Shot Peening Verification Tool with Multi-Face Sensor Frame
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The conventional method for determining peening intensity in shot peening machines is time-consuming, error-prone, and requires numerous Almen strips, which are difficult to reuse and result in significant waste.
Innovation Solution
A verification tool with a sensor support frame mounted within the shot peening machine, equipped with electronic impact sensors on multiple faces, allows for direct measurement of peening intensity by measuring the impact force of peening media.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If the conventional Almen strip method is used to determine peening intensity, then measurement can be performed, but the process is time-consuming and requires repetitive mounting and measuring of multiple strips
Solution Approach 1:
The patent replaces the mechanical Almen strip method with an electronic impact sensor system. The sensor directly measures impact force electronically, eliminating the need for physical strip mounting, peening, removal, and manual measurement. This substitution of mechanical measurement with electronic sensing resolves the time-consuming nature of the conventional process while maintaining measurement capability.
Solution Approach 2:
The patent uses electronic sensors to create an electronic copy or representation of the peening impact measurement, replacing the physical Almen strip method. Instead of physically deforming and measuring strips, the system captures impact data electronically, enabling rapid repeated measurements without physical consumption of test materials.
2Measurement precision
If multiple Almen strips are used to assess peening intensity at different locations, then comprehensive coverage is achieved, but the number of strips required becomes very large (hundreds)
Solution Approach 1:
The patent replaces numerous physical Almen strips with reusable electronic impact sensors. Each sensor can be positioned at different locations and provides digital measurement output, eliminating the need to physically handle, mount, and discard hundreds of individual strips. The electronic system maintains the ability to assess multiple locations while dramatically reducing material consumption.
3Measurement precision
If Almen strips are mounted on fixtures with complex shapes, then peening intensity can be assessed at different locations, but incorrect mounting or measurement errors occur
Solution Approach 1:
The patent replaces manual mounting and measurement operations with electronic sensors that can be directly mounted on the fixture surface. The sensors provide automated digital readings, eliminating human error in strip alignment, mounting security, and curvature measurement. This electronic substitution improves reliability by removing the subjective and error-prone manual operations inherent in the Almen strip method.
4Manufacturing precision
If peening parameters are adjusted multiple times to achieve desired intensity, then optimal peening is achieved, but the repetitive testing process becomes extremely time-consuming
Solution Approach 1:
The patent replaces the slow iterative process of mounting and measuring Almen strips with rapid electronic impact sensor measurements. Each parameter adjustment can be immediately evaluated by the sensor, providing quick feedback for optimization. This electronic measurement system enables multiple parameter iterations within the time it would take to perform just one or two conventional Almen strip tests, dramatically improving productivity during the parameter optimization phase.
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 method significantly reduces the time and effort required to determine peening intensity, minimizes waste, and provides more accurate measurements by eliminating errors associated with Almen strip mounting and measurement.
Implementation Method 1
electronic impact sensors on multiple faces, allows for direct measurement of peening intensity by measuring the impact force of peening media
Data Source
AI summary
A verification tool for a shot peening machine has a sensor support frame configured to be mounted within the shot peening machine. The sensor support frame has at least three faces facing outwardly in different directions, and each face is configured to receive an electronic impact sensor configured to measure the peening intensity of peening media discharged from one or more nozzles of the shot peening machine.