UX series 5 frequencies spectrum harmonic automatic vibration stress relief equipment

1.What industry does JINAN ZHAOYANG MACHINE CO., LTD mainly engage in?

We are engaged in VSR field...........

2.What's the VSR?

VSR is the abbreviation for vibration stress relief...............

3.What's the vibration stress relief.............

Vibration stress relief is a commonly used method for relieving residual internal stresses in engineering materials. 

It uses vibration to make the vector sum of residual internal stresses and additional vibration stresses inside the workpiece exceed the yield strength of the material, 

causing slight plastic deformation of the material, thereby relaxing and reducing the internal stresses inside the material. 

The vibration stress relief mainly consists of two parts: the vibrator and the controller, as well as accessories such as fixtures, rubber pads, sensors, etc.

4.What are the advantages of vibration stress relief?

+better stress relief result 

+Strong flexibility 

+Thoroughly solved the environmental pollution problem of thermal heat treatment furnaces and kilns 

+Less investment 

+Significant energy savings 

+High efficiency 

+Specially suitable for stress relief treatment of materials and parts that are not suitable for high-temperature

5.What's the difference between the normal VSR and spectrum harmonic VSR?

Spectrum harmonic vibratory stress relief technology:

@For high rigidity and high natural frequency workpieces, even if the workpiece frequency exceeds the speed range of the vibrator, the equipment can find harmonic frequencies to perform treatment on the workpiece.

@Treatment processing time: The total processing time for any workpiece can be scientifically set based on the stress relief situation of the workpiece, and the processing time for each peak frequency can also be scientifically set based on the stress relief situation of the workpiece. Thus eliminating the fixed mode where the total time for treatment of the five harmonic frequencies was 40 minutes, regardless of whether the residual stress of the workpiece was eliminated or not.

@The resonance frequency for treatment is within 6000rpm with very low noise.

@5 Different vibratory modes ensure multi-dimensional stress relief or homogenization of the workpiece, resulting in better effect.

@There are no special requirements for the vibration point, support point, and sensor position. All processing parameters are automatically controlled by the equipment, and the processing results are not affected by the operator. 

Controller:

@The equipment has undergone high and low temperature tests ranging from -5 ℃ to+55 ℃, vibratory tests, and 20A current overload and high current impact tests, demonstrating high reliability; The circuit board has undergone moisture-proof, waterproof, and dustproof treatment.

@In spectrum treatment mode, using spectrum analysis techniques, automatically optimize and select 5 frequencies and 2 candidate frequencies (displayed in red font) from dozens of harmonic frequencies. 

@Multi modal and multi-dimensional vibratory eliminate residual stress.

@Resonant frequency selection function. Can manually select and process the selected 7 resonant

frequencies. 

@The spectrum treatment mode of the equipment should have advanced spectrum analysis technology and vibratory processing technology with the best effect.

@Graphic interface design, English interface, human-machine dialogue, simple and intuitive operation. Users can store, open, and print time efficiency parameters and curves (including workpiece name, workpiece number, workpiece drawing number, process method, eccentricity, operator, date and time, etc.). 

@Real time dynamic display of the entire processing process of saved curves.

@Modular combination of system functions, the system can be upgraded at any time without changing or altering the hardware system.

@vibratory frequency fine tuning function. It has an automatic fine-tuning function to prevent the treatment frequency from being adjusted to the resonance peak and damaging the workpiece.

@The "file management system" can be installed on any office PC to display and print processing parameter curves at any time.

@Real time dynamic monitoring of operating parameters such as speed, acceleration, current, and time throughout the process. If overloaded, automatic shutdown protection will be implemented.

@Automatic peak crossing function for sub resonance frequency. Automatic identification of sub resonance frequencies, automatic elimination of sub resonance frequencies, and avoidance of sub resonance peaks that may cause damage to equipment due to high current.

The host system adopts industrial control chassis and industrial grade computers, which have good scalability, reliability, and anti-interference ability.

@Industrial grade 18.5-inch touch screen, with clear display of various curves and processed data.

@2 USB ports, users can back up data and archive it through a portable hard drive or USB drive.

@Adopting a data acquisition card with high-speed and multi-channel A/D conversion ensures high-speed data acquisition and real-time processing.

@It has powerful digital signal processing capabilities and can automatically determine the optimal resonant frequency group through spectrum analysis technology.

@Equipped with acceleration and current protection processing functions, it can withstand instantaneous high currents, avoiding the phenomenon of burning the fuse or being unable to continue processing due to current protection shutdown.

@Adopting an electromagnetic shielding structure to prevent signal fluctuations and distortions caused by external electromagnetic interference.

@By adopting advanced stable wave control technology, the current output is stable, without electrical noise, and the temperature rise is significantly reduced, thereby improving the reliability and service life of the vibrator's continuous operation.

@Adopting advanced IGBT overcurrent and overvoltage protection circuits can effectively prevent IGBT damaged.

@It has the function of automatic shaping of vibratory frequency technology.

@The permanent magnet DC vibrator operates stably and reliably.

@The eccentric box end cover made of cast steel has good durability.

@The cooling system significantly reduces the temperature rise of the eccentric box casing

@The bearings of the vibrator are all branded products with guaranteed quality

@Equipped with a plate type high-temperature resistant optocoupler that can withstand high temperatures, it improves the stability of the speed measurement system.

Clamps:

@The bow clamp is a precision cast steel clamp body, with a large diameter and coarse thread to press the screw, ensuring clamping rigidity, strength, and reliability.

File processing function:

@Saved data files can be opened, deleted, printed, and backed up.

Equipment working conditions:

@Power supply: 220V ± 10%, 50HZ ± 1;

@The ambient temperature of the controller ranges from 0 ℃ to+55 ℃;

@The ambient temperature of the vibrator ranges from -20 ℃ to+55 ℃;

@Relative humidity: ≤ 80%

Vibrator:

vibrator: Permanent magnet DC

@Frequency stability accuracy: ± 1rpm

@Rated speed: 8000rpm

@Excitation force: 25KN

@Maximum weight of a single workpiece that can be processed: 500T

@Rated output power: 2200W

Control box:

@Graphic interface design, English interface, human-machine dialogue, simple and intuitive operation, English input methods.

@18.5-inch touch screen can display curves and charts clearly.

@ Use a high-speed 1GB CF card;

@ Electronic hard drives can store processing data, curves, charts, etc. of tens of thousands of workpieces for easy reference at any time.

@ Human computer interface, capable of human-machine dialogue operation.

@ Port: 2 USB ports, 1 parallel port;

@ Industrial control motherboard, supporting processors such as Intel Pentium D (dual core processor), Pentium 4, Intel Celeron D.

@Two systems modes-Automatic stress relief & weld conditioning.

(Special for Aerospace and Military Industries) 

The UX series spectrum harmonic fully automatic vibration stress relief equipment is a national key technological innovation project undertaken by Jinan Zhaoyang Machine Co., Ltd. It is a new product independently developed by our company on the basis of traditional vibration stress relief equipment. This device integrates multiple high-tech technologies such as computer technology, communication technology, signal processing technology, and automatic control technology. It is developed based on a new vibration theory and adopts advanced vibration treatment methods, which tend to have the best treatment effect on various types of workpieces. And it has achieved automatic formulation of vibration process. At the same time, it greatly reduces the noise during the vibration process and is currently the most advanced vibration stress relief equipment in the world.

The UX series spectrum harmonic fully automatic vibration stress relief equipment conducts spectrum analysis on the workpiece before processing, without scanning. Through computer optimization, 5 optimal resonant frequencies are selected, and the processing time for each frequency is determined based on the optimal number of cyclic loading times. After processing, it automatically stops, prints, and saves the processing results. The data can also be transmitted to the central computer for tracking and management through copying or network transmission.

Before the end of 2001, all stress relief equipment in the world adopted sub resonant mode to eliminate residual stress. The use of sub resonance mode has significant limitations. For workpieces with complex structures, high rigidity, and high natural frequencies, the sub resonance mode cannot search for the natural frequency of the workpiece and cannot process it. Moreover, even if vibration processing is possible, due to the limited number of peak frequencies that can be processed, the processing results are not ideal. This mode can only solve approximately 23% of workpieces in the mechanical manufacturing industry. To truly replace heat treatment with vibration stress relief, sub resonant mode is clearly impossible. The UX series spectrum harmonic fully automatic vibration stress relief equipment overcomes the defect of sub resonance mode and solves the main technical problem that has existed in the invention of vibration stress relief  technology for decades. It is a high-performance green and environmentally friendly product. It solves the problem of handling high rigidity and high natural frequency workpieces, solves the problem of vibration and noise, and achieves residual stress treatment without the need for manual process formulation. It has made vibration stress relief a true reality instead of heat treatment. More importantly, the UX series spectrum harmonic fully automatic vibration stress relief  equipment can not only replace heat treatment for stress relief, but also meet technical requirements that traditional stress relief methods cannot achieve. It can greatly improve the level of mechanical manufacturing and is a low-cost and revolutionary stress relief method.

1. System configuration

1) The computer industrial control case is made of all aluminum alloy structure and has a hard anodized surface, which can safely and efficiently complete mobile work in any harsh environment (grounding circuit, common impedance path/electric field coupling, electrostatic discharge, power line conducted radiation or other radiation);

2) High speed A/D data acquisition board with powerful computing and processing capabilities for data;

3) True color LCD display screen, which can clearly display real-time processing curve images;

4) The military grade industrial control motherboard and imported software and hardware control system greatly improve the operating speed and have high-precision control capabilities for motors;

5) High memory and large electronic hard disk configuration enable high-capacity high-speed data exchange and access; Equipped with a USB interface, it can store a large amount of processing data, curves, and charts of workpieces through a large capacity USB drive for easy reference at any time;

6) The host is equipped with a floppy drive, external display interface, printer interface, etc;

7) Permanent magnet DC exciter, capable of working under high load for a long time;

8) High precision and high sensitivity accelerometer;

9) Other accessories.

2. Equipment features:

1) Spectral analysis technology was adopted to automatically optimize the selection of 5 optimal peak frequencies for processing. Multiple vibration modes were used to process the workpiece, and multi-dimensional elimination of residual stress was achieved. The processing effect was significantly better than traditional thermal aging and traditional vibration stress relief;

2) Solved the problem of handling workpieces with complex structures, high rigidity, and high natural frequencies, and can effectively eliminate stress through vibration for any workpiece;

3) Solved the problem of vibration and noise, truly a green and environmentally friendly product;

4) Implemented automatic process formulation function. There are no requirements for the positions of excitation points and pickup points, and VSR processing is achieved without the need for manual process development. The processing effect is completely unaffected by the operator's skills, and the processing effect is constant;

5) The welding vibration function can reduce welding stress, reduce welding deformation, improve welding permeability, and improve welding quality;

6) High speed, multi-channel A/D conversion ensures high-speed data acquisition and real-time processing;

7) Efficient and strict digital signal processing, without the need for full scanning, can obtain corresponding peaks and automatically determine the optimal vibration frequency group;

8) The advanced LCD graphics display method allows for clear display of speed, acceleration, current, time values, and various curves at a glance;

9) Convenient function key design, press the corresponding function button at the bottom of the display interface to quickly enter the corresponding function screen or perform corresponding function processing;

10) Powerful data management capability, capable of saving, loading, and calling the data of processed workpieces for easy reference and printing;

11) With multiple processing methods, it can meet various user requirements;

12) Multiple security and anti-interference measures make the system more stable and reliable;

13) Install power filters required for high-precision and cutting-edge equipment to prevent equipment damage caused by interference and fluctuations in the working power supply;

14) A spectrum analyzer can be used as a separate spectrum analyzer to analyze the frequency spectrum of workpieces using tapping or vibration methods.

Commissioning

We offer a range of start-up services including installation support, commissioning, product and operator training and managed trials. Through these services, our global team of engineers, process experts and servicing specialists can help you to get your new equipment set up and running as quickly as possible.

Testing before delivery............

Working video 1

Working video 2

CERTIFICATE:

WORKING VIDEO