Solutions for sensible balancing between dedicated and ... · masters (min - max) Free space for further gauge assemblies (future engine erivatives) 21 CIRP - Species WG / Dresden

1CIRP - Species WG / Dresden 2007

Solutions forsensible balancing

betweendedicated and fully flexible

gauge systems

Solutions forsensible balancing

betweendedicated and fully flexible

gauge systems

CIRP - SPECIES Working Group / Dresden - August 24th, 2007


Brief Marposs presentationBrief Marposs presentation

• Marposs produces dimensional measuring systems for machine shop environment

• Two main application fields:

• Measurements integrated in Machine Tool

• Measurements off Machine Tool

Pre-process Post-process Final check, buy-off,Part grading


Marposs productsMarposs products

• Attribute gauges (go-no-go, masters etc.)• Contact-electronic gauging• Opto-electronic gauging• Air-electronic gauging• Non Destructive Testing• Leak testing

Marposs provides complete systemsand gauge components as well,

to both End Users and Gauge Makers

• Sensors for Machine Tools• Industrial PC & software for gauge applications, statistical process & quality control

At anyautomationlevel: manual,semi- or fullyautomaticsystems


Marposs main factsMarposs main facts

• Founded in 1952

• Consolidated turnover 240 M Euro

• Headquarters and main mfg. facility in Bentivoglio - Bologna Italy

• Worldwide presence with sales & service network plus local mfg. facilities - Nearly 1800 employees - Close partnership

with both end usersand M/C Tool OEMs


The extreme basic models forgauging systems

The extreme basic models forgauging systems

Dedicated, single purposemulti-probe gauge

Single probe on CNC path- CMM -


Pros & ConsPros & Cons

• Long cycle time• Skilled operator req’d• Limited ability to cope with harsh working surrounding• Limited ability to integrate into production automation• Higher cost

• Full flexibility

• Short cycle time• Easy to use• Designed for harsh working surrounding• Easy integration into production automation with ancillary equipment (e.g marking, sorting, additional quality checks)• Lower cost

+ -

CMM’s

Dedicatedgauges

• No flexibility


Examples of M/C shop environment effectsExamples of M/C shop environment effects

Marposs gauge systems alwaysbuild a “closed” measurementchain on any transducercombination; potential vibrationsdo not affect the accuracy

Marposs gauge systems acquire alltransducers at the same time,hence no effect at all of potentialvibrations / displacement or partshape errors

Part vibration on staticmeasurements(e.g. basic dia check)

F

Part vibration / displacementon dynamic cycles

(e.g. runout check)


Examples of M/C shop gauge output & cycle timesExamples of M/C shop gauge output & cycle times

99 gauge transducers, 138 gauge parameters

25 sec. dynamic gauge cycle, plus laser marking for journalgrading in 5 mm steps = total cycle 39 sec.

6 cyl. In-line crankshaft


Examples of M/C shop gauge output & cycle timesExamples of M/C shop gauge output & cycle times

23 gauge transducers, 28 gauge parameters (min. IDtolerance 12 mm)

Additional weight measuring, opto-electronic surface check,part segregation in weight grades = floor-to-floor cycle time5,4 sec.

Connecting Rod

Mechanical reference


Steps for re-tooling, re-configuration, adapted flexibilitySteps for re-tooling, re-configuration, adapted flexibility

Basic gauge contact arrangementBasic gauge contact arrangement

Standard armsetfor meas. range

~0,5 mm

Wide range configurationWide range configuration

Special armsetfor meas. range

up to 5 mm

1) Wide range gauge cell1) Wide range gauge cell / 2) Ease of relocation/ 2) Ease of relocation

Dovetail arrangementfor easy relocation /

replacement of gaugecalliper


Typical wide range cell application for crankshaftTypical wide range cell application for crankshaft

( Three gauge sections on the samemain journal )

( Three gauge sections on the samemain journal )

Dovetail arrangementfor easy relocation /replacement of thegauge calliper

Special wide rangearmset to cover the fulldiameter variaton, asrequired

Small range armsets,aboard the wide rangegauge system

Roller for gauge contact /workpiece protectionduring gauge stationintroduction


Crankshaft M/CCrankshaft M/C

Gauge structuremain beam

Dovetail plate forpin follower support

Dovetail plate formain journal

calliper support


Wide range crankshaft M/CWide range crankshaft M/C

Wide range calliperfor main journal

Wide range calliper forpin journal, on pin

follower mechanism


3) Gauge plugs re-tooling within a given size range3) Gauge plugs re-tooling within a given size range

Con-rod gauge plug with 8 gauge transducersCon-rod gauge plug with 8 gauge transducers

Transducer armset withfinger and gauge contact,aboard pivoting plate

Pivoting plate

By replacing the nosepiecethe gauge cells areautomatically re-located to thecorrect bore ID

Positive stop (plugnosepiece) for pivoting plate


Gauge plugs re-tooling within a given size range (cont’d)

ID re-tooling rangeID re-tooling range

Small Endbore

Big Endbore


4) Full gauge station re-configuration within a givenrange of a component family - Disc brakes4) Full gauge station re-configuration within a givenrange of a component family - Disc brakes

7 - 40 mm

OD 178 - 400 mm

ID 50 - 120 mm


Full gauge station re-configuration within a given range of a component family - Disc brakes (cont’d)

Lower gauge assembly

13 gauge transducers, 27 gauge parameters (min. tolerance 10 mm onDisc Thickness Variation)

25 sec. dynamic gauge cycle

Rear gauge assembly


Full gauge station re-configuration within a given range of a component family - disc brakes (cont’d)

Gauge station ready for part loading

Lower gauge assembly,stationary

Gauge station ready to start gauge cycle

Rear gauge assemblyadvanced

Rear gauge assembly,retracted backwards

Adjustable drive finger for partrotation

Pivoting part drive ass’y


Full gauge station re-configuration within a given range of a component family - disc brakes (cont’d)

Lower gauge assemblyLower gauge assemblyRecoiling tapered nosepiece forpart centering (dedicated to a

specific ID range)

Interchangeable referencering for location of “hat” inner

bottom face

Spacer for quick heightchange over

Screw spindle for preciseheight adjustment

Screw spindle for preciseradial adjustment of ID gauge

contacts

Scales to visualize radial orheight adjustment


5) Full protection for additional, still undefined, parttypes within a component family - Cylinder heads5) Full protection for additional, still undefined, parttypes within a component family - Cylinder heads

Gauge station for determination of tappet thickness on engine assembly lineGauge station for determination of tappet thickness on engine assembly line

Engine is indexed in the gauge station

Palletized engine conveyor line

5-axis robot picks the gauge assembly and loads it to the

engine cylinder head(s)

Gauge assembly in parking position

Gauge setting masters (min - max)

Free space for further gauge assemblies (future

engine erivatives)


Full protection for additional, still undefined, part types within a component family - cylinder heads (cont’d)

Gauge station for determination of tappet thickness on engine assembly lineGauge station for determination of tappet thickness on engine assembly line

Engine index unit

Palletized engine conveyor line

Gauge assembly in parking position

Gauge assembly loaded to cyl. head(s)


6) 2-D flexibility for shaft-like parts - OPTO GAUGING

6) 2-D flexibility for shaft-like parts - OPTO GAUGING

“Shadow casting principle”“Shadow casting principle”


2-D flexibility for shaft-like parts - OPTO GAUGING (cont’d)

Opto gaugehead (200 mmrange), aboard

upper Z slide

Contact gauge assembly on NCpivot arm, to measure lateral runoutand Z distances on specific points


Thank you very much foryour kind attention

Thank you very much foryour kind attention

Documents

Solutions for sensible balancing between dedicated and ... · masters (min - max) Free space for further gauge assemblies (future engine erivatives) 21 CIRP - Species WG / Dresden