Crankshaft End Machining with Alternating Stations

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Solution Overview

Problem

Current machining technologies for crankshaft ends face challenges in balancing productivity and flexibility, leading to significant downtimes due to asymmetrical machining times and inefficient unloading, dismounting, loading, and mounting processes, which are not addressed effectively in existing solutions.

Innovation Solution

A machine with two machining heads and stations that alternates machining between spike and flange configurations, allowing simultaneous unloading, dismounting, loading, and mounting of crankshafts without adding to machining time, utilizing control means to manage the process and ensure continuous operation by alternating machining heads between stations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If dedicated transfer machines are used for high production, then productivity is improved, but flexibility is reduced

Engineering Contradiction:

Improveproduction volumeVSAvoidflexibility for adapting to changes in crankshaft characteristics

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The machine is divided into multiple machining stations (first and second machining stations) that can independently process different crankshaft ends. This segmentation allows the system to maintain high productivity through parallel processing while adapting to different crankshaft configurations by selectively activating appropriate stations.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The machining system incorporates dynamic tool selection and station activation capabilities, allowing the machine to adapt its configuration based on the specific crankshaft characteristics being processed. The control means enables dynamic switching between different machining operations and station configurations.

Inventive Principle:

Principle #15Dynamics

2Adaptability or versatility

If machining centres are used for flexibility, then adaptability is improved, but productivity is reduced

Engineering Contradiction:

Improveflexibility for fast assimilation of changes in crankshaft characteristicsVSAvoidproduction volume

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

By segmenting the machining process into multiple independent stations, the system achieves both the flexibility of machining centers and the productivity of transfer machines. Each station can be independently configured and controlled, enabling rapid adaptation while maintaining continuous production flow.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The multi-station configuration enables continuous machining operations where multiple crankshaft ends are processed simultaneously or in overlapping sequences, eliminating idle time and maintaining continuous productive action while accommodating various crankshaft types.

Inventive Principle:

Principle #20Continuity of useful action

3Ease of operation

If unloading and loading tasks are performed sequentially, then operational simplicity is maintained, but downtime increases

Engineering Contradiction:

Improvesimplicity of unloading/loading processVSAvoiddowntime during unloading and loading

Core Design Contradiction:

Ease of operationVSLoss of time

Solution Approach 1:

The system prepares the next crankshaft for loading at one station while simultaneously completing machining and unloading at another station. This preliminary preparation of subsequent operations eliminates idle downtime while maintaining operational simplicity through automated control sequences.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By overlapping unloading, loading, and machining operations across multiple stations, the system ensures that productive action continues without interruption. The control means coordinates these simultaneous operations to maintain simplicity while eliminating downtime.

Inventive Principle:

Principle #20Continuity of useful action

4Device complexity

If machining time for flange end is used as reference, then machining sequence is simplified, but total machining time increases due to idle periods

Engineering Contradiction:

Improvesimplicity of machining sequenceVSAvoiddowntime due to asymmetrical machining times

Core Design Contradiction:

Device complexityVSLoss of time

Solution Approach 1:

The system implements periodic alternating operations between spike end and flange end machining at different stations. This rhythmic coordination of machining cycles balances the asymmetrical processing times, ensuring that faster operations complete and prepare for next tasks while slower operations are simultaneously underway at other stations, eliminating idle periods.

Inventive Principle:

Principle #19Periodic action

Data Source

PatentUS8468695B2Machine and method for machining crankshaft ends

Publication Date: 2013.06.25 ETXE TAR SA

AI summary

A machine which comprises two machining heads (1, 2) designed to machine crankshaft (5) ends and two machining stations (3, 4) designed to receive and secure at least one crankshaft (5). The machining stations (3, 4) are disposed between the two machining heads (1, 2). The crankshafts (5) are mounted in such a manner as to be disposed parallel to each other and oriented at 180°.