Distance and angle detection for shot peening nozzles

Abstract

An apparatus is provided for accurately measuring the distance and angle between a shot medium nozzle and a target workpiece. The apparatus may include a nozzle attachment, including an attachment end and a front end; a sensor mounted on the nozzle attachment; a controller including a processor with computer-readable commands; and a visual display. The controller may accurately calculate the distance and angle at which the nozzle is offset from the target workpiece to which the shot peening medium is blasted, by using the distance and angle measurements provided by the sensor. The calculation of distance and angle helps in the application of consistent peening.

Description

Technical Field

[0001] (Reference to Related Applications) This application is a non-provisional conversion of U.S. Patent Application No. 63 / 509,796, entitled "DISTANCE AN ANGLE DETECTION FOR SHOT PEENING NOZZLES," filed on June 23, 2023, the content of which is incorporated herein in its entirety for all purposes.

[0002] (Technical Field) This disclosure generally relates to shot peening, and more specifically to the detection of the offset distance and angle of a nozzle of a shot peening unit relative to a target.

Background Art

[0003] Shot peening is a surface strengthening process that imparts a shallow layer of compressive residual stress to the surface of a metal component by impacting it at high speed with shot or media, which are otherwise called shot or media, such as metal, ceramic, or glass peening particles.

Brief Description of the Drawings

[0004] [Figure 1] An exemplary system for determining the position of a target surface is shown.

[0005] [Figure 2] The exemplary system of FIG. 1 having an exemplary target surface is shown.

[0006] [Figure 3] The exemplary system of FIG. 1 having an exemplary target surface is shown.

[0007] [Figure 4] A chart of point selection utilized by the exemplary system of FIG. 1 is shown.

[0008] [Figure 5] The first method used by the exemplary system in Figure 1 is shown.

[0009] [Figure 6] A second method is shown, as utilized by the exemplary system in Figure 1.

[0010] [Figure 7] Figure 1 shows a chart of the calculation method selection used by the exemplary system.

[0011] [Figure 8] This flowchart illustrates an exemplary process for selecting between a first, second, or third method for calculating the target distance and target angle. [Modes for carrying out the invention]

[0012] Shot peening is a surface enhancement process that imparts a shallow layer of compressive residual stress to the surface of a metal component by impacting it with metal, ceramic, or glass peening particles, otherwise called shots or media, at high speed. The intensity of the peening depends on the kinetic energy of the shots, which is a function of the shot's mass and velocity. This velocity varies along with various mechanical parameters, including the offset distance from the peening nozzle of the shot peening unit to the impact target (the target object or workpiece to which the shot media is applied). Throughout the peening process, the nozzle of the shot peening unit may move across the impact target, or the impact target may move relative to the nozzle, so that as the surface geometry of the impact target changes, the offset distance and angle of a particular area of ​​the impact target to which the shot media is applied may change rapidly relative to adjacent areas. Maintaining this distance constant often requires extensive control mechanisms, utilizing robotic devices. Due to the complexity of these systems, the offset distance can only be verified between cycles.

[0013] To comply with industry standards for peening scope, such as SAE J2277, the peening scope must also be maintained with great precision throughout the peening process. The peening process must be designed to ensure this compliance, which is time-consuming and requires the use of complex equipment and skilled operators. Many processes are completed with irregularly shaped targets that have holes, edges, and sharp surfaces. These configurations further complicate the design of the peening process because the offset distance and angle from the nozzle to a particular area on the impact target can change as the nozzle moves over the impact target or as the impact target moves relative to the nozzle. In peening operations, it is beneficial to know the offset distance and angle from the nozzle of the shot peening unit to the target area or region on the impact target to which the shot medium is directed.

[0014] Various embodiments are referenced in detail here. Examples of various embodiments are illustrated in the accompanying drawings. While this disclosure includes certain examples, it will be understood that this disclosure is not intended to limit the claims to these examples. On the contrary, this disclosure is intended to cover alternatives, modifications, and equivalents that may fall within the spirit and scope of the claims. Furthermore, this detailed description includes numerous specific details to provide a comprehensive understanding. However, those skilled in the art will understand that the subject matter of this disclosure may be carried out without these specific details. In other cases, well-known methods, procedures, and components are not described in detail so as not to unnecessarily obscure the aspects of this disclosure.

[0015] This disclosure includes a nozzle attachment housing a proximity detection system for use in shot peening processes. This detection system may provide the user or controller with real-time distance ("offset distance" or "distance") and incidence angle relationship ("angle") between the peening nozzle and the target surface. This data allows for more precise design of the peening process, ensuring a proper and consistent peening range without requiring the peening operation to be stopped while external measuring instruments are used to verify the nozzle offset distance and angle from the impact target.

[0016] Referring here to Figure 1, an exemplary system 100 for determining the position of a target surface is shown. System 100 includes a nozzle attachment 101 configured to be attached to the end of a shot peening nozzle 200. The nozzle attachment 101 further has a front end 107 and a connector end 108. In some examples, the nozzle attachment 101 may be integrated with the shot peening nozzle 200 or may be the same components as the shot peening nozzle 200. In the example shown in Figure 1, the nozzle attachment 101 includes a threaded nozzle insert 102 substantially located at the connector end 108 of the nozzle attachment 101 for easy mounting in a shot peening configuration. The nozzle attachment 101 may be made of a rigid, non-conductive material. System 100 further includes a sensor 103 attached to the front end 107 of the nozzle attachment 101 or substantially housed within the front end 107 of the nozzle attachment 101. In some examples, the sensor 103 may be located elsewhere on the nozzle attachment 101, such as on the side of the nozzle attachment 101, and still achieve the same function of obtaining offset distance and angle data in substantially the same way.

[0017] Furthermore, in the example shown in Figure 1, sensor 103 is a light-detecting and ranging ("LIDAR") sensor or similar sensor suitable for measuring the distance between sensor 103 and a target object. For example, a LIDAR sensor operates by using light in the form of a pulsed laser to measure a range or variable distance between the sensor and an object to which the sensor, which emits a pulsed laser, is directed. The sensor measures the elapsed time from when the pulsed laser light is emitted from the sensor until the light returns to a receiver on the sensor. The speed of the pulsed laser light emitted from the sensor is known, and therefore the distance between the sensor and the object that reflects the laser light back to the sensor can be calculated using the time it takes for the pulsed light to return to the sensor. The sensor emits at least one, and in some cases many, different pulses of light, and is directed to at least one, and in some cases many, different points within a defined area. The sensor, or a controller connected to the sensor, may average multiple times corresponding to many different pulses of light emitted from the sensor in order to provide an average distance to a point within the area targeted by the sensor. A sensor or a controller connected to a sensor may average out a large number of pulses of light emitted at many different points within a defined area to provide an average distance to the target.

[0018] Lidar sensors can have advantages over other methods or instruments used to obtain similar measurements. For example, optical sensors, such as cameras, need to be focused or adjusted not only on the target area but also on the distance or depth of the target range to achieve accurate measurements. Optical sensors and cameras can be obscured by dust particles or other obstacles, which can reduce the accuracy of the sensor or completely impair its function. However, Lidar does not need to focus on depth and emits waves that can pass through dust particles or other obstacles, thus making it advantageous for use in shot peening applications where dust and other debris may be present.

[0019] Sensor 103 communicates with controller 106 via digital signal processor 104, which in this case establishes a connection between sensor 103 and controller 106 using Ethernet communication, USB communication, a digital signal processing program, a PCB control system, or any suitable communication protocol. Controller 106 communicates with display 105 to display one or more data points generated by sensor 103.

[0020] A sensor 103 attached to a nozzle attachment 101 defines a detection zone 206, as shown in Figure 2. In one example, the LIDAR sensor may emit a number of pulses of laser light directed at at least one, and in some cases many, points within a defined area to which the sensor is directed. The area from which the sensor may emit light is defined as the detection zone 206. This detection zone 206 includes a peening zone 207, which is defined as a circular target area where the shot medium is expected to disperse, and is defined as the effective range for the sensor 103 (e.g., the area in which the sensor 103 can sense an object). In one example, the sensor's detection zone 206 may be centered on the peening zone 207 so that their centers are aligned. The shape, size, and orientation of the peening zone 207 are based on the distance between the nozzle 200 and the collision target (e.g., target 309). From within the peening zone 207, an array of points 209 is selected to further define the inspection zone 208. The array of points 209 may be selected automatically by the sensor 103, automatically by the controller 106, and / or by a user utilizing the display 105 (for example, user input on the display 105 may be translated by the display 105 or a processor coupled to the display 105 into commands for the controller 106 and / or sensor 103). The array of points 209 may be selected to maximize the amount of overlap between the inspection zone 208 and the peening zone 207 so that as many peening zones 207 as possible are contained within the inspection zone 208.

[0021] The array of points 209 may be selected to be a grid of points spaced in a plane direction (having vertical and horizontal spacing) substantially normal to the direction of the pulsed laser light emitted by the sensor 103, automatically by the sensor 103, automatically by the controller 106, and / or by a user utilizing the display 105. In one example, the array of points 209 may be selected to be an 8×8 grid of points, or an array of arrays 209 of points representing the inspection zone 208, automatically by the sensor 103, automatically by the controller 106, and / or by a user utilizing the display 105. In one example, the array of points 209 may be centered about the detection zone 206 of the sensor 103, which may be centered about the peening zone 207.

[0022] As shown in FIG. 3, the target 309 is disposed within the inspection zone 208. The target 309 may be a collision target, or any other surface on which shot peening is desired, and in this example is shown as a hammer in FIG. 3. For each point 209 within the inspection zone 208 represented by a cross in FIG. 3, the system, particularly the controller 106, measures or calculates an offset distance to create a geometric model of the target 309.

[0023] In one example, as shown in FIG. 4, the controller 106 selects two points C and F that are substantially at the center of the inspection zone 208. In one example, if the two points C and F are located on or around the detected edge such that one of the points is located on either edge where detection occurs, the controller 106 selects additional points within the inspection zone 208 such that at least one of the additional points and the first two points do not exist on the detected edge. In one example, if the two points are on or around the detected edge, the controller selects two alternative points selected from a perspective view centered on either the left, right, upward or downward leg of the inspection zone 208. The system 100 first determines the positions of one or more edges within the inspection zone 208 to determine whether the selected points are on or around the detected edge.

[0024] In one example, to determine whether two points are on the detected edge, the controller 106 determines the distance between the sensor 103 and the first point, and then determines the distance between the sensor 103 and the second point. The controller 106 calculates the distance between the first point and the second point, or the change in the distance of the delta, and compares the value with a threshold to determine whether an edge exists. The system 100 (specifically the controller 106) utilizes an algorithm that identifies edges based on a comparison of the distances from the sensor 103 to adjacent points within the inspection zone 208. In response to the difference in distance being greater than the threshold, the system 100 determines that an edge exists between two adjacent points.

[0025] In one example, if the system 100 determines by algorithm that an edge lies between two adjacent points, the system 100, in particular the sensor 103, may refocus detection zone 206, and thus inspection zone 208, to a different area of ​​peening zone 207, such that the edge is not present in detection zone 206 and / or inspection zone 208, or is located in the outermost part of them. In one example, if the system 100 determines by algorithm that an edge lies between two adjacent points, the system 100, in particular the controller 106, instructs the sensor 103 to refocus detection zone 206, and thus inspection zone 208, to a different area of ​​peening zone 207. In one example, if the system 100 determines by algorithm that an edge lies between two adjacent points, the system 100, in particular the controller 106, instructs the algorithm to move inspection zone 208 into detection zone 206, but still within the area of ​​peening zone 207.

[0026] For example, if the system 100 determines by algorithm that an edge lies between two adjacent points, the system 100, in particular the shot peening nozzle 200, may be repositioned, or the controller 106 may instruct the nozzle 200 to be repositioned so that the sensor 103, detection zone 206, inspection zone 208, and peening zone 207 are all repositioned to different areas on the target 309. For example, if the system 100 determines by algorithm that an edge lies between two adjacent points, the target 309 may be repositioned within the peening zone 207.

[0027] In some examples, a similar edge detection concept is used to detect the presence of an object or collision target 309 within the inspection zone 208. In one example, instead of determining a scalar value for the distance between the sensor 103 and the detection point, the controller 106 compares the distance itself to a threshold and converts the distance into a binary variable (e.g., within a threshold with no threshold). By converting the distance determination into a binary variable and then plotting the variable on the inspection zone 208, the controller 106 maps the relative shape of the object.

[0028] As shown in Figures 4 to 6, the controller 106 determines the angle of incidence of the collision target 309 using at least one of three methods, with respect to points C and F, the determined distances from sensor 103 to each of points C and F (given as AC and AF, respectively), and the determined angles of points C and F (with respect to the X and Y axes, respectively) (given as θ and α, respectively). The visual model of Method 1 is detailed in Figure 5, and the visual models of Methods 2 and 3 are detailed in Figure 6.

[0029] Referring here to Figure 5, Method 1 includes a controller 106 that determines the angle φ, which is the angle between point C and the X-axis, using length AC and angle θ. From these values, the controller 106 calculates lengths CG and AG, where G is the position of point C along the corresponding X-axis. Since they are congruent, AG and CB are equal, and the same is true for CG and AB. Using length AF and angle α, the controller 106 determines angle β, and the controller 106 then utilizes angle β to determine lengths AE and EF. Since they are congruent, AE and FD are equal, and the same is true for EF and AD. From there, the controller 106 determines length HF by the following:

number

[0030] The controller 106 determines the length HC as follows:

number

[0031] Finally, the controller 106 determines the angle δ that defines the angle from C to F with respect to the X axis as follows:

number

[0032] Referring here to Figure 6, Method 2 includes a controller 106 that determines the angle φ, which is the angle between point C and the X-axis, using length AC and angle θ. From these values, the controller 106 calculates lengths CD and AD, where D is the position of point C along the corresponding X-axis. Since they are congruent, AD and CB are equal, and the same is true for CD and AB. Using length AF and angle α, the controller 106 determines angle β, and the controller 106 then uses angle β to determine lengths AG and GF. Since they are congruent, AG and EF are equal, and the same is true for AE and GF. From there, the controller 106 determines length CH by the following:

number

[0033] The controller 106 determines the length HF as follows:

number

[0034] Finally, the controller 106 determines the angle δ that defines the angle from C to F with respect to the X axis as follows:

number

[0035] Method 3 utilizes the same initial steps as Method 2, but employs different formulas to determine lengths CH and HF. Specifically, the controller determines length CH as follows:

number

[0036] The controller 106 determines the length HF as follows:

number

[0037] Controller 106 then uses the same equation for angle δ as in Method 2.

[0038] In one example, the controller 106 utilizes Method 1 in response to points C and F being substantially at the relative center 210 of the inspection zone 208, or if points C and F are on the same relative side of the central axis 212 (shown as line ABE in Figure 6) of the inspection zone 208. In one example, the controller 106 utilizes Method 2 in response to points C and F being close to the center of the inspection zone 208 (e.g., within the threshold distance of the inspection zone 208), or if points C and F are on either side of the central axis 212 and the angle between points C and F (e.g., the sum of angles θ and α) is equal to 45°.

[0039] As shown in Figure 7, if the inspection zone 208 defines multiple points on a grid, in other words, an array of points 209 selected from within the inspection zone 208, the controller 106 utilizes Method 2 if points C and F are one unit of measurement (on the defined grid) from the center point of the grid. In one example, the controller 106 utilizes Method 3 in response to determining that points C and F are greater than a threshold distance from the center of the inspection zone 208. The controller 106 may prioritize Method 1 over Method 2, and may prioritize Method 2 over Method 3.

[0040] Figure 8 illustrates an exemplary process map 800 for selecting a method for calculating the distance and angle to the collision target. In step 802, the controller identifies the inspection zone from data points provided by the sensor and determines the central axis of the inspection zone. In step 804, the controller then selects two data points that are substantially at the center of the inspection zone, in other words, surrounding the central axis. In step 806, the controller calculates the resulting distance between the two data points, and in step 808, determines whether the data points are on the edge of the exemplary collision target (whether the resulting distance between the two points exceeds a threshold).

[0041] If the resulting distance exceeds the threshold, the controller proceeds to step 810B, in which step 810B, the controller selects an additional data point at a predetermined additional distance from the central axis. The controller repeats steps 806-810B until the resulting distance does not exceed the threshold. If the resulting distance does not exceed the threshold, the controller measures the distance from the last data point taken to the central axis in step 810A. In step 812A, if the distance is below the first threshold, the controller proceeds to step 814A, where it calculates the target distance and angle according to the first stored algorithm. In step 812A, if the distance is above the threshold, the controller proceeds to step 812B, where it determines whether the distance is below or above the second threshold. If the distance is below the second threshold, the controller proceeds to step 814B to calculate the target distance and angle according to the second stored algorithm; however, if the distance is above the second threshold, the controller proceeds to step 814C to calculate the target distance and angle according to the third stored algorithm.

[0042] The prior descriptions of the disclosed embodiments are provided to enable any person skilled in the art to manufacture or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the overarching principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Thus, the invention is not intended to be limited to the embodiments shown herein, but should be granted to the broadest scope consistent with the principles and novel configurations disclosed herein.

Claims

1. Apparatus for use in shot peening, A nozzle attachment configured to be tightened onto a shot peening nozzle, A sensor, which is clamped to the nozzle attachment, detects and transmits sensor data in an electronic signal, wherein the sensor data further includes a plurality of distances from the sensor to a plurality of points within an inspection zone, The controller includes a controller that receives the aforementioned electronic signals, the controller includes a processor configured to execute computer commands stored in memory, and when the computer commands are executed, the controller performs the following actions, namely: An operation to identify the inspection zone from the aforementioned sensor data, An action to define the central axis within the aforementioned inspection zone, An operation to identify a first data point located at a first distance from the sensor to a target object within the inspection zone with respect to the central axis of the inspection zone, An operation to identify a second data point located at a second distance from the sensor to the target object with respect to the central axis of the inspection zone, An operation to calculate the resulting distance between the first data point and the second data point, The operation of comparing the distance obtained as a result with a threshold, and In response to the resulting distance being less than the threshold, the operation calculates the target distance and target angle between the target object and the shot medium exit point according to the stored algorithm. To execute Device.

2. The apparatus according to claim 1, wherein the stored algorithm calculates the target distance and the target angle from the known distance and the known angle by using the trigonometric relationship between the known distance and the known angle, the target distance, and the target angle.

3. The first data point is N data points, the second data point is N+1 data points, the stored algorithm is the first algorithm, and the controller, in response to the resulting distance exceeding the threshold, performs the following additional actions, namely: An operation to identify the first additional N+1 data points, An operation to calculate the first additional resulting distance between the N+1 data point and the first additional N+1 data point, An operation to compare the distance obtained as a result of the first addition with the threshold, The operation of repeating the addition operation until the distance obtained as a result of the addition of N+1 does not exceed the threshold, The operation of calculating the final distance between the last additional N+1 data point and the central axis within the inspection zone, The operation of comparing the aforementioned final distance with a threshold for the final distance, In response to the final distance being less than the threshold for the final distance, the operation of calculating the target distance and the target angle between the target object and the shot medium exit point according to a second algorithm, and, In response to the final distance exceeding the threshold for the final distance, the operation of calculating the target distance and the target angle between the target object and the shot medium exit point according to a third algorithm, Execute The apparatus according to claim 1.

4. The apparatus according to claim 1, wherein the sensor further detects the target object substantially in front of the sensor by detecting a plurality of points on the surface of the target object.

5. The apparatus according to claim 4, wherein the controller further stores the plurality of points on the surface of the target object in the memory.

6. The device is The system further includes a visual output display that further displays the shape of the target object using the plurality of points on the surface of the target object stored in the memory, The target distance and target angle for a point on the target object are displayed on the visual output display. The apparatus according to claim 5.

7. The device is The system further includes a nozzle control unit that changes the position of the shot peening nozzle relative to the target object, The nozzle control unit changes the position of the shot peening nozzle in response to the target distance and target angle calculated by the controller. The apparatus according to claim 1.

8. Apparatus for use in shot peening, A nozzle attachment configured to be tightened onto a shot peening nozzle, Connector end and A nozzle insert that attaches the connector end of the nozzle attachment to the shot peening nozzle, Including the front end, The nozzle attachment and, A sensor that detects and transmits data in an electronic signal, and is fastened to the front end of the nozzle attachment, The aforementioned data is The inspection zone, Multiple points on the target object within the aforementioned inspection zone, The further includes a plurality of distance and angle measurements between the sensor and a point on the target object within the inspection zone, The aforementioned sensor and, Includes a controller that receives the aforementioned electronic signal, The controller further includes a processor configured to execute computer commands stored in memory, and when the computer commands are executed, the controller performs the following actions, namely: An operation to identify the inspection zone from the data transmitted from the sensor, The operation of determining the central axis of the inspection zone, An operation to define a first threshold distance from the central axis of the inspection zone, An operation to define a second threshold distance from the central axis of the inspection zone, wherein the second threshold distance is greater than the first threshold distance. An operation to identify a first data point corresponding to a first distance and angle measurement from the sensor to the target object in the inspection zone, An operation to calculate a first off-center distance from the first data point to the central axis of the inspection zone, An operation to identify a second data point corresponding to a second distance and angle measurement from the sensor to the target object within the inspection zone, and, An operation to calculate a second off-center distance from the second data point to the central axis of the inspection zone, Make it run, In response to both the first off-center distance and the second off-center distance being below the first threshold distance, the controller calculates the target distance and target angle from the shot medium exit point to the target object according to the first algorithm. If both the first off-center distance and the second off-center distance are below the second threshold distance, but at least one of the first off-center distance and the second off-center distance exceeds the first threshold distance, the controller calculates the target distance and the target angle according to a second algorithm. In response to either the first off-center distance or the second off-center distance exceeding the second threshold distance, the controller calculates the target distance and the target angle according to a third algorithm. Device.

9. The first algorithm calculates the target distance and the target angle from the known distance and the known angle by using the first trigonometric relationship between the known distance and the known angle, the target distance, and the target angle. The second algorithm calculates the target distance and target angle from the known distance and the known angle by using a second trigonometric relationship between a known distance and a known angle, the target distance, and the target angle. The third algorithm calculates the target distance and the target angle from the known distance and the known angle by using a third trigonometric relationship between a known distance and a known angle, the target distance, and the target angle. The apparatus according to claim 8.

10. The apparatus according to claim 8, wherein the sensor further detects the target object substantially in front of the sensor by a plurality of points on the surface of the target object.

11. The device further includes computer-readable memory, The controller further stores the plurality of points on the surface of the target object in the computer-readable memory. The apparatus according to claim 10.

12. The apparatus further includes a visual output display that further displays the shape of the target object using the plurality of points on the surface of the target object stored in the computer-readable memory, The target distance and target angle for a point on the target object are displayed on the visual output display. The apparatus according to claim 11.

13. The apparatus further includes a nozzle control unit that changes the position of the shot peening nozzle relative to the target object, The nozzle control unit changes the position of the shot peening nozzle in response to the target distance and target angle calculated by the controller. The apparatus according to claim 8.

14. A method for determining the position and orientation of a surface for shot peening, The sensor positioned on the nozzle of the shot peening device detects multiple points on the target object, The sensor determines the distance between each of the plurality of points and the nozzle of the shot peening device, The sensor determines the angle defined by the distance determined for each of the plurality of points, The controller includes determining the distance and angle of the nozzle relative to the target object based on the distance and angle determined, method.

15. The method according to claim 14, further comprising the controller storing the distance between each of the plurality of points and the nozzle of the shot peening device on a computer-readable medium.

16. The method according to claim 15, further comprising displaying the distance between each of the plurality of points and the nozzle of the shot peening device in a graphical user interface using a visual display.

17. The method according to claim 14, further comprising controlling the position of the nozzle in response to the distance and angle of the nozzle relative to the target object based on the determined distance and angle, by a nozzle control unit.

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