Optical Shot Peening Evaluation System
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Solution Overview
Problem
Current methods for evaluating the effectiveness of shot peening processes are subjective and inefficient, particularly for large surfaces, as they rely on visual inspection and small sample analysis, which can lead to inconsistent coverage and potential failures in production parts.
Innovation Solution
An optical inspection system using cameras and processors to analyze image data from shot-peened surfaces, determining impact coverage values by comparing pixel data to predefined thresholds, and identifying areas with incomplete coverage, providing objective and comprehensive evaluations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If visual inspection methods are used to evaluate shot peening coverage, then the inspection process is simple and requires minimal equipment, but the evaluation becomes subjective and inconsistent between different inspectors
Solution Approach 1:
The patent replaces the mechanical/visual inspection system with an optical imaging system using cameras and digital image processing. The system captures images of the shot-peened surface and uses software algorithms to automatically detect and count dimples, converting a subjective visual assessment into an objective digital measurement that eliminates inspector variability while maintaining simplicity through automated processing.
2Area of stationary object
If an inspector manually examines large surfaces, then comprehensive coverage can be achieved by walking around the part, but the inspection process becomes time-consuming and portions may still be missed
Solution Approach 1:
The patent transitions from one-dimensional manual inspection (inspector moving along the surface) to two-dimensional comprehensive imaging by capturing the entire surface area with camera(s). This allows simultaneous examination of all surface portions including hard-to-reach areas, dramatically reducing inspection time while achieving complete area coverage through digital image capture and processing.
3Productivity
If small sample analysis is used to evaluate shot peening, then the inspection process is quick and simple, but the results may not accurately reflect the effectiveness across the entire surface
Solution Approach 1:
The patent creates a universal evaluation system that can assess the entire surface area rather than relying on small samples. The imaging and image processing system provides comprehensive coverage analysis across all portions of the shot-peened surface, ensuring that the effectiveness assessment reliably reflects the actual coverage quality while maintaining high productivity through automated processing of the complete surface data.
Data Source
Figure 1A~3B
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AI summary
Apparatus and methods for shot peening evaluation are disclosed herein. An example apparatus for evaluating a surface that has undergone a shot peening process includes a camera to generate first image data of a first portion of the surface. The example apparatus includes a processor to determine an impact coverage value for the first portion based on the first image data and determine an effectiveness of the shot peening process for the surface based on the impact coverage value.