Laser-Based Carting System for Engine Alignment
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current methods for preparing and transporting mechanical power sources, such as engines and motors, for dynamometer testing are inefficient and prone to errors, leading to inaccuracies and increased downtime due to the complexity of aligning and connecting these units with testing equipment.
Innovation Solution
A laser-based carting system that uses 3D modeling to pre-assemble carts and end-effectors within a four-sided envelope, allowing for precise alignment and orientation of engines and transmissions using lasers, scales, and adjustable stanchions, enabling accurate and efficient mounting and transportation to dynamometer cells.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If conventional methods (overhead crane or wheeled pallet) are used to transport and align engine assemblies to the dynamometer room, then the engine can be moved to the testing location, but the process is time-consuming, complex, and prone to alignment errors
Solution Approach 1:
The patent replaces conventional mechanical alignment methods (overhead crane positioning, wheeled pallet systems) with a laser-based optical measurement system. Lasers provide precise alignment references that guide the positioning of engine assemblies, eliminating the need for complex mechanical positioning mechanisms and reducing alignment time significantly.
Solution Approach 2:
The patent introduces laser alignment references and measurement tools as intermediaries between the transport system and the dynamometer testing equipment. These laser references serve as a common coordinate system that facilitates accurate alignment without requiring direct mechanical coupling or complex positioning mechanisms.
2Reliability
If manual alignment and connection processes are used, then the engine can be connected to the dynamometer, but errors occur in connecting testing equipment to the power source
Solution Approach 1:
The patent replaces manual alignment procedures with an automated laser-based measurement and alignment system. The laser provides precise optical references that eliminate human error in alignment, ensuring accurate connection between the engine assembly and dynamometer testing equipment.
Solution Approach 2:
The patent implements a feedback mechanism where laser measurement tools continuously monitor the position and orientation of the engine assembly during alignment. This real-time feedback allows operators to make precise adjustments to achieve accurate alignment, ensuring reliable connection to the dynamometer.
3Ease of operation
If extensive adjustments are made during setup, then the engine can be positioned for testing, but the process becomes complex and time-consuming
Solution Approach 1:
The patent replaces complex mechanical adjustment mechanisms with a laser-based optical alignment system. The laser provides clear visual references that simplify the alignment process, allowing operators to position engine assemblies accurately without requiring extensive manual adjustments or complex positioning mechanisms.
Solution Approach 2:
The patent implements preliminary laser alignment reference setup before the engine assembly is positioned. This preliminary action establishes the alignment criteria in advance, guiding the positioning process and reducing the need for extensive adjustments during setup.
4Productivity
If the engine requires re-orientation within the dynamometer cell, then proper testing orientation can be achieved, but additional time is lost and efficiency is reduced
Solution Approach 1:
The patent performs preliminary laser-based alignment and orientation of the engine assembly during the transport and setup phase, before the engine enters the dynamometer cell. This ensures the engine is correctly oriented in advance, eliminating the need for time-consuming re-orientation operations within the dynamometer cell.
Solution Approach 2:
The patent uses laser alignment references as intermediaries to transfer precise orientation information from the setup area to the dynamometer cell. This ensures consistent alignment without requiring physical re-orientation mechanisms within the testing cell.
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
This solution reduces setup time, minimizes errors, and eliminates the need for re-orientation within the dynamometer cell, enhancing the efficiency and accuracy of the testing process by ensuring proper alignment and orientation of mechanical power sources before testing.
Implementation Method 1
utilizing a laser based carting cell, which integrates mechanical details to scan features of the properties with lasers
Data Source
AI summary
A method of aligning a property for testing in a dynamometer cell is provided, including the steps of: mounting a laser travel car to each of four risers in a repositionable manner; mounting a laser to each of the laser travel cars in a repositionable manner; securing a dyno cart into a cart receiving station between the four risers; calibrating each of the lasers; preparing the dyno cart to receive the property; mounting the property to the dyno cart; orienting the various lasers based, at least in part, upon predetermined optimal alignment dimensions to thereby provide a set of target locations; orienting the property such that predetermined locations of the property align with the set of target locations to ensure appropriate property orientation during testing; and removing the dyno cart from the cart receiving station for delivery to the dynamometer cell.