A Laser-Based Measuring System for Online Quality Control of Car Engine Block

Area of Science:

• Manufacturing Engineering
• Metrology
• Optical Measurement Systems

Background:

• Pneumatic measurement instruments are crucial for engine block diameter inspection due to their accuracy and portability.
• Limitations in pneumatic devices, such as small working spaces, necessitate manual operation, hindering efficiency and automation.
• Current methods face challenges in achieving high-speed, automated quality control for engine components.

Purpose of the Study:

• To propose a high-speed, automatic measuring system utilizing laser-based technology to overcome the limitations of pneumatic devices.
• To develop a novel measuring unit composed of multiple laser triangulation sensors (LTSs) for efficient bore diameter measurement.
• To establish a unified mathematical model for accurate calibration and measurement, independent of the measuring unit's orientation.

Main Methods:

• A laser-based measuring unit was designed, incorporating multiple laser triangulation sensors (LTSs) arranged to function as a bore gauge.
• The spatial relationships between LTSs were calibrated, and a unified mathematical model was developed for both calibration and measurement.
• The system collects sampling points from measured shaft holes, enabling automated data acquisition.

Main Results:

• The developed system enables fast and automatic measurement of engine block diameters, significantly improving efficiency.
• The unified mathematical model ensures measurement accuracy is unaffected by the relative pose between the measuring unit and the workpiece.
• Experimental validation confirmed the system's effectiveness and feasibility for industrial applications.

Conclusions:

• The proposed laser-based measuring system offers a viable, high-speed, and automatic alternative to traditional pneumatic instruments for engine production quality control.
• The system's independence from precise positioning requirements simplifies implementation and enhances its applicability in automated manufacturing environments.
• This advancement addresses the need for efficient and accurate inspection methods in modern automotive manufacturing.