Shot Peening Flow Rate Control Using Deflectable Member Sensor
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Solution Overview
Problem
Existing shot peening systems lack the ability to accurately control the flow rate of non-ferrous media, such as glass beads or ceramic materials, due to the inability to sense and respond to the actual flow rate, leading to unpredictable peening results.
Innovation Solution
A flow rate control system featuring a valve with a spindle guided for axial movement and a flow sensor with a deflectable member that measures flow rate deflection, generating an electrical signal to adjust the valve's opening, allowing for precise control of the media flow rate regardless of material type.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If a magnetic valve is used to control the flow rate of ferrous media, then the flow rate control is effective, but the system cannot control non-ferrous media such as glass beads or ceramic materials
Solution Approach 1:
The patent replaces the magnetic field-based control mechanism with a mechanical flow sensing system. A deflectable member (such as a beam or flap) is positioned in the flow path to mechanically sense the flow rate of media. This mechanical sensing approach works universally for both ferrous and non-ferrous media, eliminating the limitation of magnetic valve compatibility while maintaining reliable flow rate control through mechanical deflection proportional to flow rate.
2Manufacturing precision
If a fixed orifice is used for media dispensing, then the system structure is simple, but the peening results are unpredictable due to inability to control flow rate
Solution Approach 1:
The patent implements a feedback control system where the deflectable member senses the actual flow rate and generates a signal that is fed back to a valve actuator. This closed-loop feedback mechanism adjusts the valve position to maintain the desired flow rate, ensuring consistent and predictable peening results. The feedback loop compensates for variations in media properties, pressure fluctuations, and wear, providing precise flow rate control without requiring complex mechanical adjustments.
3Reliability
If no flow sensing is provided, then the system is simpler, but feedback for valve control is unavailable leading to poor flow rate control
Solution Approach 1:
The patent introduces a deflectable member as an intermediary element between the media flow and the control system. This beam or flap acts as a mechanical transducer, converting the kinetic energy of the flowing media into mechanical deflection, which is then converted into an electrical signal by a sensing device (such as a potentiometer or LVDT). This intermediary mechanism provides accurate flow rate measurement and feedback without requiring direct electronic sensing of the media itself, balancing measurement accuracy with system simplicity.
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
Enables precise control of the media flow rate, ensuring a predictable air-media mixture for consistent peening results, even with non-ferrous materials, by using a proximity sensor to measure beam deflection and adjust the valve accordingly.
Implementation Method 1
In response to increasing or decreasing the flow of the media through the flow path, the deflectable member will deflect more or less
Implementation Method 2
A sensing device measures the deflection in the deflectable member and generates an electrical signal that varies in response to deflection in the deflectable member
Data Source
AI summary
A shot peening flow rate control that is useful for non-ferrous shot peening media. The control has an inlet for receiving media and an orifice through which the media may pass that is in communication with the inlet. A valve selectively blocks the orifice. The valve has a spindle that is guided for axial movement between an open and closed position. The closed position blocks the orifice and the open position places the spindle spaced from the orifice to allow media to flow through the orifice. A flow sensor has a deflectable member that extends into a flow path of media leaving the orifice. In response to increasing or decreasing flow of the media through the flow path the deflectable member will deflect more or less. A sensing device measures the deflection in the deflectable member and generates an electrical signal that varies in response to deflection in the deflectable member.