Patent Application
20240165767
This specification is based upon and claims the benefit of priority from United Kingdom patent application number GB 2217181.3 filed on Nov. 17, 2022, the entire contents of which is incorporated herein by reference.
The present disclosure relates to a system and a method for controlling a treatment process that modifies surface properties of a component.
Mechanical articles typically degrade in various ways over time especially when operated for long durations of time in extremes of temperature. The degradation often primarily or at least initially tends to occur at one or more surfaces of the articles concerned. It is known in the aerospace industry to treat the surface of components, especially gas turbine components, such as compressor blades, turbine blades, and bladed integrated disks, in order to modify/enhance the performance/life and/or appearance of those components.
It is well known that polishing a metal surface can improve its appearance. It involves rubbing the surface and/or applying a chemical substance to it to make the surface smooth and shiny. Vibropolishing, aka ball pressure polishing, is a polishing method that involves placing an article in a container of specially shaped pellets and vibrating the container so that the pellets rub against the article to deburr, radius, descale, burnish, clean, and/or brighten its surface. While vibropolishing is useful for improving the surface roughness of aerospace components it can undesirably remove material and detrimentally affect aerofoil geometries.
The process of working on a metal surface to improve its material properties is known as peening. Certain types of peening reflect the manner in which the metal surface is worked upon. Peening is not restricted to metal surfaces, It is, for example, possible to peen composite materials. Shot peening is a cold working process that involves striking the surface of a metal or a composite with a shot with sufficient force to produce a compressive residual stress layer by plastic deformation. The shot can, for example, be in the form of round metallic, glass, or ceramic particles. The process is intended to modify the mechanical properties of the metal or the composite without removing any appreciable material. It is known to use shot peening to strengthen car crankshafts and connecting rods. While shot peening is useful for providing desired compressive residual stresses in aerospace components, it typically undesirably increases surface roughness.
Vibropeening is a process that combines vibratory polishing and shot peening to a single polishing process in a vibratory bowl/trough. Also known as ball polishing, it is known to be useful for improving the appearance of car wheels, various types of furniture, and cutlery. Tests have shown that vibro-treating, i.e., vibropeening or vibropolishing, a component of a gas turbine engine (e.g., a bladed disk drum and a fan blade) results in a non-uniform residual stress distribution and material properties across the length due to asymmetry of the component. This may undesirably increase treatment time and process cost.
However, currently there is no validated process control mechanism for vibropeening. This may be because vibropeening is a low energy process and may therefore take significant amount of time to perform process control checks thereby reducing the business case benefit introduced through elimination of shot peening. Further, if a drawing parameter (e.g., a process intensity) for a component is not as per drawing requirement after quantification using Almen strips, then significant time may be again required to revalidate a vibropeening setup to be deemed as fit for obtaining the drawing parameter as per the drawing requirement for the component. Further, if the drawing parameter for the component is not as per drawing requirement after quantification, the component may have to be discarded. Moreover, in conventional vibropeening techniques, human intervention is relatively high as measuring Almen intensity through saturation curves is a very labour-intensive process. Also, conventional vibropeening techniques may cause an excessive amount of cost to be spent on the sacrificial Almen strips in a production plant. Therefore, there exists a need for a system and a method that control such a treatment process in an improved/sustainable manner.
The present disclosure provides a method and a system for controlling a treatment process that modifies surface properties of a component that addresses the shortcomings of conventional polishing and peening methods, or at least provides a useful alternative to the same.
According to a first aspect there is provided a system for controlling a treatment process that modifies surface properties of a component. The system includes a treatment apparatus for carrying out the treatment process. The treatment apparatus includes a vibratory trough for receiving and retaining treatment media The treatment apparatus further includes a component support fixedly attached to the vibratory trough. The component support supports the component within the vibratory trough. The treatment apparatus further includes at least one trough vibrating mechanism that causes the vibratory trough to vibrate. The system further includes a plurality of sensor devices respectively and fixedly disposed at a plurality of heights relative to the vibratory trough.
The plurality of sensor devices is configured to respectively measure a plurality of movement/vibration parameters of the treatment media at the plurality of heights and generate a plurality of movement/vibration signals corresponding to the plurality of movement/vibration parameters. The vibration parameters may be defined by the oscillating, reciprocating, or any other periodic motion of a rigid or elastic body or medium forced from a position or state of equilibrium. The movement may be timely adjusted according to requirements, for e.g., primarily introduce high residual compressive stresses by other parameters and secondary treatment to smoothen the surface roughness which might both not be periodically. The system further includes a central controller communicably coupled to each of the plurality of sensor devices. The central controller is configured to receive the plurality of movement signals from the plurality of sensor devices. The central controller is further configured to determine a plurality of process variables corresponding to the plurality of movement signals. The central controller is further configured to control the treatment apparatus based at least on the plurality of process variables.
The central controller controls the treatment apparatus based at least on the plurality of process variables, such as a value of an energy/impulse, a coverage, and/or an intensity at respective heights relative to the vibratory trough. The central controller communicably coupled to the plurality of sensor devices fixedly disposed at the plurality of heights relative to the vibratory trough may enable the system of the present disclosure to monitor the plurality of movement signals and the plurality of process variables. In other words, the system of the present disclosure may be used to obtain a desired parameter of the treatment process (i.e., vibropeening) for a specific aerospace component according to the drawing requirement.
As the controller controls the treatment apparatus based at least on the plurality of process variables corresponding to the plurality of movement signals, the system of the present disclosure may provide uniform residual stress distribution and material properties across the component during the treatment process (i.e., vibropeening). This may improve fatigue life and/or performance of the component. This is particularly important when the component is large in size. Further, unlike conventional techniques where the component may have to be scrapped if there is any error in obtaining the drawing requirement (e.g., Almen intensity), the system of the present disclosure may enable monitoring the vibropeening at specific heights and accordingly controlling the vibropeening of the component, As a result, a likelihood of scrapping the component after the treatment process of the component may be reduced by the system of the present disclosure. Therefore, the central controller and the plurality of sensor devices may validate a process control method and/or mechanism of the treatment process for the component.
Moreover, as compared to the conventional vibropeening techniques, the system of the present disclosure may substantially reduce human intervention because of continuous determination of the plurality of process variables corresponding to the plurality of movement signals and subsequently controlling the treatment apparatus based at least on the plurality of process variables. The system of the present disclosure may enable the vibropeening which is relatively faster with less intensive manual labour which may significantly reduce developmental time and cost for research. This will enable faster optimization of the process to meet a specific drawing requirement for any given component/geometry at a specific location. Such a method also could be used for locally optimizing vibropeening for specific repair process through various fixturing/masking steps. Further, in the proposed system, there are minimal chances of wastage of sacrificial Almen strips or scrapping of components which may not meet the drawing requirements, The system of the present disclosure may be used for vibropeening of rotationally symmetric as well as asymmetric components.
In some embodiments, the system further includes a display device communicably coupled to the central controller. The display device is configured to display the plurality of process variables. The display device may display intensity of the treatment process. In some applications, an operator may also adjust or control the treatment apparatus based on the plurality of process variables displayed on the display device, The display device may be a monitor or a screen.
In some embodiments, the component support includes a support fixture and a support shaft attached to the support fixture. The support fixture fixedly attaches the support shaft to the vibratory trough and the support shaft removably mounts the component within the vibratory trough. Each of the plurality of sensor devices is fixedly attached to the support fixture. The support shaft may be mounted using a bearing assembly. The support shaft may be a substantially hollow shaft that spans across each end of the vibratory trough. The support shaft may be removably locatable within the vibratory trough and shaped to support the component to be treated in the treatment apparatus.
In some embodiments, the system further includes a frame fixedly attached to the vibratory trough. The frame further includes one or more vertical hangers. Each of the plurality of sensor devices is fixedly attached to the one or more vertical hangers of the frame, The frame may also include a plurality of holders attached to the one or more vertical hangers and configured to receive the respective plurality of sensor devices. The one or more vertical hangers may allow mounting of the plurality of sensor devices at the respective plurality of heights relative to the vibratory trough.
In some embodiments, each of the one or more vertical hangers extends at least partially into the treatment media. When each of the one or more vertical hangers extends at least partially into the treatment media, the plurality of sensor devices may respectively measure the plurality of movement parameters of the treatment media at the plurality of heights and generate the plurality of movement signals corresponding to the plurality of movement parameters.
In some embodiments, the central controller is further configured to receive a predetermined process parameter for the treatment process. The central controller is further configured to determine a measured process parameter based on the plurality of process variables. The central controller is further configured to control the treatment apparatus based on the predetermined process parameter and the measured process parameter, such that a difference between the predetermined process parameter and the measured process parameter is reduced. By reducing the difference between the predetermined process parameter and the measured process parameter, a desirable intensity and/or energy of the treatment process (i.e., vibropeening) may be obtained at the plurality of heights. The measured process parameter may be an overall intensity of the treatment process. The predetermined process parameter may be the drawing requirement.
In some embodiments, the central controller is further configured to, prior to receiving the plurality of movement signals from the plurality of sensor devices, determine a plurality of predicted process variables corresponding to the plurality of heights of the vibratory trough. The central controller is further configured to control the treatment apparatus based on the plurality of predicted process variables and the plurality of process variables, such that a difference between each of the plurality of process variables and a corresponding predicted process variable from the plurality of predicted process variables is reduced. By reducing the difference between each of the plurality of process variables and the corresponding predicted process variable from the plurality of predicted process variables, a desirable value of intensity and/or energy of the treatment process (i.e., vibropeening) may be obtained at the plurality of heights. The plurality of predicted process variables may be predicted intensities of the treatment process at the plurality of heights,
In some embodiments, the central controller is further configured to control the at least one trough vibrating mechanism of the treatment apparatus based on the plurality of process variables. Therefore, the central controller may adjust the vibration of the vibratory trough based on the plurality of process variables, such as a value of an energy, a coverage, and/ or an intensity of the treatment process.
In some embodiments, the treatment apparatus further includes at least one trough wall provided in the vibratory trough and configured to adjust a height, a volume, and/or a mass of the treatment media in the vibratory trough. The central controller is further configured to control the at least one trough wall of the treatment apparatus based on the plurality of process variables. By adjusting the height, the volume, and/or the mass of the treatment media in the vibratory trough, various characteristics and the overall intensity of the treatment process may be varied as per desirable application attributes. The trough wall may include a slot to receive the support shaft at various heights depending on application requirements.
In some embodiments, the treatment apparatus further includes a drive arrangement configured to rotate the component relative to the treatment media. The central controller is further configured to control the drive arrangement of the treatment apparatus based on the plurality of process variables. The drive arrangement may include a motor, a timing belt, and a gearbox with a variable pear ratio. The central controller may adjust a speed of the motor based on the plurality of process variables in order to control the coverage and uniformity of the treatment process (i.e., vibropeening).
In some embodiments, the treatment apparatus further includes a treatment media inlet for controllably supplying the treatment media into the vibratory trough and a treatment media outlet for controllably emptying the treatment media from the vibratory trough. The central controller is further configured to control the treatment media inlet and/or the treatment media outlet of the treatment apparatus based on the plurality of process variables. The treatment media inlet may be an inlet valve and the treatment media outlet may be an outlet valve. The treatment media inlet and the treatment media outlet may also be used to keep a desirable volume, height, and/or mass of the treatment media in the vibratory trough.
In some embodiments, each of the plurality of sensor devices includes at least two fixed electrodes for generating an electric field. An electric parameter is applied across the at least two fixed electrodes to induce the electric field between the at least two fixed electrodes. Each of the plurality of sensor devices further includes at least one movable electrode disposed between the at least two fixed electrodes. Upon vibration of the vibratory trough, the at least one movable electrode moves causing the electric field between the at least two fixed electrodes to change. Each of the plurality of sensor devices further includes an electric circuit electrically coupled to the at least two fixed electrodes and the at least one movable electrode. The electric circuit is configured to measure the corresponding movement parameter based on the change in the electric field between the at least two fixed electrodes. Each of the plurality of sensor devices further includes a processor communicably coupled to the electric circuit. The processor is configured to generate the corresponding movement signal based on the corresponding movement parameter. The processor is further configured to transmit the corresponding movement signal to the central controller, Therefore, the plurality of sensor devices generates the plurality of movement signals corresponding to the plurality of movement parameters. In other words, upon movement of the at least one movable electrode by vibration of the vibratory trough, the electric circuit measures the corresponding movement parameter (e.g., acceleration of the treatment media in the vibratory trough) based on the change in the electric field between the at least two fixed electrodes.
In some embodiments, each of the plurality of sensor devices further includes a casing. The casing includes one or more provisions for removably attaching a test strip to the casing. The test strip may be an Almen test strip that is used to quantify the intensity of the treatment process (i.e., vibropeening). The test strip may be a metal/alloy strip of a predetermined thickness to monitor the intensity of the treatment process being induced on the component.
According to a second aspect there is provided a method for controlling a treatment process that modifies surface properties of a component. The method includes providing a treatment apparatus for carrying out the treatment process. The treatment apparatus includes a vibratory trough for receiving and retaining treatment media. The treatment apparatus further includes a component support fixedly attached to the vibratory trough. The component support supports the component within the vibratory trough. The treatment apparatus further includes at least one trough vibrating mechanism that causes the vibratory trough to vibrate. The method further includes providing a plurality of sensor devices respectively and fixedly disposed at a plurality of heights relative to the vibratory trough. The plurality of sensor devices is configured to respectively measure a plurality of movement/vibration parameters of the treatment media at the plurality of heights and generate a plurality of movement/vibration signals corresponding to the plurality of movement parameters. The method further includes receiving the plurality of movement signals from the plurality of sensor devices. The method further includes determining a plurality of process variables corresponding to the plurality of movement signals. The method further includes controlling the treatment apparatus based at least on the plurality of process variables.
In some embodiments, the method further includes receiving a predetermined process parameter of the treatment process. The method further includes determining a measured process parameter based on the plurality of process variables. Controlling the treatment apparatus further includes controlling the treatment apparatus based on the predetermined process parameter and the measured process parameter, such that a difference between the predetermined process parameter and the measured process parameter is reduced.
In some embodiments, the method further includes, prior to receiving the plurality of movement signals from the plurality of sensor devices, determining a plurality of predicted process variables corresponding to the plurality of heights of the vibratory trough. Controlling the treatment apparatus further includes controlling the treatment apparatus based on the plurality of predicted process variables and the plurality of process variables, such that a difference between each of the plurality of process variables and a corresponding predicted process variable from the plurality of predicted process variables is reduced.
In some embodiments, controlling the treatment apparatus further includes controlling the at least one trough vibrating mechanism based on the plurality of process variables.
In some embodiments, controlling the treatment apparatus further includes adjusting a height, a volume, and/or a mass of the treatment media in the vibratory trough based on the plurality of process variables.
In some embodiments, controlling the treatment apparatus further includes controlling a rotation of the component relative to the treatment media based on the plurality of process variables.
In some embodiments, controlling the treatment apparatus further includes controllably supplying the treatment media into the vibratory trough and/or controllably emptying of the treatment media from the vibratory trough based on the plurality of process variables.
In some embodiments, the component is a gas turbine engine component. In some embodiments, the gas turbine engine component is a bladed disk drum, compressor airfoils made of conventional/additive manufacture methods or a fan blade.
The term “shot peening”, as used herein, is a method of modifying the mechanical properties of an article that involves striking the surface of the article, typically made of metal or composite, with shot with sufficient force to produce a compressive residual stress layer in the article by plastic deformation. The method tends to result in the article having a rough surface.
The term “vibrofinishing” (aka vibratory finishing), as used herein, is a method for polishing the surface of an article, typically made of metal or composite, which involves vibrating the article amongst certain specially shaped pellets to decrease the surface roughness of the article. Shot peened articles are often vibrofinished to reduce their surface roughness, with the vibrofinishing typically removing some material from the article but typically not affecting the residual stress created during the shot peening process, It is typically advisable to minimise any vibropolishing in order to minimise the removal of material. Indeed excessive vibropolishing shot peened articles can remove the compressive residual stress layer formed by the shot peening.
The term “vibropeening” (aka vibratory peening), as used herein, is a method of modifying the mechanical and surface properties of an article, typically made of metal of composite, that involves vibrating the article within a treatment media to polish the article, reduce its surface roughness, and to induce compressive residual stress on the article. Vibropeening tends to provide a superior surface finish to shot peening. It also tends to provide a deeper layer of compression than shot peening albeit typically providing somewhat less residual stress than shot peening.
The term “fatigue life”, as used herein, means the time by which a component or material will last before completely failing because of concentrated stresses.
Throughout this specification and in the claims that follow, unless the context requires otherwise, the word “comprise” or variations such as “comprises” and “comprising”, will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other stated integer or group of integers.
The skilled person will appreciate that except where mutually exclusive, a feature or parameter described in relation to any one of the above aspects may be applied to any other aspect.
Embodiments will now be described by way of example only, with reference to the Figures, in which:
The following table lists the reference numerals used in the drawings with the features to which they refer:
Aspects and embodiments of the present disclosure will now be discussed with reference to the accompanying figures. Further aspects and embodiments will be apparent to those skilled in the art.
Referring to
In some embodiments, the vibratory trough 102 may be composed of a metal, e.g., aluminium or steel, and lined with a polyurethane layer (not shown) to protect the vibratory trough 102 and avoid any chemical reaction with the construction material of the vibratory trough 102. The polyurethane layer may ensure a smooth flow of the treatment media 12 within the vibratory trough 102. It may also be useful to apply a layer of polyurethane to metal parts of the treatment apparatus 100 for which any polishing is not required or is undesirable. Instead of polyurethane, other materials may be used to fulfil the same or similar purpose, e.g., the vibratory trough 102 may be lined with another polymeric material.
The treatment apparatus 100 further includes a component support 104 fixedly attached to the vibratory trough 102. In some embodiments, the component support 104 may be fixedly attached to the vibratory trough 102 via fasteners, such as screws, rivets, or nut and bolts. The component support 104 supports the component 10 within the vibratory trough 102. The component support 104 is located at least partially within the vibratory trough 102. The component 10 is removably attached to the component support 104. The component support 104 may take a variety of forms so as to support the component 10 to be treated in the treatment apparatus 100.
In the illustrated embodiment of
In some embodiments, the treatment apparatus 100 further includes at least one trough wall 118 provided in the vibratory trough 102. The at least one trough wall 118 is configured to adjust a height, a volume, and/or a mass of the treatment media 12 in the vibratory trough 102. In the illustrated embodiment of
The treatment apparatus 100 further includes at least one trough vibrating mechanism 106 (schematically shown in
The at least one trough vibrating mechanism 106 includes suitable equipment for the vibratory trough 102 to be rocked or otherwise oscillated, as desired. In some embodiments, the at least one trough vibrating mechanism 106 may include a plurality of actuators (not shown) and corresponding actuator extension rods (not shown). The actuator extension rods may be individually extendable, as required. The actuators may be powered pneumatically or hydraulically.
In some embodiments, the treatment apparatus 100 further includes a drive arrangement 120 configured to rotate the component 10 relative to the treatment media 12 (schematically shown in
In some embodiments, the treatment apparatus 100 further includes a treatment media inlet 130 (shown in
The system 50 further includes a plurality of sensor devices 14 respectively and fixedly disposed at a plurality of heights relative to the vibratory trough 102. Some of the sensor devices 14 from the plurality of sensor devices 14 may be fixedly disposed at a height H1 from a base 103 of the vibratory trough 102. Some other sensor devices 14 from the plurality of sensor devices 14 may be fixedly disposed at a height H2 from the base 103 of the vibratory trough 102. Further, some other sensor devices 14 from the plurality of sensor devices 14 may be fixedly disposed at a height H3 from the base 103 of the vibratory trough 102. The plurality of sensor devices 14 is configured to respectively measure a plurality of movement parameters of the treatment media 12 at the plurality of heights (i.e., H1, H2, H3, and so on) and generate a plurality of movement signals 16 corresponding to the plurality of movement parameters. The plurality of movement parameters of the treatment media 12 may include an acceleration and/or a speed of the treatment media 12 at the plurality of heights. In some embodiments, the plurality of movement parameters may be a plurality of vibration parameters. Therefore, the plurality of movement signals 16 may be a plurality of vibration signals. In some embodiments, each of the plurality of sensor devices 14 is fixedly attached to the support fixture 110. Therefore, each of the plurality of sensor devices 14 may measure a relative movement parameter of the treatment media 12 with respect to the vibratory trough 102 at a corresponding height from the plurality of heights. In some embodiments, each of the plurality of sensor devices 14 may include an intensity prediction unit, a vibration monitoring sensor, an accelerometer, an ultrasonic senor, an infrared sensor, and/or any other sensor capable of measuring the plurality of movement parameters of the treatment media 12 at the plurality of heights.
The system 50 further includes a central controller 18 communicably coupled to each of the plurality of sensor devices 14. The central controller 18 may be a control circuit, a computer, a microprocessor, a microcomputer, a central processing unit, or any suitable device or apparatus. The central controller 18 may include one or more of a digital processor, an analog processor, a digital circuit designed to process information, an 10 analog circuit designed to process information, a state machine, and/or other mechanisms for electronically processing information. In some embodiments, the central controller 18 is communicably coupled to each of the plurality of sensor devices 14 via at least one of a wired connection and a wireless connection. Functional details of the central controller 18 will be described later in the description.
In some embodiments, each of the plurality of sensor devices 14 further includes an electric circuit 32 electrically coupled to the at least two fixed electrodes 28 and the at least one movable electrode 30. The electric circuit 32 is configured to measure the corresponding movement parameter based on the change in the electric field F between the at least two fixed electrodes 28. In some embodiments, each of the plurality of sensor devices 14 further includes a processor 34 communicably coupled to the electric circuit 32. The processor 34 is configured to generate the corresponding movement signal 16 based on the corresponding movement parameter. The processor 34 is further configured to transmit the corresponding movement signal 16 to the central controller 18.
In some embodiments, each of the plurality of sensor devices 14 further includes a data storage unit 38 configured to store the plurality of movement signals 16 and a set of instructions or a genetic algorithm that is executable by the processor 34. In some embodiments, each of the plurality of sensor devices 14 further includes a communication unit 35 to transfer data in real-time to an external unit or to connect to an external digital device. For example, the communication unit 35 of each of the plurality of sensor devices 14 may transfer the corresponding movement signal 16 to the central controller 18. The communication unit 35 may be a W-Fi or Bluetooth unit. In some embodiments, each of the plurality of sensor devices 14 further includes a power supply circuit 36 that enables charging of a battery of the corresponding sensor device 14.
In some embodiments, each of the plurality of sensor devices 14 further includes a receiver 39 that may receive data from the central controller 18. In some cases, the receiver 39 may receive data (e.g., the plurality of movement parameters) from other sensors from the plurality of sensors 14. In some embodiments, each of the plurality of sensor devices 14 further includes a digital display 40. In some embodiments, the digital display 40 is communicably coupled to the processor 34 and configured to display the corresponding movement signal 16. In some embodiments, the digital display 40 is communicably coupled to the receiver 39 and configured to display one or more values corresponding to the received data to a user. The receiver 39 includes a digital display 40 to display the values corresponding to the received data. In some embodiments, each of the plurality of sensor devices 14 further includes a user input interface 41 (e.g., one or more buttons) to configure one or more settings of the sensor device 14 or the digital display 40 of the sensor device 14.
Referring to
In some embodiments, the system 50 further includes a display device 108 (shown in
The central controller 18 is further configured to control the treatment apparatus 100 based at least on the plurality of process variables 20. In some embodiments, the central controller 18 is further configured to control the at least one trough vibrating mechanism 106 (shown in
In some embodiments, the central controller 18 is further configured to control the drive arrangement 120 (shown in
In some embodiments, the central controller 18 is further configured to receive a predetermined process parameter 22 (shown in
In some embodiments, the memory may include an external database or a library. The central controller 18 is further configured to determine a measured process parameter 24 (shown in
In some embodiments, the central controller 18 is further configured to, prior to receiving the plurality of movement signals 16 from the plurality of sensor devices 14, determine a plurality of predicted process variables 26 corresponding to the plurality of heights of the vibratory trough 102. The plurality of predicted process variables 26 may be predicted intensities of the treatment process (i.e., vibropeening) at the plurality of heights. In some embodiments, the plurality of predicted process variables 26 may be predicted based on one or more machine-learning models and/or algorithms.
In some embodiments, the central controller 18 is further configured to control the treatment apparatus 100 based on the plurality of predicted process variables 26 and the plurality of process variables 20, such that a difference between each of the plurality of process variables 20 and a corresponding predicted process variable 26 from the plurality of predicted process variables 26 is reduced. By reducing the difference between each of the plurality of process variables 20 and the corresponding predicted process variable 26 from the plurality of predicted process variables 26, desirable value of intensity and/or energy of the treatment process (i.e., vibropeening) may be obtained at the plurality of heights (i.e., H1, H2, H3, and so on, as shown in
Referring again to
As the controller 18 controls the treatment apparatus 100 based at least on the plurality of process variables 20 corresponding to the plurality of movement signals 16, the system 50 may provide uniform residual stress distribution and material properties across the component 10 during the treatment process (i.e., vibropeening), This may improve fatigue life and/or performance of the component 10. This is particularly important when the component 10 is large in size. Further, unlike conventional techniques where a component (subject part) may have to be scrapped if there is any error in obtaining the drawing requirement (e.g., Almen intensity), the system 50 may enable monitoring the vibropeening at specific heights and accordingly controlling the vibropeening of the component 10. As a result, a likelihood of scrapping the component 10 after the treatment process of the component 10 may be reduced by the system 50 of the present disclosure. Therefore, the central controller 18 and the plurality of sensor devices 14 may validate a process control method and/or mechanism for the treatment process for the component 10.
Moreover, as compared to the conventional vibropeening techniques, the system 50 may substantially reduce human intervention because of continuous determination of the plurality of process variables 20 corresponding to the plurality of movement signals 16 and subsequently controlling the treatment apparatus 100 based at least on the plurality of process variables 20. The system 50 may enable the vibropeening which is relatively faster with less intensive manual labour. Further, in the system 50, there are minimal chances of wastage of sacrificial Almen strips or scrapping of components which may not meet the drawing requirements. The system 50 may be used for vibropeening of rotationally symmetric as well as asymmetric components.
Referring to
Referring to
At step 206, the method 200 includes receiving the plurality of movement signals 16 (shown in
In some embodiments, controlling the treatment apparatus 100 further includes controlling the at least one trough vibrating mechanism 106 based on the plurality of process variables 20. For example, the central controller 18 may control one or more of the plurality of actuators and the corresponding actuator extension rods of the treatment apparatus 100 based at least on the plurality of process variables 20 to adjust the amount of vibration of the vibratory trough 102. In some embodiments, controlling the treatment apparatus 100 further includes adjusting the height, volume, and/or mass of the treatment media 12 in the vibratory trough 102 based on the plurality of process variables 20. For example, the central controller 18 may control the first trough wall 118a and/or the second trough wall 118b of the treatment apparatus 100 based at least on the plurality of process variables 20 to adjust the height, volume, and/or mass of the treatment media 12 in the vibratory trough 102. In some embodiments, controlling the treatment apparatus 100 further includes controlling a rotation of the component 10 relative to the treatment media 12 based on the plurality of process variables 20. For example, the central controller 18 may adjust a speed of rotation of the support shaft 112 and thereby, the rotation of the component 10 by controlling the gearbox 122 of the drive arrangement 120. In some embodiments, controlling the treatment apparatus 100 further includes controllably supplying the treatment media 12 into the vibratory trough 102 and/or controllably emptying of the treatment media 12 from the vibratory trough 102 based on the plurality of process variables 20. For example, the central controller 18 may control the treatment media inlet 130 and/or the treatment media outlet 132 of the treatment apparatus 100 based at least on the plurality of process variables 20 to adjust the height, volume, and/or mass of the treatment media 12 in the vibratory trough 102.
In some embodiments, the method 200 further includes receiving the predetermined process parameter 22 (shown in
In some embodiments, the method 200 further includes, prior to receiving the plurality of movement signals 16 from the plurality of sensor devices 14, determining the plurality of predicted process variables 26 (shown in
It will be understood that the invention is not limited to the embodiments above-described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2217181.3 | Nov 2022 | GB | national |
