Crankshaft Pre-Balancing via 3D Scan and Mass Distribution Modeling
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Solution Overview
Problem
Existing manufacturing processes for crankshafts are unable to accurately account for die wear and unique variations in mass distribution, leading to improper placement of the machining axis and potential scrapping of crankshafts due to unbalanced conditions.
Innovation Solution
A method involving a three-dimensional scan of the crankshaft to generate a model, which defines a pre-balancing machining axis, ensuring accurate alignment and machining operations to achieve proper balance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional spinning processes are used for pre-balancing, then the process is simple and quick, but the mass distribution cannot be accurately determined and die wear variations cannot be accounted for
Solution Approach 1:
The patent replaces traditional mechanical spinning measurement systems with a 3D optical scanning system. The method uses a 3D scanner to capture the crankshaft geometry and compute mass distribution through software algorithms, substituting mechanical measurement with optical-field-based measurement to achieve higher precision without mechanical contact.
Solution Approach 2:
The patent creates a digital 3D model (copy) of the physical crankshaft through scanning. This digital replica allows for virtual mass distribution analysis and machining axis determination without physically altering or extensively measuring the actual component, enabling precise pre-balancing planning before actual machining occurs.
2Manufacturing precision
If the machining axis is improperly placed, then pre-balancing can be completed quickly, but material over-removal occurs and the crankshaft may be scrapped
Solution Approach 1:
The patent performs preliminary 3D scanning and computational analysis to determine the optimal machining axis before any material removal occurs. By pre-calculating the precise axis location based on the actual mass distribution, the system ensures that subsequent machining operations remove only the necessary amount of material while achieving proper balance, preventing both over-removal and insufficient balancing.
3Adaptability or versatility
If die wear variations are not accounted for, then the manufacturing process is simpler, but each crankshaft has unique mass distribution variations leading to balancing issues
Solution Approach 1:
The patent applies local quality by scanning and analyzing each crankshaft's specific mass distribution characteristics individually rather than assuming uniformity across all crankshafts from the same die set. The system identifies and accommodates local variations in mass distribution caused by die wear, ensuring each component is pre-balanced according to its unique characteristics.
Data Source
AI summary
A computer program and method for pre-balancing a crankshaft. The method includes receiving data related to a three dimensional scan of the crankshaft; generating a model based on the data; and providing instructions, based on the model, for defining a pre-balancing machining axis.