Automated Caulking Apparatus for Engine Fluid Passage Sealing
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Solution Overview
Problem
Existing engine manufacturing processes face inefficiencies in automatically closing fluid passages in cylinder blocks and cylinder heads, requiring multiple manual or automated press-fitting operations to ensure watertightness, which is time-consuming and not adaptable to flexible manufacturing systems producing various engine models.
Innovation Solution
An automated apparatus comprising a conveyor unit, engine identifying unit, robot unit, and caulking device that recognizes engine models and precisely performs closing operations using a caulking device with a robot arm, enabling rapid and precise closure of fluid passages in cylinder blocks and cylinder heads.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If manual press-fitting operations are used to close fluid passage inlets, then watertightness can be ensured, but manufacturing productivity is reduced due to multiple operations being required
Solution Approach 1:
The system uses an engine model identifying unit to automatically recognize the engine type, and the control unit automatically selects and executes the appropriate closing operation parameters without manual intervention, enabling the system to serve itself and improving productivity while maintaining reliability
Solution Approach 2:
The position detecting unit provides feedback on the closing operation unit's position to the control unit, which adjusts the pressing force and position based on detected engine model characteristics, ensuring watertightness while optimizing the number of operations required
2Productivity
If automated press-fitting apparatus is used to improve productivity, then manufacturing efficiency increases, but adaptability to flexible manufacturing systems producing various engine models is reduced
Solution Approach 1:
The system dynamically adapts to different engine models by using the engine model identifying unit to recognize the specific engine type, then the control unit adjusts the closing operation parameters (position, force, number of operations) accordingly, enabling the automated apparatus to handle various engine models efficiently
Solution Approach 2:
The automated apparatus is designed with multi-functionality to handle multiple engine models through the engine model identifying unit and adaptable control unit, allowing a single apparatus to perform diverse closing operations across different engine types while maintaining high productivity
3Reliability
If multiple press-fitting operations are performed to ensure watertightness, then sealing reliability is improved, but the time required for the closing operation increases
Solution Approach 1:
The control unit changes operational parameters (pressing force, position, number of operations) based on the detected engine model characteristics, optimizing the closing process to achieve adequate sealing reliability with the minimum necessary operations, thereby reducing time loss
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
Enhances manufacturing productivity by enabling rapid and precise closure of fluid passages across various engine models, improving efficiency and adaptability in flexible manufacturing systems.
Implementation Method 1
A robot unit moves an arm thereof to a position at which the closing operation is performed and which is preset depending on the engine model
Implementation Method 2
a closing operation unit which is mounted to the housing to perform the operation of closing the inlet of the fluid passage of the engine
Data Source
AI summary
An apparatus for closing fluid passages of engines is disclosed. Preferred apparatus of the invention are able to automatically recognize inlets of several fluid passages, which exist in each engine at different positions depending on the engine model, and rapidly and precisely perform operation of closing the inlets at the recognized positions using a caulking device and a robot, thus enhancing manufacturing productivity of the engine.