Cylinder Bore Inspection
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Transcript of Cylinder Bore Inspection
1NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
Cylinder Bore Inspection
Engineering Research Center for
Reconfigurable Manufacturing Systems
2NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering
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 Goal
• Detection of non clean-up (NCU) of residual boring marks after honing of cylinder bores.
• Cycle time of 20 seconds required.
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Laser Scattering from Machined Surfaces
Laser light normally incident on a
machined surface is scattered
preferentially in a plane perpendicular
to the machining marks.
The physical phenomenon used to
distinguish between boring and honing:
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Cylinder Surface
• Scatter, not just reflection.
• Different pattern for boring vs. honing.
• Direction of scattered laser light varies with boring vs. honing.
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Probe Assembly
Laser Prism
Cylinder Surface
MirrorAperture
FiltersDetector
Slip Ring
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Manufactured Probe
Laser Prism
MirrorDetector
Slip Ring
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Typical Data
• Data collected with Labview• Plots generated with Matlab
NCU Detection Properly Honed
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Honing Problem Detection
Different honing patterns at the top and bottom of the cylinder
Axial stripes along the cylinder wall.
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Alternate Detectable Conditions
Coarse Honing Fine and Coarse Boring
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Full Scale Prototype Goals
• Technology transfer to industry.• Demonstrate parallel probe operation.• Demonstrate survivability and maintainability
of probes in a factory environment.• Accelerate implementation in ERC member
company plants.
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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.
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Machine Specifications
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Prototype Layout as in the Request for Proposal (RFP)
Vibration absorbing pads
Motion stage
Probe rotation mechanism
Probes
Block
TableInspection station computer
Environmental shield
Base
Support structure
Fork lift holes
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Full Scale Prototype Configuration as Requested by End-Users
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Completed Prototype
• Station installed week of 9-17-07.• Station and probes are operational.
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System Communication
PC 5
PC 1 PC 2 PC 3 PC 4
Rotary encoder
Cylinder tool
Rotary encoder
Cylinder tool
Rotary encoder
Cylinder tool
Rotary encoder
Cylinder tool
Linear encoderGehring PC
Gehring machine head
UM system
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Future Work
• Optimization of parallel detection at the ERC.• 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.
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A new probe is being developed.
Probe centering in a cylinder will be easily determined using this probe.
Probe uses different detector, electronics, optics and software.
New probe will measure dimensional variation as well as check surface finish.
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Dimension sensing probe
• Scatter from surface is imaged onto detector by lens.• Image position changes with distance from probe to surface.• Detector is position sensitive.
Slip Ring
Bore Surface
MirrorLensDetector Laser
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Questions?