VSR - Next Generation
Through a successful Elforsk project, we have demonstrated a reduction of energy consump-tion by up to 99% using VSR for normalization of materials instead of heat treatment (TSR). As pointed out by the industrial companies involved, this project will automate and document the VSR technology and adapt it to industry's typical part sizes.
The tested low-frequency technology is suitable for components >40kg where there is great potential in Danish industry, but the potential for items below 40 kg is even greater. Through High Frequent VSR, the technology is adapted to Danish industry with components of 0.5 to 40 kg. The adaption can reduce industry's energy consumption significantly. The project includes technology- and method development plus instructional material for industry. The project will improve the efficiency of VSR treatment and reduce costs for individual treated components plus develop a reproducible process with uniform results across simultaneous treated components. This includes further development of physical equipment in collaboration with a number of companies that provide components for testing and evaluation. The project includes 1) development of component-specific fixtures, 2) multi-sensor process monitoring systems, and 3) software-based performance and evaluation functions. Through acoustic emission, the project documents the effect of VSR technology. By cracking in a ball bearing, sound is transmitted at a frequency of 700-900,000Hz. The same is ex-pected in the normalization of metals where a change in the metal grid is expected to emit sound in the same frequency range. This assumption is backed by experts from SDU, AAU, Kistler and Swerea KIMAB.
The project is built around identification of companies that have workpieces in a size suitable for developing and testing of the VSR technology, and push VSR application to be economically feasible for smaller item sizes – this includes documentation of the effect of VSR treatment. To achieve this, various technical systems and equipment are put to work. DAMRC has among others investigated and used acoustic emission and X-ray Diffraction to map residual stress in the workpieces and investigated whether these systems could be used to document the residual stress.
Modal Analysis (Taptest) equipment and software have been used to document the natural frequency of the items. It has been concluded that both technologies acoustic emission and X-ray diffraction could not provide a clear coherence between the VSR treatment and the residual stresses. In addition, it has been documented which sources cause errors in connection with the execution of VSR. This can be both tightening, setting up, and the subject's natural frequency. To reduce costs for each workpiece in the treatment of smaller items, experiments in collaboration with processing companies that have provided specific items have been executed.
Experiments have involved fixture solutions and treatment methods that make it possible to achieve a uniform result for simultaneously treated items. It was proven that a single technician can control 2 sets of equipment at a time and thereby achieve twice as many treatments. Furthermore, possibilities for multiple treatment were tested by creating uniformity around the factors that were found important in WP3. The possibility of dealing with smaller and more industry-typical issues was also looked at. At the same time, it has been confirmed that smaller workpieces have a higher natural frequency and thus are often also outside the range of existing VSR equipment at 133Hz.
In WP5, a pneumatic motor was first tested, which has been able to run up to 208Hz. At the same time, DAMRC designed, drew, and manufactured a new VSR vibration unit where the goal was to be able to achieve 333Hz. This device is the only one that exists – as far as we know - and is expected to be able to put us a big step forward in dealing with small parts. The vibration unit has so far reached 192Hz on the vibration unit with the currently purchased motor.
DAMRC is convinced that it will be possible to reach higher if a larger motor and frequency converter is purchased and installed.
Key figures
Category
Participants
| Partner | Subsidy | Auto financing |
|---|---|---|
| Aarhus Universitet | ||
| Mercantec |
