System and application method for graded shot peening of blades based on shot peening equipment

Abstract

The system for graded shot peening of blades based on shot peening equipment includes a shot peening robot with an image acquisition unit, a database unit, a comparison unit, a control unit, and a distance acquisition unit. These units comprise application software. The robot's nozzle is mounted on the front end of the robotic arm. An electric proportional valve is connected in series between the spray gun and the shot discharge mechanism. Pressure and flow sensors are installed on the side of the pipes. A camera and a laser rangefinder are installed in front of the spray gun. The laser rangefinder, camera, pressure sensor, and flow sensor are electrically connected to the host computer. The application method of the system for graded shot peening of blades based on shot peening equipment includes five steps. This invention eliminates the need for manual operation, providing convenience for workers, reducing production costs, and ensuring that each processing position of the component meets the requirements for processing pressure, flow rate, spacing, and angle, thus achieving better shot peening quality.

Description

Technical Field

[0001] This invention relates to the technical field of machining equipment and application methods, and in particular to a system and application method for gradual shot peening of blades based on shot peening equipment. Background Technology

[0002] In industrial production, shot blasting equipment is frequently used to blast the surfaces of components (using high-speed propelled sand and iron shot to impact the workpiece surface, thereby improving some of the mechanical properties and altering the surface condition). To achieve optimal blasting results, the flow rate, pressure, distance between the shot and the component, and blasting direction of the shot blasting equipment must be controlled within specific ranges. Inappropriate flow rate, pressure, distance, or blasting direction will significantly impact the quality of the processed components.

[0003] For example, the gas turbine blades used in existing aero-engines and other gas turbines operate under complex conditions, including high temperature, high pressure, and corrosive media. To improve their service life, shot peening is used to treat specific areas during processing. Currently, the conventional shot peening method for small gas turbine blades involves 100% coverage shot peening of the tenon or the radius above the blade stem to ensure it meets the requirements of its working environment in subsequent actual operations. The aforementioned shot peening equipment can meet the actual needs using ordinary shot peening methods. However, for large blades, the weak points are generally in the blade body below the tenon or blade stem. Because the blade body is often uneven in thickness, and different parts experience different stresses or working conditions, as well as different component materials, conventional non-gradient shot peening (fixed shot peening method refers to shot peening the corresponding component under constant flow rate, constant pressure, constant position, and fixed spacing conditions. Although the distance and angle between the nozzle and the processed component, as well as the output flow rate and pressure, can be adjusted manually, this manual processing not only causes inconvenience to workers and increases production costs, but is also subject to human error.) Due to limitations in operator skills, especially inexperienced operators who cannot effectively control the flow rate, pressure, and spacing and angle between the shot and components, good shot blasting results cannot be achieved. For example, if a shot blasting machine outputs a large flow rate and pressure of shot for a part requiring low flow rate and pressure, or if the spacing is too close or the blasting direction is unsuitable, not only will the shot blasting effect be poor, but there is also a chance of damaging the equipment due to excessive force or incorrect blasting angle. Conversely, if a shot blasting machine outputs a small flow rate and low pressure of shot for a part requiring high flow rate and pressure, or if the spacing is too far or the blasting direction is unsuitable, not only will the shot blasting time be prolonged, but the shot blasting effect will also be poor, adversely affecting the application of the part. In summary, it is particularly necessary to provide a system and application method based on AI technology that can automatically adjust the shot flow rate and pressure output by shot blasting equipment, as well as change the spacing and orientation of the processed parts according to the image data of the products to be processed. Summary of the Invention

[0004] To overcome the drawbacks of existing shot blasting equipment used in processing gas turbine blades and other components, which rely on fixed or manual methods for shot blasting, as described in the background, this invention provides a system and application method for gradual shot blasting of blades based on shot blasting equipment. This system involves analyzing and comparing various data output to relevant units, and then adjusting the shot flow rate, pressure, and the distance and angle between the nozzle and the processing equipment in real time, based on data stored in a database regarding the required shot flow rate and pressure for the corresponding processing part of the gas turbine blade, as well as the distance and orientation between the nozzle and the front nozzle of the shot blasting gun. This ensures that the required processing part can be shot blasted under suitable shot pressure, flow rate, distance, and orientation conditions. This provides convenience for workers, saves labor costs, and achieves better shot blasting quality for the components.

[0005] The technical solution adopted by this invention to solve its technical problem is:

[0006] A system for graded shot peening of blades based on shot blasting equipment includes a shot blasting robot whose movement direction is controlled by a host computer. The system is characterized by further comprising an image acquisition unit, a database unit, a comparison unit, a control unit, and a distance acquisition unit. The image acquisition unit, database unit, comparison unit, control unit, and distance acquisition unit are application software installed within the host computer. The nozzle of the shot blasting robot's spray gun is installed at the front end of the robot's robotic arm. An electric proportional valve is connected in series between the spray gun and the shot discharge mechanism of the shot blasting equipment. A pressure acquisition sensor and a flow sensor are installed in parallel on the side of the pipe. A camera and a laser rangefinder are installed in front of the spray gun. The signal output terminals of the laser rangefinder, camera, pressure acquisition sensor, and flow sensor are electrically connected to the multi-channel signal input terminal of the host computer. The application method of the system for graded shot peening of blades based on shot blasting equipment includes the following steps: Step A: The host computer controls the movement direction of the spray gun of the shot blasting robot to process the gas turbine blades to be shot blasted; Step B: The camera acquires the current processing position image information of the gas turbine blades to be shot blasted and outputs the image information. Step C: The laser rangefinder collects the distance data between the spray gun and the current processing position of the gas turbine blade to be shot-polished at the image acquisition unit, and outputs the distance information to the distance acquisition unit; Step D: The image acquisition unit performs preliminary processing and classification on the collected image data, and the distance acquisition unit performs preliminary processing and classification on the collected distance data, and outputs the two types of data to the comparison unit; Step D: The comparison unit retrieves the image data of the current processing position of the gas turbine blade to be shot-polished at the database unit, compares the corresponding pressure and flow data of the shot-polishing process, and the corresponding distance and angle data required between the spray gun head and the current processing position, and outputs the corresponding output shot flow and pressure data of the current processing position of the spray gun head to the electric proportional valve. The electric proportional valve outputs the shot with the corresponding pressure and flow by changing the valve core size, and outputs the distance and angle command of the current processing position of the spray gun head and the gas turbine blade to the control unit; Step E: The control unit controls the robotic arm of the shot-polishing robot to produce corresponding actions to adjust the distance and angle with the current processing position of the gas turbine blade, and processes the component at the current position.

[0007] Furthermore, the database unit contains a large amount of overall image data of various types of gas blades that need to be shot blasted, image data of each required processing position of the gas blade, processing pressure and flow rate data of the shot required for each processing position, nozzle and processing distance angle data at that processing position.

[0008] Furthermore, the comparison unit retrieves pressure, flow rate, spacing, and angle data from the database unit, combines them with data collected by the image acquisition unit and distance acquisition unit, and compares and judges them with the current shot pressure and flow rate data of the shot discharge mechanism collected by the pressure acquisition sensor and flow sensor, thereby controlling the working mode of the electric proportional valve and the shot blasting robot in a targeted manner.

[0009] Furthermore, in the operation mode of the electric proportional valve controlled by the comparison unit, when the shot blasting flow rate and pressure are relatively high, a relatively low voltage signal is output to the electric proportional valve, and the valve core of the electric proportional valve is closed to a certain extent, thus reducing the shot flow rate and pressure output by the shot blasting equipment; when the shot blasting flow rate and pressure are relatively low, a relatively high voltage signal is output to the electric proportional valve, and the valve core of the electric proportional valve is opened to a certain extent, thus increasing the shot flow rate and pressure output by the shot blasting equipment.

[0010] Furthermore, when the robotic arm of the control unit spraying robot is in motion, the distance and angle between the spray gun head in front of the robotic arm and the corresponding position of the processed gas turbine blade are aligned with the distance and angle of the corresponding position of the processed gas turbine blade in the database unit, and then the robotic arm stops moving.

[0011] The beneficial effects of this invention are: The entire process requires no manual operation, bringing convenience to workers and reducing production costs. In application, the camera and laser rangefinder at the front end of the spray gun can collect real-time image data (including angle data) and spacing data of the gas turbine blades to be shot-blasted. This data is then output to a comparison unit for analysis and comparison. The comparison unit, based on the required shot blasting flow rate and pressure, and the spacing and orientation data between the nozzle and the spray gun nozzle stored in the database unit, adjusts the shot flow rate, pressure, and the spacing and angle between the nozzle and the processing equipment in real-time via an electric proportional valve and a robotic arm. This ensures that the corresponding positions of the parts to be processed can be shot-blasted under suitable shot pressure, flow rate, spacing, and orientation conditions, effectively guaranteeing the requirements of each processing position of the corresponding parts for shot blasting pressure, flow rate, spacing, and angle, achieving better shot blasting quality. In summary, this invention has good application prospects. Attached Figure Description

[0012] The present invention will be further described below with reference to the accompanying drawings and embodiments.

[0013] Figure 1 Application software unit architecture diagram. Detailed Implementation

[0014] Figure 1As shown, the system for gradually peening blades using a shot blasting equipment includes a multi-degree-of-freedom shot blasting robot whose robotic arm movement direction is controlled by a host computer. It also includes an image acquisition unit, a database unit, a comparison unit, a control unit, and a distance acquisition unit. The image acquisition unit, database unit, comparison unit, control unit, and distance acquisition unit are application software installed within the host computer. The nozzle of the shot blasting robot's spray gun is installed at the front end of the robot's robotic arm. An electric proportional valve is connected in series between the shot blasting equipment's spray gun and its shot discharge mechanism, and a pressure acquisition sensor and a flow sensor are installed in parallel on the side of the pipe. A camera and a laser rangefinder are respectively installed at the two ends of the front of the spray gun. The signal output terminals of the laser rangefinder, camera, pressure acquisition sensor, and flow sensor are connected to the four signal input terminals of the host computer via data cables.

[0015] Figure 1 As shown, during the processing of this invention, the part to be processed is fixed at the processing station on the side of the multi-degree-of-freedom shot blasting robot, and then shot blasting can be performed. During shot blasting, the host computer outputs command signals to control the spray gun of the shot blasting robot to control the movement direction of the spray gun according to the motion control program output in the host computer, and processes each required processing part of the gas blade component to be shot blasted one by one (after processing each corresponding processing station is completed, the host computer controls the electric proportional valve to temporarily close). During shot blasting, the camera at the side of the spray gun collects the current processing position image information (including angle data) of the part to be shot blasted in front in real time, and outputs the image information to the image acquisition unit. At the same time, the laser rangefinder collects the distance data between the nozzle tip and the current processing position of the part to be shot blasted in real time, and outputs the distance information to the distance acquisition unit (the closer the laser rangefinder is to the processing position of the part, the higher the signal voltage output to the image acquisition unit, and vice versa). During the shot blasting operation, the pressure acquisition sensor and the flow sensor collect the shot pressure and flow data output by the shot ejection mechanism in real time and output them to the signal input terminal of the host computer. The image acquisition unit performs preliminary processing on the images of the current processing position of the part to be sprayed and blasted. The distance acquisition unit performs preliminary processing on the distance between the spray gun head (nozzle) and the current processing position of the part to be sprayed and blasted. Various data are then output to the comparison unit, which subsequently judges the shot flow rate, pressure, distance and angle data required for the current processing position.

[0016] Figure 1As shown, after receiving the corresponding spacing, pressure, flow rate, and other data, the comparison unit retrieves the image data of the current processing position of the required shot blasting component (gas turbine blade) stored in the database unit, along with the corresponding pressure and flow rate data for shot blasting (the database unit pre-stores a large number of overall image data of various types of gas turbine blades that need to be shot blasted, image data of each required processing position of the gas turbine blade, processing pressure and flow rate data of the shot required for each processing position, nozzle and processing spacing and angle data at that processing position), and compares the corresponding spacing and angle data required for the current processing position with the spray gun head. It then outputs the corresponding shot flow rate and pressure data for the current processing position of the spray gun head to the electric proportional valve. The electric proportional valve, by changing the valve core size, outputs shot with the corresponding pressure and flow rate, and outputs control outputs for the spray gun head and component's current processing position. The spacing and angle commands for the work position are sent to the control unit. In practice, the comparison unit retrieves pressure, flow rate, spacing, and angle data from the database unit, combines this data with data collected by the image acquisition unit and distance acquisition unit, and compares it with the current shot pressure and flow rate data collected by the pressure and flow sensors. This comparison then allows for targeted control of the electric proportional valve and the shot blasting robot's operating mode. When the shot flow rate and pressure are relatively high, the comparison unit outputs a relatively low voltage signal to the electric proportional valve, causing the valve core to close to a certain extent, reducing the shot flow rate and pressure output by the shot blasting equipment. Conversely, when the shot flow rate and pressure are relatively low, the unit outputs a relatively high voltage signal to the electric proportional valve, causing the valve core to open to a certain extent, increasing the shot flow rate and pressure output by the shot blasting equipment. Subsequently, the control unit controls the shot blasting robot's robotic arm to perform corresponding actions to adjust the spacing and angle with the current processing position of the part, and then processes the part at that position. In practical operation, when the robotic arm of the shot blasting robot operates, the distance and angle between the spray gun head in front of the robotic arm and the corresponding position of the processed part match the distance and angle of the corresponding position of the processed part in the database unit. Then, the robotic arm stops moving, the solenoid valve opens, and the shot output from the shot blasting equipment performs shot blasting processing on the corresponding position of the part. Through the above, this invention requires no manual operation throughout the entire process, bringing convenience to workers and reducing production costs.In application, the camera and laser rangefinder at the front end of the spray gun can collect image data (including angle data) and spacing data of the gas turbine blades to be shot blasted in real time. This data is then output to the comparison unit for analysis and comparison. The comparison unit, based on the required shot blasting flow rate and pressure, and the spacing and orientation data between the nozzle and the corresponding gas turbine blade processing part stored in the database unit, adjusts the shot flow rate, pressure, and the spacing and angle between the nozzle and the processing equipment in real time via the electric proportional valve and the robotic arm. This ensures that the corresponding position of the required processing part can be shot blasted under appropriate shot pressure, flow rate, spacing, and orientation conditions, effectively guaranteeing the requirements of each processing position of the corresponding part for shot blasting pressure, flow rate, spacing, and angle. This achieves better shot blasting quality processing results.

[0017] The foregoing has shown and described the basic principles and main features of the present invention, as well as its advantages. It will be apparent to those skilled in the art that the present invention is limited to the details of the exemplary embodiments described above, and that the invention can be implemented in other specific forms without departing from its spirit or basic characteristics. Therefore, the embodiments should be considered exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of equivalents of the claims be included within the present invention.

[0018] Furthermore, it should be understood that although this specification describes the embodiments, the embodiments do not necessarily contain only one independent technical solution. This way of describing the specification is only for clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in the embodiments can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A method for applying a system of graded shot peening to blades based on shot peening equipment, characterized in that: The system for graded shot peening of blades based on shot blasting equipment includes a shot blasting robot whose movement direction is controlled by a host computer. It is characterized by further having an image acquisition unit, a database unit, a comparison unit, a control unit, and a distance acquisition unit. The image acquisition unit, database unit, comparison unit, control unit, and distance acquisition unit are application software installed within the host computer. The nozzle of the shot blasting robot's spray gun is installed at the front end of the robot's robotic arm. An electric proportional valve is connected in series between the spray gun and the shot discharge mechanism of the shot blasting equipment. A pressure acquisition sensor and a flow sensor are installed in parallel on the side of the pipe. A camera and a laser rangefinder are installed in front of the spray gun. The signal output terminals of the laser rangefinder, camera, pressure acquisition sensor, and flow sensor are electrically connected to the multi-channel signal input terminal of the host computer. The system includes the following steps: Step A: The host computer controls the movement direction of the spray gun of the shot blasting robot to process the gas turbine blades to be shot blasted; Step B: The camera acquires image information of the current processing position of the gas turbine blades to be shot blasted, and the image information package... The process involves several steps: Step C: The image acquisition unit performs preliminary processing on the acquired image data, and the distance acquisition unit performs preliminary processing on the acquired distance data. The two sets of data are then output to the comparison unit. Step D: Based on the required shot peening flow rate and pressure, as well as the distance and orientation data between the nozzle and the corresponding gas turbine blade processing part stored in the database unit, the comparison unit outputs the shot flow rate and pressure data corresponding to the current processing position of the spray gun head to the electric proportional valve. The electric proportional valve, by changing the valve core size, outputs shot with corresponding pressure and flow rate, and outputs the distance and angle command between the current spray gun head and the current processing position of the gas turbine blade to the control unit. Step E: The control unit controls the robotic arm of the blasting robot to perform corresponding actions to adjust the distance and angle between the spray gun head and the current processing position of the gas turbine blade, and processes the component at the current position.

2. The application method of the system for graded shot peening of blades based on shot peening equipment according to claim 1, characterized in that, The database unit contains a large amount of overall image data of various types of gas blades that need to be shot blasted, as well as image data of each required processing position of the gas blade, and also data on the processing pressure and flow rate of the shot required for each processing position, the nozzle, and the processing distance and angle data at that processing position.

3. The application method of the system for graded shot peening of blades based on shot peening equipment according to claim 1, characterized in that, The comparison unit retrieves pressure, flow rate, spacing, and angle data from the database unit, combines them with data collected by the image acquisition unit and distance acquisition unit, and compares them with the current shot pressure and flow rate data of the shot discharge mechanism collected by the pressure acquisition sensor and flow sensor to make a judgment, and then controls the working mode of the electric proportional valve and the shot blasting robot accordingly.

4. The application method of the system for graded shot peening of blades based on shot peening equipment according to claim 1, characterized in that, In the operation mode of the electric proportional valve controlled by the comparison unit, when the shot blasting flow and pressure are relatively high, a relatively low voltage signal is output to the electric proportional valve, and the valve core of the electric proportional valve is closed to a certain extent, thus reducing the shot flow and pressure output by the shot blasting equipment; when the shot blasting flow and pressure are relatively low, a relatively high voltage signal is output to the electric proportional valve, and the valve core of the electric proportional valve is opened to a certain extent, thus increasing the shot flow and pressure output by the shot blasting equipment.

5. The application method of the system for graded shot peening of blades based on shot peening equipment according to claim 1, characterized in that, When the robotic arm of the spraying robot is in motion, the distance and angle between the spray gun head in front of the robotic arm and the corresponding position of the processed gas turbine blade match the distance and angle of the corresponding position of the processed gas turbine blade in the database unit, and then the robotic arm stops moving.

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