Newest production technology and application

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The energy-saving, environmental protection of the car, safety is the stress that the whole world studies, and the car is energy-saving and discharge with engine closely related. Engine is the heart of the car, it is car key component. Its production quality, workmanship and equipment affect the function of the car and reliability directly. Car engine develops a trend to change directional development to sex of high rotate speed, high power, tall wear, high environmental protection and electron. In recent years, chinese car starts a mechanism to make craft and technology, especially machine processing technique obtained great progress and development. Rise further to promote its, sponsor by the unit such as advisory committee of Chinese auto industry, society of Shanghai car project and institute of Cheng of lathe work of steam of the university that be the same as aid assist do " the car launched machine technology and outfit 2005 (dozenth) international seminar " in December 2005 7 ~ are in Shanghai oasis edifice 8 days to hold. Seminar content involves: Profit of essence of life of plant of newest production technology and application, engine designs trend of development of contemporary engine technology, engine and its key component tripartite face. With respect to the seminar specific content makes the following introduction below. The seminar began in the morning on December 7, 2005, join meeting personnel to include person of Tang Baining of automobile industry expert, Gu Yongsheng, money one, Chen Guangzu, the 100 much people such as domestic and international representing attended car engine and component enterprise seminar. Committee member of committee of experts of association of Chinese auto industry Professor Chen Guangzu is in the problem " " 915 " the train of thought of automobile industry " report middle finger goes out, the eleventh of economy of our country countryman that is about to begin 5 years the program is 5 year with automobile very essential industry, will decide industry of our country automobile whether go up in the foundation of huge in the past success, true by a car big country is stridden to car powerful nation, lay next solid foundations; Future will be industry of automobile of decision our country 5 years whether stand firm on globalization road, develop a tight encirclement, farther in system of division of labor of global automobile industry him promotion is due crucial period of the position. The respect such as the data that the report passes full and accurate from 12 respects and national industry policy was elaborated " 915 " the train of thought of automobile industry. With person of fund of college of project of aid university car one professor made a problem be " tendercy of technology of product of contemporary car engine " thematic report. Energy-saving with environmental protection be tendercy of technology of product of contemporary car engine is thematic. Money professor was discussed in the report energy-saving the way with environmental protection, overall to engine on this foundation the technology undertook scanning; The key discussed gasoline engine technology of 3 big core (straight in season of alterable valve, gasoline and contractible platoon quantity) and technology of diesel engine core (aftertreatment of high-pressured eject, tail gas and pressure boost) ; Brief introducing the combustion method HCCI of chance of oil holding harbour concurrently and derv engine advantage; Finally, it is a delegate with camshaft of body of aluminium alloy air cylinder, combined-type and connecting rod craft, summarized the development tendercy of technology of contemporary motor component. Ke Ma (the title that director of program of technology of assembly line of ministry of facilities of assembly of COMAU) company motive force Mr Maurizio Sciamanda makes a speech is " the development tendercy of assembly line of contemporary car engine " . Pass the introduction of a large number of successful case, from the following the development direction that 5 respects elaborated assembly line: (1) the plane with the most reasonable assembly line is decorated. (2) the quality of assembly line assures. (3) product line of much breed mixed flow. (4) the automation degree of assembly line. (5) the device preventing a fault on assembly line. Engine of ministry of facilities of assembly of motive force of company of horse stalking or branch / the title that Michael Christie of manager of gear-box experiment technology makes a speech is " the engine on product line tests a technology " . A lot of engine make blemish can pass online test or examination of technology of online test and verify to come out only. It is very important also to although get offline,check, but enhance its quality to control a standard through online test. Breakdown discovers earlier, the loss that it causes is smaller. Use online test technology to be able to realize the date from ability of the utmost of pair of production blemish. The purpose of engine cold experiment is in assembly line mix to the production of engine finally assemble quality to undertake test and verify checks. Cold when trying, engine is in below misfire flaming circumstance of electromotor procrastinate move next checking undertaking, right now engine does not have the job according to the means that uses actually. Cold trying is the quality control method in be being used in engine to produce production project, it has the dependency of engine product and engine blemish breakdown to check a function. The program between the engine test that engine heat experimented to introduce test project, model mainly, control and data are collected etc. Still said the development trend that engine checks finally: Gasoline engine and test of small-sized diesel engine will face the directional development that eliminate and reduces heat to try substantially, emphasize producing the online test in the process more, use cold percent of pass in trying a technology to raise engine product to try in heat. On December 7 afternoon, germany overcomes Lawes - Mao Se (M of KRAUSE&MAUSER) company senior selling manager.

B.

Mr Schauerte goes up with respect to connecting rod laser craft made special subject make a speech. Cannot machining the surface after the part is detached accurately to be combined is the problem that people overcomes hard all the time, go up till hair palpability this kind of technique, make exact tally and bolt screw bisection cracks a face to become a possibility. Germany overcomes Lawes - since circle of wool a twenty-five-stringed plucked instrument is extended from beginning to end the research of unremitting goes up technology. 1995, the revolutionary laser that application machines at connecting rod goes up the technology begins to apply at European market. Accurate laser nick and go up force, make rupture subtly face can perfect assembly arrives one case. Went up to technical huge reduced cost and reduce the treatment process of 50% , compare with traditional method photograph: Machine tool investment is low, cost of material is low (only a semifinished product) , the treatment of whole craft prepares time weak point. The advantage with the biggest laser depends on needing to contact material surface to be able to undertake machining, compare with broaching photograph, laser need not contact workpiece to be able to break craft to engrave those who give place to need to rupture to go up line, wear away because of what this does not have any prop. The repeatability that manufactures technology and stability are very tall. Additional, laser is very agile, use thereby same laser can undertake to various connecting rod first-rate cut is machined namely. The life of broach is 400 about, and the life of laser optics lens can be as high as 1 000 000. Machine of gram of lukewarm brave of German dust Er creates limited company (JUNKER) the title that gentleman of a righteous person of executive president exert reports is " the crankshaft grinding technology of innovation " . The grinding of traditional crankshaft journal, often be first neck of grinding main shaft (connecting rod neck) , again neck of grinding connecting rod (main shaft neck) , final grinding differ in roll end diameter. And the concept of Yong Ke machine tool is " hold clip, full treatment " , its advantage is: Technology reliability is high, workpiece carries a number little, pitch time shortens, need not hold clip for many times, because this can be obtained more the upland machines quality, machine down time is short (if some is unit occurrence breakdown, all treatment won't be interrupted from this) . What the installation of the emery wheel in high speed grinding of Yong Ke uses is patent technology -- installed a system at 3 o'clock. Of model of series of JUCRANK of brave gram company swing dog the integral treatment that grinder is crankshaft offerred comprehensive solution. The grinder of all sorts of model is applied to from engine of odd air cylinder the crankshaft of all model to engine of 12 air cylinder is machined. The basis machines the crop of means and requirement, how to the JUCRANK grinder of model of avery kind of is designed and provide the platform of characteristic and emery wheel to wear of each. JUCRANK swings dog grinder can finish crankshaft to machine all grinding working procedure in the process almost, main shaft neck (cylindrical, concave side, convex) with connecting rod journal (cylindrical, spherical, concave side, convex) it is OK to need to hold clip only grinding ends (see a picture 1) . Treated to sclerosis round horn also can undertake grinding is machined. In addition, on craft, the limits offerring money of brave gram company still included to machine the aleatoric combination of means with other grinding. Different type and machine tool of other Yong Ke are combined, can machine fixed position journal, flange reachs gear journal. The CBN emery wheel that company early used Yong Ke to be used at high speed to machine and the combination that use oily cooling crankshaft. The experience that accumulates for a long time and knowledge apply to crankshaft of treatment car engine, quality is reliable. The advantage on the technology basically has the crankshaft grinding machine of Yong Ke company: Detect in machining a process and amend journal circularity and dimension; Contain " study function " control system, add pursue to circularity deviation and interference quantity 1 swing dog grinding principle and but the automatic compensation of the journal appearance of grinding, can undertaking compensatory disturbs a quantity is: Temperature, machinery and motivation are affected, the change of grinding surplus, the change of material and metallographic structure, of emery wheel but cutting sex, of the machine tool wear away state; Because neck of grinding main shaft and connecting rod journal hold clip, theoretic deviation is 0; Cut type grinding to reach swing type grinding; Right " sensitive workpiece " prop up, use on main shaft be opposite automatically of the center type center was worn at 3 o'clock; Supply of CNC pilot refrigerant ensured the abiding dosage of grinding area; Use static press circular slideway, without creeping effect, the pinpoint accuracy that keeps long truly (X axis slideway, feed guide screw, thrust bearing) ; Decrease brace up fight turn round lathe bed, use mineral and cast-iron pouring and into, have good suction shake fights curved function; Emery wheel axis applies to the grinding that is as high as 140m/s. Front of grinder of graph 2 JUCRANK 6000/50-50 CBN and back end appearance pursue 2 it is model is " JUCRANK 6000/50 - 50 " grinder of numerical control crankshaft. This grinder has 4 CBN emery wheel, every all can become independent grinding, hold clip but grinding is all main shaft neck and connecting rod neck (swing dog grinding) . On December 8, 2005 morning, delegate of Beijing of Shen Ke company is in Germany to build a gentleman to balanced technology and quality centering technology to make detailed introduction with respect to crankshaft on behalf of Guo Wei. Guo Wei builds a gentleman to carry technologies of pair of crankshaft dynamic balancing and balance equipment explain elaborated the following problem: 1.

The new trend that crankshaft balances (1) the initial unbalance that reduces crankshaft, the in-house quality of mature crankshaft is compensated (adopt quality centering to wait) . (2) use lopsided quantity to optimize decompose a method, decrease as far as possible corrective and rough the material purify quantity when measuring. (3) balancing machine is used modular design, rise flexible. (4) auger cut use high speed getting to cut. (5) lubricant use MOL (minim is oil-lubricated means) technology. 2.

The influence that compensation of crankshaft interior quality runs to engine (1) lopsided quantity and quality centering craft and the relation that machine degree get crankshaft the crankshaft of quality center aperture, as the development that machines degree, the lopsided quantity of crankshaft shows ascendant trend, the size of ascendant degree has main concern with semifinished product quality, semifinished product quality is poorer (bend) , ascendant trend is bigger, discard as useless even. Get the crankshaft of geometrical center aperture, as the development that machines degree, the lopsided quantity of crankshaft shows downtrend, if semifinished product quality is very poor (bend) , major crankshaft is washed out after classics rough machining. Front of grinder of graph 2 JUCRANK 6000/50-50 CBN and back end appearance pursue 2 it is model is " JUCRANK 6000/50 - 50 " grinder of numerical control crankshaft. This grinder has 4 CBN emery wheel, every all can become independent grinding, hold clip but grinding is all main shaft neck and connecting rod neck (swing dog grinding) . On December 8, 2005 morning, delegate of Beijing of Shen Ke company is in Germany to build a gentleman to balanced technology and quality centering technology to make detailed introduction with respect to crankshaft on behalf of Guo Wei. Guo Wei builds a gentleman to carry technologies of pair of crankshaft dynamic balancing and balance equipment explain elaborated the following problem: 1.

The new trend that crankshaft balances (1) the initial unbalance that reduces crankshaft, the in-house quality of mature crankshaft is compensated (adopt quality centering to wait) . (2) use lopsided quantity to optimize decompose a method, decrease as far as possible corrective and rough the material purify quantity when measuring. (3) balancing machine is used modular design, rise flexible. (4) auger cut use high speed getting to cut. (5) lubricant use MOL (minim is oil-lubricated means) technology. 2.

The influence that compensation of crankshaft interior quality runs to engine (1) lopsided quantity and quality centering craft and the relation that machine degree get crankshaft the crankshaft of quality center aperture, as the development that machines degree, the lopsided quantity of crankshaft shows ascendant trend, the size of ascendant degree has main concern with semifinished product quality, semifinished product quality is poorer (bend) , ascendant trend is bigger, discard as useless even. Get the crankshaft of geometrical center aperture, as the development that machines degree, the lopsided quantity of crankshaft shows downtrend, if semifinished product quality is very poor (bend) , major crankshaft is washed out after classics rough machining. Graph the car vehicle of 3 crankshaft pulls craft to pursue the car vehicle of 3 crankshaft helps technology (2) of aperture of crankshaft quality center and geometrical center aperture it is good to choose quality of ① semifinished product, mental allowance is small and mental allowance distributings even. At this moment the quality center aperture of crankshaft and geometrical center aperture are basic coincide, need not cost higher funds to purchase quality centering equipment. Quality of ② semifinished product is poorer, mental allowance Dajujia is versed in surplus distributings inhomogenous, actor chooses choose first quality center aperture. Because initial unbalance is bigger, if drill geometrical center hole, quality distributings inhomogenous, moment of inertia is bigger, attaint follow-up machines equipment precision. Moreover, use geometrical center opening, when undertaking dynamic balancing, initial unbalance may exceed a balance to confidential is begged and cannot be balanced. Answer below this kind of circumstance preferential choose quality centering engine. If quality of ③ semifinished product is again poor, no matter be,get geometrical center aperture to won't have how old effect, achieve whole through the measure such as mill music arm the balance is real it is unqualified (odd turn is lopsided) , it is a kind of false appearance. The meeting after machine of outfit of this kind of crankshaft produces twist to be out of shape afresh, cause vibration and noise, also affect overall life. From this knowable, raising product quality key is the quality that improves semifinished product. 3.

Full automatic crankshaft places the working principle of machine of crankshaft quality centering to slide in two end unit flange dish prop up go up and by clamp, flange dish centre of turning circle is formed measure central line. In circumgyrate process, the position that support, namely the position of crankshaft is adjusted ceaselessly, make quality center line stands by line of centre of turning circle. When crankshaft semifinished product lopsided amount is very small, when be close to set to be worth, auger cut unit to drill central hole. The fixed position that this center aperture regards follow-up treatment as measure is standard. Shanghai is general the title that production engineer Mr Qi Xin makes a speech is " assemble type camshaft workmanship to introduce " . In assembling type camshaft to make wider and wider application be machined in camshaft, its marked characteristic is: Camshaft total mass the workpiece with lighter, high strenth, short, inferior technological process discards as useless rate, flexible turn production. Assemble type camshaft to make treatment have characteristic of the following craft: (1) omited the rough machining of wool blank, technological process is simple. Each buildup member surplus that assemble type camshaft are small, precision is tall, need not want in that way like traditional camshaft from wool blank (cast fire forging) begin to undertake many semifinished product rough machining, want to have semifinishing machining and precision work after assemble only, shortened thereby whole technological process. (2) mental allowance is small, facilitate efficient production. Component of each essence casting makes mental allowance small, equipment treatment is only a time is short, produce can big, be helpful for dimensions turning production. For instance cam piece presses casting of final figure essence, reduced grinding surplus to shorten thereby grinding time. (3) different component can use different material to taste function of function and treatment in order to raise high yield. Product to different component (journal, cam piece, gear) having diverse performance demand, assemble type camshaft to be able to use different data on different component, for instance cam uses pulverous metallurgy, tine base is used cast-iron, this will be helpful for optimizing product function to ask, also can improve camshaft processability to be able to be mixed according to the circumstance optimize cost. (4) get used to a product much breed is flexible the requirement that change. The cam molded lines that through changing different main shaft neck and grinding differ, can produce the crankshaft that gives much variety. Shanghai is general the title that production engineer Dr. Scott Hacker makes a speech is " online quality controls crankshaft " . Dr. Scott Hacker introduced product line of crankshaft of company of Shanghai general motors to machine technological process. Crankshaft is the core component of the normal movement that assures engine, the external diameter of neck of products plan countershaft and circularity have very high demand, tolerancepublic errand is controlled normally in 0.

002 ~ 0.

005mm less than, stop requirement of public errand of the width that choose a side is in normally 0.

005mm less than, and these dimension are the most crucial factor in crankshaft whole treatment, ask to be improved ceaselessly. Dr. Scott Hacker introduced a few kinds of commonly used quality to control a method when the control that stresses treatment quality: (1) after treatment online measure the quality that is used after spare parts of test and verify is machined, establish ties normally in product line, 100% detect workpiece discovers reject. (2) in machining a process online measure implementation to be controlled to machining the real time of dimension, can prevent to make a reject. (3) sample from the line detect finish by jockey detect the job, but general need not this kind of means undertakes compensating to equipment. Apply to plan to have sampling observation according to control, ensure those who machine quality is stable. Dr. Scott Hacker still introduced car of essence of life online measuring instrument is main characteristic and the influence to product output: The method that can use short-term facilities ability to analyse finishs the test stop work for the day of equipment ability to make, initial stage is debugged in equipment, not certain need uses online feedback system to make eligible work. Use detect data feedback system, can solve a few statistical inextricability problem, the error that changes knife place to cause for example, circumstance that break a knife. Fine vehicle is online the measuring instrument is couplet of alone labour bit string in product line, measure time weak point at machining metre, do not have an influence to productivity so. According to the demand of crop, product line may need to install the machine tool of stage or two above, but the need that enough of an online measuring instrument satisfies manufacturing metre. Online measuring instrument still has car of essence of life changing knife and condition of cutting tool tatty to leave automatic feedback system, compensate automatically to machining error. Grinding is online the grinding dimension that metrical effect basically is journal of rigid control crankshaft, it is the effective device that prevent a fault. Head feed is measured when essence of life is ground, dog the change of dimension of record external diameter: Grinder of much emery wheel of main shaft neck uses two measuring instruments at the same time normally, dominate crankshaft from beginning to end respectively the neck of two main shaft of two end, measuring instrument of grinder of connecting rod neck controls the grinding dimension of neck of every archives connecting rod. Polishing is online metrical main characteristic is: The first working procedure is thick cast, applicable and online measuring instrument controls polishing dimension, essence of the 2nd working procedure is cast, the purpose is to reduce exterior surface roughness to be worth. On December 8 afternoon, science of car of Shanghai traffic university and project academy are advanced and advisory, engine of former Shanghai masses senior engineer Mr Gu Yongsheng made class of plant factory manager, professor sum up a speech. Consider a professor to affirm the positive effect of this seminar adequately, preliminary the central topic for discussion that discussed a seminar. The person that point out this delibrate joint performance is told is manufacturer of foreign automobile equipment and applied business, below one will invite manufacturer of outstanding equipment of a few home, and engine and the experience that component manufacturer introduces a few successes, engine of common stimulative our country and component create horizontal promotion. CNC Milling