Cylinder Block Positioning Fixture for Multi-Surface Machining
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Solution Overview
Problem
The machining of cylinder crankcases is complex due to the need for precise positioning and accessibility of multiple surfaces, including cylinder bores, crankshaft bores, and oil pan sealing surfaces, which requires intricate clamping and alignment procedures, making it difficult to achieve efficient and accurate machining.
Innovation Solution
A positioning device with a machining through-opening and auxiliary device that allows for the cylinder crankcase to be clamped and aligned in a way that multiple machining tools can access the surfaces without changing the crankcase's position, using a support element with pivotable clamping units and alignment elements, and an auxiliary device with clamping surfaces that interact with the positioning device for secure fixation and alignment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If the cylinder crankcase is clamped and repositioned for different machining operations, then all surfaces can be accessed, but the positioning and clamping complexity increases significantly
Solution Approach 1:
The support element is designed with multiple functions: it provides support for the cylinder crankcase, contains a machining through-opening for tool access, and incorporates alignment elements. This multi-functional design eliminates the need for multiple positioning devices and repositioning operations, resolving the contradiction between surface accessibility and positioning complexity
Solution Approach 2:
The support element is divided into functional segments: a support surface for clamping, a machining through-opening for tool access, and alignment elements. This segmentation allows each feature to serve its specific purpose while integrated into a single device, reducing overall system complexity while maintaining versatility
2Adaptability or versatility
If the cylinder crankcase is repositioned between machining operations, then all surfaces can be machined, but the machining time increases
Solution Approach 1:
The machining through-opening in the support element enables continuous machining operations without interruption. The cylinder crankcase remains clamped in one position while machining tools access different surfaces through the opening, eliminating downtime for repositioning and maintaining continuous productive action
Solution Approach 2:
The support element is pre-configured with the machining through-opening and alignment features before the machining process begins. This preliminary preparation allows all necessary machining operations to be performed from a single clamped position, preventing time-consuming repositioning during the machining sequence
3Manufacturing precision
If multiple clamping units are used to secure the cylinder crankcase, then positioning accuracy improves, but the device complexity increases
Solution Approach 1:
Multiple clamping functions are merged into a single support element structure. The support element integrates the support surface, machining through-opening, and alignment elements into one unified component, achieving accurate positioning without requiring separate complex clamping devices for each function
Data Source
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AI summary
A positioning device (16) for a cylinder block (2) has a support element (20) which is pivotable about a pivot axis (23) by means of at least one electric drive motor (22). At least one clamping unit (35, 36) is arranged on the support element (20) for fixing the cylinder block (2) connected to an auxiliary device (19). The support element (20) has a processing through opening (25) for a processing tool (27) for processing at least one cylinder bore (26) of the cylinder block (2). This enables that an oil sump side and/or a crankshaft bore of the cylinder block (2) can be processed, in addition to the at least one cylinder bore (26). The positioning device (16) and the associated auxiliary device (19) thus enable a simple and economic processing of cylinder blocks (2).