Engine Block Insert Height Measurement Fixture
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Solution Overview
Problem
Existing methods for remanufacturing engine blocks fail to accurately verify the height of inserts around cylinder bores relative to the deck surface, leading to potential misalignment and performance issues or shortened engine life due to increased production costs associated with complex setups like motor and magnetic field generators.
Innovation Solution
A method involving a detachable fixture with fasteners and a dial gauge to determine the height of the insert's upper surface relative to the top deck surface of the engine block, using notches on the fixture to access and measure local heights with the dial gauge's probe, allowing for accurate positioning without the need for costly equipment.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If motor and magnetic field generator setup is used to measure insert height, then measurement precision is improved, but device complexity and production cost increase
Solution Approach 1:
The patent replaces complex motor and magnetic field generator systems with a simple mechanical dial gauge and fixture assembly. The dial gauge with probe provides direct mechanical measurement of insert height, eliminating the need for expensive and complex electromagnetic measurement systems while maintaining adequate measurement precision for the application.
Solution Approach 2:
The patent employs inexpensive, simple fixtures and dial gauges that can be easily replaced or recalibrated, rather than investing in expensive, complex measurement equipment. The fixture is a simple mechanical assembly that can be manufactured at low cost and discarded or replaced if needed, significantly reducing production costs.
2Device complexity
If insert height verification is delayed until after cylinder liner assembly installation, then device complexity is reduced, but ease of repair worsens due to extensive disassembly required
Solution Approach 1:
The patent performs insert height verification as a preliminary step before installing the cylinder liner assembly. The fixture is installed on the engine block and the dial gauge measures insert height while the insert is still accessible. This preliminary measurement allows any necessary adjustments to be made before final assembly, avoiding the need for extensive disassembly later for repair or adjustment.
Solution Approach 2:
The patent introduces a specialized measurement fixture as an intermediary tool that enables access to and measurement of the insert height in a position that is accessible before final assembly. The fixture acts as a mediator between the measurement requirement and the physical constraints of the engine block, allowing verification without requiring disassembly of surrounding components.
3Manufacturing precision
If multiple measurement points are taken around the insert, then manufacturing precision is improved, but loss of time increases due to multiple measurements
Solution Approach 1:
The patent divides the measurement process into multiple discrete measurement points around the insert circumference. The fixture includes multiple notches that position the dial gauge probe at specific locations (e.g., 12 o'clock, 3 o'clock, 6 o'clock, 9 o'clock positions). Each location is measured separately and recorded, allowing comprehensive verification of insert height uniformity while maintaining an organized and efficient measurement sequence.
Solution Approach 2:
The patent measures at multiple locations around the insert, which may be more measurements than strictly necessary for basic verification. This excessive action ensures thorough verification of insert height uniformity and detects any localized deviations or irregularities that a single measurement might miss, thereby improving manufacturing precision and quality assurance.
Data Source
AI summary
The present disclosure is related to a method of determining a height of an upper surface of an insert relative to a top deck surface of a cylinder block. The method includes detachably coupling a fixture to the top deck surface of the cylinder block. The method also includes disposing a dial gauge on the top deck surface adjacent to each of a plurality of notches defined in the fixture. The method includes inserting a probe of a dial gauge through each of the plurality of notches to contact each of corresponding portions of the upper surface of the insert. The method also includes determining local heights of the upper surface of the insert relative to the top deck surface at the corresponding portions of the upper surface. The height of upper surface of the insert relative to the top deck surface is determined based on the local heights.