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Overview of Vibration Aging Device

Vibration aging device is a specialized equipment that eliminates or reduces residual stresses inside metal components by applying periodic vibration energy. Its working principle is based on resonance theory, which uses an exciter to induce resonance in the component. During the resonance process, residual stress inside the component is superimposed with vibration stress. When the composite stress exceeds the yield limit of the material, microscopic plastic deformation occurs, thereby achieving stress release and homogenization. This technology has significant advantages such as energy saving, high efficiency, and no environmental pollution, and is widely used in fields such as mechanical manufacturing, aerospace, ships, pressure vessels, wind power equipment, etc. It can effectively improve the dimensional stability, fatigue strength, and service life of components, replacing traditional thermal aging processes.

Main components and functions

1. vibration exciter

The exciter is the core power component of the vibration aging device, which converts electrical energy into mechanical energy and applies periodic excitation force to the processed workpiece. According to different structural forms, common types of exciters include eccentric block type, electromagnetic type, etc. The eccentric block type exciter generates centrifugal force by driving the eccentric mass block to rotate through a motor. By changing the relative position or speed of the eccentric block, the magnitude and frequency of the excitation force can be adjusted; Electromagnetic exciters use the principle of electromagnetic induction to generate alternating force. Exciters are usually equipped with rigid or flexible connection devices to reliably connect with workpieces of different shapes and sizes, ensuring effective transmission of vibration energy.

2. Control and Measurement System

The control and measurement system is a vibration aging device“brain”Responsible for parameter setting, real-time monitoring, data collection, and processing throughout the entire time efficiency process. It mainly includes the following key modules:

• control unitUsing a microprocessor orPLCAs the core controller, users can set process parameters such as excitation frequency range, scanning speed, aging time, excitation force, etc. through the touch screen or buttons, and achieve automatic or manual control mode switching.

• sensorIncluding acceleration sensors and velocity sensors, they are usually installed in key parts of the workpiece to collect real-time vibration response signals (such as amplitude, frequency, vibration acceleration, etc.) of the workpiece, providing a basis for the system to determine resonance points and monitor timeliness effects.

• Data Collection and Analysis ModuleFilter and amplify the signals collected by sensorsA/DAfter conversion, spectral analysis, time-domain analysis and other processing are performed to automatically identify the natural frequency (resonance frequency) of the workpiece, and vibration curves (such as amplitude frequency curve and time-domain vibration curve) are drawn to intuitively reflect the changes in vibration characteristics during the aging process.

• Feedback regulation mechanismBased on the deviation between the real-time monitored vibration parameters and the set values, the output frequency and excitation force of the exciter are automatically adjusted to ensure that the workpiece is always in the optimal resonance state for aging treatment.

3. support system

The support system is used to stably support the workpiece in a suitable position, allowing the workpiece to vibrate freely during the vibration process and avoiding the influence of rigid constraints on resonance effects. The choice of support method should be determined based on the shape, weight, and structural characteristics of the workpiece. Common support methods include elastic support (such as rubber pads, spring support) and rigid support (such as adjustable brackets). Elastic support can effectively isolate the transmission of vibration to the ground and reduce its impact on the surrounding environment; Rigid support is suitable for large and heavy workpieces to ensure the stability of the support. The number and location of support points are crucial and should usually be selected at the nodal line or in areas with small vibration displacement of the workpiece to avoid interference from the support on the vibration mode of the workpiece.

4. auxiliary device

• Connecting fixturesDesign specialized connection fixtures or top rods based on the shape of the workpiece to ensure a rigid connection between the exciter and the workpiece, reducing vibration energy loss.

• Safety protection deviceIncluding emergency stop button, overload protection, leakage protection, etc., when the equipment encounters abnormal conditions (such as overload, overspeed, sensor failure), it can quickly cut off the power supply to ensure the safety of the equipment and operators. Some devices are also equipped with soundproof or protective covers to reduce vibration noise and prevent accidental movement of workpieces during vibration.

• power systemTo provide stable power supply for exciters, control systems, etc., usually including regulated power supply and motor drive power supply, ensuring stable operation of equipment under different grid voltage fluctuations.

workflow

1. Workpiece clamping and support

Select appropriate support methods and points based on the structural characteristics of the workpiece, place the workpiece steadily on the support system, and ensure that the workpiece is in a free state or close to a free state. Then, by connecting the fixture, the exciter is firmly installed at the excitation position of the workpiece (usually selecting a location with a larger vibration response, such as the middle or near the center of gravity of the workpiece), and an acceleration sensor is installed at the monitoring point of the workpiece.

2. Parameter setting and frequency scanning

Activate the control and measurement system, input basic information of the workpiece (such as material, weight, structural type) and process parameters (such as expected aging time). The system enters sweep mode and controls the exciter within the set frequency range (usually10-1000Hz）Perform continuous frequency scanning while collecting vibration response signals of the workpiece through sensors. During the frequency scanning process, the system automatically draws an amplitude frequency curve. When the excitation frequency approaches the natural frequency of the workpiece, the amplitude will significantly increase, thereby identifying the resonance frequency point of the workpiece.

3. Resonance aging treatment

After determining the resonance frequency, the system locks the output frequency of the exciter at that resonance frequency and begins formal aging processing based on the set excitation force and aging time. During the aging process, the workpiece undergoes significant vibration displacement in a resonant state, and internal residual stresses gradually release and redistribute. The control and measurement system monitors the changes in vibration parameters (amplitude, frequency, vibration acceleration) in real time, and records the aging curve through the data acquisition module. Operators can monitor the aging process in real time through the display screen.

4. Effect testing and conclusion

After reaching the set time limit, the system automatically stops exciting. To evaluate the effectiveness of aging, frequency sweep testing can be performed again by comparing the amplitude frequency curve changes before and after aging (such as the movement of resonance peaks and amplitude changes) or using stress testing methods (such as blind hole methodXThe X-ray diffraction method directly measures the reduction amplitude of residual stress inside the workpiece. If the effect meets the requirements, the entire vibration aging process will end; If the standard is not met, the process parameters can be adjusted (such as extending the aging time, changing the excitation force) and the aging treatment can be carried out again.

Technical features and advantages

1. High Efficiency and Energy Saving

Compared to traditional thermal aging (heating the workpiece to500-650℃And keep warm for several hours), vibration aging does not require high-temperature heating of the workpiece, which can save a lot of energy (energy-saving rate can reach)80%-90%）At the same time, it greatly shortens the processing time (usually30Minutes to2Hours), significantly improving production efficiency.

2. no environmental pollution

During the vibration aging process, no pollutants such as exhaust gas, wastewater, and waste residue are generated, and there are no oxidation or decarbonization problems caused by high temperature heating. There is no adverse effect on the material and surface quality of the workpiece, which meets the requirements of green manufacturing and environmental protection.

3. Wide range of applications

It can handle metal components of various shapes and sizes, ranging from small parts weighing a few kilograms to large welded structural parts weighing hundreds of tons, castings, forgings, etc. It is particularly suitable for large, complex, thin-walled, and non heat aging workpieces (such as precision machine tool beds, large pressure vessels, wind turbine flanges, etc.).

4. Improve workpiece performance

By eliminating or reducing residual stress, the dimensional stability of the workpiece can be effectively improved, and deformation during subsequent processing and use can be reduced; Simultaneously improving the internal organizational structure of the workpiece, enhancing its fatigue strength and corrosion resistance, and prolonging the product's service life.

5. Easy and flexible operation

The equipment has a relatively small volume and strong mobility, making it easy to operate in the workshop or installation site. The control system has a high degree of automation, and operators can take up their posts after simple training. The process parameters are easy to adjust and optimize.

development trend

• Intelligence and automationIntegrating artificial intelligence algorithms to achieve automatic optimization and adaptive control of process parameters, combined with machine vision technology to achieve automation of workpiece clamping and positioning, further improving the intelligence level and processing efficiency of equipment.

• Multi-functional integrationDevelop a comprehensive system that integrates vibration aging, stress detection, data analysis, and report generation to achieve full closed-loop control and quality traceability of the aging process.

• Lightweight and portableDevelop miniaturized and lightweight vibration exciters and portable control systems to meet the on-site processing needs of large workpieces, and improve the mobility and flexibility of equipment.

• Green energy-saving technology upgradeAdopting efficient and energy-saving motors and drive systems, optimizing control algorithms, further reducing equipment energy consumption, while developing low-noise exciters to improve the working environment.

• Expand application areasExplore the application of vibration aging technology in residual stress relief of non-metallic materials (such as composite components), as well as micro vibration aging technology in precision instruments, electronic devices, and other fields.

  Vibration aging device, as a residual stress relief technology, plays an increasingly important role in modern industrial production. With the continuous innovation and development of technology, its application prospects will be even broader.

Vibration aging machine, vibration aging equipment Vibration time efficiency price Vibration aging manufacturerPrinciple of vibration aging: From the analysis of the vibration aging process, the workpiece undergoes tens of thousands of sub resonant vibrations within half an hour of vibration, which inevitably leads to micro plastic deformation. Moreover, the deformation has stabilized and the residual stress has decreased Low and uniform, in a state of equilibrium. On the other hand, during the installation and use of the machine, the workpiece will not be in a resonance state and will not be subjected to external forces greater than the resonance force. Therefore, the workpiece after vibration aging will not emerge again The stress has deformed now.

vibrate Dynamic time analyzerVibration aging machine, vibration aging device, aging vibration instrument, and vibration aging equipment analyze the dynamic stress during the vibration process. During vibration aging, the workpiece will be subjected to a large alternating dynamic stress, which will be superimposed with residual stress. After reaching a certain value, at the stress concentration point, it will exceed the yield limit and undergo plastic deformation, thereby reducing the residual stress at that point and effectively preventing stress deformation. Vibration aging instrument, vibration aging machine, vibration aging device, aging vibration instrument, vibration aging equipment. The vibration aging process is used for stress relief of metal workpieces such as welding, casting, forging, etc. It is mainly divided into several series such as intelligent vibration aging, fully automatic vibration aging, and economical vibration aging. It improves the disadvantages of high cost, long aging cycle, and complicated process of traditional thermal aging treatment, truly achieving green, environmentally friendly, energy-saving, easy operation, and reduced aging treatment costs. The reason why vibration aging can partially replace thermal aging is because this technology has some obvious characteristics.

1. The mechanical performance is significantly improved. After vibration treatment, the residual stress of the components can be eliminated by about 30% to 80%, and the elimination of high tensile stress areas is greater than that of low stress areas. Therefore, it can improve the strength and fatigue life of use, and reduce stress corrosion. It can prevent or reduce the occurrence of micro cracks caused by processes such as heat treatment and welding. It can improve the deformation resistance of components, stabilize the accuracy of components, and enhance mechanical quality.

2. Strong applicability: Due to its simple and easy to move equipment, it can be processed on-site in any location. It is not limited by component size and material, and vibration aging technology can be used for components ranging from tens of kilograms to hundreds of tons. Especially for some large components that cannot be treated with thermal aging, vibration aging has more prominent characteristics.

3. Save time, energy, and costs. Vibration efficiency only takes 30 minutes to proceed to the next process. And thermal aging requires at least one to two days and a large amount of energy such as kerosene and electricity. Therefore, compared to thermal aging, vibration aging can save more than 90% of energy and costs, especially saving the huge investment in building large-scale kilns.

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