or 0.3 meters or less, or 0.2 meters or less, or 0.1 meters or less, or 0.05 meters or less, or 0.01 meters or less.
Embodiment 37. The abrasive article of embodiment 2, 14, or 31, wherein the overall length of at least one lead is at least 100 microns, e.g., at least 200 microns, or at least 500 microns, or at least 1000 microns, or at least 10,000 microns, or at least 50,000 microns, and 10 meters or less, e.g., 8 meters or less, 5 meters or less, 3 meters or less, 2 meters or less, 1.5 meters or less, 1.2 meters or less, 1.0 meters or less, 0.8 meters or less, 0.5 meters or less, 0.3 meters or less, 0.2 meters or less, 0.1 meters or less, 0.05 meters or less, or 0.01 meters or less.
Embodiment 38. The abrasive article of embodiment 2, 14, or 31, wherein each of the at least one lead comprises an electrical circuit.
Embodiment 39. The abrasive article of embodiment 2, 14, or 31, wherein at least one lead is a plurality of leads, and the plurality of leads are combined in an electrical circuit.
Embodiment 40. The abrasive article of embodiment 2, 14, or 31, wherein the at least one reed comprises at least 2 reeds, or at least 3 reeds, at least 5 reeds, at least 7 reeds, or at least 9 reeds.
Embodiment 41. The abrasive article of embodiment 2, 14, or 31, wherein at least one reed comprises 100 or less reeds, e.g., 80 or less reeds, 60 or less reeds, 50 or less reeds, 30 or less reeds, 20 or less reeds, 15 or less reeds, or 10 or less reeds.
Embodiment 42. The abrasive article of embodiment 2, 14, or 31, wherein the logic device further comprises a communication device for wireless communication with an external controller.
Embodiment 43. The abrasive article of embodiment 42, wherein the communication device is a transceiver.
Embodiment 44. The abrasive article of embodiment 43, wherein the communication device is an RFID transceiver.
Embodiment 45. A system for detecting wear in an abrasive article, comprising: an abrasive body comprising abrasive particles contained within an adhesive material; and a wear detection system coupled to the abrasive body, the wear detection system comprising: a wear detection sensor including at least one lead configured to change state between an active state and an inactive state; and at least one logic device coupled to the wear detection sensor and configured to detect the change in state of the at least one lead and generate a wear signal based on the change in state.
Embodiment 46. The system of embodiment 45, wherein the wear signal corresponds to a voltage change measured across an electrical circuit of at least one lead.
Embodiment 47. The system of embodiment 45, wherein each lead of the at least one lead has an independent electrical circuit, and an inactive state of the at least one lead corresponds to an interrupted electrical circuit.
Embodiment 48. A system for detecting wear in an abrasive article, comprising: an abrasive body comprising abrasive particles contained in an adhesive material; and a wear detection system coupled to the abrasive body, the wear detection system comprising: a wear detection sensor including at least one lead configured to change resistance during wear of the abrasive body; and at least one logic device coupled to the wear detection sensor and configured to measure the resistance of the at least one lead and generate a wear signal based on the change in the measured resistance.
Embodiment 49. The system of embodiment 48, wherein at least one lead is an elongated plate or wire adapted to vary in resistance with the length of the elongated plate or wire.
Embodiment 50. The system of embodiment 48, wherein at least one lead comprises an electrical circuit including two wires connected by a plurality of resistors, the resistors being positioned parallel to one another at different locations along the length of the two wires.
Embodiment 51. A method for detecting wear in an abrasive article, comprising: performing a material removal process on an abrasive body comprising abrasive particles contained within an adhesive material; removing at least a portion of a wear detection sensor embedded in at least a portion of the abrasive body; and generating a wear signal based on removing at least a portion of the wear detection sensor.
Embodiment 52. The method of embodiment 51, wherein the wear detection sensor includes at least one lead configured to change state between an active state and an inactive state.
Embodiment 53. The method of embodiment 51, wherein the wear signal is generated by removing at least a portion of at least one lead and changing the lead state from an active state to an inactive state.
Embodiment 54. The method of embodiment 51, wherein the wear signal corresponds to a voltage change measured across an electrical circuit of at least one lead.
Embodiment 55. The method of embodiment 51, wherein the wear signal corresponds to a measured resistance change of at least one lead.
Embodiment 56. The method of embodiment 51, wherein at least one lead is an elongated plate or wire, and the resistance change corresponds to a decrease in length of the elongated plate or wire during wear of the abrasive body.
Embodiment 57. The method of embodiment 51, wherein at least one lead comprises an electrical circuit including two wires connected by a plurality of resistors, the resistors being positioned parallel to each other at different locations along the length of the two wires, and the change in total resistance of the circuit corresponds to the amount of resistors broken down during wear of the abrasive body.
Embodiment 58. An abrasive article comprising:
an abrasive body including abrasive particles contained within a bonding material;
a wear detection sensor coupled to the grinding body;
a wear detection sensor configured to detect a change in a dimension of the abrasive body;
An abrasive article, wherein the wear detection sensor comprises at least one electronic device.
Embodiment 59. The abrasive article of embodiment 58, wherein at least a portion of the wear detection sensor is in direct contact with a portion of the abrasive body.
Embodiment 60. The abrasive article of embodiment 58 or 59, wherein at least one electronic device comprises an antenna.
Embodiment 61. The abrasive article of any one of embodiments 58-60, wherein the wear detection sensor comprises at least one, at least two, at least four, or at least six antennas.
Embodiment 62. The abrasive article of any one of embodiments 58-61, wherein the electronic device is attached to a major surface of the abrasive body, a peripheral surface of the abrasive body, or a combination thereof.
Embodiment 63. The abrasive article of any one of embodiments 58-61, wherein the electronic device is at least partially embedded in the abrasive body.
Embodiment 64. The abrasive article of any one of embodiments 58-61, wherein the electronic device is fully embedded within the abrasive body.
Embodiment 65. The abrasive article of any one of embodiments 58-64, wherein the wear detection sensor comprises an electrical component coupled to at least one electronic device, the electrical component comprising a capacitor, a resistor, an inductor, or a combination thereof.
Embodiment 66. The abrasive article of embodiment 65, wherein the electrical component comprises a first capacitive plate and a second capacitive plate spaced apart from the first capacitive plate.
Embodiment 67. The abrasive article of embodiment 65 or 66, wherein the abrasive body comprises an inner circumferential region and an outer circumferential region, a first capacitive plate is positioned on the inner circumferential region and a second capacitive plate is positioned on the outer circumferential region.
Embodiment 68. The abrasive article of any one of embodiments 65-67, wherein the electrical component is attached to a portion of the abrasive body or is at least partially embedded in the abrasive body.
Embodiment 69. The abrasive article of any one of embodiments 65-68, wherein at least one of the first and second capacitive plates is attached to a major surface of the abrasive body, a peripheral surface of the abrasive body, or a combination thereof.
Embodiment 70. The abrasive article of any one of embodiments 65-69, wherein both the first and second capacitive plates are attached to a major surface or a peripheral surface of the abrasive body.
Embodiment 71. The abrasive article of any one of embodiments 65-69, wherein a first capacitive plate is attached to a major or peripheral surface of the abrasive body and a second capacitive plate is at least partially embedded within the abrasive body.
Embodiment 72. The abrasive article of any one of embodiments 65-68, wherein both the first and second capacitive plates are at least partially embedded in the abrasive body.
Embodiment 73. The abrasive article of any one of embodiments 65-68, wherein both the first and second capacitive plates are entirely embedded within the abrasive body.
Embodiment 74. The abrasive article of any one of embodiments 58-73, wherein the wear detection sensor comprises a loop circuit.
Embodiment 75. The abrasive article of embodiment 74, wherein the loop circuit comprises a resistive wire loop coupled to at least one electronic device.
Embodiment 76. The abrasive article of embodiment 74 or 75, wherein the wear detection sensor comprises a loop circuit comprising an electrical component.
Embodiment 77. The abrasive article of any one of embodiments 74-76, wherein the loop circuit further comprises a resistive element.
Embodiment 78. The abrasive article of embodiment 77, wherein the resistive element comprises a resistor, a resistive wire, or a combination thereof.
Embodiment 79. The abrasive article of any one of embodiments 74-78, wherein the loop circuit comprises a plurality of capacitors, a plurality of resistors, a plurality of inductors, or a combination thereof.
Embodiment 80. The abrasive article of any one of embodiments 58-64, wherein the at least one electronic device comprises an electronic element and an antenna directly and electrically connected to the electronic element, the electronic element comprising a chip, an integrated circuit, logic, a transponder, a transceiver, a memory, a passive element, or any combination thereof.
Embodiment 81. The abrasive article of embodiment 80, wherein the wear detection sensor comprises a plurality of electronic devices including at least one electronic device.
Embodiment 82. The abrasive article of embodiment 80 or 81, wherein the wear detection sensor comprises a plurality of electronic devices, at least some of the electronic devices comprising an antenna.
Embodiment 83. The abrasive article of any one of embodiments 80-82, wherein the wear detection sensor comprises a plurality of electronic devices, each one of the electronic devices comprising an antenna.
Embodiment 84. The abrasive article of any one of embodiments 80-83, wherein the wear detection sensor comprises an electronic device comprising at least one, at least two, at least three, or at least four antennas directly and electrically coupled to the electronic element.
Embodiment 85. The abrasive article of any one of embodiments 80-84, wherein the antenna comprises a thin film antenna.
Embodiment 86. The abrasive article of any one of embodiments 80-85, wherein the antenna comprises a surface area greater than a surface area of the electronic element.
Embodiment 87. The abrasive article of any one of embodiments 80-87, wherein the antenna extends over a larger surface area of the abrasive body as compared to the electronic element.
Embodiment 88. The abrasive article of any one of embodiments 80-87, wherein the antenna is directly and electrically coupled to an integrated circuit.
Embodiment 89. The abrasive article of any one of embodiments 86-88, wherein the electronic device comprising an antenna is coupled to a non-abrasive portion of the abrasive article.
Embodiment 90. The abrasive article of any one of embodiments 80-89, wherein the antenna extends along a portion of the main surface, the peripheral surface, or both toward the material removal surface of the abrasive body.
Embodiment 91. The abrasive article of any one of embodiments 80-90, wherein the antenna is at least partially or entirely embedded in the abrasive body.
Embodiment 92. The abrasive article of any one of embodiments 80-91, wherein the antennas extend radially, axially, circumferentially, or a combination thereof, about the abrasive body.
Embodiment 93. The abrasive article of any one of embodiments 80-92, wherein the antennas are arranged in a loop, a serpentine shape, or a combination thereof.
Embodiment 94. The abrasive article of any one of embodiments 80-93, wherein the electronic element is positioned within an interior circumferential region of the abrasive body, the electronic element comprising an integral element, and the integral element is positioned within the interior circumferential region.
Embodiment 95. The abrasive article of any one of embodiments 80-94, wherein the electronic element is positioned within the non-abrasive portion of the abrasive body and the antenna is positioned within the abrasive portion of the abrasive body.
Embodiment 96. The abrasive article of any one of embodiments 80-95, wherein the wear detection sensor comprises a package that includes at least a portion of the electronic element, the antenna, or a combination thereof.
Embodiment 97. The abrasive article of embodiment 96, wherein the package comprises a protective layer.
Embodiment 98. The abrasive article of embodiment 97, wherein the protective layer comprises a material comprising polydimethylsiloxane (PDMS), polyethylene naphthalate (PEN), polyimide, polyetheretherketone (PEEK), or any combination thereof.
Embodiment 99. The abrasive article of embodiment 98 or 99, wherein the protective layer encapsulates the electronic elements and the antenna.
Embodiment 100. The abrasive article of any one of embodiments 80-99, wherein the wear detection sensor comprises a plurality of antennas, the plurality of antennas having different lengths compared to one another.
Embodiment 101. The abrasive article of embodiment 100, wherein the relative difference in length between the plurality of antennas can be at least 5%, at least 10%, at least 15%, at least 17%, at least 20%, at least 30%, at least 40%, or at least 50%.
Embodiment 102. The abrasive article of embodiment 100 or 101, wherein the relative difference in length between the plurality of antennas can be at most 80%, at most 70%, at most 60%, at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%.
Embodiment 103. The abrasive article of embodiment 102, wherein the multiple antennas extend different distances along the abrasive body toward the material removal surface.
Embodiment 104. The abrasive article of any one of embodiments 100-103, wherein at least one of the antennas is positioned within an interior circumferential region of the abrasive body.
Embodiment 105. The abrasive article of any one of embodiments 100-104, wherein at least one of the antennas extends from the inner circumferential region into the outer circumferential region.
Embodiment 106. The abrasive article of any one of embodiments 100-105, wherein at least one of the antennas is positioned within an outer circumferential region of the abrasive body.
Embodiment 107. The abrasive article of any one of embodiments 80-106, wherein the wear detection sensor comprises a plurality of antennas, at least one of the antennas comprising a flared body.
Embodiment 108. The abrasive article of embodiment 107, wherein each of the plurality of antennas comprises a flared body.
Embodiment 109. The abrasive article of embodiment 107 or 108, wherein at least one of the plurality of antennas extends radially, axially, or a combination thereof from a central region of the abrasive body toward the material removal surface, and the width of the flared body increases as the antenna extends from the central region of the abrasive body toward the material removal surface.
Embodiment 110. The abrasive article of embodiment 107 or 108, wherein at least one of the plurality of antennas extends radially, axially, or a combination thereof across at least a portion of the central region and across at least a portion of the inner circumferential region of the abrasive body.
Embodiment 111. The abrasive article of any one of embodiments 107-110, wherein at least one of the plurality of antennas extends from a central region, over an inner circumferential region, and into an outer region of the abrasive body.
Embodiment 112. The abrasive article of embodiment 111, wherein at least one of the plurality of secondary antennas comprises an end aligned with the material removal surface.
Embodiment 113. The abrasive article of embodiment 111 or 112, wherein each of the plurality of antennas extends over a portion of the interior circumferential region of the abrasive body and into the exterior region.
Embodiment 114. The abrasive article of any one of embodiments 111-113, wherein at least one of the plurality of antennas comprises at least a portion exposed to an exterior environment.
Embodiment 115. The abrasive article of any one of embodiments 111-114, wherein at least one of the plurality of antennas is partially embedded in the abrasive body.
Embodiment 116. The abrasive article of any one of embodiments 111-115, wherein each of the antennas is partially embedded in the abrasive body.
Embodiment 117. The abrasive article of any one of embodiments 111-116, wherein at least one of the antennas comprises a portion that protrudes outside of a surface portion of the inner circumferential region of the abrasive body.
Embodiment 118. The abrasive article of any one of embodiments 111-117, wherein at least one of the antennas extends along a portion of a major surface of the abrasive body.
Embodiment 119. The abrasive article of any one of embodiments 111-118, wherein each of the antennas extends along a portion of a major surface of the abrasive body.
Embodiment 120. The abrasive article of any one of embodiments 80-118, wherein the wear detection sensor comprises a plurality of antennas, and one or more of the plurality of antennas comprises a body including a curved portion.
Embodiment 121. The abrasive article of embodiment 119 or 120, wherein at least one of the plurality of antennas has a curved body, at least a portion of the curved body extending circumferentially about the abrasive body.
Embodiment 122. The abrasive article of embodiment 119 or 120, wherein at least one of the plurality of antennas has a length that extends in a circumferential direction.
Embodiment 123. The abrasive article of any one of embodiments 119-122, wherein each one of the antennas has a length that extends circumferentially about the abrasive body.
Embodiment 124. The abrasive article of any one of embodiments 119-122, wherein one or more of the antennas extend radially, circumferentially, axially, or a combination thereof.
Embodiment 125. The abrasive article of any one of embodiments 119-124, wherein the wear detection sensor may include first and second antennas extending in opposite directions from the same electronic device.
Embodiment 126. The abrasive article of any one of embodiments 119-125, wherein the, or each, of the antennas extends along a portion of the inner circumferential region, a portion of the outer circumferential region, or a combination thereof.
Embodiment 127. The abrasive article of any one of embodiments 119-126, wherein each of the antennas is positioned outside a central region of the abrasive body.
Embodiment 128. The abrasive article of any one of embodiments 119-127, wherein at least one of the electronic elements is positioned outside of a central region of the abrasive body.
Embodiment 129. The abrasive article of any one of embodiments 119-128, wherein each of the electronic elements is positioned outside a central region of the abrasive body.
Embodiment 130. The abrasive article of any one of embodiments 119-129, wherein at least one of the antennas extends along a portion of a major surface of the abrasive body.
Embodiment 131. The abrasive article of any one of embodiments 119-130, wherein at least one of the antennas is attached to a major surface of the abrasive body.
Embodiment 132. The abrasive article of any one of embodiments 119-131, wherein each one of the antennas extends along a portion of a major surface of the abrasive body.
Embodiment 133. The abrasive article of any one of embodiments 119-132, wherein each one of the antennas is attached to a major surface of the abrasive body.
Embodiment 134. The abrasive article of any one of embodiments 119-133, wherein at least one of the antennas is at least partially embedded in the abrasive body.
Embodiment 135. The abrasive article of any one of embodiments 119-134, wherein each of the antennas is at least partially embedded in the abrasive body.
Embodiment 136. The abrasive article of any one of embodiments 119-135, wherein at least one of the antennas comprises a portion exposed to the outside environment.
Embodiment 137. The abrasive article of any one of embodiments 119-136, wherein at least one of the antennas comprises a portion that projects outwardly of a surface portion of the inner circumferential region.
Embodiment 138. The abrasive article of any one of embodiments 119-137, wherein each antenna comprises a portion that projects outwardly of a surface portion of the inner circumferential region.
Embodiment 139. The abrasive article of any one of embodiments 119-138, wherein the antennas have different lengths compared to one another.
Embodiment 140. The abrasive article of any one of embodiments 58-60, wherein the wear detection sensor comprises a plurality of electronic devices.
Embodiment 141. The abrasive article of embodiment 140, wherein the wear detection sensor comprises at least two electronic devices, at least three, at least five, at least six, or at least eight electronic devices, each of which extends along a portion of the abrasive body toward the material removal surface of the abrasive body.
Embodiment 142. The abrasive article of embodiment 141, wherein at least one of the electronic devices extends radially, axially, or a combination thereof, of the abrasive body.
Embodiment 143. The abrasive article of embodiment 141 or 142, wherein at least one electronic element of the electronic device is positioned at an interior circumferential region of the abrasive body.
Embodiment 144. The abrasive article of embodiment 143, wherein the electronic elements include integrated circuits, the integrated circuits being positioned at the inner circumferential region.
Embodiment 145. The abrasive article of any one of embodiments 141-144, wherein at least one of the electronic devices has an end that is aligned with the material removal surface of the abrasive body.
Embodiment 146. The abrasive article of embodiment 145, wherein the wear detection sensor comprises a first electronic device and a second electronic device, the first and second electronic devices being spaced apart from one another and extending along a portion of the abrasive body.
Embodiment 147. The abrasive article of embodiment 146, wherein the first electronic device is positioned closer to the material removal surface compared to the second electronic device.
Embodiment 148. The abrasive article of embodiment 146 or 147, wherein the second electronic device is positioned closer to the inner circumference of the abrasive body compared to the first electronic device.
Embodiment 149. The abrasive article of any one of embodiments 146-148, wherein the first electronic device has a first length extending from a first end to a second end of the first body toward the outer periphery, and the second electronic device has a second length extending from a third end to a fourth end of the first body toward the outer periphery, the first end being closer to the inner periphery than the third end, and the second end being farther from the outer periphery than the fourth end.
Embodiment 150. The abrasive article of embodiment 149, wherein the first length and the second length extend in a radial or axial direction of the abrasive body.
Embodiment 151. The abrasive article of embodiment 149 or 150, wherein the first electronic device is parallel to the second electronic device.
Embodiment 152. The abrasive article of any one of embodiments 149-151, wherein the first and second electronic devices are staggered.
Embodiment 153. The abrasive article of any one of embodiments 149 to 152, wherein the distance δdI1 between the first end and the inner circumference is greater than the distance δdI2 between the third end and the inner circumference, and the relative difference between δdI1 and δdI2 is at least 2%, at least 5%, at least 10%, at least 12%, at least 15%, at least 20%, at least 30%, at least 40%, or at least 50%.
Embodiment 154. The abrasive article of embodiment 153, wherein the relative difference between δdI1 and δdI2 is at most 80%, at most 70%, at most 60%, at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%.
Embodiment 155. The abrasive article of any one of embodiments 149-154, wherein the distance δdO2 between the fourth end and the outer periphery is greater than the distance δdO1 from the second end to the outer periphery, and the relative difference between δdO1 and δdO2 is at least 2%, at least 5%, at least 10%, at least 12%, at least 15%, at least 20%, at least 30%, at least 40%, or at least 50%.
Embodiment 156. The relative difference between δdO1 and δdO2 is at most 80%, at most 7
0%, at most 60%, at most 50%, at most 45%, at most 40%, at most 35%, or at most 30%.
Embodiment 157. The abrasive article of any one of embodiments 58-156, wherein the wear detection sensor comprises an electronic device, the device comprising a chip, an integrated circuit, a data transponder, a radio frequency based tag or sensor with or without a chip, an electronic tag, an electronic memory, a sensor, an analog to digital converter, a transmitter, a receiver, a transceiver, a modulator circuit, a multiplexer, an antenna, a near field communication device, a power source, a display (e.g., an LCD or OLED screen), an optical device (e.g., an LED), a global positioning system (GPS) or device, fixed or programmable logic, or any combination thereof.
Embodiment 158. The abrasive article of any one of embodiments 58-157, wherein the wear detection sensor comprises an electronic device comprising a radio frequency identification tag or sensor, a near field communication tag or sensor, or a combination thereof.
Embodiment 159. The abrasive article of any one of embodiments 58-158, wherein the wear detection sensor comprises a plurality of electronic devices, at least one of the electronic devices being disposed in an interior circumferential region of the abrasive body.
Embodiment 160. The abrasive article of embodiment 159, wherein each of the electronic devices is disposed outside of the exterior circumferential region of the abrasive body.
Embodiment 161. The abrasive article of embodiment 159 or 160, wherein each of the electronic devices is disposed outside a central region of the abrasive body.
Embodiment 162. The abrasive article of embodiment 160 or 161, wherein at least one of the electronic devices is disposed in a central region of the abrasive body.
Embodiment 163. The abrasive article of any one of embodiments 58-162, wherein the wear detection sensor comprises a plurality of electronic devices comprising a plurality of integrated circuits.
Embodiment 164. A system for detecting wear in an abrasive article, comprising:
164. An abrasive article according to any one of embodiments 58 to 163;
a data receiving unit configured to receive data generated by the wear detection sensor.
[0081] Embodiment 165. The system of embodiment 164, wherein the data receiving unit is further configured to transmit data.
[0081] Embodiment 166. The system of embodiment 164 or 165, wherein the data receiving unit is configured to provide energy to the wear detection sensor.
Embodiment 167. The system of embodiment 166, wherein the wear detection sensor comprises an antenna and an electronic element, and the antenna, the electronic element, or both are wirelessly powered by the data receiving unit.
[0081] Embodiment 168. The system according to any one of embodiments 164 to 167, wherein the data receiving unit is configured to transmit a signal to the wear detection sensor and to receive a response from the wear detection sensor.
Embodiment 169. The system of any one of embodiments 164 to 168, further comprising an antenna, the antenna not being coupled to the wear detection sensor.
[0081] Embodiment 170. The system of any one of embodiments 164-169, wherein the antenna is configured to boost a signal generated by the wear detection sensor, the data receiving unit, or both.
[0071] Embodiment 171. The system of any one of embodiments 164-170, wherein the data receiving unit comprises a reader, an interrogator, a mobile phone, a computer, a database, or a combination thereof.
Embodiment 172. The method of embodiment 51, wherein removing at least a portion of the wear detection sensor includes removing a portion of the antenna.
Embodiment 173. The method of embodiment 51 or 172, wherein generating the wear signal is based on a reduction in antenna surface area, length, or a combination thereof.
Embodiment 174. The method of any one of embodiments 51 and 172-173, wherein generating the wear signal includes generating a first wear signal based on removing at least a first portion of the wear detection sensor, and generating a second wear signal based on removing at least a second portion of the wear detection sensor.
Embodiment 175. The method of embodiment 174, further comprising comparing the first wear signal and the second wear signal to determine wear of the abrasive body.
Embodiment 176. The method of embodiment 174 or 175, wherein the wear detection sensor comprises a plurality of electronic devices, a first portion of the wear detection sensor comprises a first portion of a first electronic device, and a second portion of the wear detection sensor comprises a second portion of a second electronic device.
Embodiment 177 The method of embodiment 51, wherein the portion of the wear detection sensor comprises a portion of an antenna.
Embodiment 178. The method of embodiment 177, wherein the wear signal comprises a reduction in energy reflected by the antenna, and the dimension of the abrasive body is a function of the reduction.
Embodiment 179. The method of embodiment 178, further comprising determining a first dimension of the abrasive body based on the first wear signal and a second dimension of the abrasive body based on the second wear signal.
Embodiment 180. The method of embodiment 179, further comprising comparing the first and second dimensions and determining wear of the abrasive body.

Example 1. Manufacturing an abrasive wheel for grinding railroad tracks, including a wear detection sensor The abrasive body of the grinding wheel is formed and pressed. Before the external fiber winding is applied to the wheel, a plurality of five leads are attached to the outer surface of the wheel by gluing, so that the leads extend in the axial direction x towards the outer grinding surface of the wheel, as also shown in FIG. 1. After the external fiber winding and the hub are applied to the wheel, a logic device in the form of a microcontroller is connected to the leads via electrical wiring and is mounted on the inner diameter of the abrasive body of the wheel. The logic device includes an RFID chip for wirelessly transmitting data regarding the wear stage of the abrasive body to an external control device handled by an operator.

Example 2. Wheel operation during track grinding A number of grinding wheels manufactured as described in Example 1 are mounted on a railroad track grinding machine. During the grinding operation, the leads of the wear detection sensor on each wheel break according to the wear of the grinding body. The exact wear of each wheel is measured by the amount of broken leads, which corresponds to the amount of change of the leads from the active phase to the inactive phase (closed circuit to open circuit), and is registered by the logic device. Based on the amount of broken leads, the logic device of each wheel calculates the number of remaining grinding wheel life in % and transmits this number by RFID chip to the control device. The control device collects data of each wheel mounted on the track grinding machine and indicates by a flashing red light bulb during the grinding operation when a particular wheel needs to be replaced.

The above-described embodiments relate to bonded abrasive products, particularly grinding wheels, that represent a departure from the state of the art.

Benefits, other advantages, and solutions to problems have been described above with respect to certain embodiments. However, the benefits, advantages, solutions to problems, and any feature(s) by which any benefit, advantage, or solution may occur or become more pronounced should not be construed as important, essential, or essential features of any or all claims. A material comprising one or more components herein may be construed to include at least one embodiment in which the material consists essentially of one or more of the identified components. The term "consisting essentially of" is construed to include a composition that includes the identified materials and excludes all other materials apart from minor contents (e.g., impurity contents) that do not significantly change the properties of the material. Additionally or alternatively, in certain non-limiting embodiments, any of the compositions identified herein may be essentially free of materials not expressly disclosed. It will be understood that the embodiments herein include ranges of content for certain components in a material, with the content of the components in a given material totaling 100%. The specification and illustrations of the embodiments described herein are intended to provide a general understanding of the structure of the various embodiments. The specification and examples are not intended to serve as an exhaustive and comprehensive description of all elements and features of apparatus and systems that use the structures or methods described herein. Separate embodiments may also be provided in combination in a single embodiment, and conversely, various features that are described for brevity in the context of a single embodiment may also be provided separately or in any subcombination. Furthermore, references to values stated in ranges include any and all values within that range. Many other embodiments will be apparent to those of skill in the art upon merely reading this specification. Other embodiments may be derived from the present disclosure, such that structural substitutions, logical substitutions, or other changes may be made without departing from the scope of the present disclosure. Thus, the present disclosure should be considered illustrative rather than limiting.

Claims (10)

1. An abrasive article comprising:
an abrasive body including abrasive particles contained within a bonding material;
a wear detection sensor configured to detect a change in a dimension of the abrasive body, at least a portion of the wear detection sensor being coupled to and extending along at least a portion of the abrasive body;
the wear detection sensor comprises an electronic device including at least one antenna coupled to an electronic element extending over an outer surface of the abrasive body, at least a portion of the at least one antenna being positioned in an abrasive portion of the abrasive body;
Abrasive articles. The abrasive article of claim 1, wherein the at least one antenna extends toward and has an end aligned with a material removal surface of the abrasive body. The abrasive article of claim 2, wherein the at least one antenna comprises a flared body, the width of the flared body increasing as the length of the antenna extends. The abrasive article of claim 1, wherein the at least one antenna extends over a larger surface area of the abrasive body compared to the electronic element. The abrasive article of claim 1, wherein the wear detection sensor further comprises a loop circuit coupled to the electronic device that extends along a portion of the outer surface, the length of the loop extending toward a material removal surface of the abrasive body. The abrasive article of claim 5, wherein the loop circuit comprises a plurality of capacitors arranged in parallel. The abrasive article of claim 1, wherein the electronic device is a first electronic device, the at least one antenna includes a curved portion extending circumferentially around the abrasive body, and the wear detection sensor includes a second electronic device including at least one antenna including a curved portion extending circumferentially around the first electronic device, and at least one of the antennas extends over at least 1/10 of the circumference of the abrasive article. The abrasive article of claim 1, wherein the electronic device is embedded within a protective layer, the protective layer comprising a material including polydimethylsiloxane (PDMS), polyethylene naphthalate (PEN), polyimide, polyolefin, polyether ether ketone (PEEK), or any combination thereof. The abrasive article of claim 1, wherein the wear detection sensor further comprises a plurality of capacitive plates coupled to the electronic device, the plurality of capacitive plates being spaced apart from one another on the outer surface of the abrasive article in a radial, axial, or circumferential direction of the abrasive article, or any combination thereof. 1. A system for detecting wear in an abrasive article, comprising:
An abrasive article according to claim 1;
a data receiving unit configured to receive data generated by the wear detection sensor.