Wheel Flange Planeness Detection Using Dial Indicators
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Solution Overview
Problem
Current methods for detecting wheel flange planeness and sinking are inefficient, as they rely on manual inspection and three-coordinate measurement systems, which fail to achieve 100% detection in real-time, leading to delayed identification of out-of-tolerance flange planeness and increased reject rates.
Innovation Solution
A wheel flange planeness detection device that includes a frame, lifting cylinder, servo motor, visual sensor, intelligent dial indicators, and a chain drive system, allowing for automatic, real-time monitoring and adjustment of wheel position to measure flange planeness accurately, with the ability to detect wheels of varying diameters and face widths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual inspection and three-coordinate measurement systems are used to measure flange planeness, then measurement accuracy can be maintained, but detection efficiency decreases and 100% detection cannot be achieved
Solution Approach 1:
The patent replaces the traditional three-coordinate measurement system with a specialized dial indicator detection system. The dial indicators are mounted on a movable carrier that can be positioned along the flange face, providing rapid mechanical measurement of flange planeness and sinking conditions. This substitution enables 100% detection while maintaining adequate measurement precision for quality control purposes.
Solution Approach 2:
The patent changes the measurement parameters by using dial indicators to directly measure the vertical displacement (sinking) of the flange face relative to the wheel rim, rather than using complex coordinate sampling. This parameter transformation simplifies the measurement process and enables rapid continuous detection of all wheels passing through the inspection station.
2Extent of automation
If random manual inspection is performed to detect flange plane sinking, then equipment complexity can be kept simple, but detection coverage decreases and misjudgment increases
Solution Approach 1:
The detection device is segmented into functional modules: a carrier assembly that holds multiple dial indicators, a positioning mechanism with guide rails, and a control system. Each dial indicator independently measures a specific region of the flange face, and the modular structure allows the system to achieve automatic detection without excessive complexity. The segmented design enables easy maintenance and adjustment.
Solution Approach 2:
The detection device is designed with universal applicability to detect both flange planeness and flange sinking conditions using the same basic mechanism. The dial indicators can measure various features of the wheel flange assembly, and the positioning system can accommodate different wheel sizes and configurations, providing multi-functional detection capability without requiring separate specialized equipment for each measurement type.
3Speed
If three-coordinate measurement system is used for flange planeness detection, then measurement comprehensiveness can be maintained, but detection speed decreases and continuous production is disrupted
Solution Approach 1:
The dial indicators are pre-positioned on the carrier assembly at optimal locations for measuring flange planeness and sinking. The carrier is designed to automatically align with the wheel flange geometry, so that measurement points are established before contact is made. This preliminary positioning enables rapid data collection without compromising the comprehensiveness of the detection, as the critical measurement points are predetermined based on standard flange geometries.
Data Source
AI summary
Disclosed is a wheel flange planeness detection device, comprising a frame, a lifting cylinder, a lifting platform, guide posts, a support frame, a servo motor, a bearing seat, a shaft, a bearing, a rotating platform, guide rails, a sliding block, a small chain wheel, a large chain wheel, a clamping cylinder, a chain wheel driving motor, a left sliding plate, rotating shafts, rotating wheels, a visual sensor, clamping guide rails, gear rack structures, a right sliding plate, intelligent dial indicators, a support plate, a linear motor and a motor support. The device may monitor the state of flange planeness in an automatic production line in real time; when the flange planeness is out of tolerance, the device may immediately give an alarm, and the technologist adjusts the machining process in time after receiving the alarm, thereby avoiding a large batch of rejects.