Automatic tool truing for an led lens cavity lapping system

Fusaomi Nagata, Takanori Mizobuchi, Keigo Watanabe, Maki K. Habib, Tetsuo Hase, Zenku Haga, Masaaki Omoto

Research output: Contribution to journalArticlepeer-review

Abstract

A computer-controlled desktop machine tool with an automatic truing function of a wood-stick tool is described for the long-time lapping process of an LED lens cavity. We have experimentally found that a thin wood stick with a ball-end tip is very suitable for the lapping tool of an LED lens cavity. When the lapping is conducted by a skilled worker, a special oil including minute diamond lapping paste, whose grain size is smaller than 3 μm, is poured into each concave area on the cavity. The wood material tends to compatibly fit both the metallic material of cavity and the diamond lapping paste due to the soft characteristics of wood. The serious problem in using a wood-stick tool is the abrasion of the tool tip. For example, an actual LED lens cavity has 180 concave areas so that the cavity can form small plastic LED lenses with mass production at a time. However, after about five concave areas are finished, the tip of the wood-stick tool is deformed from the initial ball shape. Therefore, to realize a complete automatic lapping system, a novel automatic tool truing is required. The truing of a wood-stick tool means the reshaping to the initial contour, i.e., ballend tip. In this paper, a novel and simple automatic truing method by using cutter location data is proposed and its effectiveness and validity are evaluated through an experiment. The cutter location data is called the CL data, which can be produced from the main processor of 3D CAD/CAM widely used in industrial design fields. The proposed machine tool can easily carry out the truing of a wood-stick tool based on the generally known CL data, which is adistinctive feature of our proposed machine tool.

Original languageEnglish
Pages (from-to)419-431
Number of pages13
JournalInternational Journal of Robotics and Automation
Volume26
Issue number4
DOIs
Publication statusPublished - 2011

Keywords

  • Automatic truing
  • Cutter location data
  • Force sensor
  • LED lens cavity
  • Lapping process
  • Multi-control modes

ASJC Scopus subject areas

  • Software
  • Control and Systems Engineering
  • Modelling and Simulation
  • Mechanical Engineering
  • Electrical and Electronic Engineering
  • Artificial Intelligence

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