Description:TECHNICAL FIELD
[001] The present disclosure generally relates to pressing tools, and more particularly, the present disclosure relates to an alignment tool suitable for use in a press machine for aligning holes of structural members and a related method. More specifically, to the alignment tool for use in the press machine for aligning a hole defined in a cam bush to a hole defined in an engine crankcase oil gallery.

BACKGROUND
[002] Pressing tools are used in mechanical, pneumatic and hydraulic presses to produce sheet metal components in large volumes. Pressing tools also find wide application in automobile industry especially in the manufacturing of various components of engines and vehicles. One such application of pressing tool is found in press fitting a cam bush in a crankcase of an engine. The crankcase is a central component of an engine as it houses the entire crank mechanism including pistons, cylinders and connecting rods. The crankcase also stores lubricating oil required for lubricating the engine parts. Passages or holes commonly called as oil galleries, are provided in the crankcase for passage of the lubricating oil to all parts of the engines. The oil galleries are essential to allow passage of oil to different parts of the engine, so that the parts are lubricated and cooled for maintaining engine efficiency.
[003] A cam bush is press fitted into a cam bore of the crankcase using the pressing tool. The cam bush is provided with hole(s) to allow passage of oil when press fitted into the cam bore of the crankcase. It is crucial that the hole in the cam bush is aligned with the hole in the oil gallery of the crankcase. A misalignment of the cam bush hole with the oil gallery will block the passage of oil through the crankcase and will affect the functioning of the engine.
[004] Conventionally, the hole in cam bush is manually aligned with the oil gallery of the crankcase while press fitting the cam bush in the cam bore. A manual error in mismatching of holes results in engine functioning/ efficiency issues. Therefore, in manual hole alignment, human precision is highly important.
[005] In some pressing tools, a guiding component is provided in the pressing tool to guide the hole of the cam bush in the exact position into the cam bore. An operator is required to align the hole of the cam bush with the guiding component to ensure that the cam bush is press fitted at the exact position. An error of misalignment of hole with the guiding component, results in mismatching of hole in cam bush with the oil gallery. Also, the pressing tools and the press machine lack the ability to stop the fitment of the cam bush into the cam bore when the hole is not aligned.
[006] Pressing tools with sensors to detect misalignment of hole and ability to automatically align the hole are available currently. However, such pressing tools are complex to operate, slower, and include multiple components which increases the maintenance cost and time of the press machine.
[007] Therefore, there is a need for an alignment tool for use in the press fitting of the cam bush into the cam bore of the crankcase which aligns the hole of the cam bush with the hole in the oil galleries of the crankcase, while overcoming the aforementioned drawbacks of existing pressing tools.

OBJECTS
[008] The principal object of an embodiment of this invention is to provide an alignment tool suitable for use in a press machine for aligning holes of structural members.
[009] Another object of an embodiment of this invention is to provide the alignment tool for use in press fitting of a cam bush into a cam bore of a crankcase while aligning a hole of the cam bush with a hole in the oil gallery of the crankcase.
[0010] Another object of an embodiment of this invention is to provide the alignment tool which automatically stops operation of the press machine when the hole of the cam bush is misaligned with the hole of the oil gallery of the crankcase.
[0011] Yet another object of an embodiment of this invention is to provide the alignment tool with a hole guiding mechanism for guiding the alignment of the hole of the cam bush with the hole of the oil gallery of the crankcase.
[0012] Still another object of an embodiment of this invention is to provide the alignment tool with a gap sensor which detects a misalignment of hole through the hole guiding mechanism and communicates/relays an output signal to stop operation of the press machine.
[0013] Yet another object of an embodiment of this invention is to provide the alignment tool with additional guide pin assembly which prevents the pressing of cam bush inside the cam bore when the cam bush is not aligned in a predetermined position.
[0014] Still another object of an embodiment of this invention is to provide the alignment tool which prevents human error in aligning hole of the cam bush with the hole of the oil gallery of the crankcase,
[0015] Still another object of an embodiment of this invention is to provide the alignment tool which is efficient, and cost effective.
[0016] These and other objects of the embodiments herein will be better appreciated and understood when considered in conjunction with the following description and the accompanying drawings. It should be understood, however, that the following descriptions, while indicating embodiments and numerous specific details thereof, are given by way of illustration and not of limitation. Many changes and modifications may be made within the scope of the embodiments herein without departing from the spirit thereof, and the embodiments herein include all such modifications.

BRIEF DESCRIPTION OF DRAWINGS
[0017] The embodiments herein are illustrated in the accompanying drawings, throughout which like reference letters indicate corresponding parts in the various figures. The embodiments herein will be better understood from the following description with reference to the drawings, in which:
[0018] Fig 1 is a schematic diagram of an alignment tool comprising of bush pressing and alignment tool, a gap sensing mechanism, a pneumatic press machine, and a crankcase, according to an embodiment of the invention as disclosed herein;
[0019] Fig 2a is a schematic diagram of the alignment tool with a hole guiding mechanism for guiding the alignment of the hole of the cam bush with the hole of the oil gallery of the crankcase, according to an embodiment of the invention as disclosed herein;
[0020] Fig. 2b is another schematic diagram of the hole guiding mechanism of the alignment tool, according to an embodiment of the invention as disclosed herein;
[0021] Fig 3 is a schematic diagram of the hole guiding mechanism, when a hole of the cam bush is not aligned with a guiding ball of the guiding mechanism, according to an embodiment of the invention as disclosed herein;
[0022] Fig 4 is a schematic diagram of the hole guiding mechanism, when the hole of the cam bush is aligned with the guiding ball of the guiding mechanism, according to an embodiment of the invention as disclosed herein; and
[0023] Fig. 5 depicts a flowchart of a method for aligning holes in structural members, according to an embodiment of the invention as disclosed herein.

DETAILED DESCRIPTION
[0024] The embodiments herein and the various features and advantageous details thereof are explained more fully with reference to the non-limiting embodiments that are illustrated in the accompanying drawings and detailed in the following description. Descriptions of well-known components and processing techniques are omitted so as to not unnecessarily obscure the embodiments herein. The examples used herein are intended merely to facilitate an understanding of ways in which the embodiments herein may be practiced and to further enable those of skill in the art to practice the embodiments herein. Accordingly, the examples should not be construed as limiting the scope of the embodiments herein.
[0025] The embodiments herein achieve an alignment tool for aligning holes of structural members in a mechanical component which aligns a hole in a cam bush with a hole in an oil gallery of a crankcase. Further, the embodiments herein achieve the alignment tool with a hole guiding mechanism for guiding the alignment of cam bush hole with an oil gallery of the crankcase. Furthermore, the embodiments herein achieve the alignment tool with a gap sensing mechanism which detects misalignment of the hole of cam bush through a gap detecting sensor, and automatically stops working of a press machine when the hole of cam bush is misaligned. Moreover, the embodiments herein achieve the alignment tool with a guiding pin assembly which prevents the pressing of cam bush inside a cam bore when cam bush hole is not aligned in the required position. Additionally, the embodiments herein achieve the alignment tool which prevents human error in aligning hole of cam bush with the hole of the oil gallery, therefore increasing the efficiency of press fitting the cam bush in the crankcase. Furthermore, the embodiments herein achieve the alignment tool which provides better precision, is efficient, and cost effective. Moreover, the embodiments herein achieve a method for aligning hole of a structural member with a mechanical component using an alignment tool which eliminates the error of misalignment of cam bush hole with a hole of an oil gallery of crankcase. Additionally, the embodiments herein achieve the method, which is efficient, precise and increases productivity. Referring now to the drawings, and more particularly to FIGS. 1 through 5, where similar reference characters denote corresponding features consistently throughout the figures, there are shown embodiments.
[0026] Press fitting tools or pressing tools are operated through press machines which control the pressing and releasing of the pressing tools. Press machines such as hydraulic, pneumatic, and mechanical press machines apply controlled pressure on the pressing tool in a predetermined direction to press fit a particular component in a manufacturing process. Pressing tools have wide application in automobile manufacturing. One such application is press fitting of a cam bush in a cam bore of a crankcase. The crankcase comprises of multiple oil galleries to allow the passage of oil to engine parts. Therefore, the cam bush is provided with a hole to align with the oil gallery in the cam bore of the crankcase. It is crucial that the cam bush hole is matched and aligned with the oil gallery. Conventionally, in manufacturing process, the cam bush hole is manually aligned with a hole guiding component on the pressing tool and the pressing tool is aligned such that the cam bush aligns with the oil gallery in cam bore. If the cam bush hole is misaligned in such process, the cam bush is still inserted in the cam bore. The misaligned insertion of the cam bush blocks the oil gallery, which affects the efficiency of an engine.
[0027] Fig.1 depicts a schematic diagram of an alignment tool (500) comprising of a pressing and alignment device (100) (hereinafter also referred to as pressing tool), a gap sensing mechanism (200), a press unit (300) connected to the pressing and alignment device (100) and communicating with a controller, wherein a cam bush (105) is press fitted in a cam bore (400A) of a crankcase (400) through the pressing and alignment device (100), according to an embodiment as disclosed herein. In an embodiment, a gap sensor (201) is connected to the pressing and alignment device (100) at a predetermined position and communicates with the controller. A relay (202) is operationally connected with the gap sensor (201), and a shut-off valve (203) is connected with the relay (202). Further, a direction valve (204) is operationally connected with the shut-off valve (203). The pressing and alignment device (100) is coupled with the press unit (also referred to as press) (300). In another embodiment, the press unit (300) comprises of a pneumatic press. The pressing and alignment device (100) is operated through the press (300), wherein the press punches and releases the pressing and alignment device (100) for press fitting the cam bush (105) in the cam bore (400A) of the crankcase (400). In another embodiment, alignment tool (500) comprises of a pressing and alignment device (100) designed to receive a structural member of predetermined dimension, and align hole in the structural member of predetermined dimension with a mechanical component and press fitting the structural member into a bore of the mechanical component.
[0028] As shown in Fig. 2a which depicts a schematic diagram of the pressing and alignment device (100), according to an embodiment as disclosed herein. The pressing and alignment device (100) includes a cap (101), a main body (102), a guiding pin assembly comprising of a guide plate (103) and a guide pin (104), and a hole guiding mechanism. The cam bush (105) is inserted on the main body (102) of the pressing tool (100) at a predetermined position. The cap (101) is attached above the main body (102). The guide plate (103) is attached between the main body (102) and the cap (101). The guide pin (104) is inserted through the guide plate (103) extending towards the main body (102). In an embodiment, the guide pin (104) comprises of a step pin and an undercut is defined towards the main body (102) of the pressing tool (100). In another embodiment, a structural member of predetermined dimension is inserted in a body of the pressing and alignment device (100), having predetermined dimensions. In an embodiment, the main body (102) comprises of a cylindrical body with a wider cylindrical upper end. The upper end of the main body (102) is attached with the guide plate (103) which comprises of an annular body. The cap (101) is connected with the main body (102) at the upper end, wherein the guide plate (103) is fixed between the cap (101) and the main body (102).
[0029] Fig 2b depicts a schematic diagram of the hole guiding mechanism of the pressing and alignment device (100) disposed within the main body (102) of the pressing and alignment device (100), according to an embodiment of the invention as disclosed herein. In an embodiment, the hole guiding mechanism comprises of a guiding ball (106), an adjustment screw (107), a liner pin (108) comprising of an orifice (108A) for passage of compressed air, a spring (109) operationally connected with the liner pin (108) at predetermined position, a cap nut (110) connected with the spring (109), a push-in fitting (111), wherein an upper end of the push-in fitting (111) is attached to the cap (101) at a predetermined position to receive compressed air from the Gap sensor (201), a compressed air supply circuit (112) connected and extending transversely from said liner pin (108) at a predetermined position such that the compressed air from the push-in fitting (111) is received by the compressed air supply circuit (112), and an exhaust channel (113) defined into the main body (102) at a predetermined position and extending into the cap (101) of the pressing tool (100). The orifice (108A) of the liner pin (108) is connected with the exhaust channel (113) such that when an opening (108B) defined into the liner pin (108) at a predetermined position is aligned with the compressed air supply circuit (112), the compressed air received from the compressed air supply circuit (112) is passed into the exhaust channel (113) through the orifice (108A) of the liner pin (108). The guiding ball (106) is attached at a predetermined position in the main body (102) such that when the cam bush hole (105A) is aligned with the guiding ball (106). In another embodiment, the hole guiding mechanism includes the at least one guiding ball (106) having a diameter slightly lesser than cam bush hole (105A). The guiding ball (106) is adapted to move between a first position and a second position in a space defined the body (102) of the pressing and alignment device (100). The liner pin (108) is slidably disposed adjacent to the guiding ball (106). The least one spring (109) is engaged with the liner (108) such that movement of the liner pin (108) causes the spring (109) to expand or retract. Further, the hole guiding mechanism includes a gap sensor (201) which is connected to said compressed air supply circuit.
[0030] Fig 3 is a schematic diagram of the hole guiding mechanism of the pressing and alignment device (100) when a hole (105A) of the cam bush (105) is not aligned with the guiding ball (106), according to an embodiment of the invention as disclosed herein. When the cam bush hole (105A) is not aligned with the guiding ball (106), guiding ball (106) moves inwards. Due to the movement of the guiding ball (106), the liner pin (108) is also pushed inwards, compressing the spring (109). Due to the inward movement of the liner pin (108), the opening (108B) of the liner pin (108) aligns with the compressed air supply circuit (112). The compressed air received from the compressed air supply circuit (112) passes through the orifice (108A) of the liner pin (108) towards the exhaust channel (113). The gap sensor (201) is connected with the compressed air supply circuit (112) at a predetermined position. Since the compressed air passes out through the exhaust channel (113), there is no back pressure sensed by the gap sensor (201) in the compressed air supply circuit (112). The gap senor (201) detects no gap due to absence of back pressure in the compressed air supply circuit (112) and sends a first signal to the relay (202) of the gap sensing mechanism (200). After receiving the first signal, the relay remains in an open position. This does not operate the shut-off valve (203), which further does not operate the direction valve (204). Since the direction valve (204) remains in a closed position, the press machine (300) does not turn on/ does not operate. Therefore, the cam bush (105) is not pushed into the cam bore (400A) of the crankcase, ensuring that the cam bush hole (105A) is not misaligned with the oil gallery of the crankcase (400).
[0031] Fig 4 is a schematic diagram of the hole guiding mechanism of the pressing and alignment device (100) when the cam bush hole (105A) is aligned with the guiding ball (106), according to an embodiment of the invention as disclosed herein. When the cam bush hole (105A) is aligned with the guiding ball (106) of the guiding mechanism, the guiding ball (106) moves outwards. The outward movement of the guiding ball (106) causes the liner pin (108) to move outwards, in the direction of movement of the guiding ball (106). Due to the outward movement of the guiding ball (106), the spring (109) expands and exerts a pushing force on the liner pin (108). The opening (108B) in the liner pin (108) is blocked due to the outward movement of the liner pin (108). Therefore, the compressed air received through the compressed air supply circuit (112) does not pass through the opening (108B) and into the orifice (108A) of the liner pin (108). Due to the blockage of the orifice (108A) and the opening (108B) of the liner pin, the compressed air is accumulated, and a back pressure is created in the compressed air supply circuit (112). The gap sensor (201) detects the back pressure and sends a second signal relaying the detection of gap. The relay (202) receives the second signal, wherein the relay (202) is switched to a close position. The relay (202) further operates the shut-off valve (203), wherein the shut-off valve (203) is opened. The opening of the shut-off valve (203) results in the operation of the direction valve (204) to an ON position. The direction valve (204) in an open position supplies compressed air to the press machine (300), which further operates the pressing tool (100). Therefore, when the cam bush hole (105A) is aligned with the guiding ball (106), the press (300) operates, and the cam bush (105) is press fitted into the cam bore (400A) of the crankcase (400).
[0032] Further, the alignment tool (500) includes the guide pin assembly comprising of the guide plate (103) and the guide pin (104) comprising of a step pin, which further facilitate in alignment of the cam bush (105) with the cam bore (400A) of the crankcase (400) in the precise position. An undercut is defined into the main body (102) of the pressing and alignment device (100) at a predetermined position to assist in the alignment of the cam bush (105). The guide pin (104) is positioned on the pressing tool (100) such that if the guide pin (104) is not aligned with a corresponding hole defined in the crankcase (400) for guiding the cam bush (105), the cam bush (105) will not be pressed into the cam bore (400A). In another embodiment, the guide pin assembly facilitates alignment of a structural member with a mechanical component, wherein the guide pin is aligned with a corresponding guide hole defined in a body of the mechanical component at a predetermined position.
[0033] Fig. 5 depicts a flowchart of a method (600) for aligning a hole of a structural member (105) in a mechanical component (400) through an alignment tool (500), according to an embodiment of the invention as disclosed herein. The method (600) includes inserting a structural member (105) of predetermined dimension into a body of a pressing and alignment device (100) at a predetermined position. In an embodiment, the method (600) includes inserting a cam bush (105) into the main body of the pressing and alignment device (100). Further, the method (600) includes aligning a hole of the structural member (105A) with a guiding ball (106) of a hole guiding mechanism, wherein a gap sensor (201) detects alignment of said hole of structural member (105A) and communicates with a controller which operates a press machine (300) in an on position. In an embodiment, a cam bush hole (105A) is aligned with the guiding ball (106). Furthermore, the method (600) includes aligning a guide pin (104) with a guiding hole defined in a body of a mechanical component (400) at a predetermined position. In another embodiment, the guide pin (104) comprises of a step pin and the step pin is aligned with an M8 hole defined on a crankcase (400). Moreover, the method (600) includes pressing the pressing and alignment device (100) into a receiving bore (400A) of the mechanical component (400), wherein a hole of the structural member (105A) is aligned with a corresponding hole in the mechanical component (400). In an embodiment, the cam bush (105) is press fitted into the cam bore (400A) of the crankcase (400), wherein the cam bush hole (105A) is aligned with a hole of an oil gallery in the cam bore (400A) of the crankcase (400) through the operation of a pneumatic press machine (300).
[0034] The technical advantages achieved by the embodiments disclosed herein include elimination of manual error of misalignment of a cam bush hole with an oil gallery of crankcase, automatic stopping of a press machine when a bush hole is misaligned, non-insertion of cam bush in cam bush bore of a crankcase when the guide pin is misaligned, increased precision of press fitting a cam bush in a crankcase, and an efficient and faster method for press fitting a bush with precision.
[0035] The foregoing description of the specific embodiments will so fully reveal the general nature of the embodiments herein that others can, by applying current knowledge, readily modify and/or adapt for various applications such specific embodiments without departing from the generic concept, and, therefore, such adaptations and modifications should and are intended to be comprehended within the meaning and range of equivalents of the disclosed embodiments. It is to be understood that the phraseology or terminology employed herein is for the purpose of description and not of limitation. Therefore, while the embodiments herein have been described in terms of preferred embodiments, those skilled in the art will recognize that the embodiments herein can be practiced with modification within the spirit and scope of the embodiments as described herein.

Reference to numerals in Figs:
100 Bush pressing and alignment tool
101 Cap
102 Main body
103 Guide plate
104 Guide pin
105 Cam bush
105A Cam bush hole
106 Guiding ball
107 Adjustment screw
108 Liner pin
108A Liner pin orifice
108B Liner pin vertical opening
109 Spring
110 Cap nut
111 Push-in fitting
112 Compressed air channel
113 Exhaust channel
200 Gap sensing mechanism
201 Gap sensor
202 Relay
203 Shut-off valve
204 Direction valve
300 Pneumatic press machine
400 Crankcase
400A Cam bore
500 Bush pressing system with hole alignment
600 Method for press fitting a bush through a bush pressing system
, Claims:We claim,
1. An alignment tool (500) for aligning holes of structural members in a mechanical component, comprising:
a pressing and alignment device (100) operable by a press machine (300), said pressing and alignment device (100) having a body (102) of predetermined shape,
a hole guiding mechanism disposed within said body (102) at a predetermined position;
a guide pin assembly attached to said body at a predetermined position; and
a controller in communication with said hole guiding mechanism and said guide pin assembly.

2. The alignment tool (500) as claimed in claim 1, wherein the hole guiding mechanism includes:
at least one guiding ball (106) having a diameter lesser than said hole of cam bush, said guiding ball (106) adapted to be move between a first position and a second position in a space defined by said body (102);
a liner pin (108) slidably disposed adjacent to said guiding ball (106) in said space defined by said body (102);
at least one spring (109) engaged with said liner (108);
a compressed air supply circuit operatively connected above said liner pin (108); and
a gap sensor (201) provided in communication with said compressed air supply circuit.

3. The alignment tool (500) as claimed in claim 1, wherein said gap sensor (201) is provided in communication with said controller and configured to communicate an output signal corresponding to an open or closed position of said liner pin (108) disposed within the space defined in said body (102), said controller controls an operation of said press machine (300) based on said output signal received from the gap sensor (201).

4. The alignment tool (500) as claimed in claim 2, wherein the hole guiding mechanism comprises of:
an adjustment screw (107) disposed adjacent to the guiding ball (106) in a bore defined by said liner pin (108);
said liner pin (108) comprising of a vertical opening (108B) and a latitudinal orifice (108A), wherein the liner pin (108) is operatively coupled with the guiding ball (106) through the adjustment screw (107), such that the liner pin (108) is displaced in the direction of the displacement of the guiding ball (106);
said spring (109) operationally attached with the liner pin (108), wherein the spring (109) expands when the guiding ball (106) moves in an outward direction and the spring (109) compresses when the guiding ball (106) moves in an inward direction;
a cap nut (110) operationally connected with the spring (109);
said compressed air supply circuit (112) connected to said liner pin (108) and extending transversely from said liner pin (108); and
an exhaust channel (113) defined vertically at a predetermined position in said main body (102) and extending towards an upper end of a cap (102) of the alignment tool (100), wherein a compressed air received through the orifice (108A) of the liner pin (108) is passed into the exhaust channel (113), when said liner pin (108) is held at liner pin open position.

5. The alignment tool (500) as claimed in claim 4, wherein the hole guiding mechanism comprises of a push-in fitting (111) disposed within the main body (102) of the bush pressing and alignment tool (100), such that the push-in fitting (111) passes a compressed air received from the gap Sensor (201) into the compressed air supply circuit (112).

6. The alignment tool (500) as claimed in claim 3, wherein the guide pin assembly comprises of:
a guide plate (103) attached between the main body (102) and the cap (101) of the alignment tool (100), and
a guide pin (104) comprising of a step pin inserted into the guide plate (103) at a predetermined position, wherein the guide pin (104) extends downwards and towards the main body (102).

7. The alignment tool (500) as claimed in claim 6, wherein an undercut is defined in the main body (102) at a predetermined position.

8. The alignment tool (500) as claimed in claim 1, wherein the gap sensor (201) communicates said output signal to a relay (202) which is operationally coupled with the gap senor (201), wherein the relay (202) operates said alignment tool (500) when said liner pin (108) is held in said liner pin closed position and the relay (202) stops operation of the alignment tool (500) when said liner pin (108) is held in said liner pin open position.

9. The alignment tool (500) as claimed in claim 1, wherein said relay (202) is provided in communication with a shut-off valve (203), wherein the relay (202) does not operate shut-off valve (203) when said gap sensor (201) detects said liner pin (108) in said liner pin open position, whereby shut-off valve remains in closed position.

10. The alignment tool (500) as claimed in claim 1, wherein a direction valve (204) is operationally connected to the shut-off valve (203) and the press machine (300), wherein the direction valve (204) operates the press machine (300) when said shut-off valve (203) is moved to an open position through the relay (202).
11. The alignment tool (500) as claimed in claim 3, wherein the gap sensor (201) is connected in the compressed air supply circuit (112) at a predetermined position, said gap sensor (201) is at least a pressure sensor.

12. The alignment tool (500) as claimed in claim 5, wherein the guiding ball (106) comprises of a spherical steel ball of a predetermined diameter.

13. The alignment tool (500) as claimed in claim 1, wherein the press machine (300) is at least a pneumatic press machine.

14. The alignment tool (500) as claimed in claim 1, wherein the alignment tool is used in the press machine (300) for aligning a hole defined in a cam bush to a hole defined in an engine crankcase oil gallery.

15. A method (600) for aligning a hole of a structural member (105) in a mechanical component (400) through an alignment tool (500) comprising:
inserting a structural member (105) of predetermined dimension into a body of a pressing and alignment device (100) at a predetermined position;
aligning a hole of the structural member (105A) with a guiding ball (106) of a hole guiding mechanism defined in the pressing and alignment device (100) at a predetermined position;
aligning a guide pin (104) with a guiding hole of a mechanical component (400) defined in a body of the mechanical component (400) at a predetermined position; and
pressing the pressing and alignment device (100) into a receiving bore (400A) of the mechanical component (400).