Shot sorting and feeding system and method for electromagnetic shot blasting

Abstract

The invention provides a shot sorting and feeding method for electromagnetic shot blasting, relates to the technical field of shot blasting processing, and aims to solve the problem that an existing shot blasting supply system is difficult to adapt to electromagnetic drive shot blasting requirements, a large number of disordered shots are compulsively sorted into a primary queue arranged in a single row in a primary supply module, and the primary queue enters a fine screening module; the visual system detects each projectile, rejects the projectiles which do not meet the standard, ensures that only qualified projectiles with consistent postures enter the charging module, pass through a corona discharge electric field and carry net charges, and electrified projectiles enter the transmission module and are sorted into a final queue with stable intervals, so that the projectiles are output in a predictable and accurate sequence; and a guarantee is provided for acquiring the projectiles on demand and on time by the electromagnetic accelerator.

Description

Technical Field

[0001] This invention relates to the field of shot peening technology, and specifically to a shot sorting and feeding system and method for electromagnetic shot peening. Background Technology

[0002] Shot peening strengthens metal workpieces by impacting the surface of a shot stream, introducing a residual compressive stress layer, thereby improving the workpiece's fatigue strength, resistance to stress corrosion, and service life. Traditional shot peening technology relies on compressed air or centrifugal wheels to accelerate a large number of shot streams, forming a disordered shot stream. This method is inherently "statistical" and "empirical," and its strengthening effect depends on the control of macroscopic process parameters (such as air pressure, shot peening time, and coverage), making it difficult to precisely control the energy, trajectory, and impact position of individual shot. This results in a process that heavily relies on operator experience, making it difficult to quantitatively strengthen critical local areas of complex components, and also suffers from low efficiency, high shot consumption, and poor surface quality consistency.

[0003] Electromagnetically driven ordered shot peening achieves intelligent surface strengthening by independently accelerating individual shot particles using electromagnetic technology, enabling digital programming control of their kinetic energy and ejection timing. The engineering application of electromagnetic shot peening technology requires a stable and reliable supply of single, ordered shot particles with specific electrical properties to the electromagnetic accelerator. The electromagnetic accelerator demands that the shot particles enter the acceleration orbit in a single-file queue, separated from each other, with consistent attitudes, and at precise timing. Furthermore, to achieve optimal electromagnetic acceleration efficiency, the shot particles typically need to carry a small net charge or possess good magnetic permeability. Traditional shot peening equipment, such as vibratory feeders and chutes, outputs randomly piled-up shot particles, directly causing electromagnetic accelerator failure and failing to meet the requirements of electromagnetically driven shot peening. Summary of the Invention

[0004] In view of this, the present invention provides a shot sorting and feeding system and method for electromagnetic shot peening, which can provide charged shot that meets the requirements for electromagnetically driven shot peening.

[0005] The first objective of this invention is to provide a shot sorting and feeding system for electromagnetic shot peening, employing the following solution: include: The primary supply module includes a hopper and a feeding mechanism. One end of the feeding mechanism is connected to the hopper, and the other end forms a single-row output channel for projectiles. The fine screening module includes a vision component and a rejection component. The rejection component includes a rejection execution structure and a detection channel connecting the material channel. The vision component acquires images of the projectiles on the detection channel, and the rejection execution mechanism can reject the projectiles on the detection channel. The charging module includes a charging channel and a charging component. The charging channel is connected to the detection channel, the charging component forms a corona discharge electric field, and the charging channel passes through the corona discharge electric field. The transmission module includes an output channel that is connected to a charging channel, enabling the projectiles to be output in a queue.

[0006] Furthermore, the feeding mechanism includes an electromagnetic vibrating feeder and a chute. The output end of the electromagnetic vibrating feeder is a material channel, which is connected to the detection channel through the chute.

[0007] Furthermore, a screen is provided at the bottom of the material channel, and the width of the end of the material channel that connects to the chute is greater than one times the diameter of the projectile and less than two times the diameter of the projectile.

[0008] Furthermore, the charging component includes a high-voltage electrode and a grounding plate. The high-voltage electrode is connected to a DC power supply, and a corona discharge electric field is formed between the high-voltage electrode and the grounding plate.

[0009] Furthermore, the transmission module includes a linear vibration mechanism and a linear track, the linear track forming an output channel, and the linear vibration mechanism driving the projectile to move in a jumping motion along the linear track.

[0010] A second objective of this invention is to provide a projectile sorting and feeding method for electromagnetic shot peening, utilizing the projectile sorting and feeding system for electromagnetic shot peening as described in the first objective, comprising: Shot loading uses a single-line input detection channel; Visual inspection is performed on the projectiles in the inspection channel to identify and remove unqualified projectiles, while qualified projectiles enter the charging channel. The projectile is charged within the charging channel, so that it carries a preset amount of net charge. The charged projectiles are supplied to the external electromagnetic accelerator in a queue.

[0011] Furthermore, the identification of defective projectiles includes identifying projectiles that are stuck together, damaged, or misaligned, and removing them using high-pressure air blowing.

[0012] Furthermore, the charging channel is an insulated transport channel. When the projectile passes through the corona discharge electric field, the surrounding air is ionized under the action of the high voltage electric field, and the ions attach to the surface of the projectile, making it charged.

[0013] Furthermore, when the charged projectiles are supplied to the outside in a queue through the output channel, the projectiles are made to jump along a linear track and adjust to form a queue with even intervals.

[0014] Furthermore, the input speed of the detection channel is adjusted according to the supply speed of the charged projectile to the outside.

[0015] Compared with the prior art, the advantages and positive effects of this invention are: To address the issue that current shot peening supply systems are ill-suited to the demands of electromagnetically driven shot peening, a large number of disordered projectiles are forcibly organized into a single-row preliminary queue in the primary supply module. This preliminary queue then enters the fine screening module, where a vision system inspects each projectile, discarding those that do not meet the standards. This ensures that only qualified projectiles with consistent orientations enter the charging module, pass through the corona discharge electric field carrying net charge, and then enter the transmission module, where they are organized into a final queue with stable spacing. This allows the projectiles to be output in a predictable and precise sequence, ensuring that the electromagnetic accelerator can acquire projectiles on demand and on time.

[0016] By combining machine vision recognition with mechanical actuators, accurate screening and attitude correction of individual projectiles are achieved, reducing the failure rate of jamming, excessive material, and empty material, and meeting the stringent requirements of electromagnetic acceleration for consistent material feeding. Servo control of the queue transmission module allows for direct and precise setting and control of the projectile supply rate, enabling digital programming of shot peening intensity. The electrostatic charging function is seamlessly integrated into the feeding process, solving the problem of projectile pretreatment, simplifying the overall system structure, and improving efficiency. Attached Figure Description

[0017] The accompanying drawings, which form part of this invention, are used to provide a further understanding of the invention. The illustrative embodiments of the invention and their descriptions are used to explain the invention and do not constitute an improper limitation of the invention.

[0018] Figure 1 This is a schematic diagram of the functional modules of the shot sorting and feeding device for electromagnetic shot peening in Embodiments 1 and 2 of the present invention.

[0019] Figure 2 This is a schematic diagram of the primary supply module in embodiments 1 and 2 of the present invention.

[0020] Figure 3 This is a schematic diagram of the fine screening module in embodiments 1 and 2 of the present invention.

[0021] The components are: 1. hopper; 2. shot; 3. feed channel; 4. chute; 5. vision assembly; 6. rejection assembly; 7. defective shot; 8. scrap bin; and 9. charging assembly. Detailed Implementation

[0022] Example 1 In a typical embodiment of the present invention, such as Figures 1-3 As shown, a shot sorting and feeding system for electromagnetic shot peening is presented.

[0023] Currently, electromagnetic shot peening requires a high quantity of projectiles 2, but existing shot peening equipment's feeding methods, such as vibrating feeders and chutes 4, are insufficient to supply single, ordered projectiles 2 with specific electrical characteristics. Therefore, this embodiment provides a projectile sorting and feeding system for electromagnetic shot peening, including a primary feeding module, a fine screening module, a charging module, and a transmission module.

[0024] like Figure 1 As shown, the primary supply module includes a hopper 1 and a feeding mechanism. One end of the feeding mechanism is connected to the hopper 1, and the other end forms a material channel 3 for single-row output of projectiles 2. The fine screening module includes a vision component 5 and a rejection component 6. The rejection component 6 includes a rejection execution structure and a detection channel connected to the material channel 3. The vision component 5 acquires an image of the projectiles 2 on the detection channel, and the rejection execution mechanism can reject the projectiles 2 on the detection channel. The charging module includes a charging channel and a charging component 9. The charging channel is connected to the detection channel, and the charging component 9 forms a corona discharge electric field. The charging channel passes through the corona discharge electric field. The transmission module includes an output channel, which is connected to the charging channel, so that the projectiles 2 are output in a queue.

[0025] Specifically, such as Figure 2 As shown, the projectiles 2 in the projectile 2 magazine first enter the primary supply module, which includes a sealed container and an electromagnetic vibrating feeder. The output end of the electromagnetic vibrating feeder is the feed channel 3, which is connected to the detection channel via a chute 4. The feed channel 3 is spiral-shaped, and a screen is provided at the bottom of the feed channel 3 to filter debris. The width at the end is slightly larger than the size of the projectile 2. The width of the end of the feed channel 3 that connects to the chute 4 is greater than one times the diameter of the projectile 2 but less than twice the diameter of the projectile 2, forcing the projectiles 2 to initially arrange themselves into a single row for output.

[0026] The fine screening module employs a combination of online machine vision recognition and high-speed air-blowing rejection, rather than relying on mechanical tracks with limited precision. The vision component 5 uses a high-speed industrial camera to acquire images and performs real-time analysis using existing duty cycle and contour matching algorithms. This accurately identifies defective projectiles 7 due to adhesion, damage, or incorrect posture. The rejection component 6 uses high-pressure air nozzles in conjunction with a high-pressure air source. A central controller controls a solenoid valve to control the movement of the high-pressure air nozzles, rejecting defective projectiles 7 and collecting them in the waste bin 8. This ensures a high pass rate for the projectile queue 2.

[0027] like Figure 3As shown, the fine screening module includes a detection channel, a high-speed industrial camera, a light source, and a rejection assembly 6. The high-speed industrial camera acquires images of the projectiles 2 passing through the detection points on the detection channel, and the images are transmitted to the image processing unit of the central controller. The image processing unit uses machine vision technology to determine whether multiple projectiles are stuck together by calculating the duty cycle of the image area, and uses a contour matching algorithm to determine whether the projectiles 2 are damaged or have incorrect posture. Once a defective projectile 7 is identified, the controller triggers the rejection assembly 6 to blow it away from the detection channel and into the waste bin 8.

[0028] Individual projectiles 2, selected through screening, enter the charging module. This embodiment seamlessly integrates the electrostatic charging function of the projectiles 2 into the feeding process. Traditional shot peening eliminates this step; in this embodiment, a corona discharge charging device is designed as the charging component 9, ensuring that each qualified projectile 2 is given a preset amount of net charge during transport. By optimizing the electrical characteristics of the projectiles 2, the induction efficiency and energy conversion rate of the subsequent electromagnetic acceleration module are significantly improved, enhancing the overall system performance from the source.

[0029] The charging module can employ a corona discharge charging device as the charging component 9, including a charging channel, a high-voltage electrode (such as a tungsten wire electrode), a grounding plate, and an adjustable high-voltage DC power supply. The high-voltage electrode is connected to the adjustable high-voltage DC power supply, and a corona discharge electric field is formed between the high-voltage electrode and the grounding plate. When the projectile 2 passes through the high-voltage electric field region, the surrounding gas is ionized, and ions adhere to the surface of the projectile 2, making it charged. The charging component 9 can also employ a contact charging method, for example, by having the projectile 2 contact a charged conductor to achieve charge transfer.

[0030] In this embodiment, the transmission module also serves as a queue transmission and interface module. This module is not only for transmission but also crucial for achieving quantitative and orderly control of the entire system. It forms a stably spaced queue through precise vibration, and the signal generated by the shot 2 detection sensor at its end directly serves as the synchronization clock signal to trigger the operation of the electromagnetic accelerator. The shot sorting and feeding system for electromagnetic shot peening provided in this embodiment is not only a supply source but also a cycle controller for the entire orderly shot peening process, achieving deep coordination between feeding and acceleration.

[0031] The transmission module includes a linear vibration mechanism, which serves as the conveying mechanism and can employ methods such as piezoelectric ceramic actuators or electromagnetic vibrators. This mechanism uses micro-amplitude, high-frequency vibrations to propel the projectile 2 along a linear track in a skipping motion, automatically adjusting to form a uniformly spaced queue. At the end of the transmission module is a projectile 2 detection sensor, such as a photoelectric sensor, used to detect the projectile 2's arrival signal and transmit it to the central controller. The controller uses this signal as a trigger event, synchronously sending it to the electromagnetic accelerator's main control system to control the acceleration sequence.

[0032] The central controller monitors the system status in real time, receives the set target shot peening frequency, and dynamically adjusts the vibration intensity of the queue transmission module or the supply rate of the primary supply module based on the feedback signal from the shot 2 detection sensor, thereby achieving closed-loop control of the shot output rate.

[0033] By combining machine vision recognition with mechanical actuators, accurate screening and attitude correction of individual projectiles 2 are achieved, reducing the failure rate of jamming, excessive material, and empty material, and meeting the stringent requirements of electromagnetic acceleration for consistent material supply. Servo control of the queue transmission module allows for direct and precise setting and control of the projectile 2 supply rate, thereby enabling digital programming of shot peening intensity. The electrostatic charging function is seamlessly integrated into the feeding process, solving the projectile 2 pretreatment problem, simplifying the overall system structure, and improving efficiency.

[0034] Example 2 In another typical embodiment of the present invention, such as Figures 1-3 As shown, a projectile sorting and feeding method for electromagnetic shot peening is provided, utilizing the projectile sorting and feeding system for electromagnetic shot peening as described in Example 1, including: Bullet 2 is fed using a single-line input detection channel; Visual inspection is performed on projectile 2 in the inspection channel to identify and remove unqualified projectile 7, while qualified projectile 2 enters the charging channel. The projectile 2 is charged in the charging channel so that the projectile 2 carries a preset amount of net charge; The charged projectiles 2 are supplied to the external electromagnetic accelerator in a queue.

[0035] The identification of defective projectiles 7 includes identifying projectiles 2 that are stuck, damaged, or misaligned, and removing them by high-pressure air blowing; the charging channel is an insulated transport channel. When the projectile 2 passes through the corona discharge electric field, the surrounding air is ionized under the action of the high-voltage electric field, and the ions attach to the surface of the projectile 2, making it charged.

[0036] When the charged projectiles 2 are supplied to the outside in a queue through the output channel, they are made to move forward in a skipping motion along a linear track, and the queue is adjusted to form evenly spaced columns. The input speed of the detection channel is adjusted according to the supply speed of the charged projectiles 2 to the outside.

[0037] Specifically, the shot sorting and feeding method for electromagnetic shot peening will be explained using cast steel wire cut shot 2 with a diameter of 0.6 mm and an aspect ratio of 1 as an example.

[0038] The central controller first powers on and initializes, setting the target shot peening frequency (e.g., 200 shots / second) via the human-machine interface. The controller then calculates and sets the initial operating parameters for each module. The shot 2 is stored in a sealed stainless steel hopper 1 and initially fed via an electromagnetic vibrating feeder. This vibrating feeder has a spirally ascending feed channel 3 inside, with a screen at the bottom to filter debris. The width of the end is precisely machined to be slightly larger than the length of the shot 2 (approximately 1 mm), thus forcing the shot 2 to initially align in a single row for output.

[0039] The initially sorted pellets 2 slide into the fine screening module via chute 4 for attitude recognition and fine screening. The core of this module is a high-precision sapphire glass channel serving as the detection channel. Its V-shaped cross-section guides most of the shredded pellets 2 to pass through with their long axis parallel to the channel direction. At a specific detection point above the detection channel, a machine vision system consisting of a 5-megapixel high-speed CMOS industrial camera and an LED coaxial light source captures images of the pellets 2 at a rate of 1000-5000 frames per second. The images are transmitted in real-time to the image processing unit of the central controller. The unit calculates the duty cycle of the image area to determine if multiple pellets 2 are stuck together and uses a contour matching algorithm to detect whether the pellets 2 are damaged or have incorrect attitudes. If a pellet is identified as unqualified, the controller immediately triggers a high-pressure air nozzle installed behind the detection point, precisely blowing the unqualified pellets 7 into the waste bin 8 with a short airflow lasting approximately 1-20 milliseconds, while the qualified pellets 2 continue forward.

[0040] The selected, qualified projectiles 2 then enter the electrostatic charging module. This section of the transport channel has been replaced with a ceramic insulating tube. A tungsten wire electrode, connected to an adjustable high-voltage DC power supply (0-10 kV), is suspended approximately 2 mm above the insulating tube, with a grounded copper plate positioned below it, thus creating an asymmetric strong electric field. As the projectile 2 passes through, it ionizes the surrounding air (corona discharge), and ions adhere to the surface of the projectile 2, giving it a fixed charge. The amount of charge is controlled by adjusting the voltage of the high-voltage power supply.

[0041] The fully charged projectile 2 falls to the starting point of the queue transmission and interface module. A piezoelectric ceramic-driven linear vibrating guide rail generates high-frequency, low-amplitude vibrations, causing the projectile 2 to move forward in a skipping motion along precise linear grooves at the bottom of the rail, automatically adjusting to form a stable, evenly spaced queue. When the projectile 2 at the front of the queue reaches the end of the rail, it is detected by a photoelectric sensor. The resulting positioning signal is sent to the central controller, which then uses a high-speed communication interface (such as EtherCAT) as a trigger signal to synchronously send this signal to the main control system of the electromagnetic accelerator, informing it that the projectile 2 is in position. The accelerator then activates its acceleration coils at a precise moment to draw the projectile 2 into the accelerator.

[0042] The entire process is repeated cyclically. The central controller monitors the system status in real time and dynamically fine-tunes the vibration intensity of the linear vibrating guide or the supply rate of the primary vibrating plate based on the actual shot discharge frequency fed back by the end photoelectric sensor, thereby achieving closed-loop control of the shot discharge rate and ensuring that it remains stable at the set value.

[0043] Using this specific implementation scheme, the system successfully achieved a sorting success rate of over 99.8% for 0.6mm shredded shot 2, with the shot output rate continuously adjustable within the range of 50-500 shots / second and a control accuracy error of less than ±1%. The charge on the shot 2 was uniform and stable (variance coefficient <5%), and it could run continuously and stably for more than 8 hours without failure, providing a solid foundation for electromagnetic shot peening process.

[0044] The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A shot sorting and feeding system for electromagnetic shot peening, characterized in that, include: The primary supply module includes a hopper and a feeding mechanism. One end of the feeding mechanism is connected to the hopper, and the other end forms a single-row output channel for projectiles. The fine screening module includes a vision component and a rejection component. The rejection component includes a rejection execution structure and a detection channel connecting the material channel. The vision component acquires images of the projectiles on the detection channel, and the rejection execution mechanism can reject the projectiles on the detection channel. The charging module includes a charging channel and a charging component. The charging channel is connected to the detection channel, the charging component forms a corona discharge electric field, and the charging channel passes through the corona discharge electric field. The transmission module includes an output channel that is connected to a charging channel, enabling the projectiles to be output in a queue.

2. The shot sorting and feeding system for electromagnetic shot peening as described in claim 1, characterized in that, The feeding mechanism includes an electromagnetic vibrating feeder and a chute. The output end of the electromagnetic vibrating feeder is a material channel, which is connected to the detection channel through the chute.

3. The shot sorting and feeding system for electromagnetic shot peening as described in claim 2, characterized in that, The bottom of the material channel is equipped with a screen, and the width of the end of the material channel connected to the chute is greater than one times the diameter of the projectile and less than two times the diameter of the projectile.

4. The shot sorting and feeding system for electromagnetic shot peening as described in claim 1, characterized in that, The charging assembly includes a high-voltage electrode and a grounding plate. The high-voltage electrode is connected to a DC power supply, and a corona discharge electric field is formed between the high-voltage electrode and the grounding plate.

5. The shot sorting and feeding system for electromagnetic shot peening as described in claim 1, characterized in that, The transmission module includes a linear vibration mechanism and a linear track. The linear track forms an output channel, and the linear vibration mechanism drives the projectile to move in a jumping manner along the linear track.

6. A method for sorting and feeding projectiles for electromagnetic shot peening, utilizing the projectile sorting and feeding system for electromagnetic shot peening as described in any one of claims 1-5, characterized in that, include: Shot loading uses a single-line input detection channel; Visual inspection is performed on the projectiles in the inspection channel to identify and remove unqualified projectiles, while qualified projectiles enter the charging channel. The projectile is charged within the charging channel, so that it carries a preset amount of net charge. The charged projectiles are supplied to the external electromagnetic accelerator in a queue.

7. The shot sorting and feeding method for electromagnetic shot peening as described in claim 6, characterized in that, The identification of defective projectiles includes identifying projectiles that are stuck together, damaged, or misaligned, and removing them using high-pressure air blowing.

8. The shot sorting and feeding method for electromagnetic shot peening as described in claim 6, characterized in that, The charging channel is an insulated transport channel. When the projectile passes through the corona discharge electric field, the surrounding air is ionized under the action of the high voltage electric field, and the ions attach to the surface of the projectile, making it charged.

9. The shot sorting and feeding method for electromagnetic shot peening as described in claim 8, characterized in that, When the charged projectiles are supplied to the outside in a queue through the output channel, the projectiles move forward in a jumping manner along a linear track and are adjusted to form a queue with even intervals.

10. The shot sorting and feeding method for electromagnetic shot peening as described in claim 6, characterized in that, The input speed of the detection channel is adjusted according to the rate at which the charged projectile is supplied to the outside.

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