Robotic Peening Device with Real-Time Distance Feedback
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Solution Overview
Problem
The peen forming method faces challenges in accurately predicting deformation processes and positioning shots for complex three-dimensional aircraft parts, leading to potential strength reduction and deformation issues, especially at corners, due to the difficulty in accurately blasting shots without causing unintended deformation during machining.
Innovation Solution
A part manufacturing system incorporating a peening device with a nozzle section and detection units that adjust the position and orientation of the peening device using a robot device, along with a protection section to prevent deformation of specific areas, ensures accurate shot projection and prevents deformation of non-target regions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the peen forming method is used to deform the workpiece by continuously projecting shots, then the workpiece can be deformed into a three-dimensional shape, but the deformation process becomes difficult to predict and control
Solution Approach 1:
The patent introduces a detection unit that detects the position of the workpiece in real-time during the peen forming process. The control unit uses this feedback information to adjust the projection conditions of the shots, enabling precise control and prediction of the deformation process while achieving the desired three-dimensional shape.
2Productivity
If the nozzle or impeller is separated from the workpiece by a predetermined distance, then the shots can be projected to the workpiece, but the shot projection accuracy is reduced
Solution Approach 1:
The patent employs a robot device that can dynamically adjust the position of the peening device, allowing the nozzle to move closer to the workpiece surface during operation. This dynamic positioning enables both effective shot projection and high accuracy in targeting specific areas of the workpiece.
3Strength
If a rubber sheet is attached to protect corners from deformation, then corner strength is maintained, but time and labor are required for attachment and the rubber sheet may peel off during high-speed shot projection
Solution Approach 1:
The patent uses a detection unit to automatically identify corner regions of the workpiece and the control unit automatically controls the shot projection to avoid these regions. This self-regulating system eliminates the need for manual attachment of protective sheets while ensuring corner strength is maintained throughout the peen forming process.
4Adaptability or versatility
If projection conditions of shots are changed during continuous projection, then different regions can be processed, but unexpected deformation occurs during transient periods
Solution Approach 1:
The detection unit continuously monitors the workpiece position during shot projection. When the peening device needs to move between regions or change projection conditions, the real-time feedback from the detection unit allows the control unit to adjust the shot projection timing and conditions, eliminating unexpected deformations during transient periods while maintaining the ability to process different regions.
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 system enables precise and accurate machining of complex aircraft parts by ensuring shots are accurately blasted to predetermined positions, reducing the risk of strength reduction and deformation, while eliminating the need for labor-intensive protective measures like rubber sheets and minimizing unexpected deformation during machining.
Implementation Method 1
The peen forming method is a machining method of plastically deforming a workpiece by projecting steel balls (having a diameter of 5 mm, for example) called 'shots' to the workpiece
Implementation Method 2
a main machining step of forming, by projecting shots at a high speed to add a plastic strain, a surface of a flat plate section
Data Source
AI summary
An object is to enable accurate machining by enabling shots to be accurately blasted on a workpiece even while workpiece is being deformed. A part manufacturing system includes: a peening device including a nozzle that projects a plurality of shots toward a workpiece, and a sensor that detects a distance to the workpiece; and a machining robot including a hand to which the peening device is attached, and a control unit that adjusts a position or an orientation of the peening device by controlling the hand based on the distance detected by the sensor.