Digital measurement method and device for oil sludge thickness of oil sump

Abstract

The application discloses a kind of digital measurement method and device for oil sludge thickness of oil sump, comprising: using range scanner to scan the surface of unused new oil sump to be measured, and determining the measurement point coordinates of oil sump based on scanning data;Using range scanner, according to the preset scanning path, the metal base of the new oil sump corresponding to the determined measurement point is measured, and the measurement result is used as the reference distance;Using range scanner, according to the preset scanning path, the measurement point on the oil sump to be measured covered by oil sludge after test is measured, and the measurement distance is obtained;Based on reference distance, measurement distance and combined with temperature correction, the oil sludge thickness of the oil sump to be measured is calculated.The application can realize the automatic, digital, high-precision measurement of oil sludge thickness, and improve the detection efficiency and stability.

Description

Technical Field

[0001] This invention relates to the field of engine deposit measurement and evaluation technology, and in particular to a digital measurement method and device for oil pan sludge thickness. Background Technology

[0002] The oil pan, as a core component of the engine, primarily stores lubricating oil and provides continuous and reliable lubrication for all moving parts of the engine. Sludge is a colloidal deposit formed in the lubricating oil during use due to oxidation and impurity buildup. It cannot flow in the oil pan but can be wiped away with a soft cloth. The amount of sludge formed is directly related to the detergency, dispersibility, and antioxidant properties of the lubricating oil. Sludge score is one of the key evaluation indicators of lubricating oil quality. The score is calculated based on the sludge thickness and coverage area. The amount of sludge formed affects the engine's cooling efficiency and the smoothness of lubricating oil circulation. Therefore, accurately measuring the sludge thickness in the oil pan is of great significance for engine durability assessment and lubricating oil performance optimization.

[0003] Current methods for measuring oil pan sludge thickness primarily rely on manual measurement, using sludge depth gauges and depth comparison cards for single-point measurements on the disassembled oil pan. This approach has the following drawbacks: traditional manual methods are time-consuming and labor-intensive; using sludge depth gauges is highly destructive to the sludge; the selection of measurement locations and the operation of the measurement process are greatly affected by human factors, making it difficult to perform numerous repeated measurements, resulting in relatively large measurement errors; measurement data requires manual recording, which is prone to omissions and recording deviations; and the measurement results largely depend on the subjective judgment of the measurement personnel, demanding a high level of professional skill. Furthermore, the fluidity of lubricating oil significantly decreases at low temperatures, and the sludge thickness is also affected by temperature, further increasing the measurement deviation.

[0004] Therefore, there is an urgent need for a technical solution that can digitally measure the thickness of sludge in the engine oil pan, with high detection efficiency, strong stability, and no destructive effect on the sludge, in order to overcome the shortcomings of existing technologies. Summary of the Invention

[0005] The purpose of this invention is to overcome the shortcomings and defects of the prior art and provide a digital measurement method and apparatus for oil pan sludge thickness. The digital measurement apparatus and method of this application are suitable for measuring oil pan sludge thickness after engine lubricating oil bench tests and road tests. It can achieve automated, digital, and high-precision measurement of sludge thickness, while also possessing real-time data storage and query functions, improving detection efficiency and stability.

[0006] One aspect of the present invention provides a method for digitally measuring the thickness of sludge in an oil pan, comprising the steps of:

[0007] The surface of the unused new oil pan is scanned using a range scanner, and the coordinates of the measurement points on the oil pan are determined based on the scan data.

[0008] Using a distance measuring scanner, the metal substrate of the new oil pan corresponding to the determined measurement point is measured according to the preset scanning path, and the measurement result is used as the reference distance.

[0009] The distance is measured by using a distance measuring scanner to measure the measurement points on the oil pan covered with sludge after the test, following a preset scanning path.

[0010] Based on the reference distance, the measured distance, and combined with temperature correction, the sludge thickness of the oil pan to be tested is calculated.

[0011] Preferably, the surface to be tested includes the side and bottom surfaces of the new oil pan.

[0012] Preferably, the reference distance is the distance between multiple measuring points on the new oil pan, and the measuring distance is the distance between multiple measuring points on the oil pan to be tested.

[0013] Preferably, the step of calculating the sludge thickness of the oil sump under test based on the reference distance, the measurement distance, and in conjunction with temperature correction includes:

[0014] The initial sludge thickness at each measurement point of the oil pan under test is calculated based on the reference distance and the measurement distance. Then, the initial sludge thickness at each measurement point is compensated by correcting the temperature based on the temperature data at the current measurement time, and finally the final sludge thickness at each measurement point is obtained.

[0015] Preferably, after the step of calculating the sludge thickness of the oil sump based on the reference distance, the measurement distance, and temperature correction, the method further includes:

[0016] The final sludge thickness at each measurement point in the oil pan to be tested is associated with the measurement point coordinates, measurement time, and measurement area identifier to form a complete sludge thickness data set, which is stored in the cloud and / or local storage devices.

[0017] Preferably, after the complete sludge thickness data set is generated, a thermal map of the overall thickness distribution of the oil pan is further generated to visually and intuitively present the overall distribution of sludge in the oil pan.

[0018] Preferably, the ranging scanner is a non-contact ranging device, including at least a laser rangefinder. When using a laser rangefinder for ranging, laser triangulation is used for ranging.

[0019] Preferably, the ranging scanner is driven by a drive mechanism to move along a preset scanning path for scanning and measurement.

[0020] Preferably, the ranging scanner uses a temperature compensation module to synchronously collect the ambient temperature at the time of measurement during scanning.

[0021] Another aspect of the present invention provides a digital measuring device for oil pan sludge thickness, used to implement the digital measuring method for oil pan sludge thickness, comprising a measuring box, a rigid anti-vibration support, an oil pan fixing fixture, a ranging scanner, a signal processing controller, a temperature compensation module, and a driving device for driving the ranging scanner to move along a preset scanning path; the oil pan fixing fixture is arranged on the upper surface of the rigid anti-vibration support, the ranging scanner is connected to the signal processing controller, and the temperature compensation module is installed inside the measuring box;

[0022] Preferably, it also includes an LED cold light source and a power supply. The LED cold light source is arranged on the top inside the measuring box, and the power supply is used to provide power to the electrical equipment of the measuring device and is arranged on the inner side wall surface of the measuring box.

[0023] This invention uses a distance scanner for measurement, which has a measurement accuracy far exceeding that of traditional manual measurement. It has high measurement accuracy and achieves automatic scanning of multiple measurement points through an automated positioning module, eliminating the need for manual intervention. This high degree of automation avoids human operation errors and improves measurement efficiency and consistency.

[0024] This invention does not damage the sludge during the entire measurement process, can accurately locate the measurement position, and has high repeatability. Furthermore, by using a signal processor, the distance signal is converted into digital sludge thickness data, which can display the thickness value and distribution heat map in real time, intuitively presenting the sludge deposition pattern, realizing the integration of digitization and visualization, and solving the problem that traditional measurements cannot be visualized.

[0025] This invention adopts a dual storage mode of local and cloud to prevent data loss and ensure data storage security. It supports multi-dimensional queries by time, test number, etc., and the query is convenient to trace the source of measurement data, providing reliable data support for engine test data analysis and lubricant performance evaluation.

[0026] This invention is highly adaptable and, in conjunction with a temperature compensation module and a shock-absorbing bracket, can adapt to the detection environment and temperature changes of the oil pan. It is also compatible with oil pans of both regular and irregular shapes, making it suitable for a wide range of applications. Attached Figure Description

[0027] Figure 1 This is a flowchart of the digital measurement method for oil sludge thickness in oil pans according to the present invention.

[0028] Figure 2 This is a schematic diagram of the digital measurement device for oil sludge thickness in the oil pan according to the present invention.

[0029] Figure 3This is an operation flowchart of the digital measurement device for oil sludge thickness in the oil pan according to the present invention.

[0030] Explanation of reference numerals in the attached figures:

[0031] 1- Rigid anti-vibration support; 2- Motion controller; 21- Z-axis lifting mechanism; 22- Rotary swing arm assembly; 23- Stepper motor; 24- X-axis motion mechanism; 3- Limit sensor; 4- Signal processing controller; 5- Distance scanner; 6- Oil pan fixing fixture; 7- Oil pan to be tested; 8- LED cold light source; 9- Power supply; 10- Measuring box; 11- Temperature compensation module. Detailed Implementation

[0032] The present invention will be further described in detail below with reference to the accompanying drawings and specific embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention.

[0033] In an exemplary embodiment of this application, the digital measurement method for the thickness of sludge in an oil pan involves using a positioning mechanism to vertically align a ranging scanner with the metal substrate surface of the measurement point on a new oil pan without sludge coverage. The distance from the ranging scanner to the measurement point is used as a reference distance. Then, the reference distances of all measurement points are measured sequentially, and the measurement path is stored. Then, all measurement points on the oil pan covered with sludge are measured according to this path. The distance difference between the two measurements is calculated, and the thickness value of the sludge is calculated based on this difference. The sludge is then evaluated according to its corresponding thickness grade.

[0034] See Figure 1 As shown in the exemplary embodiment of this application, the digital measurement method for oil sludge thickness in the oil pan includes the following steps:

[0035] S1. Use a rangefinder scanner to scan the surface of the unused new oil pan to be measured, and determine the coordinates of the measurement points on the oil pan based on the scan data;

[0036] S2. Using a distance measuring scanner, measure the metal substrate of the new oil pan corresponding to the determined measurement point according to the preset scanning path, and use the measurement result as the reference distance;

[0037] S3. Use a distance measuring scanner to measure the measurement points on the oil pan covered with sludge after the test according to the preset scanning path to obtain the measurement distance;

[0038] S4. Based on the reference distance, the measurement distance, and combined with temperature correction, calculate the sludge thickness of the oil pan to be tested.

[0039] In this embodiment of the application, the surface to be tested includes the side and bottom surfaces of the new oil pan.

[0040] In this embodiment of the application, the reference distance is the distance between multiple measurement points of the new oil pan, and correspondingly, the measurement distance is the distance between multiple measurement points of the oil pan to be tested.

[0041] In this embodiment of the application, the calculation of the sludge thickness of the oil pan under test based on the reference distance, the measurement distance, and combined with temperature correction includes:

[0042] The initial sludge thickness at each measurement point of the oil pan under test is calculated based on the reference distance and the measurement distance. Then, the initial sludge thickness at each measurement point is compensated by correcting the temperature based on the temperature data at the current measurement time, and finally the final sludge thickness at each measurement point is obtained.

[0043] In this application, the ambient temperature at the time of measurement is also collected simultaneously during the measurement of the scanning distance. The temperature data is used to compensate for the initial sludge thickness at each measurement point by correcting the temperature, and finally the final sludge thickness at each measurement point is obtained, thereby improving the accuracy of the measurement data.

[0044] In this embodiment of the application, after the step of calculating the sludge thickness of the oil pan to be measured based on the reference distance, the measurement distance and combined with temperature correction, the method further includes:

[0045] The final sludge thickness at each measurement point in the oil pan to be tested is associated with the measurement point coordinates, measurement time, and measurement area identifier to form a complete sludge thickness data set, which is stored in the cloud and / or local storage devices.

[0046] By adopting a dual storage mode of local and cloud storage, data loss is prevented and data storage is secure. It supports multi-dimensional queries by time, test number, etc., and the query is convenient to trace the source of measurement data, providing reliable data support for engine test data analysis and lubricant performance evaluation.

[0047] In this embodiment, after the complete sludge thickness data set is generated, a thermal map of the overall sludge thickness distribution in the oil pan is further generated, visually presenting the overall distribution of sludge in the oil pan. By converting the distance signal into digital sludge thickness data through a signal processor, the thickness values ​​and distribution thermal map can be displayed in real time, intuitively presenting the sludge deposition pattern and achieving a fusion of digitization and visualization, solving the problem of traditional measurements being unable to visualize.

[0048] In this embodiment, the ranging scanner is a non-contact ranging device, including at least a laser rangefinder, but other ranging devices such as infrared rangefinders, ultrasonic rangefinders, and visual rangefinders can also be used. When using laser ranging, the laser triangulation method is used. The laser ranging scanner has a built-in anti-reflective filter, which can effectively deal with the laser scattering problem caused by the roughness of the oily surface. It can be sealed with a fluororubber oil-proof shell. For example, the range of the laser rangefinder is 0-10mm, the measurement accuracy is ±0.001mm, the sampling frequency is 10kHz, and the spot size is 5μm.

[0049] In this embodiment, the ranging scanner is driven by a drive mechanism to move along a preset scanning path for scanning and measurement. The drive mechanism can be any available machine or device, such as a robot or robotic arm.

[0050] In this embodiment, the ranging scanner uses a temperature compensation module to synchronously collect the ambient temperature at the time of measurement during scanning. The temperature compensation module can be an independent module, such as an infrared thermometer, installed inside the measurement box. The temperature compensation module has a measurement range of 0-50℃, a measurement accuracy of ±0.5℃, and a response time of 10ms.

[0051] In a specific embodiment of this application, the oil pan can be placed on a fixture during measurement. The fixture can be fixed on a shock-absorbing base or arranged in a measuring box.

[0052] In another aspect, the present invention provides a digital measuring device for oil pan sludge thickness, used to implement the aforementioned digital measuring method for oil pan sludge thickness, such as... Figure 2 As shown, the system includes a measuring box 10, a rigid anti-vibration support 1, an oil pan fixing fixture 6, a limit sensor 3, a signal processing controller 4, a distance measuring scanner 5, a temperature compensation module 11, and a motion controller 2 that drives the distance measuring scanner to move along a preset scanning path. The oil pan fixing fixture 6 is arranged on the upper surface of the rigid anti-vibration support 1. The distance measuring scanner 5 is connected to the signal processing controller 4. The limit sensor 3 is connected to the signal processor 4 and the motion controller 2. The temperature compensation module 11 is installed inside the measuring box. Specifically, the signal processing controller includes an industrial PC equipped with a data acquisition card and a motion control card.

[0053] In one exemplary embodiment, the motion controller 2 may be equipped with a stepper motor 23, such as a two-phase hybrid stepper motor, connected to the Z-axis lifting mechanism and the X-axis motion mechanism to control Z-axis lifting and X-axis movement. The motion controller 2 may be equipped with a Z-axis lifting mechanism 21, such as a Z-axis electric lifting platform, with a stroke of 0-800mm, a positioning accuracy of ±8mm, and a repeatability of ±4mm. The motion controller 2 may be equipped with an X-axis motion mechanism 24, with a stroke of 0-600mm, a positioning accuracy of ±6mm, and a repeatability of ±3mm. m; The motion controller 2 may be equipped with a rotating swing arm assembly 22, which is connected to the Z-axis lifting mechanism 21 and the X-axis motion mechanism 24. The Z-axis lifting mechanism 21 drives it to move up and down along the Z-axis, and the X-axis motion mechanism 24 drives it to move along the X-axis. Its load capacity is 5kg. It is equipped with a stepper motor with a reduction ratio of 1:10 and an angle encoder (resolution 0.01°). Its rotation range meets 0-360°, driving the scanner and other components to perform rotational scanning. The distance measuring scanner, signal processing controller and limit sensor are installed at the end of the rotating swing arm assembly to perform scanning measurement.

[0054] Of course, the motion controller 2 is not limited to this structure; it can be any available machine platform or robotic arm, as long as it can drive the scanning device and temperature compensation module to move and scan along a preset path, vertically aligned with the metal substrate of the oil pan. Figure 2 The structure of motion controller 2 shown is illustrated.

[0055] In one exemplary embodiment of this application, an LED cold light source 8 and a power supply 9 are also included. The LED cold light source is arranged on the top of the inside of the measuring box to provide the required light source for scanning measurement. The power supply is used to provide power to the electrical equipment of the measuring device and is arranged on the inner side wall surface of the measuring box. Specifically, the power supply adopts an AC 220V to DC 12V / 24V switching power supply and is equipped with a 12V backup lithium battery.

[0056] The measuring device based on the embodiments of this application has the following measurement implementation steps, as follows: Figure 3 As shown:

[0057] 1. Equipment installation and global benchmark calibration: Fix the unused new oil pan on the testing platform, use a distance scanner to scan the surface of the oil pan to be tested (side and bottom), fit and segment the scanned image to determine the coordinate position of the measurement point, and then measure the metal substrate of the measurement point as the benchmark distance. Record and store the data, and the controller drives the distance scanner to return to the initial position.

[0058] 2. Automated full-area multi-point scanning distance measurement: After the test, the oil pan covered with sludge is installed and fixed on the test platform. The benchmark distance measurement steps are performed. The distance scanner is used to complete the scanning of all measurement points and the distance signal is collected and transmitted to the signal processing controller.

[0059] 3. Data Processing and Output: The signal processor controls the noise reduction of the distance signal, calculates the initial sludge thickness by combining it with the reference distance of the corresponding measurement area, and then corrects the influence of temperature on the measurement results through the temperature compensation module to obtain the final sludge thickness data of each measuring point. At the same time, the measuring point coordinates, measurement area identification, and measurement time information are associated to form a complete data set.

[0060] 4. Data visualization, storage and query: The signal processor controls the combination of sludge thickness data and measurement point location coordinates to generate a heat map of the overall thickness distribution of the oil pan, which intuitively presents the overall distribution of sludge. At the same time, the complete data set is automatically stored locally, and the measurement data can be exported to Excel / CSV format for subsequent experimental analysis.

[0061] 5. Measurement completion and equipment reset: After all measuring points are measured, the controller drives the motion controller to move the distance scanner back to the initial position, and the device enters standby mode.

[0062] The foregoing has shown and described the basic principles, main features, and advantages of the present invention. It will be apparent to those skilled in the art that the present invention is not limited to the details of the above exemplary embodiments, and that the present invention can be implemented in other specific forms without departing from the spirit or basic features of the present invention.

[0063] Therefore, the embodiments should be regarded as exemplary and non-limiting in all respects, and the scope of the invention is defined by the appended claims rather than the foregoing description. Thus, it is intended that all variations falling within the meaning and scope of the equivalents of the claims be included within the invention.

[0064] Furthermore, it should be understood that although this specification describes embodiments, not every embodiment contains only one independent technical solution. This narrative style is merely for clarity. Those skilled in the art should consider the specification as a whole, and the technical solutions in each embodiment can also be appropriately combined to form other embodiments that can be understood by those skilled in the art.

Claims

1. A digital measurement method for oil sludge thickness in oil pans, characterized in that, Including the following steps: The surface of the unused new oil pan is scanned using a range scanner, and the coordinates of the measurement points on the oil pan are determined based on the scan data. Using a distance measuring scanner, the metal substrate of the new oil pan corresponding to the determined measurement point is measured according to the preset scanning path, and the measurement result is used as the reference distance. The distance is measured by using a distance measuring scanner to measure the measurement points on the oil pan covered with sludge after the test, following a preset scanning path. Based on the reference distance, the measured distance, and combined with temperature correction, the sludge thickness of the oil pan to be tested is calculated.

2. The digital measurement method for oil sludge thickness in oil pans according to claim 1, characterized in that, The surfaces to be tested include the sides and bottom of the new oil pan.

3. The digital measurement method for oil sludge thickness in oil pans according to claim 1, characterized in that, The reference distance is the distance between multiple measurement points on the new oil pan, and the measurement distance is the distance between multiple measurement points on the oil pan to be tested.

4. The digital measurement method for oil sludge thickness in oil pans according to claim 1, characterized in that, The calculation of the sludge thickness in the oil sump under test, based on the reference distance, the measured distance, and combined with temperature correction, includes: The initial sludge thickness at each measurement point of the oil pan under test is calculated based on the reference distance and the measurement distance. Then, the initial sludge thickness at each measurement point is compensated by correcting the temperature based on the temperature data at the current measurement time, and finally the final sludge thickness at each measurement point is obtained.

5. The digital measurement method for oil sludge thickness in oil pans according to claim 4, characterized in that, After the step of calculating the sludge thickness of the oil pan to be measured based on the reference distance, the measured distance, and temperature correction, the method further includes: The final sludge thickness at each measurement point in the oil pan to be tested is associated with the measurement point coordinates, measurement time, and measurement area identifier to form a complete sludge thickness data set, which is stored in the cloud and / or local storage devices.

6. The digital measurement method for oil sludge thickness in oil pans according to claim 5, characterized in that, After the complete sludge thickness data set is generated, a thermal map of the overall thickness distribution of the oil pan is further generated, which visually and intuitively presents the overall distribution of sludge in the oil pan.

7. The digital measurement method for oil sludge thickness in oil pans according to claim 1, characterized in that, The ranging scanner is a non-contact ranging device, including at least a laser rangefinder. When using a laser rangefinder for ranging, laser triangulation is used for ranging.

8. The digital measurement method for oil sludge thickness in oil pans according to claim 1, characterized in that, The ranging scanner is driven by a drive mechanism to move along a preset scanning path to perform scanning measurements.

9. The digital measurement method for oil sludge thickness in oil pans according to claim 1, characterized in that, During the scanning measurement, the ranging scanner uses a temperature compensation module to synchronously collect the ambient temperature at the time of measurement.

10. A digital measuring device for oil sludge thickness in oil pans, characterized in that, A digital measurement method for oil pan sludge thickness as described in any one of claims 1-9 includes a measuring box, a rigid anti-vibration support, an oil pan fixing fixture, a distance measuring scanner, a signal processing controller, a temperature compensation module, and a driving device for moving the distance measuring scanner along a preset scanning path within the measuring box; the oil pan fixing fixture is arranged on the upper surface of the rigid anti-vibration support, the distance measuring scanner is connected to the signal processing controller, and the temperature compensation module is installed inside the measuring box; Preferably, it also includes an LED cold light source and a power supply. The LED cold light source is arranged on the top inside the measuring box, and the power supply is used to provide power to the electrical equipment of the measuring device and is arranged on the inner side wall surface of the measuring box.

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