Dynamic systems for form measurement and surface inspection of engines

Transcription

1 OPTICAL SYSTEMS LASERS & MATERIAL PROCESSING INDUSTRIAL METROLOGY TRAFFIC SOLUTIONS DEFENSE & CIVIL SYSTEMS Dynamic systems for form measurement and surface inspection of engines Precision is our business.

2 Industrial Metrology Your partner for industrial metrology Hommel-Etamic, the Industrial Metrology Division of the Jenoptik Group, is a leading manufacturer and system provider of high-precision, tactile and nontactile production metrology. The range of products provided include total solutions for a wide range of measurement tasks such as testing surfaces, form, and determining dimensional tolerances throughout all phases of the production process, for fi nal inspection or in a metrology lab. Our product portfolio is rounded off by a wide range of services in consulting, training and service, including long-term maintenance contracts. Hommel-Etamic. Precision is our business. Precise measurement in engine development and production Our products are used in the automotive industry for engine development - both for monitoring research and development results and for quality control and documentation. Our products are always up-to-date with customer requirements. For over 25 years, major engine manufacturers and their suppliers have been using incometer and topometer products because they trust their quality. Measurement of distortion and wear of engines with incometer technology The piston ring and cylinder bore system has an essential infl uence on the quality of modern internal combustion engines. Insuffi cient sealing of the combustion chamber results in higher exhaust emissions, increased oil consumption and increased wear. If the cylinder bore deviates from its nominal shape, the piston ring can only seal within the frame of its limited fi lling capacity. This reduces with increasing form error of the cylinder bore. From early development until fi nal series production, appropriate measurements and corresponding tests concerning shape deviation of the cylinder bore are necessary in order to guarantee the function of the piston ring and cylinder wall system. Our incometer systems create fast, reliable and precise measurement data for the analysis of the cylinder piston confi guration. 2

3 Measuring systems Overview of our measuring systems incometer for measuring form and roundness Our incometer systems allow fast, precise measurement of form and roundness in cylinder bores. They are particularly used for measurements of cylinder bores in combustion engines. Their small, compact design enables them to be used as stationary tools in the measuring room or as mobile tools on the production line. incometer V Flexible measuring system for form and roundness in cylinder bores. Measures cylinder distortion, cylinder wear, temperature infl uences and piston ring dimensions in engine development and production. incometer VS Flexible measuring system for form and roundness. Measures cylinder distortion, cylinder wear, temperature infl uences and piston ring dimensions in small engines (e.g. 2-stroke engines). incometer V110 Flexible measuring system with extended neck section for form and roundness in cylinder bores. Measures cylinder distortion, cylinder wear, temperature infl uences and piston ring dimensions, ideally in extremely fl at V-engines. incometer P The multi-sensor head measures roundness and form in engine production. topometer for optical and tactile surface inspection The topometer allows optical and tactile inspection of the structure and roughness of fi ne-machined (e.g. honed) surfaces in cylinder bores. It allows complete identifi cation of surface characteristics such as honing angle, valley structure, blowhole size, residual turning valleys, and roughness of cylinder bores in development and production. 3

4 incometer V Flexible measuring system for form and roundness in cylinder bores Measurement of cylinder distortion cylinder wear temperature infl uence piston ring dimensioning for engine development and production Roundness Straightness Cylindricity Parallelism Inner diameter The incometer V offers quick, accurate measurements for analytic examination of cylinder piston confi gurations in engine block development. Flexible and mobile The incometer V has a compact design. Its clamping mechanism makes it easy to adjust to various cylinder dimensions, ensuring it can be used on a fl exible and mobile basis during development and testing. Its insensitivity to vibrations means it is also ideal for measuring during production. Convenient The probe s self-adjustment facility eliminates timeconsuming alignments of the workpiece. Any eccentricities or inclined positions of the cylinder axes to the measuring probe are automatically corrected by the INCOWIN software. Concentricity 4

5 incometer V Easy to use The PC-driven system is controlled via the user-friendly Windows Software INCOWIN. Measuring routines are predefi ned so only the appropriate values are chosen and entered. This eliminates time consuming programming. By changing the appropriate parts (measuring tips and clamping jaws), the probe easily adapts to different diameters. Measurement of cylinder distortion The incometer V is especially suited for measuring and evaluating the infl uence of cylinder heads and gaskets on bore distortion in combustion engines. It can be installed on the crankshaft side for measuring in cylinder bores with a mounted cylinder head. The wear rates and cylinder distortions can also be monitored during long-term testing. Probe V200 with electronics Temperature distortion Simple fi xturing and high speed allow for measurement of engine blocks, even under high temperature conditions. This makes it possible to analyze the critical warm-up phase, where there are extreme temperature differences between cylinder head and engine block. External plate for fi xing the probe Mounting device and accessories 5

6 incometer VS Form measuring system for small cylinder bores Measurement of cylinder distortion cylinder wear temperature infl uence piston ring dimensioning for engine development and production Roundness Parallelism Straightness Inner diameter Cylindricity Concentricity The incometer VS offers rapid and reliable measurement with maximum precision for detailed testing of cylinder bores on small engines. The system has been developed on the basis of the invometer V. The large range of diameters from mm enables its use in many different engine types. Mature system Thanks to the scanning measuring method with up to 14,400 points per position and up to 40 positions (as with the incometer V), the incometer VS delivers maximum distortion information within the market s fastest measuring times. This and the correction of the inclination and eccentricity of the probe to the bore make the system unique. For small engines The incometer VS has been specially designed for the measurement and analysis of cylinder distortions of small engines (e.g. 2-stroke engines). They are mainly used in small agricultural and forestry appliances. Other applications include compressors in large cooling systems. The incometer VS is predominantly used in measuring rooms for research and development, but can also be used in production thanks to its design. Simple and rapid use The INCOWIN software allows for easy adaptation and programming of the system through a menu. This minimizes operator training and enables its simple and effective use. Measurement data can be saved centrally with a network connection and easily printed out via the document assistant. Isometric form with 40 levels 6 Isometric form with automatic masking-off External plate for fi xing the probe

7 incometer V110 Flexible form measuring system for special engine block geometries Measurement of cylinder distortion cylinder wear temperature infl uence piston ring dimensioning for engine development and production Roundness Parallelism Straightness Inner diameter Cylindricity Concentricity The incometer V110 is a fast, reliable and highly accurate way to determine measuring data for analytical testing of the cylinder-piston confi guration during engine development for engines with very diffi cult installation requirements (e.g. extremely fl at V-engines). Flexible and mobile The incometer V110 s compact design and clamping mechanism make it easy to adjust to various cylinder dimensions, ensuring it can be used on a fl exible and mobile basis during development and testing. Simple operation and handling The PC-controlled system is operated by the convenient Windows software INCOWIN. Measurement routines are pre-defi ned; only corresponding values are entered and selected. As a result, there is no need for timeconsuming programming tasks. The device can be adapted to different diameters quickly and easily by changing accessory parts such as measuring tips and clamping jaws. Convenient The probe s self-adjustment facility dispenses with time-consuming alignments of the workpiece. Any eccentricities or inclined positions of the cylinder axes to the measuring probe are automatically corrected by the INCOWIN software. Measuring cylinder distortion and temperature distortions The incometer V110 has the same characteristics as the incometer V in this area. incometer V110 mounted on the crankshaft side 7

8 incometer P Quick measurement of form in cylinder bores Precision measurement in seconds of roundness form in production areas Roundness Parallelism Straightness Inner diameter Cylindricity The incometer P quickly and reliably generates highly accurate data of cylinder bores, directly in the production area. Minimal concact High demands are placed on the system during production-related measuring. The incometer P has minimal direct connection with the vibrating infl uences that disrupt the object being measured. The automatic correction of inclinations and eccentricities by the INCOWIN software means there are no longer any lengthy adjustment processes, which is a signifi cant factor in production. Flexible application The replaceable measuring tips allow the system to be modifi ed to different bore diameters quickly, which makes it ideal for fl exible production lines. Probe with 5 sensors and electronics Protocol of a cylinder block measurement 8

9 incometer P Simple operation The clearly structured INCOWIN software ensures that operating the measuring system is easy, even with no previous experience. Once the measurements have been taken, all procedures such as saving and printing the results and their statistical evaluation can be performed automatically. The advanced user administration (optional) allows hierarchical access to the individual functions of the INCOWIN software. Easy handling and fast measurement To take a measurement, the incometer P is inserted into the cylinder bore. Plastic guide rails are integrated into the measuring head to avoid damage to the cylinder wall. A centering collar on the incometer P unit and a fi xture plate mounted on the engine block are coupled together by a clamping lever. This ensures that the incomter P is in the correct measuring position on the engine block. After starting the measurement, the head begins a scanning rotation of 360. Measurement values from each sensor are taken simultaneously at a constant speed. This means it only takes a few seconds to measure the cylinder bore, and the measured values are immediately available. The head can optionally be used with up to seven sensors. Inserting of the probe Mobile use Thanks to its small size and light weight, the incometer P is ideal for use on different production lines. Fixing of the probe Isometric plot of a cylinder measurement Radial plot of a cylinder bore Axial plot of a cylinder bore 9

10 INCOWIN Control and evaluation software for incometer Clearly arranged desktop The advantages of INCOWIN at a glance Multi-tasking Windows application User-friendly interface Central data backup possible via network operation Rapid setup of all customer specifi c requirements High-resolution scanning measurement Software options for R&D and production Optimum system portability with notebook PC Upgrading of older systems possible The control and evaluation software INCOWIN offers all the advantages of the Windows environment: A user-friendly interface, simple creation of new measuring reports and network-compatibility for data backup. There are also several display options to make it easier to analyze results. The screen and printout forms can be designed freely and customized to your company. Dynamic measurement The system offers extensive measuring functions and is equipped with a standardized high-resolution scanner. It has a maximum of 14,400 steps and allows evaluations of up to 1024 measuring points per position. Scanned axial measurements are also possible with a maximum of 600 measuring points per millimeter. This ensures a very high-resolution and detailed representation of the actual geometry of the cylinder bore. The high data density allows standardized fi lter methods to be used (e.g. Fourier and Gauss fi lter or median fi lter for eliminating individual outliers) with a wide variety of choices. Despite this high resolution, measuring time for the scanning method is only approx. 10 seconds per measurement position. 10

11 INCOWIN Print preview Numerous support tools Language selection The INCOWIN software is available in three languages (German, English, and French). You can select the user language you require during the application. The printing language can also be selected independently of this setting. Retrofi t possibilities Measuring systems not equipped with the INCO2 interface and the EC110 electronics can be retrofi tted at any time. Depending on the age and technological status of the system, the extent of the retrofi tting differs and must be defi ned individually. Optimal mobility The INCOWIN control and evaluation software can be used in a multi-task environment. The overall logic is generated on the INCO2 interface card, which is installed in the EC110 electronics unit. A serial interface cable is used to connect the computer and EC110 electronics unit, thereby enabling mobile operation of the incometer system with a notebook. Range of functions can be customized individually The standard INCOWIN software version can be enhanced by optional software packages to provide customized functions, ensuring maximum transparency. Offl ine software (option) This module allows external (offl ine) evaluation and analysis of measurement data on a separate computer. 11

12 INCOWIN Software options for research and development Wear measurement To determine and measure the wear in TDC of cylinder bores, the bore is measured in high-resolution with equally distributed axial scans. Measurement results can be displayed in a wide range of display options. Measuring temperature distortion Rapid cylinder measurement (only approx. 1-3 minutes) means, it is also possible to use the incometer to measure hot engines ( 100 C). Temperature distortions can therefore be measured on live objects, and not just simulated. Wear measurement Fourier analysis Distortions are calculated using the Fourier analysis for a more precise description of the cylinder form. Coeffi cients can be calculated for the 255th order and displayed as a graph for better clarity. Copy & paste/data export Graphs and parameter lists can easily be pasted into other Windows applications to customize reports and documentation. Alternatively, data can be exported into a different format (jpg, txt, etc.). Differentiation For analyzing changes of the distortion with different confi gurations of the cylinder head, cylinder head seal, and crank case, or for heat distortion evaluations, a difference value for measurements that were carried out at different times can be generated in order to compare the results directly. Fourier analysis Data import External data (Polar, Cartesian or as Fourier coeffi - cients) can be imported into the INCOWIN software, evaluated with the same algorithms as the normal measurements, and compared with the incometer measurements. 12 Differentiation

13 INCOWIN Software options for production Block measurement and complete evaluation For measuring a complete crank case with one-time input of the reference data. The operator is guided through the entire measuring procedure via diagrams. All cylinder measurements of a crank case are saved to a single fi le. The evaluation contains the printout of the form parameters for all cylinders in a table and provides a graphic display of the radial and axial measurement and the isometries for all cylinders on one page. The user can specify the maximum number of graphs per page (max. 20). Data transfer to qs-stat The qs-stat -interface certifi ed by Q-DAS allows the measurement results to be transferred to a statistics package for further process data analysis. Block measurement Determining the absolute diameter For determining the absolute diameter of the cylinder of a crank case. The incometer must be calibrated to the nominal dimension of the cylinder diameter before each measurement. This calibration is implemented in a special support, which either has integrated calibration rings or a support plate with integrated calibration rings for assembly on the cylinder head seal surface. Another option is production of a calibration cylinder with the nominal dimensions of the cylinder bore. qs-stat -interface Advanced user administration For creating different users and user groups with their own profi les. Individual users can each be assigned to a specifi c group. Access to the software can be protected for each user by a personal password. Automatic functions For automating processes such as data backup, printing, etc., in order to reduce errors resulting from incorrect inputs or user mistakes. User administration 13

14 topometer Surface inspection system for cylinder bores Measurement and assessment of surface features such as Crosshatch-angles Dimension of surface structure Area of blowholes Stroke reversal radius Laser honing structures Roughness of cylinder bores in R&D and production areas The topometer is the ideal inspection system for fast, precise, and reliable testing of fi nely machined (e.g. honed) surfaces of cylinder bores during development, tests and production. Optical testing of surface structure characteristics and tactile testing of surface roughness is carried out using a compact measuring probe. High fl exibility The topometer is available in two versions: The basic model for pure optical testing, and the advanced version, which includes roughness measurement. It is possible to upgrade the basic model with the functions from the advanced version. The probes have a working length of 150 mm or 210 mm, and can be used in bores from 60 mm cylinder diameter. Different bore diameters can be modifi ed by simply replacing adapter collars. These are also used for positioning and centering the probe. Easy handling The complete system is controlled centrally via a PC that is equipped with additional circuit boards for digital image processing and roughness measurements. The TOPOWIN software is clearly structured and guides the user through the measuring program step-by-step. 14

15 topometer All important functions (e.g. motorized axial positioning or setting the zoom and regulating illumination) are either carried out directly on the probe itself or using the input function on the PC. The radial positioning of the probe in the cylinder is set manually. As soon as the probe is inserted into the cylinder bore, the enlarged image of the surface appears on the monitor. Industrial housing for use in production environments Complete evaluation of the cylinder surface With a great number of optical measurements and roughness analyses at every desired position, the system allows a complete evaluation of the cylinder. Other standards are also available. Sensitive, adjustable light sources provide good illumination of the surface section to be inspected. Mobile use in production The topometer size and weight mean the system is ideal for mobile use on site. A special mobile workshop vehicle ensures the system can be transported easily within the production area. Lighting unit and roughness probe Display of the cylinder surface, angle defi nition Display of surface roughness profi le 15

16 TOPOWIN Control and evaluation software for topometer Measurement functions main window Main window The user-friendly TOPOWIN software enables measurement of such values as the honing angle, mean width of the profi le elements and the curve radii, and the size of silicon crystals, blowholes or other defects. Optical measurements and roughness measurements in the optical range are possible via automatic repositioning of the probe. The results are available on the screen within a few seconds and can then be documented. Documentation A color printer provides an immediate printout of the screen section, including the reference lines displayed and the determined measurement data of the surface. The numerical and graphical output of the roughness indicators and the profi les can be combined with the screen evaluations in one report to provide compact and informative documentation. High inspection rates A reference fi eld with the respective tolerance widths is displayed on the screen for fast inspection of the honing angle. The user places the reference image at the crossing of an angle and can determine whether the target honing angle is correct. Data transfer to qs-stat (option) The qs-stat -interface allows measurement results to be transferred to a statistics package for further analysis. 16

17 TOPOWIN Sample printout Measurement and evaluation of laser-structured surfaces (option) In combustion engines, grooves can be cut into the upper reverse area of the piston with a laser to reduce wear rates. This creates a higher oil pressure volume for improved lubrication of the piston rings. This software module makes it easy to determine the geometric dimensions of the laser hone structures. A measuring assistant guides the user through the measuring process. Automatic positioning at preselected inspection heights (option) This software module allows the user to preselect specifi c measuring heights, which are then used to automatically carry out a sequence of several roughness measurements. Analysis of laser hone structures 17

18 incometer Technical data HOMMEL-ETAMIC incometer incometer V incometer VS incometer P V80 V115 V150 V200 V110 VS100 P100 Diameter of the cylinder* mm mm mm Clamping length min. 20 mm 20 mm 25 mm 30 mm 40 mm ext. fi xture ext. fi xture Axial measuring range 80 mm 115 mm 150 mm 200 mm 110 mm 100 mm max. 300 mm Measuring path on the circumference Radial measuring range ± 400 μm ± 500 μm ± 500/1000 μm*** Resolution 0.1 μm 0.1 μm 0.1 μm Number of measured values per rotation 14,400/1,024 14,400/1,024 14,400/1,024 Number of sensors 1 1 max. 7 Repeating accuracy Roundness 1.0 μm 1.0 μm 1.0 μm Cylinder form 1.5 μm 1.5 μm 1.0 μm Parallelism 1.5 μm 1.5 μm Measuring accuracy Roundness 1.0 μm 2.0 μm 1.0 μm Cylinder form 1.5 μm 2.0 μm 1.5 μm Parallelism 1.5 μm 2.0 μm Temperature range of use** C C C Power supply 230 V / 50 Hz 230 V / 50 Hz 230 V / 50 Hz 115 V / 60 Hz 115 V / 60 Hz 115 V / 60 Hz Power consumption 150 W 150 W 150 W Weight of the sensor 2.9 kg 1.9 kg 8 kg*** * Further diameters on demand ** Measuring of the warm distortion on demand (up to 130 C) *** Dependant on diameter Product range for incometer Ø min/max Height / Depth Width of part Laboratory Offl ine Cylinder bore mm 200 mm 200 mm incometer VS incometer P incometer V Cylinder liners mm 200 mm 200 mm incometer VS incometer P incometer V Camshaft bearing bore mm 100 mm 100 mm incometer VS 18

19 topometer Technical data HOMMEL-ETAMIC topometer O150 / O210 OR150 / OR210 Diameter* mm Axial measurement length 150 / 210 mm Optical zoom times (on the screen) Test zone (approx.) 40 times: 5.0 x 5.0 mm 100 times: 1.1 x 1.0 mm 120 times: 0.8 x 0.8 mm Resolution ½ CCD camera 752 (H) x 582 (V) Presentation on the screen 512 (H) x 512 (V) Illumination Direct / indirect Axial position Motor-driven Radial position Manual Focus adjustment Motor-driven Power supply 230 V / 50 Hz 115 V / 60 Hz Power consumption 200 W Operating modes Scanning mode Scanning mode Measuring mode Measuring mode Roughness measuring Evaluation (optic) Hone angle Stroke reversal radius Spaces / width of grooves Detection of porous spots Tolerance zone (angle) Metric / inch Laser structure (optional) Evaluation (Roughness) All standard parameters according to DIN and ISO such as Ra, Rpk, Rvk, Tpi etc. Documentation Axial height of view Set magnifi cation Date / time Parts identifi cation * Further diameters on demand 19

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