Hybrid Cylinder Bore Grooving With Automatic Depth Positioning
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for cutting oil grooves in cylinder bores, such as laser processing and mechanical processing, face challenges in precision and efficiency due to equipment costs, complexity, and difficulty in maintaining constant depth and alignment, leading to increased processing time and potential engine efficiency deterioration.
Innovation Solution
A hybrid cutting apparatus with a grooving tool and honing tool integrated, featuring a driving motor, cam member, harmonic drive, piezo actuator, and tool position control system that automatically adjusts the grooving tool's position based on distance measurements, allowing for precise and efficient groove cutting without the need for separate tool replacements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If laser processing method is used to form oil groove, then groove depth can be controlled, but equipment cost increases and equipment size becomes large
Solution Approach 1:
The patent combines the honing tool and grooving tool into a single integrated tool assembly that can perform both honing and groove formation operations. This merging eliminates the need for separate laser processing equipment and multiple tool changes, reducing equipment cost and complexity while maintaining groove depth control through the integrated tool design
Solution Approach 2:
The patent replaces the laser processing system with a mechanical grooving tool that uses controlled mechanical contact to form the oil groove. This substitution eliminates the need for expensive and large-scale laser equipment while achieving comparable groove formation through mechanical means, specifically using a grooving tool with controlled engagement depth
2Device complexity
If mechanical processing method is used to form oil groove, then equipment cost is reduced, but processing time increases due to measurement and alignment requirements
Solution Approach 1:
The patent incorporates preliminary alignment features in the tool design, including a positioning mechanism that automatically aligns the grooving tool with the cylinder bore center. This preliminary action eliminates the need for time-consuming measurement and alignment procedures that would otherwise be required, reducing processing time while maintaining the cost advantages of mechanical processing
Solution Approach 2:
The tool assembly includes self-aligning and self-positioning mechanisms that automatically adjust the tool position and orientation without requiring external measurement equipment or manual alignment. The honing tool and grooving tool are designed to work together in a sequence where the honing operation prepares the surface and the grooving operation automatically follows, with the tool itself performing the alignment function
3Device complexity
If mechanical processing method is used to form oil groove, then equipment simplicity is improved, but groove depth consistency deteriorates due to axis alignment sensitivity
Solution Approach 1:
The patent incorporates a control system that monitors the grooving process and provides feedback to maintain consistent groove depth. The system measures parameters such as tool engagement depth and adjusts the machining parameters in real-time to compensate for any deviations, ensuring uniform groove depth across the entire cylinder bore surface while maintaining simple mechanical equipment
Solution Approach 2:
The patent uses a dynamic control mechanism that allows the grooving tool to adjust its position and engagement depth during the machining process. The tool is designed with controlled flexibility and movement capabilities that enable it to adapt to slight variations in the cylinder bore geometry, maintaining consistent groove depth even when perfect axis alignment is not achieved
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 precise and effective grooving processing even if the cylinder bore is not circular or if the grooving tool is not accurately centered, enhancing work efficiency and productivity by allowing continuous honing and grooving without tool replacement.
Implementation Method 1
The moving unit may include a piezo actuator
Implementation Method 2
a cam member having one end that is concentrically connected with a shaft of the driving motor and the other end that is connected with the grooving tool to be eccentric from the shaft of the driving motor
Implementation Method 3
a harmonic drive that is installed between the driving motor and the cam member to decelerate rotation power
Implementation Method 4
a cutting tip that performs a cutting processing of a groove in the cylinder bore
Data Source
Figure 1
Figure 2
Figure 3
AI summary
A hybrid cutting apparatus and a method of cutting a groove are provided. The hybrid cutting apparatus includes: a main body that is connected with a rotation shaft of a machine tool; a grooving tool that is coupled to one side of the main body and for forming a groove at an interior circumference of a workpiece; and a tool position control means that controls a position of the grooving tool to correspond to a cutting surface position of the workpiece.