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.
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.
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.
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
- Load the component on the fixture
- Scan the component barcode
- Lock the component pressing the green button
- Wait for the gauge to complete gauging
- Unlock the component
- 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
- The operator manually loads the hub on the specially designed gauging locator and presses the required buttons.
- 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)
- 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.
- 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.
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.