Innovations
Archiv Innovations
Hardness variance scanner muraR
The hardness of components is a critical property for wear resistance and is adjusted with a suitable heat treatment. Hardness can also be affected by other manufacturing processes. For example, care must be taken during grinding operations to ensure that no grinding burn occurs. The detection of such hardness defects can be performed particularly quickly and yet sufficiently accurately by evaluating the signal width of an X-ray signal. sentenso presents the muraR, a very efficient way to determine hardness profiles on surfaces of steel components.
Structure and functions
Hardness variations on component surfaces can be determined quickly and automatically with an X-ray diffractometer by evaluating the half-width (FWHM). The half-width is a characteristic value of the X-ray beam diffracted at the crystal lattice and describes the signal width at half the height of the maximum. The X-ray signal from the chromium X-ray source is detected by scintillation counters without contact. Since the X-ray half-width increases with increasing hardness, a hardness profile can be determined for known materials by means of a surface scan. In this way, undesirable differences in surface hardness can be revealed. Since the X-ray tube operates at a low tube current, this results in very low radiation emission, which can be avoided altogether by simple protective measures. At a safe distance of 1.5 m or behind a 5 mm thick PVC pane, no additional radiation exposure to the natural radiation can be detected. Automated measurement tasks can be easily programmed and implemented using an optional collaborative robot.
The muraR can be used in a variety of different measurement tasks:
– Checking the hardness profile after heat treatments
– Detection of grinding burn
– Automated test procedures in production
The muraR allows fast and high-resolution hardness scans with a high degree of automation. These can be demonstrated in the sentenso laboratory or also in a video conference with customer-specific samples.
sentenso PeenBots – Fortschrittliche Peening-Technologie
The new sentenso PeenBots are highly automated, extremely innovative and user-friendly compressed air blasting systems with blasting nozzles guided by robots.
PeenBots represent the consistent implementation of our experience from over 12 years of process engineering practice and customer-oriented product development. Our best ideas, products and systems have been incorporated into a machine concept that is not oriented towards the improvement of known designs, but rather pursues approaches that are actually obvious – the uncompromising control of all process-technical parameters, the downsizing of the system technology to what is necessary, as well as flexible, repeatable and, if desired, offline programmable movements of the blasting nozzles.
Based on the above approaches, the following basic principles of advanced shot peening technology can be implemented:
sentenso PeenBots – Fortschrittliche Peening-Technologie
PeenLean
Lean Peening is one of the most important trends in modern blasting process management. To implement this principle of optimized process management, the PeenBot process technology is based on an efficient blasting system, flexibly programmable blast nozzle guidance, and intelligent system control. The PeenBot thus allows lean, fast and yet fully controlled processes with consummate consistency and efficiency.
PeenGreen
Green Peeningis the consistent implementation of the commitment to reduce energy and resource consumption to the necessary minimum. To achieve this, process and plant technology for abrasive acceleration and control must be rethought instead of just identifying potential savings.
PeenClean
Clean Peening is the concept for ensuring a safe working environment for the system operators, blasted components that are as clean as possible, and a blast cabinet largely free of deposits of abrasive grains and dust. The exhaust air from the blasting system can be returned to the workshop without any worries thanks to the integrated HEPA secondary filter.
PeenSmart
Smart Peening offers the latest Industrie 4.0 technologies for digital process management, providing the acquisition, collection and evaluation of process data for the digital twin of the blasted component. From the data, further information can be obtained for effective plant management, including predictive maintenance.
Automated analysis of particle velocities
In addition to the abrasive properties, the particle velocity during shot peening is the determining process parameter for the shot peening intensity.
sentenso now offers VelocityEasy, a software solution for evaluating video images from a high-speed camera. This makes it possible for the first time to analyze particle velocities and trajectories with a comparatively simple measurement setup. This consists of a high-speed camera with network connection and a high-intensity illumination unit for recording the fast-flying jet particles, which are viewed in incident or backlight.
The analysis of the high-speed images includes:
- Determination of the velocity distribution of the single grains in a histogram
- Determination of the beam angle distribution of the single grains in a histogram
- Determination of the velocity over the beam angle in an XY-diagram
- Output of the measurement data of all detected single particles in a log file
Automated analysis of particle velocities
Structure and functions
takes over the automatic communication with the high-speed camera and the readout of the camera settings. The intuitive user guidance allows the parameterization of the evaluation algorithm and the program control. Video recording, tracking of the detected individual particles, particle marking on the image sequence, evaluation of the recordings and display of all measurement results in the form of values and diagrams are performed automatically.
The software also offers extensive additional functions for checking and managing measurement data. These include the integrated video player with operating function for single image analysis, the load function for existing videos and measurement data sets as well as the debug output with
detailed measurement information. The additional functions allow a detailed plausibility check of the results and the subsequent evaluation of existing recordings.
VelocityEasy is installed on a customer’s Windows PC and is ideally prepared for connection to a blasting system control. Via the integrated TCP interface, an external plant control system can start the software remotely in the preset parameterization and retrieve measurement results. Within the control system, the measurement results can then be
be processed within the control system, e.g. to check the compliance with a target speed.
sentenso also supplies the associated speed measurement system with a low-cost high-speed camera and a measurement channel with illumination unit as a complete solution from a single source on request.
Residual stress determination – quick and easy
Shot peening is an important process for the strengthening of dynamically loaded components due to the targeted introduction of residual compressive stresses. Blasting process development as well as ongoing quality assurance often require fast and automated acquisition of residual stress states beyond simple single measurements.
Pulstec’s µ-X360s X-ray diffractometer is fully mobile, capturing residual stress state on shot-peened ferritic components within 35 seconds, opening up new potential in the lab and production.
Now we are introducing StressEasy, an advanced software solution that enables a variety of automated measurement procedures for determining residual stress states using the μ-X360s X-ray diffractometer and a compact six-axis robot.
Residual stress determination – fast and easy
The field-proven software extension StressEasy opens up far-reaching possibilities for measurement automation to the user. While the standard software only controls single measurements and manages their results, StressEasy can do much more.
StressEasy allows parameterization and combination of single measurements to an overall picture. In combination with the mobile, compact and fast X-ray diffractometer µX360s, StressEasy develops its full potential when used with a six-axis robot for automated movement of the sensor unit from measurement to measurement.
The following measurements can be performed automatically:
– Determination of the complete stress tensor
– Determination of stress at non-planar stress states
– Residual stress mappings
– Stack measurements
– Test measurements for stress control (IO/NIO)
– Oscillation during measurement (linear, circular, psi angle)
Your contact person:
Jörg Behler
+49 2363 36650-0
jbehler@sentenso.de
Mobile Roto Flap Peening rethought
Roto Flap Peening is a manual process for surface strengthening with bonded blasting medium. Beyond the familiar repair applications on aircraft, the process is developing great potential for localized strengthening in limited areas of a wide variety of components.
Now, for the first time, we are introducing the RotoFlapMaster, a battery-powered unit for mobile, speed-controlled roto flap peening.
The new RotoFlapMaster is compliant with the requirements of SAE AMS2590 and other relevant standards and specifications. The device concept is oriented towards the most efficient use possible in daily work.
Mobile Roto Flap Peening rethought
The RotoFlapMaster is an extremely user-friendly, compact and fully mobile device for manual but process-safe surface consolidation. The clearly arranged control panel allows speed adjustment according to requirements depending on the set values of the shot peening intensity with the help of stored calculation formulas. The speed and direction of rotation of the flap is constantly displayed. In addition, the operator is notified visually and acoustically if the speed falls below the setpoint.
The control unit and handpiece are connected by a flexible and pluggable cable. Start and stop of the rotary drive are triggered simply by pressing the button directly on the handpiece. When creating saturation curves, the operator can start the integrated timer by pressing the button twice, without having to take his hand or eyes off the handpiece.
The RotoFlapMaster is particularly mobile thanks to its rechargeable battery and practical, padded carrying strap. The attractive design of the control unit, display elements and handpiece support the valuable overall impression. The overall package is enhanced by extensive accessories such as a spare battery, charger and a user license of IntensityEasy, the practical software for determining the shot peening intensity.
The RotoFlapMaster is supplied in a compact and high-quality rollable transport case. The device and accessories are safely stored in molded foam elements. In addition, practical complete packages with the necessary measuring equipment are available with the RotoFlap Kits.
You can find an application example here on our video channel. Further product information is available here on our website. For all questions or a non-binding offer, please contact us.
Your contact person:
Wolfgang Hennig
+49 2363 36650-0
whennig@sentenso.de
