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Cylinder Bore Inspection. Engineering Research Center for Reconfigurable Manufacturing Systems. NCU (residual boring marks after honing of cylinders) detection requested by power train. Applicable scattering phenomenon observed in laboratory.

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Cylinder bore inspection

Cylinder Bore Inspection

Engineering Research Center forReconfigurable Manufacturing Systems


Project background

NCU (residual boring marks after honing of cylinders) detection requested by power train.

Applicable scattering phenomenon observed in laboratory.

Defect detection: Go/No-Go vs. conventional metrology.

Project Background

Project Goal

  • Detection of non clean-up (NCU) of residual boring marks after honing of cylinder bores.

  • Cycle time of 20 seconds required.


Laser scattering from machined surfaces
Laser Scattering from Machined Surfaces detection requested by power train.

The physical phenomenon used to distinguish between boring and honing:

Laser light normally incident on a machined surface is scattered preferentially in a plane perpendicular to the machining marks.


Cylinder surface
Cylinder Surface detection requested by power train.

  • Scatter, not just reflection.

  • Different pattern for boring vs. honing.

  • Direction of scattered laser light varies with boring vs. honing.


Probe assembly
Probe Assembly detection requested by power train.

Slip Ring


Manufactured probe
Manufactured Probe detection requested by power train.

Detector

Mirror

Laser

Prism

Slip Ring


Typical data
Typical Data detection requested by power train.

  • Data collected with Labview

  • Plots generated with Matlab

NCU Detection

Properly Honed


Honing Problem Detection detection requested by power train.

Different honing patterns at the top and bottom of the cylinder

Axial stripes along the cylinder wall.


Alternate detectable conditions
Alternate Detectable Conditions detection requested by power train.

Fine and Coarse Boring

Coarse Honing


Full scale prototype goals

Technology transfer to industry. detection requested by power train.

Demonstrate parallel probe operation.

Demonstrate survivability and maintainability of probes in a factory environment.

Accelerate implementation in ERC member company plants.

Full Scale Prototype Goals


Full scale prototype requirements

Inspect one bank of V blocks, all cylinders of straight 4 blocks.

Demonstrate parallel operation.

Easily reconfigurable.

Inspect blocks from different manufacturers-straight 4,V-6, and V-8.

Minimum cost.

Full Scale Prototype Requirements



Prototype layout as in the request for proposal rfp
Prototype Layout as in the Request for Proposal (RFP) blocks.

Environmental shield

Block

Probe rotation mechanism

Probes

Motion stage

Table

Inspection station computer

Base

Support structure

Fork lift holes

Vibration absorbing pads



Completed prototype
Completed Prototype blocks.

  • Station installed week of 9-17-07.

  • Station and probes are operational.


System communication
System Communication blocks.

UM system

PC 5

PC 1

PC 2

PC 3

PC 4

Rotary encoder

Rotary encoder

Rotary encoder

Rotary encoder

Cylinder tool

Cylinder tool

Cylinder tool

Cylinder tool

Gehring machine head

Linear encoder

Gehring PC


Future work

Optimization of parallel detection at the ERC. blocks.

Factory implementation of prototype system.

Possible detection of rough hone or boring stages.

A probe to measure dimensional variation and detect NCU is being developed.

Future Work


A new probe is being developed
A new probe is being developed. blocks.

New probe will measure dimensional variation as well as

check surface finish.

Probe centering in a cylinder will be easily determined using this probe.

Probe uses different detector, electronics, optics and software.


Dimension sensing probe

Scatter from surface is imaged onto detector by lens. blocks.

Image position changes with distance from probe to surface.

Detector is position sensitive.

Dimension sensing probe

Bore Surface

Slip Ring

Mirror

Lens

Detector

Laser


Questions? blocks.


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