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PROBLEM: Zero defect requirement, automotive engine production
A major automotive engine manufacturer producing 2000 engines/day was finding 10-20 engines failing at hot test due to a missing connecting rod bearing. Some engines with missing connecting rod bearings got by hot test and were installed in vehicles and reached customers.
SOLUTION: UAI non-contact distance gage with TIR software
UAI distance gages were installed at the torque to turn station, to measure piston travel (stroke). At torque to turn, the engine crankshaft is spun two revolutions. The UAI gages measure piston stroke and compares to a stored set point. Missing bearings result in low stroke and the engine is rejected. UAI connecting rod bearing detection system eliminated problem of missing bearing inserts.