The line is machined to go up in engine crankshaft, application detects the technology undertakes online quality is controlled, can make sure crankshaft dimension achieves treatment requirement, through data feedback seasonable control machines a process likelihood the trend of out of tolerance, achieve the goal that pursues 0 blemish to make. 0 blemish are made main by " do not accept blemish, do not make blemish and do not pass defect " 3 parts composition. In actual production, carry out through managing what with the technology the improvement of two respects can raise 0 blemish. As technical progress, achieve 0 blemish to make from the angle of hardware had become a possibility. The line is machined to go up in engine crankshaft, application detects the technology undertakes online quality control can achieve the goal that pursues 0 blemish to make. Its fundamental is seasonable treatment dimension makes detect in the treatment process of crankshaft, pass " instant " and " after the event " means of feedback of two kinds of data, to machining a process the trend of out of tolerance undertakes the likelihood be controlled effectively, the treatment dimension that assures a spare parts is inside tolerancepublic errand limits, avoid the generation of reject thereby. Machining craft and requirement crankshaft is engine one of 5 big crucial component. Nowadays, the crankshaft of high speed, efficient, compound treatment makes means had gotten applied extensively. Graph the plane of a be my factory 1 technological process that arranges line of crankshaft of 4 crocks of engine continuously and equipment arranges a plan. This is a more compact crankshaft treatment product line, by manipulator join machines working procedure each, and alternated on product line detect at the line more device. Working procedure of OP110, OP140, OP240 is had measure immediately, the function that closed circuit feedbacks, OP165 and OP250 are series connection inside working procedure special and online detect equipment, have the effect that feedbacks to after the event. These are online detect device is the essential condition that makes sure the relevant measure of crankshaft achieves treatment to ask, also be the reliable safeguard that seeks 0 blemish to make. Graph 2 it is a few crucial dimension in crankshaft treatment. Among them, the external diameter of connecting rod journal and main shaft neck and circularity have very high demand, tolerancepublic errand is controlled normally control in 10 μ M, stop ordinary control is in public errand of the width that choose a side less than of 50 μ M. Online detect the control of the technology that uses the production of the product to cannot leave measure. Use on product line online detect the treatment quality that device can adjust workpiece quickly. In actual production, because cutting tool wears away to be out of shape with heat,often cause cutting tool dimension to produce metabolic then to cause occurrence error of dimension of treatment spare parts, the automatic compensation function that online check provides, can solve this problem effectively, assure to stabilize treatment continuously. And this kind online detect device avoided to adjust compensation dimension often artificially, from go up at all put an end to cannot the occurrence of repair reject. This is a kind the most active, most the economy, control technology that can foreknow and avoids a mistake. Current, the control method that quality machines on crankshaft product line has 3 kinds as follows: The final character after ● is machined is online detect the quality that is used after spare parts of test and verify is machined, establish ties normally in product line, 100% detect workpiece. Once the spare parts is unqualified,can discover immediately. Of character of the process after ● is machined online detect dimension of opposite Cheng treatment undertakes real time monitoring and feedback, can prevent the generation of reject effectively. ● samples from the line detect normally basis " servy record of machine treatment working procedure is expressed " requirement, use check leaving a line to provide a stage to finish by jockey detect the job. This kind of method need not undertake compensating to equipment commonly. In the crankshaft treatment line that Nextpage shows 1 times in the graph, online detect technical application basically behaves in 4 respects: 1, fine vehicle is online of the detector use a figure 1 in the fine vehicle of OP165 working procedure is online the main characteristic of the detector is as follows: The capacity that ● can use the method that short-term facilities ability analyses to complete installation checks and accept the job; ● equipment debugs initial stage, not certain need is used online detect feedback system will make eligible work; ● is used detect data feedback system, can solve a few statistical inextricability problem, if bit dies,blade and the knife that because change a knife,cause fill the error such as outfit of fault of setting mistake, razor blade. Because be couplet of alone labour bit string,be in product line, measure metre comparing to machine metre weak point, so OP165 does not have an influence to productivity. Because measure metre very short, install the lathe of stage or two above, can use same station online detector and do not affect crop. OP165 has pair of OP160 to machine dimension to have compensatory function. The process that first machine after OP160 switchs on the mobile phone can divide carry out for two paces: The first pace, equipment set not cutting arrives final measure, leave the surplus with have certain; After OP165 of spare parts classics is measured, dimension of will effective treatment and the deviation feedback that set is worth give a machine tool, regard a machine tool as the compensation of treatment. The 2nd pace, the correction that second treatment feedbacks before equipment basis, machine the spare parts final measure. And, in machining a process normally, machine a spare parts every time, equipment will machine dimension and the deviation feedback that set is worth actually to give a machine tool, undertake compensating to machining a process the next time as compensation. Such, realized a spare parts effectively to machine the automata of quality. 2, of online and final detector use a figure 1 in OP250 working procedure is crankshaft is final detect labour, the worker worker that surveys crankshaft axis diameter namely. The main characteristic of this working procedure is: ● measures a head to be standard component, set last process in product line, use at 100% pairs of finished product to have quality inspection; ● this working procedure has buffer of a paragraph of raceway, main in order to deposits Reject spare parts (detect decide for unqualified spare parts) . Normally jockey is in new cleanness, after rinsing a spare parts, undertake be metricaled again, the spare parts that to still shoulding not dimension asks treats waste; To measuring the part of qualification, laser hits sign chance to will make mark, these information can use spare parts date from; ● uses PFMEA (craft is potential failure mode) analytic tool, be aimed at the certain eigenvalue of high risk, increase when equipment is made a few measure a head, in order to detect these eigenvalue of the product, undertake preventing a fault; ● is online detected temperature compensates a function. The cooling fluid temperature that crankshaft uses in OP240 polish working procedure is 20 ℃ , and the crankshaft surface temperature after OP245 cleaning machine is cleaned is 33 ℃ on average, the temperature difference of around working procedure, bring about spare parts heat to bilge, measures diameter has bigger error. The main shaft neck that measures after OP240 polish is average the diameter is a diameter 56. 0010 - 0.
0026 Mm, and after OP245 of spare parts classics is cleaned, eventually if the Marposs equipment of check OP250 shuts temperature to compensate a function, measures diameter is a diameter on average 56.
0010+0.
0072mm; And if open temperature to compensate a function, measures diameter is a diameter on average 56.
0010 - 0.
0028mm. This shows, temperature compensation function is OK the to spare parts dimension effect that because temperature change is caused,utmost ground reduces. Because the ● influence to crop is couplet of alone labour bit string is in product line, pitch time is shorter, do not have an influence basically to the output of crop so. ● is final to the influence of installation cost cost after a treatment is finished, the spare parts is cleaned, measure and system of manipulator of the makings below finished product still can use unit of a control, because this is opposite,the cost of automatic connection system of entire line affects minimum. 3, online detect OP110 working procedure and OP140 working procedure are applied mediumly to be diameter of main shaft of wide choice grinding and connecting rod diameter in grinding and polishing craft, its are thick essence of life grinds treatment process to be connected together, the method that adopts the feed that adjusts emery wheel will achieve the demand that wide choice worries. Landis grinder contains on-line Marposs to measure check to provide randomly (see a picture 3) , the diameter that is used at controlling the part when grinding is machined, circularity and taper. After the kibble that finish, marposs measures a shift and detect workpiece diameter, like 0.
≤ of surplus of 20mm ≤ grinding 0.
50mm, criterion equipment continues to carry out essence of life to grind, complete the treatment to the spare parts; Be like grinding surplus ＜ 0.
20mm or grinding surplus ＞ 0.
50mm, criterion the machine tool stops, carry out the rest essence to grind measure no longer. Graph 3Landis grinder contains on-line Marposs to measure check to provide grinding randomly the main characteristic of online detector: Nicety controls the final measure of the spare parts; As the device that prevent a fault; When essence of life is ground the feed that measure a head dogs dimension of record external diameter changes. Grinder of much emery wheel of main shaft neck uses two measuring instruments at the same time normally, dominate crankshaft from beginning to end respectively the main shaft neck of two end. Measuring instrument of grinder of connecting rod neck controls the grinding dimension of neck of every archives connecting rod. NextpageOP240 working procedure is versed in for the polish of crankshaft. The first working procedure is thick cast, the polish with use thicker particle is taken, by online measuring instrument (see a picture 4) control polish dimension. The 2nd working procedure is cast for essence of life, the purpose is improve the appearance bright and clean degree. Graph 4 polish are online detector polish is online the main characteristic of the detector: ● is online the size that measures thick polish, according to polishing change of the following size measures axial diameter size, carry out measure immediately; ● measures head and a complete set of to measure unit to be the standard component of the industry. 4, the part leaves what line check provides to apply appearance of ● rough machining to detect the measuring projector that its job principle is similar to a lab to use, basically apply to neck of the connecting rod after rough machining and appearance of main shaft neck to detect. Its characteristic is to measure time short, efficiency is tall, belong to blame contact to measure, can prolong the service life of equipment. The spare parts that be measured must pass strict clean gift measurable, and after be being cleaned normally because cooling fluid is sordid or leftover liquid stays on the spare parts, should use cause on the spare parts without adhere of cloth with soft nap of hairiness of the meeting when spinning cloth to wipe crankshaft measure forbid, because this proposal is used right now industrial chamois undertakes crankshaft cleanness. Appearance of ● finish machining detects double head axis kind appearance measuring instrument can allow what use different type at the same time to measure a head to be measured respectively homocentric reach eccentric shafe neck. The measurement of connecting rod neck must be used wide model measure a head, costlier; Of main shaft neck measure can use gyro wheel model measure a head, service life is longer; Double measure a head to be measured at the same time can save measure time. Small to finish machining public errand part is measured, must use this kind of high accuracy to measure a technology. Detector of ● surface surface roughness is whole measure a process implementation is full automatic, need not jockey is participated in. Additional, still have flexible process designing function, neck of measurable connecting rod, main shaft neck and stop surface roughness of the surface that choose a side. The maintenance that online check provides and maintain online detect those who measure an outcome is accurate depended on safeguard what online check provides daily perfect with what maintain degree. General and online detect measure a head to be rinsed automatically or compress air to rush by the cooling fluid above equipment blow, but use time one long, the surface that measure a head and the Master that measure check to provide all are put in pollution likely. Online check has friend need is cleaned regularly with maintain, had done daily TPM (complete member preventive maintain) , assure to measure the authenticity of process feedback data. The place on epilogue put together is narrated, online detected the biggest advantage is to be able to come true " 0 blemish " likelihood, remove the quality issue that cannot be solved through counting manage statistic, can bring production cost subsequently drop, achieve the goal that seed profit produces finally. But detect the spare parts is movement of after the event only, go after 0 blemish to should be established " quality is to make those who come out " concept, avoid to be immersed in " quality is to examine come out " error. As engine technology content rise ceaselessly and enterprise synergism falls of this concept deepen, drive the promotion of production technology necessarily, online detect the technology is sure more and more be taken seriously. Current, the control of the crucial point such as the surface roughness in crankshaft production process and circularity already had new breakthrough. If online surface roughness surveys the plant that prevent a fault, basically use at treatment of leakage of the monitoring in grinding or the part that did not obtain complete treatment; Can undertake circularity of connecting rod neck automatic compensatory is online circularity compensates appearance, already came out by equipment supplier development. These are online detect new check is provided sure the 0 blemish crankshaft that gives future is made bring further requirement to assure. CNC Milling