Real-Time Feedback Control for Variable Needle Peen Forming
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Solution Overview
Problem
Existing mechanical systems for processing metal workpieces into final components are inefficient and require additional processing time and costs to meet design requirements, especially when achieving compressive residual stress and dimensional variations.
Innovation Solution
A method and apparatus that securely positions a metal workpiece and applies multiple impacts using a driven member, with predetermined processing parameters adjusted in real-time based on sensed physical conditions, such as depth or thickness, to control the impacting process and achieve the desired final component without unnecessary additional processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If prior peening systems (shock, ultrasonic, laser) are used to process metal workpieces, then the workpiece can be processed into useful components, but additional processing is required to meet design requirements, increasing production costs and processing time
Solution Approach 1:
The patent implements a feedback control system where sensors continuously monitor the peening process parameters (impact force, depth, distribution) and workpiece condition, transmitting this data to a controller that adjusts the peening parameters in real-time. This closed-loop feedback enables the system to automatically optimize the peening process to meet design requirements without requiring additional post-processing steps, thereby reducing both production costs and processing time while maintaining high manufacturing precision.
2Manufacturing precision
If additional processing is applied to achieve design requirements, then component quality improves, but production costs and processing time increase
Solution Approach 1:
The feedback control system continuously monitors process parameters and workpiece condition, enabling real-time adjustments that ensure design requirements are met during the primary peening operation itself, eliminating the need for time-consuming additional processing steps
Solution Approach 2:
The system maintains continuous monitoring and adjustment throughout the peening process, ensuring that quality requirements are met in a single continuous operation rather than requiring intermittent additional processing steps, thereby reducing total processing time while maintaining component quality
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach significantly reduces production costs and processing time by allowing for efficient, one-step processing of metal workpieces into final components with controlled physical characteristics, minimizing additional processing needs.
Implementation Method 1
A surface of the workpiece is impacted multiple times by a driven member for achieving the final metal component
Implementation Method 2
shock peening, ultrasonic peening, and laser peening
Implementation Method 3
sensing currently existing physical conditions of the workpiece during the impacting, including sensing a depth or thickness of the workpiece at a next section to be impacted
Implementation Method 4
A feedback system transmits the sensed physical conditions of the workpiece to the controller for adjusting the predetermined processing parameters into adjusted processing parameters
Data Source
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AI summary
Method and apparatus are provided for processing and changing the physical characteristics of a metal workpiece into a final metal component. Predetermined processing parameters are established for achieving a final metal component. The metal workpiece is positioned securely on a support during the changing of the physical characteristics. Impacts are applied to a surface of the workpiece multiple times for achieving the final metal component while controlling the impacting with the predetermined processing parameters. A sensor is provided for continuously sensing the currently existing physical conditions of the workpiece during impacting. The predetermined processing parameters are changed into adjusted processing parameters and the impacts are changed in reaction to the currently existing physical conditions of the workpiece from the sensing and processing of the workpiece until the final metal component has been achieved.