Deep Rolling Crankshaft Measurement via Shearing Arm Geometry
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Solution Overview
Problem
Existing deep rolling procedures face challenges in accurately measuring the engaging depth of deep rollers in crankshaft recesses and radii, and the deep rolling force, due to space constraints and contamination risks near the workpiece surface, with pneumatic sensing methods being less direct and prone to inaccuracy.
Innovation Solution
Measuring the engaging depth by determining the reciprocal position of shearing arms at a rotating joint, and measuring the deep rolling force through wire strain gauges on the shearing arms, allowing for precise and contamination-free data collection without occupying valuable machine space.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a measuring device is attached near the deep rolling contact point to measure engaging depth, then measurement accuracy is improved, but the risk of contamination increases and space availability is reduced
Solution Approach 1:
The measurement function is transferred from the contact zone to the rotating joint, utilizing the angular position dimension of the shearing arms to indirectly determine engaging depth. This spatial relocation eliminates contamination exposure while preserving measurement capability through geometric relationship calculation.
Solution Approach 2:
The angular position of the shearing arms at the rotating joint serves as an intermediary measurement parameter. Instead of directly measuring engaging depth at the contaminated contact point, the system measures arm position and calculates depth through the known geometric relationship, acting as a contamination-free intermediary.
2Measurement precision
If measuring devices are added to the deep rolling tool, then measurement capability is improved, but the device complexity increases
Solution Approach 1:
The rotating joint and shearing arm structure serve multiple functions: mechanical articulation for deep rolling operation and measurement reference for engaging depth determination. This multi-functionality avoids adding separate measurement components, reducing overall device complexity while enabling precise measurement.
Solution Approach 2:
The shearing arm's own deflection under deep rolling force serves as the measurement indicator. The arm's structural deformation, caused by the measurement target force itself, provides the measurement signal through wire strain gauges, eliminating the need for separate force sensing components.
3Measurement precision
If wire strain gauges are attached to the shearing arm to measure deep rolling force, then measurement accuracy is improved, but the device complexity increases
Solution Approach 1:
The mechanical deflection of the shearing arm under load is converted into an electrical signal through wire strain gauges. This substitution transforms direct mechanical force measurement into an electrical measurement system, providing higher accuracy and easier signal processing while maintaining relatively simple implementation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables accurate control of the deep rolling process with precise measurements of engaging depth and deep rolling force, maintaining easy accessibility and high resolution, thus optimizing the deep rolling unit's performance.
Implementation Method 1
a wire strain gauge is attached to one of the two long sides of a shearing arm, which measures the deflection of the shearing arm when subjected to the deep rolling force
Data Source
AI summary
The invention relates to a method for deep rolling the passes or radii on the transitions between journal and cheeks or flanges of crankshafts by means of a deep rolling device (1) of a deep rolling machine, said deep rolling device having a lazy tongs-type design. The deep rolling device (1) has two tongs arms (2, 3) that are articulated to each other via a pivot joint (24). The corresponding outer ends (4, 5, 9, 10) of the tongs arms (2, 3) are provided with a deep rolling tool (6) or a force generator (11) for generating the deep rolling force. A measuring tape (18) and a sensor (19) which are provided on the pivot joint (24) are used to measure the impression depth of the deep rolling rollers (12) under the effect of the deep rolling force. A measuring device (22) mounted on the exterior (21) of a tongs arm (2) is used to measure the degree by which the tongs arm (2) bends under the effect of the deep rolling force.