Claims:We claim:

1. A semi-automatic system for measuring and recording the cylinder liner projection on an automotive engine block, the system comprises:

• a computing unit (CPU) connected to input device, output device, digital monitor and a printer;

• a reset sensor;

• a transmitter-receiver unit;

• a metallic mounting plate fitted with handles for handling thereof;

• a plurality of digital dials equipped with respective sensors, a respective pair of digital dials for each bore being electrically connected to the controller;

• a gauge-block for mounting and supporting the digital dials;

• a respective nut and collet pairs for holding each digital dial on the mounting plate;

• a battery-operated controller (PLC) to transmit captured data received from the sensors on the dials to the microchip through a transmitter;

• a transmitter and receiver unit for data transmission;

wherein a respective pair of digital dial is placed over each bore for measuring and recording the cylinder liner projection and the battery-operated controller is equipped with a microchip stored with the preset tolerance limits for the liner projection for comparing the measured liner projection values and saving and printing the captured data by pressing a push button provided on the controller.

2. System as claimed in claim 1, wherein the gauge block is mounted on the mounting plate by means of suitable fasteners, preferably bolts.

3. System as claimed in claim 1, wherein each dial is mounted on the gauge block by means of a respective pair of nut and collet.

4. System as claimed in claim 1, wherein the controller is mounted on the mounting plate in a box made of acrylic material.

5. System as claimed in claim 1, wherein at least two sensors are placed on the mounting plate for performing ‘Master detect’ and ‘Job detect’ functions.

6. System as claimed in claim 5, wherein the sensors are inductive proximity sensors.

7. System as claimed in claim 1, wherein the system is placed on the master plate for initial ‘Zero’ resetting before starting measurement of liner projection.

8. System as claimed in claim 1, wherein the data from the controller is transmitted to the microchip by means of the transmitter and receiver unit.

9. System as claimed in anyone of the claims 1 to 8, wherein the system is configurable according to the number of cylinders/bores in the automotive engine block, preferably to 4-cylinder and 6-cylinder automotive engine block.

10. A method for measuring and recording the cylinder liner projection on an automotive engine block by means of the semi-automatic system as claimed in anyone of the claims 1 to 9, the method comprises the steps of:

(f) placing the guide block mounted with the plurality of digital dials on the master plate to activate ‘Master detect’ function and resetting the system to ‘Zero’ reading;

(g) Transferring the reset system from the master plate and properly locating the same on the bores of the engine block;

(h) Observing the ‘Job detect’ function activation and capturing liner projection readings displayed on the monitor and adjusting the system by moving the gauge block thereof, if necessary;

(i) Pressing the push button on the controller box and obtaining the captured data on a label printed by the printer; and

(j) Placing the guide block mounted with the plurality of digital dials again on the master plate and repeating the steps (a) to (d) after automatically resetting the same to ‘0’ reading for commencing measurements on the next engine block.

Dated: this day of 29th September 2017. SANJAY KESHARWANI
APPLICANT’S PATENT AGENT , Description:FIELD OF INVENTION

The present invention relates to an automotive engine’s cylinder liner projection system. In particular, the present invention relates to a system for checking the cylinder liner projection in an internal combustion engine. More particularly, the present invention relates to a system for checking liner projection or protrusion for accurate checking of cylinder liner projection albeit with less fatigue and time.

BACKGROUND OF THE INVENTION

Liner protrusion refers to how far the cylinder liner protrudes above the spacer plate on the top of the block. If the liner does not protrude enough, the head gasket can, and will, fail. A correct liner protrusion or a little bit over protrusion, facilitates a better sealing and helps the cylinder head gasket to withstand the forces, to which it is subjected under normal and severe working conditions.

Basically, “Liner protrusion/projection” is the distance by which the cylinder liner protrudes above the cylinder block’s deck (spacer plate) surface. The main object of the cylinder liner protrusion or sleeve protrusion is to impart a certain degree of “crush” on the cylinder head gasket for ensuring that the cylinder head crushes the gasket evenly and to the correct specification, once it is torqued.

Therefore, it is quite important to measure the liner protrusion at several, preferably four (4) locations about each cylinder. It also caters to record the exact amount of variation in liner protrusion from the permissible limits. Moreover, these liner protrusion measurements must not only be consistent concentrically around each cylinder bore, but also from one cylinder to the other.

In case, it is observed during the cylinder liner projection measurements that the recorded values are not consistent from cylinder to cylinder, then it implies that the cylinder head gasket is crushing/sealing properly on one side of the engine and not sealing on the other side. So, an incorrect liner protrusion might lead to catastrophic IC engine failure.

In engine assembly, normally the cylinder liner projection or protrusion is checked manually with the conventional fixture consisting of two dials, a gauge block made of hardened EN-31 and a master block made of hardened OHNS. For checking liner projection, the fixture is kept on the 1st bore of the engine block. Readings are observed and manually recorded on the route card. Subsequently, the fixture is placed on the 2nd bore followed by observing and recording the readings therefor. This procedure is usually repeated four times for each of four/six bores and therefore human errors may occur therein. Further, continuous recording of the readings causes extreme stress on the liner projection inspector’s eyes.

The process sequence (Figure 1) followed during an inspection using a conventional manual liner projection unit involves the steps of:

- Initially placing (10) the dial gauge on the master plate.

- Pressing (20) the master table button to reset the dial gauge to zero.

- Placing (30) dial gauge on 1st bore of the engine block.

- Observing (40) 1st bore liner projection reading.

- Recording (50) the observed 1st bore liner projection reading.

- Repeating (60) the same procedure (10-50) above for the rest of the cylinder bores.

PRIOR ART

US 4372156 A discloses a method of determining the projection of the upper end of a cylinder liner above the top surface of a cylinder block structure. The cylinder liner is caused to be fully inserted into the cylinder bore by a press ring acting on the upper end of the cylinder liner concurrently with the measurement of its position. The press ring is resiliently forced against the top surface of the cylinder liner by a plurality of pressure springs and a pressure plate. The pressure plate is urged into engagement with the cylinder block structure top surface by a hold-down bar. The measuring system utilizes a gage indicator having a probe which is selectively engaged with the upper surface of the cylinder liner adjacent positions of force transfer between the press ring and cylinder liner. The probe is caused to determine the position of the cylinder block structure upper surface selectively directly or indirectly. In effecting a direct determination, the probe is inserted through a zeroing hole in the pressure plate to determine the disposition of the lower surface of the pressure plate. The probe is directly engaged with the upper surface through recesses in the periphery of the pressure plate.

However, the method and apparatus disclosed herein is manually operated and suitable only for use in the maintenance and rebuilding thereof. Moreover, is includes a complex arrangement for checking the cylinder liner projection.

DISADVANTAGES WITH THE PRIOR ART

However, the problem with the conventional method and apparatus used for cylinder liner projection or protrusion involve fully manual inspection and recording, which requires a plurality of measurements, thus leads to inaccurate liner projection measurements due to human errors creeping in therein.

Therefore, there is an existing need for developing a semi-automatic liner projection measurement system, which facilitates liner projection inspection and recording more accurately and also eliminates the manual work involved therein.

OBJECTS OF THE INVENTION

Some of the objects of the present invention - satisfied by at least one embodiment of the present invention - are as follows:

An objective of the present invention is to provide a liner projection measurement and recording system, which eliminates human errors therein.

Another objective of the present invention is to provide a semi-automatic liner projection measurement and recording system, which is more accurate than the conventional manual system.
Still another object of the present invention is to provide a semi-automatic liner projection measurement and recording system, which reduces cycle time by checking all the bores at one go.

Yet another object of the present invention is to provide a semi-automatic liner projection measurement and recording system reducing operator’s fatigue.

A further object of the present invention is to provide a semi-automatic liner projection measurement and recording system, which is light weight and involves an ergonomic configuration.

These and other objects and advantages of the present invention will become more apparent from the following description, when read with the accompanying figures of drawing, which are however not intended to limit the scope of the present invention in any way.

DESCRIPTION OF THE INVENTION

Accordingly, the liner projection system configured in accordance with the present invention consists of a specially designed fixture with eight (8) or twelve (12) dials which can be placed on all the four/six bores. A microchip is configured for displaying and storing data of the observed readings of multiple liner projections. The microchip includes a programmable controller and is mounted on the fixture itself to receive the input signal from the dials and to transmit the measurement data from these dials to the microchip through a transmitter and receiver unit by using WIFI connection and to display it on the monitor screen. Initially, the fixture is placed on a master plate to automatically reset the data to zero using the sensor provided for ‘master detect’.

Subsequently, the fixture is placed on the engine block and accordingly, the job presence sensor is activated and this is displayed on the monitor screen. The individual readings along with bore to bore readings are also displayed on this screen.
A push button is mounted on the controller, which on pressing saves the data in the microchip and a label is printed to show the measurement results, such as engine serial number, recorded values and whether passes the tolerance limits or fails the specified liner projection limits.

This printed label can now be pasted on the route card and passed further. This avoids noting down the readings manually.

In case, the liner projection limits are not within specified limits, the label is still printed, but further operation is performed only when the system is bypassed. This can be done by using the key system provided therewith. The data for each and every engine block can be saved in the microchip.

SUMMARY OF THE INVENTION

In accordance with the present invention, a semi-automatic system for measuring and recording automotive cylinder liner projection is provided, which comprises:

• A mounting plate made of Aluminum to act as the fixture base and to support the plurality of digital dials, controller and sensors;

• A fixture provided with two inductive proximity sensors thereon for performing the master detect and job detect functions.

• At least four gauge-blocks to mount and support the plurality of digital dials;

• At least eight nuts and collets for holding the digital dials;

• At least eight digital dials connected to the PLC controller through WIFI;

• A battery-operated controller to transmit captured data from the digital dials to the microchip through the transmitter;

• At least two side-handles for handling of the overall system; and

• A transmitter-cum-receiver unit for data transmission taking place therebetween through WIFI communication.

In accordance with the present invention, a method is also provided for measuring and recording automotive cylinder liner projection by using the aforesaid semi-automatic system, the method comprises the following steps:

• Initially placing the fixture on a master plate. Two inductive proximity sensors are provided on the fixture for master detect and job detect. A push button is provided on the controller for saving the test id and actuating the print.

• Bolting the gauge block on the mounting plate provided with a little play for proper resting of fixture on the engine block.

• Mounting the digital dials on the gauge block using nuts and collets.

• Fixing the PLC circuit inside an acrylic box mounted on the mounting plate and connecting the digital dials to the PLC.

In accordance with the present invention, the method of measurement and recording the cylinder liner projection comprises the steps of:

(a) Transferring the fixture from the master plate and placing it on the engine block;

(b) Observing the ‘job detect’ activation and readings on the monitor screen; adjusting the fixture by moving the gauge block, if required.

(c) Pressing the push button on PLC to obtain printed label from the printer;

(d) Placing the fixture on the master plate and passing the engine block forward, which automatically resets liner projection value to ‘0’.

STATEMENT OF THE INVENTION

In accordance with the present invention, there is provided a semi-automatic system for measuring and recording the cylinder liner projection on an automotive engine block, the system comprises:

• a computing unit (CPU) connected to input device, output device, digital monitor and a printer;

• a reset sensor;
• a transmitter-receiver unit;

• a metallic mounting plate fitted with handles for handling thereof;

• a plurality of digital dials equipped with respective sensors and a respective pair of digital dials for each bore electrically connected to the controller;

• a gauge-block for mounting and supporting the digital dials;

• a respective nut and collet pairs for holding each digital dial on mounting plate;

• a respective pair of digital dials electrically connected to the controller;

• a battery-operated controller (PLC) to transmit captured data received from the sensors on the dials to the microchip through a transmitter;

• a transmitter and receiver unit for data transmission;

wherein a respective pair of digital dial is placed over each bore for measuring and recording the cylinder liner projection and the battery-operated controller is equipped with a microchip stored with the preset tolerance limits for the liner projection for comparing the measured liner projection values and saving and printing the captured data by pressing a push button provided on the controller.

Typically, the gauge block is mounted on the mounting plate by means of suitable fasteners, preferably bolts.

Typically, each dial is mounted on the gauge block by means of a respective pair of nut and collet.

Typically, the controller is mounted on the mounting plate in a box made of acrylic material.

Typically, at least two sensors are placed on the mounting plate for performing ‘Master detect’ and ‘Job detect’ functions.

Typically, the sensors are inductive proximity sensors.

Typically, the system is placed on the master plate for initial ‘Zero’ resetting before starting measurement of liner projection.
Typically, the data from the controller is transmitted to the microchip by means of the transmitter and receiver unit.

Typically, the system is configurable according to the number of cylinders/bores in the automotive engine block, preferably to 4-cylinder and 6-cylinder automotive engine block.

In accordance with the present invention, there is also provided a method for measuring and recording the cylinder liner projection on an automotive engine block by means of the semi-automatic system as claimed in anyone of the claims 1 to 9, the method comprises the steps of:

(a) placing the guide block mounted with the plurality of digital dials on the master plate to activate ‘Master detect’ function and resetting the system to ‘Zero’ reading;

(b) Transferring the reset system from the master plate and properly locating the same on the bores of the engine block;

(c) Observing the ‘Job detect’ function activation and capturing liner projection readings displayed on the monitor and adjusting the system by moving the gauge block thereof, if necessary;

(d) Pressing the push button on the controller box and obtaining the captured data on a label printed by the printer; and

(e) Placing the guide block mounted with the plurality of digital dials again on the master plate and repeating the steps (a) to (d) after automatically resetting the same to ‘0’ reading for commencing measurements on the next engine block.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

The present invention will be briefly described with reference to the accompanying drawings.

Figure 1 shows a conventional procedure for manually measuring the cylinder liner projection on automotive engine blocks.

Figure 2 shows the assembly of the conventional fixture for manually measuring the cylinder liner projection placed on an automotive engine block.

Figure 3 shows a schematic circuit diagram of the semi-automatic system configured in accordance with the present invention for measuring and recording the cylinder liner projection on an automotive engine block.

Figure 4 shows the assembly of the semi-automatic system configured in accordance with the present invention for measuring and recording the cylinder liner projection for an automotive engine block placed on conveyor.

Figure 5 shows the semi-automatic system configured in accordance with the present invention placed on the master plate in home position thereof.

Figure 6 shows a schematic flow chart of the method devised by using the semi-automatic system configured in accordance with the present invention for measuring/recording the cylinder liner projection on automotive engine block.

DETALED DESCRIPTION OF THE ACCOMPANYING DRAWINGS

In the following, the semi-automatic system configured in accordance with the present invention for measuring and recording the cylinder liner projection an automotive engine block is described in more details with reference to the accompanying drawings without limiting the scope and ambit of the present invention in any way.

Figure 1 shows a conventional procedure for manually measuring the cylinder liner projection on automotive engine blocks.

Figure 2 shows the assembly of the conventional fixture 20 for liner projection measurement placed on an automotive engine block 02 disposed on a conveyor 04. The fixture ensures an accurate placing on the engine block 02. Accordingly, the gauge block 06 is placed on the engine block 02 using the handle bar 08 provided. If needed, the gauge block 06 is manually moved slightly for proper alignment. After properly placing the gauge block 06, liner projection measurement data captured from the dials 10 fixed by means of nut and collet arrangements 12 is manually noted by the operator and readings are recorded in the engine card (not shown).

Figure 3 shows a schematic circuit diagram of the semi-automatic system 100 configured in accordance with the present invention for measuring and recording the cylinder liner projection on an automotive engine block, e.g. having four (4) cylinder bores 1- 4. The system comprises CPU 22, COM1 24, COM3 26, reset sensor 28, transmitter-receiver unit 30 and bypass 32 connected thereto via 0V and 24V lines, keyboard 34, mouse 36, a monitor 38 and printer 40 connected to CPU 22. The monitor 38 can display liner projection data 42, readiness for measurement 44, master detect 46 and job present 48 for liner projection measurements.

Figure 4 shows the assembly of the semi-automatic system 100 configured in accordance with the present invention for measuring and recording the cylinder liner projection for an automotive engine block 02 placed on conveyor 04. The system 100 ensures an accurate placement thereof on the engine block 02. Accordingly, the system 100 is mounted on the mounting plate 102 provided with the handle 104 is placed on the engine block 02. If needed, the gauge block 106 is manually moved slightly for proper alignment. After properly placing the system 100, sensor 108 detects the presence of the job to be measured, by sensing the engine block 02 and ensures its proper location. Subsequently, data from the digital dials 110 fixed on the gauge block 02 by using nut and collets 112 is transmitted with the help of the transmitter and receiver unit 114 to the microchip 116. The push button 118 on the programmable logic controller 120 is pressed to print the label of results captured. The gauge block 106 is preferably made up of EN-31 material, which does not affect the liner material and it is also provided with a play for adjusting of the system 100 on the engine block 02, if needed.
Figure 5 shows the semi-automatic system 100 configured in accordance with the present invention placed on the master plate 150 in home position thereof. Handles 104 are provided for fatigue-free picking and placing of the system 100. Two inductive proximity sensors 108 are provided for performing master detect and job detect functions respectively. Here, each digital dial 110 is mounted on the gauge block 106 by means of a respective nut and collet 112, 130 pair.

Figure 6 shows a schematic flow chart of the method devised by using the semi-automatic system 100 configured in accordance with the present invention for measuring/recording the cylinder liner projection on automotive engine block. The process flow diagram is self-explanatory.

WORKING OF THE INVENTION

The liner projection sequence performed for measuring and recording the cylinder liner projection for an automotive engine block by using the system 100 configured in accordance with the present invention is as follows:

• Fixture from master plate 150 (Fig. 5) is picked and placed on engine block 02.

• Job detect by sensor 108 and necessary readings are observed.

• Push button on the controller 120 is pressed to issues the printed label.

• The system 100 is again placed on master plate 150 and it resets automatically.

• If result is ‘fail’, then the system 100 needs to be bypassed by using the key arrangement 32 (Fig. 3) provided.

TECHNICAL ADVANTAGES AND ECONOMIC SIGNIFICANCE

The semi-automatic system for liner projection configured in accordance with the present invention has the following technical and economic advantages:

• Associated operator’s fatigue is eliminated due to ergonomic, light weight and compact design.

• Avoids manual recording of the readings causing stress on liner projection inspector’s eyes.

• No chances of the occurrence of human errors.

• Bore to bore readings are made possible.

• All bores can be checked by covering them by the system in one go.

• Cycle time reduced by about 20 Seconds.

• Light-weight system for user-friendly operation and material selection.

The exemplary embodiments described in this specification are intended merely to provide an understanding of various manners in which this embodiment may be used and to further enable the skilled person in the relevant art to practice this invention. The description provided herein is purely by way of example and illustration.

Although, the embodiments presented in this disclosure have been described in terms of its preferred embodiments, the skilled person in the art would readily recognize that these embodiments can be applied with modifications possible within the spirit and scope of the present invention as described in this specification by making innumerable changes, variations, modifications, alterations and/or integrations in terms of materials and method used to configure, manufacture and assemble various constituents, components, subassemblies and assemblies, in terms of their size, shapes, orientations and interrelationships without departing from the scope and spirit of the present invention.

While considerable emphasis has been placed on the specific features of the preferred embodiment described here, it will be appreciated that many additional features can be added and that many changes can be made in the preferred embodiments without departing from the principles of the invention. These and other changes in the preferred embodiment of the invention will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation.
Many of the fastening, connection, processes and other means and components utilized in this invention are widely known and used in the field of the invention described, and their exact nature or type is not necessary for an understanding and use of the invention by a person skilled in the art and they will not therefore be discussed in significant detail.

The numerical values given of various physical parameters, dimensions and quantities are only approximate values and it is envisaged that the values higher or lower than the numerical value assigned to the physical parameters, dimensions and quantities fall within the scope of the disclosure unless there is a statement in the specification to the contrary.

Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, shall be understood to implies including a described element, integer or method step, or group of elements, integers or method steps, however, does not imply excluding any other element, integer or step, or group of elements, integers or method steps.

The use of the expression “a”, “at least” or “at least one” shall imply using one or more elements or ingredients or quantities, as used in the embodiment of the disclosure in order to achieve one or more of the intended objects or results of the present invention.

Also, any reference herein to the terms ‘left’ or ‘right, ‘up’ or ‘down, or ‘top’ or ‘bottom’ are used as a matter of mere convenience, and are determined by standing at the rear of the machine facing in its normal direction of travel.

Furthermore, the various components shown or described herein for any specific application of this invention can be widely known or used in the art by persons skilled in the art and each will likewise not therefore be discussed in significant detail. When referring to the figures, like parts are numbered the same in all of the figures.