System and method for detecting contact during processing

Abstract

Systems and methods for detecting contact between a manufacturing device and an article processed by the manufacturing device are provided. Vehicles including the article are also provided. The system includes a manufacturing device configured to perform a process on an article, a signal emitter configured to apply an input signal to the article during the process such that the input signal is conducted through the article, a signal receiver configured to monitor a first component of the manufacturing device to detect a conduction of the input signal through the first component during the process, and a signal processor configured to determine whether contact has occurred between the first component of the manufacturing device and the article based on the detection of the input signal by the signal receiver.

Description

Technical Field

[0001] The technical field generally relates to methods for detecting unintentional contact between components during manufacturing, and more specifically, to methods for detecting unintentional contact between manufacturing equipment and articles processed by the manufacturing equipment. Background Technology

[0002] An internal combustion engine includes at least one crankshaft that converts the reciprocating linear motion of a piston into rotational motion about the crankshaft axis to provide torque to propel a vehicle, such as, but not limited to, a train, boat, airplane, or automobile, or to drive any other device powered by the engine.

[0003] During crankshaft manufacturing, the crankshaft undergoes various processes, many of which are performed by automated manufacturing equipment. During these processes, components of the manufacturing equipment may become misaligned, for example, due to component wear, operational vibrations, etc. In such cases, one or more components of the manufacturing equipment may inadvertently come into contact with the crankshaft surface, causing damage to the crankshaft and / or the manufacturing equipment. Seemingly minor damage, such as scratches on the crankshaft, can have significant consequences. In particular, these scratches can each define stress concentrations (i.e., stress gradients), which, under the high torques typically applied to the crankshaft during operation, can lead to crankshaft breakage and ultimately catastrophic failure. Unfortunately, scratches caused by inadvertent contact with components of the manufacturing equipment can be extremely difficult to detect without thorough crankshaft analysis.

[0004] Therefore, it is desirable to provide a method for detecting unintentional contact between components of a manufacturing apparatus and articles thus processed (e.g., crankshafts). Furthermore, other desirable features and characteristics of the invention will become apparent from the following detailed description and appended claims, taken in conjunction with the accompanying drawings and the foregoing technical and background information. Summary of the Invention

[0005] A system and method are provided for detecting contact between manufacturing equipment and articles processed by the manufacturing equipment. A vehicle comprising the articles is also provided.

[0006] A system includes: a manufacturing apparatus configured to perform processing on an article; a signal transmitter configured to apply an input signal to the article during processing, such that the input signal is conducted through the article; a signal receiver configured to monitor a first component of the manufacturing apparatus to detect the conduction of the input signal through the first component during processing; and a signal processor configured to determine, based on the detection of the input signal by the signal receiver, whether contact has occurred between the first component of the manufacturing apparatus and the article.

[0007] In some embodiments, the signal processor is configured to generate or activate an alarm in response to determining that contact has occurred between a first component and an article of the manufacturing equipment.

[0008] In some embodiments, the manufacturing equipment is configured to automatically stop processing in response to a signal processor determining that contact has occurred between a first component of the manufacturing equipment and an article.

[0009] In some embodiments, the signal transmitter is configured to apply an electrical signal as an input signal, and the signal receiver is configured to monitor and detect the electrical signal.

[0010] In some embodiments, the signal transmitter is configured to apply an ultrasonic signal as an input signal, and the signal receiver is configured to monitor and detect the ultrasonic signal.

[0011] In some embodiments, a second component of the manufacturing apparatus is configured to contact the article during processing. The first component is formed of a first material, and the second component is formed of a second material. The first material is more conductive than the second material.

[0012] In some embodiments, the manufacturing equipment is a crankshaft ultra-precision machining station, and the article is a crankshaft. The crankshaft ultra-precision machining station can be configured to polish the crankshaft with a polishing film during processing, and the first component can be a bearing bush configured to guide the polishing film. A signal processor can be configured to determine whether contact has occurred between the bearing bush and the fillet of the crankshaft's main bearing journal or pin bearing journal.

[0013] A method includes: performing a process on an article using a manufacturing apparatus; during the process, applying an input signal to the article using a signal transmitter such that the input signal is conducted through the article; during the process, monitoring a first component of the manufacturing apparatus using a signal receiver to detect the conduction of the input signal therethrough; and based on the detection of the input signal by the signal receiver, determining, using a signal processor, whether contact has occurred between the first component of the manufacturing apparatus and the article.

[0014] In some embodiments, the method may include generating an alarm in response to determining that contact has occurred between a first component of the manufacturing equipment and an article.

[0015] In some embodiments, the method may include automatically stopping processing in response to determining that contact has occurred between a first component of the manufacturing equipment and an article.

[0016] In some embodiments, the input signal is an electrical signal.

[0017] In some embodiments, the input signal is an ultrasonic signal.

[0018] In some embodiments, the process includes contacting the article with a second component of the manufacturing equipment. The first component is formed of a first material, and the second component is formed of a second material. The first material is more conductive than the second material.

[0019] In some embodiments, the manufacturing equipment is a crankshaft ultra-precision machining station, and the article is a crankshaft. The process may include polishing the crankshaft with a polishing film from the crankshaft ultra-precision machining station, and the first component may be a bearing bush configured to guide the polishing film. The method may include determining whether contact has occurred between the bearing bush and the fillet of the crankshaft's main bearing journal or pin bearing journal.

[0020] A vehicle includes the aforementioned items.

[0021] In some embodiments, the article is a crankshaft. Attached Figure Description

[0022] Exemplary embodiments will now be described in conjunction with the following accompanying drawings, wherein the same reference numerals denote the same elements, wherein:

[0023] Figure 1 This is a schematic diagram of a system for detecting unintentional contact between a crankshaft ultra-precision machining station and a crankshaft, according to an embodiment.

[0024] Figure 2 According to the embodiments Figure 1 The polishing arm assembly of the crankshaft ultra-precision machining station and Figure 1 A schematic diagram of some components of the system;

[0025] Figure 3 This is a flowchart of a method for detecting unintentional contact between a manufacturing apparatus and an article processed by the manufacturing apparatus, according to an embodiment; and

[0026] Figure 4 The vehicle according to the embodiment includes a crankshaft. Detailed Implementation

[0027] The following detailed description is merely exemplary in nature and is not intended to limit application or use. Furthermore, there is no intention to be bound by any express or implied theory presented in the foregoing technical field, background art, summary of the invention, or the following detailed description.

[0028] As used herein, the word “exemplary” means “serving as an example, instance, or illustration.” As used herein, “a,” “an,” or “the” means one or more, unless otherwise stated. The term “or” can be a conjunction or a disjunctive word. Open-ended terms such as “comprising,” “including,” or “containing” mean “comprising,” but in some embodiments may mean “consisting of.” In some embodiments, figures representing quantities, material ratios, material physical properties, and / or uses in this specification may be understood to be modified by the word “about.” The term “about,” used in conjunction with numerical values ​​and claims, represents a range of precision familiar and acceptable to those skilled in the art. Typically, such a range of precision is ±10%. All figures representing quantities, material ratios, material physical properties, and / or uses in this specification may be understood to be modified by the word “about,” unless otherwise expressly stated.

[0029] These figures are simplified schematic forms and are not to scale. Furthermore, terms such as “up,” “down,” “above,” “above,” “below,” “under,” “upward,” and “downward” are used descriptively in the figures and do not represent a limitation on the scope of the subject matter as defined by the appended claims. Any numerical names such as “first” or “second” are illustrative only and are not intended to limit the scope of the subject matter in any way. Note that while embodiments may be described herein with reference to automotive applications, those skilled in the art will recognize their broader applicability.

[0030] The embodiments described herein provide for the detection of unintentional contact between manufacturing equipment and articles processed by that equipment. These embodiments allow for the determination of whether the manufacturing equipment requires inspection, maintenance, and / or repair, and whether the articles being processed may be damaged and / or require analysis. While the specific embodiments described herein include a crankshaft ultra-precision machining station and a crankshaft polished therewith, this description is not limiting. Other manufacturing equipment and articles processed therefrom are also contemplated. In particular, various drilling equipment, milling equipment, grinding equipment, balancing equipment, and various articles processed therefrom are all conceivable.

[0031] In some examples, an input signal can be applied to an article when the manufacturing equipment processes it. Simultaneously, at least a first component of the manufacturing equipment can be monitored to detect the conduction of the input signal through that component. If the first component inadvertently comes into contact with the article, the input signal will be conducted through the article to the first component of the manufacturing equipment. Upon detecting an input signal in the first component of the manufacturing equipment, it is determined whether the first component has come into contact with the article; if so, an alarm can be generated.

[0032] Now for reference Figure 1 and Figure 2An example of a system, referred to below as system 200, is shown, configured to detect unintentional contact between components of crankshaft superfinishing station 100 and the crankshaft 20 thus machined. Crankshaft 20 is of the type suitable for internal combustion engines, and crankshaft superfinishing station 100 can be operated during the production process of crankshaft 20 to polish its surface.

[0033] The crankshaft 20 includes a shaft extending along the crankshaft axis. The shaft includes main bearing journals 26, arms 27, and pin bearing journals 28 (i.e., crank pins). The main bearing journals 26 are concentrically arranged around the crankshaft axis. Each main bearing journal 26 is coupled to at least one arm 27. Each pin bearing journal 28 is laterally offset from the crankshaft axis and is attached to an adjacent main bearing journal 26 on opposite sides of the pin bearing journal 28 via a pair of arms 27.

[0034] Station 100 includes a plurality of polishing arm assemblies 102 located between spindle box 104 and footstock 106. For polishing crankshaft 20, the ends of crankshaft 20 can be fixed to spindle box 104 and footstock 106, and each polishing arm assembly 102 can receive a portion of crankshaft 20 located between its upper bearing shell 108 and lower bearing shell 110.

[0035] During operation of the crankshaft superfinishing station 100, the crankshaft 20 rotates about its axis and oscillates between the headstock 104 and the tailstock 106. A polishing film 112, coupled to the polishing arm assembly 102, travels along a path on a portion of the crankshaft 20, contacting the crankshaft 20 to polish its surfaces. These surfaces of the crankshaft 20 may include, but are not limited to, the outer surfaces of the main bearing journal 26 and the pin bearing journal 28. To conform the polishing film 112 to the surfaces of the crankshaft 20, the upper bearing shell 108 and the lower bearing shell 110 include curved recesses corresponding to the curvature of the crankshaft 20, configured to guide the polishing film 112 around the surfaces of the crankshaft 20. The upper bearing shell 108 and the lower bearing shell 110 may be hinged in a direction toward the crankshaft 20 to maintain contact between the polishing film 112 and the surfaces of the crankshaft 20.

[0036] Misalignment of the polishing arm assembly 102 may cause contact between the upper bearing shell 108 and / or the lower bearing shell 110 and the fillets positioned along the edges of the main bearing journal 26 and / or the pin bearing journal 28. This contact may cause scratches, nicks, etc., on the fillets. These scratches can each define stress concentrations (i.e., stress gradients), which, under the high torques typically applied to the crankshaft 20 during operation, can lead to crankshaft 20 breakage and ultimately catastrophic failure.

[0037] Therefore, system 200 can be functionally coupled to crankshaft superfinishing station 100 to detect unintentional contact between components of polishing arm assembly 102 (e.g., upper bearing 108 and / or lower bearing 110) and surfaces of crankshaft 20 (e.g., fillets of main bearing journal 26 and / or pin bearing journal 28). System 200 includes a signal transmitter 210, one or more signal receivers 212, and a signal processor 214. The signal transmitter 210 is configured to transmit input signal 220 (in...) Figure 1 An input signal 220 (represented by concentric arcs) is applied to the crankshaft 20, causing the input signal 220 to be conducted through the crankshaft 20. In this example, the input signal 220 may be applied to the spindle housing 104 and conducted through the spindle housing 104 to the crankshaft 20. In some examples, the input signal 220 may be automatically activated, for example, by a programmable logic controller (PLC) 216. Automatic activation of the input signal 220 may be in response to specific events, such as the start-up of the crankshaft superfinishing station 100 or the activation of an oscillation mode during crankshaft 20 oscillation. In other examples, the input signal 220 may be manually activated. During operation of the crankshaft superfinishing station 100, the input signal 220 may be applied to the crankshaft 20 continuously or periodically.

[0038] Signal receiver 212 is configured to monitor polishing arm assembly 102 or its components to obtain input signal 220 transmitted therethrough. Upon detecting input signal 220, signal receiver 212 is configured to transmit this detection to signal processor 214. Signal processor 214 is configured to receive communication from signal receiver 212 and analyze the communication to determine whether contact (hereinafter referred to as an unintentional contact event) may have occurred between certain components of polishing arm assembly 102 and crankshaft 20.

[0039] In some examples, signal receiver 212 may be configured to send a detection signal to signal processor 214, and signal processor 214 may be configured to identify the detection signal as an indication of an unintentional contact event. Optionally, signal processor 214 may compare the detection signal to a predetermined threshold before identifying the detection signal as an indication of an unintentional contact event. For example, the threshold may relate to the minimum duration of the detected input signal 220, and signal processor 214 may filter out input signals 220 detected by polishing arm assembly 102 or its components whose duration is less than the threshold.

[0040] When signal processor 214 determines that an unintentional contact event has occurred, signal processor 214 can generate an alarm or communicate with another device to generate an alarm. For example, in Figure 1In this configuration, signal processor 214 communicates with operator console 218, which is configured to generate an alarm in response to the signal processor 214 detecting an unintentional contact event. The alarm can be any communication suitable for drawing the attention of a designated person or system to the unintentional contact event. As a non-limiting example, the alarm may include audible alarms (e.g., bells) and / or visual alarms (e.g., flashing lights, markings displayed on a digital display). In some examples, crankshaft overfinishing station 100 may be configured to deactivate and / or stop certain operations in response to an alarm.

[0041] In response to the generated alarm, designated personnel and / or systems may take appropriate actions, such as deactivating the crankshaft superfinishing station 100, removing the crankshaft 20 from the crankshaft superfinishing station 100, analyzing the crankshaft 20 to identify any damage thereto, and / or inspecting the crankshaft superfinishing station 100 and performing any necessary maintenance, repairs and / or calibrations thereto to reduce the likelihood of subsequent unintentional contact incidents.

[0042] Various types of input signals and sensing techniques can be used in system 200 to detect unintentional contact events. In some examples, input signal 220 is an electrical signal (e.g., current, voltage, etc.). For example, signal transmitter 210 can generate an electrical signal, such as a low-voltage pulse signal, and apply this signal as input signal 220 to spindle housing 104. Since spindle housing 104 and crankshaft 20 are formed of conductive material (e.g., metallic material), the electrical signal is conducted through spindle housing 104 to crankshaft 20. During normal operation of crankshaft superfinishing station 100, the electrical signal should not be conducted to polishing arm assembly 102 because polishing film 112 is formed of insulating material. However, other components of polishing arm assembly 102, such as upper bearing 108 and lower bearing 110, can be formed of conductive material. Therefore, if one of these conductive components unintentionally contacts crankshaft 20, the electrical signal will be conducted from crankshaft 20 through the conductive components of polishing arm assembly 102 and detected by the corresponding signal receiver 212. For example, where the input signal 220 is an electrical signal (e.g., current, voltage, etc.), the signal receiver 212 may include, for example, a voltage sensor (e.g., capacitor, resistor, etc.) or a current sensor (e.g., Hall effect, Rogowski coil, etc.).

[0043] In other examples, the input signal 220 can be an ultrasonic signal (i.e., a sound wave with a frequency greater than 20 kHz). For example, the signal transmitter 210 can generate an ultrasonic signal and apply it as the input signal 220 to the spindle housing 104. Similar to the aforementioned electrical signal example, the ultrasonic signal is conducted to the crankshaft 20 through the conductive material of the spindle housing 104. Since the polishing film 112 is formed of an insulating material, the ultrasonic signal is not conducted to the polishing arm assembly 102. However, if one of the conductive parts of the polishing arm assembly 102 inadvertently comes into contact with the crankshaft 20, the ultrasonic signal will be conducted from the crankshaft 20 through the conductive part of the polishing arm assembly 102 and detected by the corresponding signal receiver 212.

[0044] System 200 provides a method 300 for detecting unintentional contact between manufacturing equipment and the articles processed therefrom. For example... Figure 3 As shown in step 310, method 300 may include performing processing on an article using a manufacturing apparatus. In step 320, method 300 includes applying an input signal to the article using a signal transmitter during processing. In step 330, method 300 includes monitoring the manufacturing apparatus to detect the conduction of the input signal through it using a signal receiver during processing. Method 300 may include continuing to monitor the conduction of the input signal through the manufacturing apparatus as long as processing is in progress and the signal receiver does not detect an input signal. In step 340, upon detecting the conduction of the input signal through the manufacturing apparatus, method 300 includes determining, based on the detection of the input signal, whether unintentional contact has occurred between the manufacturing apparatus and the article being processed thereunder. If it is determined that no unintentional contact has occurred, method 300 may include continuing to monitor the conduction of the input signal through the manufacturing apparatus. In step 350, method 300 includes generating an alarm in response to determining that unintentional contact has occurred.

[0045] In some examples, the process being performed may include intentional physical contact between a first component of the manufacturing equipment (e.g., polishing film 112) and the article, and method 300 may include analyzing an input signal detected by a signal receiver to determine whether physical contact has occurred between a second component of the manufacturing equipment (e.g., upper bearing 108 or lower bearing 110) and the article. In such examples, the first component may be formed of a first material (e.g., an insulating material), and the second component may be formed of a second material (e.g., a metallic material), wherein the first material has lower conductivity than the second material.

[0046] In some examples, the item may be a component configured for installation in a vehicle, such as a car, train, boat, or airplane. For example, crankshaft 20 may be secured to the engine block of an internal combustion engine installed in the vehicle at main bearing journal 26 by bearings disposed around and supported thereby located between crankshaft 20 and engine block. Each pin bearing journal 28 supports the bearings around it and provides a connection point where connecting rods connect pistons to crankshaft 20. Reciprocating pistons may be connected to pin bearing journals 28 via connecting rods. The force applied from the pistons to crankshaft 20 by the offset connection between the pistons generates torque in crankshaft 20, which causes crankshaft 20 to rotate about crankshaft axis. Figure 4 A non-limiting example of a vehicle 400 including a crankshaft 20 mounted therein is shown.

[0047] While at least one exemplary embodiment has been described in the foregoing detailed description, it should be understood that numerous variations exist. It should also be understood that the one or more exemplary embodiments are merely examples and are not intended to limit the scope, applicability, or configuration of this disclosure in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient roadmap for implementing one or more exemplary embodiments. It should be understood that various changes can be made to the function and arrangement of the elements without departing from the scope of this disclosure as set forth in the appended claims and their legal equivalents.

Claims

1. A system comprising: A manufacturing apparatus configured to perform processing on an article, wherein the manufacturing apparatus includes a first component and a second component, wherein the first component is configured to contact the article during processing and the second component is configured not to contact the article during processing, wherein the first component and the second component contact each other during processing; A signal transmitter configured to generate an input signal during processing and to apply the input signal to an article such that the input signal is conducted through the article, wherein a first component is formed of a first material that insulates against the input signal, and a second component is formed of a second material that conducts against the input signal; A signal receiver configured to monitor at least a second component of a manufacturing apparatus to detect the conduction of an input signal through the second component during processing caused by unintentional contact between the second component and an article, wherein the signal receiver is configured to continue monitoring the input signal as long as processing is being performed and the input signal is not detected; as well as A signal processor configured to determine, in response to the detection of an input signal by a signal receiver, whether contact has occurred between a second part of the manufacturing equipment and an article during processing.

2. The system according to claim 1, wherein, The signal processor is configured to generate or activate an alarm in response to determining that contact has occurred between a second component of the manufacturing equipment and the article.

3. The system according to claim 1, wherein, The signal transmitter is configured to generate and apply an electrical or ultrasonic signal as the input signal, and the signal receiver is configured to monitor and detect the electrical or ultrasonic signal.

4. The system according to claim 1, wherein, The manufacturing equipment is a crankshaft ultra-precision machining station, the article is a crankshaft, the crankshaft ultra-precision machining station is configured to polish the crankshaft with a polishing film during the processing, wherein the first component is the polishing film, and the second component is a bearing bush configured to guide the polishing film, wherein the input signal is not transmitted from the first component to the second component during the processing, and wherein the signal processor is configured to determine whether contact occurs between the bearing bush and the fillet of the main bearing journal or pin bearing journal of the crankshaft.

5. A method comprising: The article is processed using manufacturing equipment, wherein the processing includes intentionally bringing the article into contact with a first part of the manufacturing equipment, and not intentionally bringing the article into contact with a second part of the manufacturing equipment, the second part being in contact with the first part during the processing; During processing, an input signal is generated by a signal transmitter and applied to an article, such that the input signal is conducted through the article, wherein the first component is formed of a first material that insulates against the input signal, and the second component is formed of a second material that conducts against the input signal; The signal receiver monitors at least a second component of the manufacturing equipment to detect the conduction of an input signal through it during processing caused by unintentional contact between the second component and the article, and continues to monitor the input signal with the signal receiver as long as processing is being performed and the input signal is not detected. as well as Based on the detection of the input signal by the signal receiver, the signal processor determines whether unintentional contact has occurred between the second part of the manufacturing equipment and the article during processing.

6. The method of claim 5, further comprising generating an alarm in response to determining that contact has occurred between a second component of the manufacturing equipment and the article.

7. The method according to claim 5, wherein, The input signal is an electrical signal or an ultrasonic signal.

8. The method according to claim 5, wherein, The manufacturing equipment is a crankshaft ultra-precision machining station, the article is a crankshaft, the process includes polishing the crankshaft with a polishing film of the crankshaft ultra-precision machining station, wherein the first component is the polishing film and the second component is a bearing bush configured to guide the polishing film, wherein the input signal is not transmitted from the first component to the second component during the process, and the method further includes determining whether contact occurs between the bearing bush and the fillet of the main bearing journal or pin bearing journal of the crankshaft.

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