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.

3NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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:

4NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Cylinder Surface

• Scatter, not just reflection.

• Different pattern for boring vs. honing.

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

5NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Probe Assembly

Laser Prism

Cylinder Surface

MirrorAperture

FiltersDetector

Slip Ring

6NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Manufactured Probe

Laser Prism

MirrorDetector

Slip Ring

7NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Typical Data

• Data collected with Labview• Plots generated with Matlab

NCU Detection Properly Honed

8NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Honing Problem Detection

Different honing patterns at the top and bottom of the cylinder

Axial stripes along the cylinder wall.

9NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Alternate Detectable Conditions

Coarse Honing Fine and Coarse Boring

10NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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.

11NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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.

12NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Machine Specifications

13NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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

14NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Full Scale Prototype Configuration as Requested by End-Users

15NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Completed Prototype

• Station installed week of 9-17-07.• Station and probes are operational.

16NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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

17NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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.

18NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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.

19NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

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

20NSF Engineering Research Center for Reconfigurable Manufacturing SystemsUniversity of Michigan College of Engineering

Questions?