Cylinder-Head Valve Train Assembly Without Head Flipping
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Solution Overview
Problem
The existing methods for assembling valve trains in cylinder-head assemblies are inefficient, often requiring manual labor and multiple equipment setups, and involve flipping the cylinder-head, which complicates the installation process and increases manufacturing costs.
Innovation Solution
An automated assembly system using two robots and an end effector with an adapter plate and pneumatic actuators to install spring caps, retainer keys, and valves into the cylinder-head without flipping it, ensuring precise alignment and compression of valve springs without the need for additional hardware or manufacturing steps.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual assembly methods are used for valve train installation, then flexibility and adaptability are maintained, but productivity is low and manufacturing precision is insufficient
Solution Approach 1:
The assembly system is divided into multiple specialized robots: a first robot for installing spring caps and retainer keys, and a second robot for installing valves. This segmentation allows each robot to perform its specific function efficiently while maintaining overall system productivity and precision without requiring a single complex automated system.
Solution Approach 2:
The cylinder head assembly fixture is designed to accommodate multiple cylinder head configurations and orientations. The fixture can position cylinder heads in different orientations (first orientation for spring cap installation, second orientation for valve installation) without requiring complete reconfiguration, providing universal applicability across different engine models.
2Ease of operation
If the cylinder-head is flipped over during assembly, then access to valve stems is improved, but manufacturing complexity increases and production time is extended
Solution Approach 1:
The fixture dynamically repositions the cylinder head between orientations during the assembly process. The cylinder head is initially positioned in a first orientation for spring cap and retainer key installation, then repositioned in a second orientation for valve installation. This dynamic repositioning maintains ease of operation while minimizing time loss compared to complete disassembly and reassembly.
Solution Approach 2:
Spring caps and retainer keys are installed on the valve stems while the cylinder head is in the first orientation, before the head is repositioned for valve installation. This preliminary action prepares the valve stems in advance, so that when the cylinder head is repositioned, the valves can be installed directly onto the pre-prepared stems without additional setup time.
3Manufacturing precision
If multiple separated cells or stations are used for valve installation, then manufacturing precision is improved, but device complexity and plant space requirements increase
Solution Approach 1:
Multiple assembly functions are merged into a single integrated fixture: spring cap installation, retainer key installation, and valve installation all occur in one fixture rather than requiring separate cells or stations. The fixture accommodates multiple cylinder head orientations and configurations, combining the functionality of what would traditionally require multiple separate assembly stations, thereby reducing plant space requirements while maintaining precision through specialized positioning for each operation.
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 streamlines the assembly process, reduces manufacturing complexity, and maintains the cylinder-head in a single position, enhancing efficiency and reducing production costs by eliminating the need for additional equipment and plant space, while ensuring proper installation and inspection of valvetrain components.
Implementation Method 1
Porting is provided through the shaft to a central region of the mating surface to convey pressurized air upon a plurality of retainer keys within the spring cap
Implementation Method 2
The compression is released so that the spring engages the spring cap thereby loading the valve plug into engagement with the cylinder-head
Data Source
AI summary
An assembly method is provided by orienting a cylinder-head at a first orientation. A first plurality of spring caps and a first plurality of retainer keys are installed into the cylinder-head in the first orientation by a first robot. A first plurality of valves is installed into the cylinder-head in the first orientation by a second robot, into engagement with the first plurality of retainer keys. An end effector is provided with an actuator supported upon an adapter plate. A shaft extends from the actuator with a mating surface to engage a spring cap. Porting is provided through the shaft to convey pressurized air upon a plurality of retainer keys within the spring cap. A plurality of gripper fingers extend from the distal end of the shaft to grip a valve spring while retaining a spring cap between the valve spring and the mating surface of the shaft.