Multi-Station Fuel Injector Drilling System with Optical Measurement
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Solution Overview
Problem
Traditional production equipment designs for fuel injector nozzles often compromise on either nozzle flow variation, cycle time, efficiency, flexibility, or change-over times, failing to achieve optimal control over hole diameter, position, geometric accuracy, and surface finish simultaneously.
Innovation Solution
A multi-station machine tool system integrating measurement, cutting, and laser drilling stations with robotic part transfer and positioning systems, capable of creating small holes with multiple diameters, allowing for high-accuracy and high-productivity drilling of fuel injector nozzles by determining whether to measure or drill based on pre-existing features.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional production equipment designs are used, then some characteristics like nozzle flow variation control can be achieved, but production economics, cycle time, efficiency, change-over time, and flexibility deteriorate
Solution Approach 1:
The system is divided into multiple independent stations (measurement station, first drilling station, second drilling station) that can operate in sequence. Each station performs a specific function with high precision, while the overall system maintains high productivity through automated part transfer and parallel processing capabilities.
Solution Approach 2:
The machine tool system is designed to handle multiple operations (measurement, step-hole drilling, through-hole drilling) within a single integrated system. The system can accommodate different part types and hole configurations, providing both precision and versatility without requiring multiple separate machines.
2Manufacturing precision
If traditional production equipment designs are used, then some characteristics can be achieved, but cycle time and efficiency deteriorate
Solution Approach 1:
The measurement station performs preliminary measurement of the raw part surface or existing step-hole before the drilling operations begin. This allows the control system to pre-calculate precise positioning and drilling parameters, eliminating measurement time from the critical drilling cycle and enabling faster, more accurate production.
Solution Approach 2:
The system maintains continuous productive action through automated robotic part transfer between stations and overlapping operation cycles. While one part is being measured or drilled at one station, other parts can be processed at different stations, minimizing idle time and maintaining high efficiency throughout the production cycle.
3Productivity
If traditional production equipment designs are used, then production efficiency can be maintained, but change-over time and flexibility deteriorate
Solution Approach 1:
The system incorporates programmable control and automated tool changing capabilities that allow rapid reconfiguration between different part types and hole patterns. The robotic part transfer system and positioning mechanisms can be dynamically adjusted through software programming, enabling quick change-overs without sacrificing production efficiency.
Solution Approach 2:
The system uses programmable parameters for hole positions, diameters, depths, and drilling speeds that can be modified through software without physical reconfiguration. This allows the same hardware system to efficiently produce different part designs by simply changing the control program, providing both high productivity and design flexibility.
4Manufacturing precision
If tight tolerances are enforced for hole diameter, position, and geometric accuracy, then nozzle performance is improved, but manufacturing complexity and cost increase
Solution Approach 1:
The system replaces complex mechanical measurement and positioning systems with optical measurement technology and computer-controlled positioning. The measurement station uses optical sensors to precisely measure part surfaces and existing holes, while the control system calculates and executes precise drilling positions, achieving high geometric accuracy through software-based control rather than complex mechanical adjustments.
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
The system achieves high-accuracy, high-productivity, and flexibility in creating small holes with controlled diameters, enhancing production economics by optimizing cycle time and accommodating design changes while maintaining tight tolerances and surface quality.
Implementation Method 1
a second drilling unit at a second station... laser drilling (flow-hole creating) stations
Data Source
Figure 1A
Figure 1B
Figure 1C
AI summary
The present disclosure is directed toward a machine tool configured to perform small- scale, high-accuracy drilling operations for small-hole applications. The small-hole applications for which the machine tool is designed includes holes with one or more diameters. A part may have a larger-diameter hole that penetrates through a fraction of the thickness of a part and a smaller-diameter hole that penetrates from the bottom of the larger-diameter hole through the remainder of the part thickness. Additionally, the machine tool may be used with parts in any of the following categories: (i) both the step-hole and the flow-hole are created using the machine tool; or, (ii) the step-hole is created with an up-stream process and the machine tool may accept the part, measure the step- holes and create the flow-holes; or, (iii) no step-hole is used and the machine tool may accept the part, measure the raw surface and create the flow-holes.