Blisk blade shot blasting gun anti-collision method based on multi-sensor fusion

Abstract

The invention provides a blisk blade shot blasting gun anti-collision method based on multi-sensor fusion, and the method comprises the following steps: importing a blisk three-dimensional model, and calibrating a collision high-risk area; the 3D laser radar scans to generate point cloud data, and the inertial measurement unit feeds back the attitude of the nozzle; calculating a collision probability by using the collision prediction model, and triggering a corresponding classification strategy; a collision avoidance path is generated, and the mechanical arm executes dynamic adjustment; and based on the dynamic spectrum data, the motion stability of the mechanical arm is optimized in real time. The method has the advantages that collision is extremely easy to generate in the shot blasting process of the blades of the blisk of the aero-engine, and in order to ensure the safety of the shot blasting process, the running track path of a spray gun needs to be confirmed once every 5-10 blades, so that the processing process is discontinuous, and the production efficiency is reduced. The problem that the collision risk is high when the spray gun operates between the blades is solved, the machining process continuity is improved, and the collision risk of the spray gun and the blades is avoided.

Description

Technical Field

[0001] This invention relates to the field of aero-engine technology, and in particular to a collision prevention method for shot peening guns on integral bladed disks based on multi-sensor fusion. Background Technology

[0002] The integral bladed disk (IBD) is a core component of an aero-engine, significantly impacting its performance. Its complex structure and poor openness necessitate shot peening of all areas within the blade-shaped flow channel to improve fatigue resistance. To ensure uniform shot peening of the blade surface, the shot peening gun must be inserted into the flow channel cavity. Due to the significant changes in blade curvature, the nozzle is prone to collision with the blade body, leading to component failure. Current manufacturing methods heavily rely on stopping the machine during processing to adjust the path, resulting in low efficiency.

[0003] The intelligent collision avoidance method based on multi-sensor fusion integrates three-dimensional lidar and inertial measurement, and combines convolutional neural network collision prediction and path optimization to achieve active obstacle avoidance control of the spray gun posture, thereby improving the safety of the overall bladed disk shot peening process and the adaptability to complex workpieces.

[0004] Therefore, there is an urgent need to invent a collision prevention method for the shot peening process, improve the continuity of the processing, and avoid the risk of collision between the spray gun and the blade. Summary of the Invention

[0005] The purpose of this invention is to address the high collision risk associated with shot peening of integral bladed disks (IBDs) in aero-engines. This patent proposes a collision avoidance method for shot peening guns on IBDs based on multi-sensor fusion. By integrating 3D lidar and inertial measurement units, and utilizing convolutional neural networks for collision prediction and path optimization, collision prediction and active avoidance of complex curved surface interference structures are achieved. Pose control based on multi-sensor data fusion reduces the need for manual intervention in the shot peening process and improves the automation level of the IBD shot peening process.

[0006] This invention provides a collision prevention method for shot peening guns on integral bladed disks based on multi-sensor fusion, with the specific system composition as follows: 3D LiDAR scans the blade surface to generate a corona discharge, which is then compared with a preset 3D model. An inertial measurement unit monitors the attitude and vibration of the spray gun in real time. Data fusion module: fuses data from lidar and inertial measurement unit to construct a dynamic range field; Collision prediction model: Input historical pose data and real-time data analysis, output the probability of collision within the next 0.5 seconds; Six-degree-of-freedom robotic arm: drives the spray gun to achieve movement, rotation, and posture adjustment; Vibration suppression module: Based on the spectrum analysis of the inertial measurement unit, it actively adjusts the joint torque of the robotic arm to suppress posture jitter.

[0007] Method and Flow: 1. Import the overall bladed disk 3D model and mark the high-risk collision zone (blade edge, high curvature variation range); 2. 3D LiDAR scanning generates point cloud data, and the inertial measurement unit provides feedback on the nozzle attitude; 3. Utilize the collision prediction model to calculate the collision probability and trigger a graded response strategy; IV. Generate collision avoidance path and the robotic arm performs dynamic adjustments; V. Optimize the stability of robotic arm motion in real time based on dynamic spectrum data.

[0008] Advantages of this invention: The complex interference structures of aero-engine integral bladed disks and blades, with their intricate blade shapes and significant spatial twisting, make them highly susceptible to collisions during shot peening. To ensure safety, the trajectory of the shot peening gun must be checked every 5-10 blades, resulting in discontinuous processing and reduced production efficiency. Furthermore, the high risk of collisions when the shot peening gun travels between blades necessitates that the shot peening process be performed in the final stage of part manufacturing, as blades that collide with other parts are rendered unusable.

[0009] With the upgrading of aero engines, the application of integral bladed disk structures is becoming more and more widespread. The use of efficient new intelligent methods to gradually reduce the collision risk in the shot peening process can shorten the parts processing cycle and reduce the collision risk in the process. Therefore, this invention has broad market demand and application prospects.

[0010] During shot peening of integral bladed disks for aero engines, collisions are highly likely. To ensure safety, the trajectory of the spray gun needs to be checked every 5-10 blades, causing discontinuity in the processing and reducing production efficiency. This invention solves the problem of high collision risk when the spray gun is running between blades, improves the continuity of the processing, and avoids the risk of collision between the spray gun and the blades. Detailed Implementation

[0011] The present invention will be further explained below with reference to specific implementation schemes, but this explanation is not intended to limit the present invention. All explanations are provided in conjunction with the contents disclosed in the specification for those skilled in the art to understand and read, and are not intended to limit the conditions under which the present invention can be implemented. Therefore, they have no substantial technical significance. Any modifications to the structure, changes in the proportional relationship, or adjustments to the size, without affecting the effects and objectives that the present invention can produce, should still fall within the scope of the technical content disclosed in the present invention.

[0012] Example The integral bladed disk is made of titanium alloy. The integral bladed disk dimensions are: outer diameter Φ900mm, height 300mm; blade width 200mm. Implement according to the following steps: 1) Import the 3D model: Import the overall bladed disk 3D model into the control system, including the standard intake and exhaust edges and areas with large curvature changes;

[0013] 2) Real-time scanning: 3D lidar scans the entire blade surface of the bladed disk to generate real-time point cloud data, and the inertial measurement unit feeds back nozzle attitude data. 3) Collision prediction: Using a collision prediction model, the collision probability is calculated. When the probability of collision caused by the spray gun swing reaches 30%-85%, a dynamic path correction signal is triggered. When the collision probability is greater than 85%, the spray gun movement stops and exits after stabilization.

[0014] 4) Path optimization: Based on real-time analysis data, a detour path is generated. The six-degree-of-freedom robotic arm drives the nozzle to retract 1-3mm and deflect 1°. 6) Vibration suppression: The inertial measurement unit detects that the vibration of the robotic arm joint exceeds the threshold and actively adjusts the torque to reduce the amplitude by 50%.

[0015] 7) Complete shot peening, with the entire blade surface of the blade disk fully covered by shot peening, without any collision incidents, and the entire blade profile covered by shot peening.

[0016] Matters not covered in this invention are common knowledge.

[0017] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A multi-sensor fusion-based integral blade disk blade shot gun collision avoidance method, characterized by: The specific system composition is: 3D laser radar, scanning the blade surface to generate corona, and comparing with the preset three-dimensional model; Inertial measurement unit, real-time monitoring of the attitude and vibration of the spray gun; Data fusion module: fusion of laser radar and inertial measurement unit data, construction of dynamic distance field; Collision prediction model: input historical pose data and real-time data analysis, output collision probability within 0.5 seconds in the future; Six degrees of freedom mechanical arm: drive the spray gun to realize moving rotation attitude adjustment; Vibration suppression module: according to the frequency spectrum analysis of the inertial measurement unit, actively adjust the joint torque of the mechanical arm to suppress the attitude jitter; Method flow: I. Import the three-dimensional model of the integral blade disk, calibrate the high-risk collision area (blade edge, high curvature change range); II. 3D laser radar scanning generates point cloud data, and the inertial measurement unit feeds back the nozzle attitude; III. Use the collision prediction model to calculate the collision probability and trigger the corresponding strategy; IV. Generate a collision avoidance path, and the mechanical arm executes dynamic adjustment; V. Based on dynamic spectrum data, real-time optimization of mechanical arm motion smoothness.

2. The multi-sensor fusion-based integral blade disk blade shot gun collision avoidance method according to claim 1, characterized by: The integral blade disk is made of titanium alloy material; the integral blade disk size is Φ900mm in outer diameter and 300mm in height; the blade width is 200mm; and the following steps are implemented: 1) Three-dimensional model import: import the three-dimensional model of the integral blade disk into the control system, and standardize the inlet and outlet edges and the area with large curvature change; 2) Real-time scanning: 3D laser radar scans the surface of the integral blade disk blade to generate real-time point cloud data, and the inertial measurement unit feeds back the nozzle attitude data; 3) Collision prediction: use the collision prediction model to calculate the collision probability, and predict that when the collision probability caused by spray gun swing reaches 30%-85%, a dynamic path correction signal is triggered, and when the collision probability is greater than 85%, the spray gun motion is stopped and exits after stabilization; 4) Path optimization: generate a detour path combined with real-time analysis data, and drive the nozzle to retreat 1-3mm and deflect 1° in angle by the six degrees of freedom mechanical arm; 6) Vibration suppression: when the inertial measurement unit detects that the joint vibration of the mechanical arm exceeds the threshold, actively adjust the torque to reduce the amplitude by 50%; 7) Complete shot: the integral blade disk blade surface is fully covered with shot, there is no collision event, and the blade full surface is covered with shot.