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 avoid grinding burn. The detection of such hardness defects can be carried out especially quickly and yet with sufficient accuracy by evaluating the signal width of an X-ray signal. With the muraR, sentenso presents a very efficient solution to determine hardness variations 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 full width half-maximum (FWHM). The half-value width is a characteristic value of the X-ray 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 without contact via scintillation counters. The FWHM increases with increasing hardness, which is why a hardness variation can be determined via a surface scan for known materials. Since the X-ray tube operates with a low tube current, there is a very low radiation emission, which can be completely avoided by simple protective measures. At a safe distance of 1.5 m or behind a 5 mm thick PVC shield, no additional radiation exposure to the natural radiation can be detected. Automated measurement tasks can be easily programmed and implemented using an optional collaborative or industrial robot.
The muraR can be used in a variety of different measurement tasks:
• Check of hardness variation after heat treatments
The muraR allows for fast and high-resolution hardness scans with a high degree of automation. These can be demonstrated in the sentenso laboratory or in a video conference with customer-specific samples.
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:
Jörg Behler
+49 2363 36650-18
info@sentenso.de
sentenso PeenBots – Advanced Peening Technology
The new sentenso PeenBots are highly automated, extremely innovative and user-friendly compressed air peening systems with peening nozzles controlled by robots.
PeenBots represent the consistent implementation of our experience from over 12 years of process technology practice and customer-oriented product development. Our best ideas, products and systems have been incorporated into a machine concept that is not just oriented towards the improvement of known designs, but rather pursues approaches that are actually obvious - the uncompromising control of all process parameters, the downsizing of the system design to what is necessary, as well as flexible, repeatable and, if desired, offline programmable movements of the peening nozzles.
Based on the above approaches, the following basic principles of advanced shot peening technology can be implemented:
sentenso PeenBots – Advanced Peening Technology
PeenLean
Lean Peening is one of the most important trends in modern peening process management. To implement this principle of optimised process management, the PeenBot process technology is based on an efficient peening system, flexibly programmable peening nozzle motion and intelligent system control. The PeenBot thus allows lean, fast and yet fully controlled processes with perfect consistency and efficiency.
PeenGreen
Green Peening is the consistent implementation of the commitment to reduce energy and resource consumption to the necessary minimum. To achieve this, process and machine technology for media acceleration and control must be rethought instead of just uncovering potential savings.
PeenClean
Clean Peening is the concept for ensuring a safe working environment for the system operators, peened components that are as clean as possible and a peening cabinet largely free of deposits of media grains and dust. The exhaust air from the machine can be returned to the workshop without any worries thanks to the integrated HEPA secondary filter.
PeenSmart
Smart Peening offers the latest Industry 4.0 technologies for digital process management, providing the capture, collection and evaluation of process data for the digital twin of the peened component. From the data, further information can be obtained for effective machine management, including predictive maintenance.
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:
Volker Schneidau
+49 2363 36650-0
info@sentenso.de
Automated Analysis of Particle Velocity
In addition to the media 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. For the first time, it is now possible to determine particle velocities and analyse trajectories with a comparatively simple measurement setup. This setup consists of a high-speed camera with network connection and a high-intensity illumination unit for recording the fast peening particles, which are viewed in incident or backlight.
The analysis of the high-speed videos includes:
- Determination of velocity distribution of single particles in a histogram
- Determination of flight angle distribution of single particles in a histogram
- Determination of velocity over flight angle in an XY diagram
- Output of the measurement data of all detected single particles in a log file
Automated Analysis of Particle Velocity
Setup and Functions
VelocityEasy automatically communicates with the high-speed camera and reads out the camera settings. The intuitive user interface allows the setup of the evaluation algorithm and the programme control. Video recording, tracking of the detected individual particles, particle marking on the image sequence, evaluation of the recordings as well as the presentation of all measurement results in the form of values and diagrams all take place automatically.
The software also offers extensive additional functions for checking and managing measurement data. These include the integrated video player withthe capability for single image analysis, the loading 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 prepared for connection to a peening system control. Via the integrated TCP interface, an external system control can start the software remotely in the current setup and retrieve measurement results. The measurement results can then be further processed within the control system, e.g. to check compliance with a desired speed.
On request, sentenso also supplies the associated speed measurement system with a low-cost high-speed camera and a measuring channel with lighting unit as a complete solution from one source.
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:
Daniel Brendebach
+49 2363 36650-0
dbrendebach@sentenso.de
Residual Stress Analysis - fast and easy
Shot peening is an important process for strengthening dynamically
loaded components due to the targeted introduction of residual
compressive stresses. The blasting process development as well as the
ongoing quality assurance often require a fast and automated recording
of residual stress states beyond a simple single measurement.
The µ-X360s stress analyzer
from Pulstec is completely mobile, records the residual stress state on
shot-peened ferritic components within 35 seconds and is therefore
ideal for opening up new potential in the laboratory and production.
Now we are introducing StressEasy,
an advanced software solution that uses the μ-X360s stress analyzer and
a compact six-axis robot to enable a variety of automated measurement
procedures for determining residual stress states.
Residual Stress Analysis - 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 individual measurements and
manages their results, StressEasy can do much more.
StressEasy
enables the parameterisation and combination of individual measurements
into an overall picture. In combination with the mobile, compact and
fast X-ray stress analyzer µX-360s, 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
• Batch measurements
• Stress limit checks
• Oscillation methods (linear, circular, psi angle)
Your contact:
Jörg Behler
+49 2363 36650-0
jbehler@sentenso.de
Mobile Rotary Flap Peening Rethought
Rotary Flap Peening is a
manual process for surface enhancement with bonded peening media. In
addition to the well-known repair applications on aircrafts, the process
develops a great potential for local plastification in limited areas of
various components.
With the RotoFlapMaster, we are now presenting for the first time a battery-powered device for mobile, speed-controlled Roto Flap Peening.
Mobile Rotary Flap Peening Rethought
The RotoFlapMaster is an extremely user friendly, compact and completely mobile device for manual but process-safe surface work hardening. The clearly laid out control panel allows speed adjustment according to requirements, depending on the nominal values of the shot peening intensity with the help of related calculation formulas. The speed and direction of the flap rotation is constantly displayed, and the operator is also informed optically and acoustically if the speed falls below the setpoint.
The control unit and the handpiece are connected with a flexible and pluggable cable. Start and stop of the rotary drive are simply triggered by pressing the button right on the handpiece. When creating saturation curves, the operator can start the integrated timer by pressing the button twice, without releasing his hand or gaze from the handpiece.
The RotoFlapMaster is particularly mobile thanks to its rechargeable battery and the practical, padded carrying strap. The attractive design of the control unit, display elements and handpiece support the valuable overall impression. The total package is enhanced by a wide range of accessories such as a replacement battery, charger and a user licence for IntensityEasy, the practical software for determining the shot peening intensity.
The RotoFlapMaster is supplied in a compact and high-quality rollable transport case. The unit and accessories are safely stored in milled foam elements. In addition, the available RotoFlap Kits provide practical complete packages with the necessary measuring equipment.
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:
Wolfgang Hennig
+49 2363 36650-0
whennig@sentenso.de
