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Why are engine manufacturers using non-contact, highly accurate, ultrasonic measuring equipment on their manufacturing lines? Ultrasonic Arrays" DMS-5000 Distance Measuring System can detect engines with missing connecting rod bearings, preventing them from reaching the hot test, or, even worse, from being assembled into an automobile. Missing inserts can be detected and reworked at minimal cost.
"This system is providing a reliable means of assuring that each engine manufactured in our plant has been inspected," says a Controls Engineer at an engine plant in Flint, Michigan. "Missing inserts can happen frequently on the assembly line; however, this in-process station inspects and eliminates these problems while saving time and money," he added.
The DMS-5000 system is installed at the torque-to-turn station. There, an electronic signal initializes the DMS-5000's and the crank of the engine is mechanically cycled two revolutions. While the piston moves through its stroke, the gauge continuously measures the distance to the piston surface without touching it. The gauge stores the highest and lowest measurements to the piston in memory. The low measurement is subtracted from the high measurement to determine piston stroke, which is displayed by the DMS-5000. A cylinder with a missing insert will exhibit a shorter stroke because full travel of the piston is not achieved. The engine is rejected for rework of the missing insert.
The gauge comes programmed with special curve fitting software to eliminate inaccurate readings caused by potential noise sources. Both maximum and minimum readings are available via an RS-232 serial communications port.
Fixturing
An advantage of the UAI system is its non-contact and fixed-position mounting. Unlike other systems, UAI"s sensors are permanently mounted normal to the piston surface, out of the way, during block transfer, eliminating the need to index into position as each block is presented. The fixturing has no moving parts, initial costs are greatly reduced, as are future maintenance costs and downtime.
As described above, the micro-processor-based DMS-5000 system provides a differential reading (high minus low), so that precise fixturing is not critical. The block can be presented with the pan side up or down. The DMS-5000 includes all setup and alignment aids required for operation and a self-contained air purge system for industrial environments.
