Engine Connecting Rod Assembly Machining on a Single CNC Mill-Turn
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Solution Overview
Problem
Current manufacturing methods for engine connection rods require multiple machines and complex processes, increasing time, labor, and costs due to the need for separate machining of the rod and cap components.
Innovation Solution
A CNC mill turn machine is used to simultaneously machine both the rod and cap components, incorporating tools for turning, milling, and drilling, with a controller managing the machine's movements to perform various operations without removing the components from their mounts, thereby integrating multiple machining steps into a single process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple separate machines are used to machine the rod and cap components, then each component can be machined with dedicated tools, but the manufacturing process becomes complex and production time increases
Solution Approach 1:
The patent combines multiple separate machining machines into a single integrated machine system. The rod and cap are mounted on separate mounts that can be independently positioned and machined by a shared spindle head, eliminating the need for multiple separate machines while maintaining machining precision through coordinated control of the mounts and spindle head.
Solution Approach 2:
The spindle head is designed as a universal tool that can machine both the rod and cap components using the same tooling. The system achieves multi-functionality by enabling a single spindle head to perform machining operations on two different components mounted on separate rotating mounts, reducing device complexity while maintaining manufacturing precision.
2Manufacturing precision
If separate machining processes are used for the rod and cap, then each component receives dedicated attention, but labor and production time increase
Solution Approach 1:
The system enables continuous machining operations by allowing the spindle head to machine the rod on one mount and then immediately machine the cap on another mount without interrupting the production flow. The independent rotating mounts and coordinated spindle head movements ensure that useful machining action continues uninterrupted, improving productivity while maintaining component quality.
Solution Approach 2:
The machining system is segmented into independent functional units: separate rotating mounts for the rod and cap, and a shared spindle head that can service both mounts. This segmentation allows simultaneous or sequential machining of both components without interference, improving production efficiency while ensuring each component receives dedicated machining attention.
3Adaptability or versatility
If multiple machines are deployed, then comprehensive machining capabilities are available, but overall manufacturing costs increase
Solution Approach 1:
The patent implements a universal machining system where a single spindle head with interchangeable tools can machine both rod and cap components. This multi-functional approach provides comprehensive machining capabilities equivalent to multiple dedicated machines while reducing the total number of machines required, thereby lowering manufacturing costs while maintaining adaptability.
Solution Approach 2:
The system merges the functionality of multiple separate machining machines into one integrated platform. By combining the rod mount, cap mount, and shared spindle head into a single coordinated system, the patent achieves comprehensive machining capabilities with reduced equipment investment and lower overall manufacturing costs.
Data Source
AI summary
A method of manufacturing an engine connecting rod includes mounting a rod on a first mount configured to rotate, mounting a cap on a second mount configured to rotate, positioning a spindle head such that a tool of the spindle head contacts a first connecting end of the rod, machining the first connecting end by spinning the first mount, machining the first connecting end by moving the spindle head, positioning the spindle head such that the tool of the spindle head contacts a second connecting end of the cap configured to be coupled to the first connecting end, machining the second connecting end by spinning the second mount, and machining the second connecting end by moving the spindle head. The spindle head is moveable in a first direction extending between the first and second mounts, a second direction perpendicular to the first direction, a third direction perpendicular to the first and second directions, and rotatable about an axis.