Cars are a highly commodified industrial product, and in response to intense market competition and the growing demand for personalized consumer experiences, automotive manufacturers have increasingly adopted diverse product strategies. These strategies have become a common trend in the industry. Within this context, the quality monitoring methods used in production workshops have evolved significantly alongside changes in manufacturing processes. On-line inspection devices, installed near production line stations, play a crucial role in sampling and checking parts. Their function extends beyond simply assessing the physical quality of workpieces—they also provide statistical analysis that reflects the operational state of the process and helps evaluate the overall quality of the manufactured components.
As the automotive industry continues to evolve, the on-line detection equipment deployed between production stages has become simpler and more flexible, occupying an important place in many new production lines. However, the configuration and features of these testing devices are heavily influenced by the specific manufacturing processes used. This article explores this topic through a detailed case study of crankshaft production.
One of the most significant trends in detection methods is the simplification and flexibility of inspection systems. Looking at the evolution of engine production lines over several generations, it's clear that the need to support a multi-variety product strategy has driven major developments in engine manufacturing technology. Taking the crankshaft as an example, its production process typically includes three stages: roughing, heat treatment, and finishing. Each stage involves substantial changes, with the finishing stage—particularly journal grinding—being one of the most critical.
From the 1990s to the early 2000s, CNC high-speed special crankshaft grinders were the mainstream for journal grinding. Main journals were usually processed using multi-wheel cutting machines, while connecting rod journals were handled by multiple grinders. For example, a four-cylinder gasoline engine might use two grinders to machine the connecting rod journals of cylinders 1–4 and 2–3. Most often, rough grinding and fine grinding were done on the same machine.
However, starting from the early 21st century, more efficient and flexible grinding machines began to replace traditional systems. For instance, the EA888 series engine produced by Shanghai Volkswagen in 2009 used Landis and Volkswagen Powertrain (Shanghai) grinders, while the EA111/EA211 engines in the second phase of the project featured Junker’s advanced systems.
These modern CNC grinders are equipped with wheel-following and tracking functions, which represent a major advancement in crankshaft finishing technology. They offer greater flexibility by allowing different workpieces to be processed with simple program adjustments. Additionally, since both main and connecting rod journals can be machined in one clamping, the resulting manufacturing errors are reduced, and machining accuracy is improved. The use of CBN grinding wheels and coolant further enhances tool life and production efficiency, while integrated measurement and data processing systems improve dimensional and shape accuracy.
For example, by using the Adcole 1200 precision measuring chamber to measure the roundness of the crankshaft journal, the control system can adjust and compensate to enhance the final quality. This has led to a significant improvement in roundness control, from 4–4.5 μm to within 2 μm. Such improvements highlight the effectiveness of modern detection and control systems.
With the diversification of production modes and continuous technological advancements, on-line inspection tools have become simpler and more adaptable. An example is the inspection station placed next to the crankshaft grinding line, as shown in Figure 1. While both gauges are intelligent, Figure 1a presents a semi-automatic multi-parameter comprehensive gauge used for five main journals, while Figure 1b shows an intelligent test bench composed of multiple handheld single-parameter gauges, reflecting a more flexible approach.
The latter is particularly suited for new grinding processes, where the same machine can handle both main and connecting rod journals. This not only improves flexibility but also enhances manufacturing quality, especially in terms of geometric tolerances like roundness. The use of advanced equipment and technologies, such as the Adcole 1200 instrument, has enabled tighter control over these parameters.
In summary, the evolution of crankshaft production and inspection methods demonstrates a clear shift toward simplicity, flexibility, and precision. As the industry continues to advance, these trends will likely shape the future of automotive manufacturing.
Ceiling lights are a common lighting device with characteristics and attributes such as bright and uniform, space saving, safety and reliability, diversified design, energy conservation and environmental protection, dimming function, and intelligent control
LED ceiling lights ,Customize multiple ceiling lights,Customized ceiling lights
Hanghong Lighting (Linyi) Co., Ltd. , https://www.sdhhzm.com