Novel Robotic Test Rig for Camshaft Geometry Measurement with a Collaborative Robot

Area of Science:

• Robotics and Automation
• Metrology and Quality Control
• Mechanical Engineering

Background:

• High-volume production demands efficient and reliable quality control methods for critical components like camshafts.
• Traditional inspection methods for camshaft geometry can be time-consuming, prone to human error, and lack flexibility.
• There is a need for automated, repeatable, and scalable solutions for preventive quality control in camshaft manufacturing.

Purpose of the Study:

• To design and experimentally validate an innovative robotic test stand for automated measurement of camshaft cam geometry.
• To develop a comprehensive measurement methodology for acquiring and processing geometric features critical to camshaft performance.
• To assess the repeatability and accuracy of the robotic test stand by comparing its measurements with conventional metrology tools.

Main Methods:

• Integration of a collaborative robot (cobot) with a specialized measurement setup for precise camshaft positioning.
• Development of an automated data acquisition procedure and signal processing techniques to determine key cam geometry parameters.
• Utilization of an indirect ultrasonic measurement model combined with a quadrant-based sensor strategy and 90° camshaft indexing for full-profile acquisition.

Main Results:

• Experimental validation confirmed the robotic test stand's ability to provide repeatable measurement results.
• Stable identification of critical geometric features was achieved across multiple trials.
• High agreement was observed between measurements from the robotic stand and reference data from conventional metrology tools.

Conclusions:

• The cobot-based test stand is suitable for preventive quality control in industrial camshaft production.
• The proposed system offers a scalable, flexible, and efficient alternative to manual inspection and dedicated gauges.
• This innovative approach enhances inspection throughput and standardizes quality control workflows in manufacturing environments.