Modular Crankshaft Twisting for Precise Angular Positioning
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Solution Overview
Problem
Current crankshaft twisting equipment causes significant deformations due to two-phase operation and complex tooling, requiring expensive and time-consuming calibration, especially for engines with nonplanar parting surfaces and unique crankpin arrangements like five-cylinder engines.
Innovation Solution
The equipment employs modular twisting modules with independently rotating and linearly displacing tools that perform all rotations simultaneously, reducing stressing and allowing precise dimensional tolerances without subsequent calibration, using a combination of hydraulic and electrical driving mechanisms for efficient crankpin positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If two-phase twisting operation is used with traditional press equipment, then the crankshaft can be twisted to required angular positions, but significant deformations occur requiring expensive and time-consuming calibration
Solution Approach 1:
The twisting operation is divided into multiple independent twisting modules, each capable of performing the twisting action simultaneously. This segmentation allows all crankpins to be twisted in parallel during a single phase, eliminating the need for sequential two-phase operation and subsequent calibration.
Solution Approach 2:
Multiple twisting modules are combined into a single integrated system that performs all twisting operations simultaneously in one phase. The merging of multiple twisting functions into one coordinated operation eliminates the need for separate calibration phase, improving both precision and productivity.
2Manufacturing precision
If two-phase twisting operation is used with traditional press equipment, then the crankshaft can be twisted to required angular positions, but expensive and time-consuming calibration is required to achieve required tolerances
Solution Approach 1:
The tooling is segmented into multiple independent twisting modules, each with its own driving mechanism. This modular segmentation allows precise control of each module independently, achieving required tolerances without complex calibration procedures while maintaining manageable device complexity through standardization.
Solution Approach 2:
The twisting modules incorporate adjustable and movable components that can be dynamically positioned and controlled. This dynamic capability allows the system to adapt to different crankshaft configurations and achieve precise tolerances through real-time adjustment rather than complex pre-calibration.
3Adaptability or versatility
If multiple twisting shafts are added to accommodate five-cylinder engines with 72° crankpin angles, then all crankpins can be positioned correctly, but equipment complexity increases
Solution Approach 1:
Each twisting module is designed as a universal unit capable of handling different crankpin configurations. The modules can be arranged and configured to accommodate various engine types (3, 4, 5, 6, 8 cylinders) without requiring additional specialized shafts, as the same modular units can be adapted to different angular requirements.
Solution Approach 2:
The twisting modules incorporate adjustable mechanisms that allow dynamic reconfiguration for different crankpin angles and arrangements. This dynamic adaptability enables the system to handle five-cylinder engines with 72° angles and other configurations without adding permanent complex infrastructure, reducing overall device complexity.
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 approach minimizes deformations and simplifies tooling design, reducing process complexity and time, achieving precise dimensional tolerances and eliminating the need for final calibration, while accommodating various crankpin configurations with reduced equipment complexity.
Implementation Method 1
The crankshaft twisting equipment used today is formed primarily by a hydraulic press with a main cylinder
Implementation Method 2
Said twisting shafts transmit the rotation to a lower tool holder and are actuated by means of two or four twisting cylinders
Data Source
Figure 1a~1b
Figure 2a~2c
Figure 3a~3c
AI summary
The present invention relates to equipment and a method for twisting crankshafts (A), comprising three modules (1), each comprising an upper tool (1') and a lower tool (1"), both having an inner face by means of which they are facing one another, each tool (1', 1") having a cavity on said inner face the geometry of which corresponds with the outer shape of a crankpin of the crankshaft (A) to be twisted, such that the cavity defined by the facing tools (1', 1") of one and the same module (1) corresponds with the complete outer shape of the crankpin, where the tools (1', 1") of each module (1) are arranged on a supporting element (2) that can rotate independently with respect to an axis of rotation (3) coinciding with a longitudinal axis (A') of the crankshaft (A) when said crankshaft (A) is arranged in the equipment, where the tools (1', 1") of each module (1) can only effect a linear displacement with respect to the supporting element (2) in which they are arranged, said linear displacement being perpendicular to the axis of rotation (3).