Successful Delivery of Runout Measurement System in General Motors India

In June this year, TASK successfully developed and delivered a runout measurement machine for General Motors India. This machine has been designed and manufactured completely in-house by the TASK team. It is an automated inspection system measuring the runout of the Inner Diameter of the hub. Using online SPC analysis, the results are used to achieve quality control.

The system has been successfully commissioned and checks 900 components each day, in three shifts throughout the day.

Runout Measurement System for General Motors

It implements Poka Yoke using automated safety curtains installed and utilized for total operator safety. This is necessary since heavy cylinders and motors are operational in the system. The safety curtain disables the machine if its breached.

safety curtains on runout measurement system
Automated Safety Curtains to implement Poka Yoke

In the article below, our design team takes you through the process involved from start to end of the development of the Runout Measurement System.

Designer’s point of view

We start designing keeping in mind the customer’s requirement and the focal parameters that are to be gauged in the component.  Once we receive the valuable order, we ask the customer to send us detailed 3D and 2D component drawings along with the actual component to help us know the look and feel of the component. This also helps us design the dowelling of the component on the fixture and understand the different types of surface roughness observed on the component.

After we receive the component, we start the designing process and begin the  drafting of the design approval (DAP) manual.

The DAP contains a complete parameters list, the overall layout of the system and detailed drawings of the system. It also includes detailed information about gauge fixture in all the three views explaining the checking process of the component. Bill of Materials is given mentioning the different parts which are present in the gauge, the material used to make these parts and also the different types of treatments these parts will undergo e.g. dull chrome, blackening, hardening, phosphating etc. The BOM also enlists the different bought out parts to be used in the system along with their manufacturers.

Along with this, the ‘Master’ is also a very important to the design process. It is crucial to the design and implementation of the gauge. The DAP contains detailed drawings of the ‘Master’. The material, surface finish, surface treatment of the ‘Master’ are all found in this drawing.

‘Master’

Thereafter,  the complete operation flow of the gauge from the operator’s point of view is explained in the DAP.  For example, in this machine the process would include

  1. Load the component on the fixture
  2. Scan the component barcode
  3. Lock the component pressing the green button
  4. Wait for the gauge to complete gauging
  5. Unlock the component
  6. Unload the component

The video below shows the designed machine working as per the operation flow in 3D. The DAP basically covers every single point in the machine and communicates this to the customer

Finally the DAP ends with the acceptance criteria of the gauge along with the detailed DAP acknowledgement points. This takes us through the entire design process of the machine.

Moving on, we will explain what happens in the gauge from start to end as the operator loads the component in this section

Gauge Operation
  1. The operator manually loads the hub on the specially designed gauging locator  and presses the required buttons.

    Dowelling locations
  2. The  specified heavy cylinder is activated which gives the desired preload, and also attaches the hub to the rotating mechanism. The preload achieved on the component is checked with the help of an integrated load cell and the load is also displayed on the monitor/HMI. (See Video)
  3. This is followed by the Auto rotation of the component at the desired calculated speed. A brush assembly is provided for cleaning the hub ID surface for rotation of 720 degrees. After cleaning, the gauging sensor is activated which checks the runout for 360 degrees and displays it on the monitor/HMI.
  4. If the runout checked is within the specified range, green signal is displayed and automated pen marking of the system is done distinguishing the checked & OK components from the others. In the case of the checked runout being outside the specified limits, red signal and buzzer is flashed alerting the operator.
monitor showing the results
Monitor showing the results

The video below shows the Runout measurement system in action

This machine has been designed keeping in mind the simplicity of the user and is a  simple gauging system which helps in checking and controlling a very important parameter. This has helped achieving the desired quality control required by top automobile manufacturers and its ancillaries. This is proved buy the fact that the machine checks 900 critical components a day with consistent accuracy and performance.

 

The Precision and Technology behind Conrod Multi-Gauging!

After our last post on the multi-gauging of a cylinder block and head, we take you through the multi-gauging of one of the most important components inside a cylinder block. The amount of precision that goes into the manufacturing of these parts can be understood when we study the precise measures used to achieve the quality standards required.

The Conrod Multigauging Station is a high speed performing machine made of a robust structure with its entire X & Y axis Precision Movements controlled by high definition FLC/PLC Controllers, Hydraulic Cylinders, Precision Slides and in- house customized software to suit the shop floor condition and environment for 100% inspection of all the manufactured components having Repeatability and Reproducibility (R&R) within 10% of the total tolerance.

The assembly inside a cylinder block is one of the most critical and precise piece of engineering. The quality desired can only be achieved with multi-gauging stations that precisely gauge the parameters with R&R within 10% of the total tolerance.

Parameters measured by a Conrod Multigauging System

Some of the Parameters inspected are Big End (Crank Bore) Diameter, Ovality and Taper, Small End (Piston Bore) Diameter, Ovality and Taper, Centre Distance, Bend, Twist, Big End Squareness, Width of both ends, Stem thickness.

corned-gauging

The actual gauging is done by precise LVDT probes which make numerous readings during the process. These readings taken from the machined surfaces of the Conrod become the basis of measurement of all parameters of the Conrod.

The Critical Job done by the Software in the System

Parameters such as bend and twist are determined by the in built software after crunching the numbers received from the LVDT probes. Each program is designed according to the needs of the client and the SPC analysis desired.

Thousands of readings and reports generated by the software are saved and used whenever needed by the manufacturer, which in turn increases the productivity and gives a quality-conscious client a complete database that can be used as a blueprint for future design and manufacturing alterations.

conrod parameters

System Integrated weighing and Quality Marking

A marking machine which may be a laser, dot pin etc can be used to mark the Conrod after measurement engraving the particular grade of the conrod along with its weight for unique identification.

A weight machine is often integrated with the system in order to grade the conrod according to its weight. The weight machine is a high accuracy machine which has a least count of 0.1 grams.

Automated or Manual Grading

The system has automated/manual grading bins in order to place the different conrod’s as per the grades indentified by the gauging station.

This makes the entire process totally operator friendly and error free.

In automated grading bins, only the flap of a particular bin is opened with the help of pneumatics depending upon the feedback received from the gauging station after gauging of the conrod has been done, so the operator can place the conrod only in that bin, since all the other bins are closed.

Sneak Peak into a Conrod Multigauging Station

The video below takes you through the complete process on the TASK Conrod Multi-gauging System!

In manual grading bins, led indicators are present above different bins. Only the led light above the correct bin flashes depending upon the feedback received from the gauging station after gauging of the conrod has been done.

If the operator places the conrod in the wrong bin, an alarm is sounded and further gauging cannot be done unless the conrod is placed in the right grade bin.

grading bins in a conrod gauging station

Acceptance of the System

The automated system will confirm R&R norms for acceptance by total component variation method covering full range of tolerance. If components covering full range of tolerance  are not available then appropriate masters covering full range are used as components. R&R study has to be within 10% for acceptance of the system.

Decoding the Multi-gauging of a Cylinder Block

Task is a leading force in the multi-gauging industry in India since the last three decades with systems designed and manufactured for all the top auto industries and engine manufacturers across different Indian Industrial hubs. We take a look at multi-gauging in this article which will help you understand the technology behind multi-gauging in simple words. Multi-gauging of a cylinder block is one of the most important processes on the engine manufacturing line and plays a critical role in whether the block is ok for assembly or not.

What is Multi-gauging of a cylinder block? 

An automated multi-gauging system for a cylinder block is deployed on the line to measure and inspect upto 100 conventional parameters within 100 seconds with online SPC analysis at an accuracy of upto 0.001 mm.

multi-gauging of a two wheeler
Cylinder Block of a two wheeler

Some even go up to an accuracy of 0.0001 mm and can only be achieved in a controlled environment.

Such results are only obtained when the system used to do the job are manufactured by experienced technicians using top notch machines with a high level of quality control and excellence in design.

What is measured in a multi-gauging system for a cylinder block?

Shown below are some examples of cylinder blocks from two wheelers, four wheelers and tractors with a few conventional parameters denoted

multi-gauging of a cylinder head
Some parameters of a cylinder block measured using multi-gauging systems
multi-gauging of a cylinder head
Some parameters of a two wheeler cylinder block measured using multi-gauging systems

Cylinder Bore Diameter, Bore Ovality, Bore taper, Bore cylindricity, Bore perpendicularity, Concentricity of cam bore w.r.t crank bore, Crank bore diameter, Crank bore ovality, Crank bore taper, Cam bore diameter, Length of all the bores, Center distance of all the bores, Crank bore axis distance w.r.t face, Perpendicularity of crank bore axis w.r.t piston bore, Crush height, Grading are some of the important parameters that the Task Cylinder Block Multi Gauging System checks.

How does a basic Multi-gauging Station work?

The measuring station is a high speed performing machine made of a robust structure with its entire X & Y axis Precision Movements controlled by high definition FLC/PLC Controllers, Hydraulic Cylinders, Precision Slides and in- house customized software to suit the shop floor condition and environment for 100% inspection of all the manufactured components having Repeatability and Reproducibility (R&R) within 10% of the total tolerance.

Let us now take you through some of the important components of a multigauging system which are so critical to achieve the accuracy desired.

  1. Special design and controls are used for loading and unloading to eliminate any human intervention during gauging. The video below shows how the TASK multi-gauging system loads the cylinder block
  2. Task’s cylinder block multi-gauging system is a complete electronic gauging system in which the measurement is done with the help of electronic LVDT probes. The probes along with the electronics are the heart of the system. Marposs /Solatron or our Task-made probes are the most commonly used probes in Task Systems.
  3. The video below is a fascinating video showing the processes involved in measuring some of  the parameters of a cylinder block on a multi-gauging station!
  4. The in built software performs SPC analysis on the data received from the multi-gauging system. Desired reports are generated for a number of applications
So what makes Multi-gauging Systems so special?

We take you through some of the manufacturing processes involved in the manufacturing of certain components of the multi-gauging system

  1. All Contact Plugs viz Liner, Crank & Cam plugs are hardened, Sub Zero Treated & Chrome plated for accuracy & wear resistance.
  2. An Air nozzle is present at the entry of the plugs for cleaning of dust & moisture present in the cylinder block crank, cam & liner bores.
  3. Automated air plug gauges check small bores like timing & idling bores
  4. Base bed of the fixture is made of C-channels with ribs of MS plates welded on it. The fixture is stress relieved & ground for maintaining accuracy & robustness.
  5. Fixture is also dull chrome plated for corrosion free resistance & long life.
  6. Special roller conveyors are designed for easy sliding of the cylinder block.

The level of accuracy expected from a multi-gauging systems only  achieved  when the system used to do the job is manufactured by experienced technicians using top notch machines with a high level of quality control and excellence in design. 

About TASK Precision Industries

Task Precision Industries are a leading manufacturer of Universal & Customized Gauging Systems, Gauging Automation Systems & Low Cost Automation Projects with in house mechanical, software and electronic expertise which gives them total control over the manufacturing and quality control of their systems.