FIELD OF THE INVENTION

The present invention is related to piston ring installation apparatus to be used for automatically inserting piston ring to piston assembly and particularly to an automated insertion of rings on piston assembly by using an automated apparatus and mechatronics to handle multiple variants. The present invention includes a process to handle multiple variants by means of identifying the variant specific two dimensional matrixes.
Particularly, the invention is concerned with an automatic piston ring inserting apparatus using a sensing unit for determining variant and inserts the piston rings into the piston assembly efficiently, effectively, quick, and which has a relatively simple construction and can work with various sizes of pistons and rings without reconstruction or a procedure changing work.

BACKGROUND OF THE INVENTION
Conventionally piston ring insertion has been done through manual process. In this process operator has to select piston ring of accurate variant and to insert on piston assembly of accurate diameter. This process require higher amount of accuracy and precision while performing operation of ring insertion into a piston assembly. In manual ring insertion process into piston assembly operator often carry number of rings of multiple variants at the same time. Many times it has been observed that operator install piston ring of wrong variant on wrong part of piston assembly.
With the introduction of new variants and increase in complexity of the piston rings, there is a need to identify the variants for insertion of correct piston ring having correct orientation with correct piston type in correct variant.
Further introduction of these variants, have led to the increase in complexity in variant handling which needs to be identified and inserted the right part in right variant. Once piston ring of wrong diameter has inserted on wrong piston then it leads to abnormal functioning of piston assembly after certain working hours and further leads to utter failure of system. During abnormal functioning of piston assembly, it often observed, engine get stalled, seizure or high fuel consumption during whole ignition process. Hence because of a mistake during installation of piston ring of piston assembly entire fuel ignition process in engine became ineffective, costly, time consuming and less efficient.
Piston manufacturer gives warranty to consumer on each piston assembly sold to them. This warranty is in terms of number of working hours of piston assembly or in terms of number of working hours of engine. The abnormal functioning of piston assembly due to insertion of wrong piston ring on wrong piston assembly leads to reduce the life of engine and further it leads to failure in claimed warranty by manufacturer.
In the conventional manual piston ring insertion process requires dedicated separate station for installing rings of different variants. There is more space required as numbers of variants get increased.
The another problem associated with the conventional manual piston ring insertion process is that there is no record on numbers of piston rings of different variant used for number of piston assembly. Hence there is failure in logistics, spare parts data management in conventional manual piston ring insertion process.
The abovementioned conventional piston ring insertion on piston assembly process does not have poka yoke for insertion of piston ring of right diameter on right piston assembly.
Moreover present manual process for ring insertion on piston assembly leads to accidents and make injury and not safety to operator. Also the existing manual process is having operator fatigue by excess movement with less ergonomics and expensive.
To overcome abovementioned shortcoming and problems associated with conventional system, it is more desirable to achieve a control method that is more simple, fast and energy-efficient than previously known methods and solves or at least relieves some of the problems discussed above.
It is therefore an object of the present invention is to overcome one or more problems associated with the prior art.
Yet another object of the present invention is to develop a machine for automated piston ring installation on piston assembly.
Yet another object of the present invention is to develop an automatic piston ring inserting apparatus using a sensing unit for determining variant and inserts the piston rings into the piston assembly.
Yet another object of the present invention is to develop process for piston ring insertion on piston assembly which is quick, efficient, and effective.
Yet another object of the present invention is to develop an automated piston ring insertion process which has inbuilt logistics, spare parts data management system.
Yet another object of the present invention is to develop process for piston ring insertion on piston assembly which has a relatively simple construction and can work with various sizes of pistons.

SUMMARY OF THE INVENTION
The present invention is related to an automated piston ring installation apparatus and method for the same. In one of the aspect of the present invention, an automated piston ring installation apparatus and method of the same comprises a piston assembly loading station, a sensing unit for identify and differentiate piston assembly with respect to outer diameter of piston assembly, an automated apparatus for ring insertion, servo motor driven mandrel, a sensing unit for measuring inner or outer diameter of piston ring, a control unit for communicating data with centrally located parts logistic database, a piston ring unloading station and an outer protection cover to provide safety work environment to operator.
A piston assembly is placed at said ring loading station where vision sensing unit identify and differentiate each piston assembly with other piston assembly on basis of inner and/or outer diameter of piston assembly. Further the piston assembly is picked from ring loading station with the help of gripper mounted at arm of said automated apparatus for inserting ring and placed on top side of mandrel where cone is mounted to insert ring onto it.
An another aspect of the present invention, a sensing unit identify and differentiate each piston ring with another piston ring on basis of inner and/or outer diameter of piston ring. An automated piston ring installation apparatus place a piston assembly at matching piston ring inserting station with the help of gripper. The servo motor driven mandrel mechanism rotates mandrel in upward direction about vertical axis in order to pop-up corresponding piston ring and further it is mounted on the piston assembly. The information related to each and every picked and placed piston assembly and piston ring assembly is communicated to centrally managed parts logistic database through control unit. Real time data related to usage of number of piston assembly and piston ring assembly communicated to centrally managed parts logistic database and hence information related to total used piston assemblies, piston rings, total available piston assemblies, piston rings in stock can be tracked by operator and other persons. This data also gives information about number of piston assemblies on which rings got inserted and number of piston rings and piston assemblies required in logistic to enable future ring insertion operations.
The piston assembly is placed at piston assembly unloading station with the help of gripper after completion of ring insertion process onto piston assembly. The piston assembly can be picked and placed to stock form piston assembly unloading station manually or in assistance with machine or both.
The automated piston ring installation system for automatically inserting piston ring to piston assembly is surrounded by single or multiple layer protection cover to provide safety work environment to operator.

BRIEF DESCRIPTION OF THE DRAWINGS
With reference to the following drawings, a more detailed description of different exemplary embodiments of the invention will follow below.
In the drawings:
Figure 1 shows a perspective view of an automated piston ring installation system;
Figure 2 shows an automated piston ring installation system along with some embodiments;
Figure 3shows a representation of mandrel;
Figure 4 shows prospective view of piston assembly loading station;
Figure 5 shows an another view of mandrel; and
Figure 6 shows a representation of gripper mounted on the automated apparatus for inserting piston ring onto a piston assembly.

DETAILED DESCRIPTION OF THE INVENTION
Hereinafter the invention will be described in more details with reference to embodiments of the present invention.
In FIG.1, a perspective view of layout of the automated piston ring installation system 10 is shown. An automated apparatus for inserting at least one piston ring onto a piston assembly 111 is placed inside the protective cover 112. The layout design of the automated piston ring installation system 10 may be in any shape and layout illustrated in FIG. 1 is merely shown as example.
An Electronic/Programmable control unit 113 for the automated apparatus for inserting at least one piston ring onto a piston assembly 111 and Electronic/Programmable control unit114 of said the automated piston ring installation system may be placed nearby and/or outside of layout design of the automated piston ring installation system. All piston assemblies on which ring insertion process to be done are placed inside the said layout design.
As shown in FIG.2, the automated piston ring installation system 20 provided with a piston loading station 211, an automated apparatus for ring insertion 219, vision sensing unit 212, piston assembly 213, mandrel 215, piston ring assembly 216, servo motor 220, gripper 214, sensing unit for identify piston ring 217, piston assembly unloading station 218.
Further reference to FIG.2, a piston assembly 213 is placed at piston loading station 211. The said visual sensing unit 212 measure inside and/or outer diameter of said piston assembly 213. The said visual sensing unit 212 further connected with Electronic/Programmable control unit 114 as shown in FIG.1 hereinafter called as ECU/PLC (not shown in FIG.2). The input data from said visual sensing unit 212 transferred to ECU/PLC 114 where each piston assembly 213 identified and differentiated with other piston assemblies available in logistics.
The visual sensing unit 212 may be camera, laser sensor, image sensor or any other means.
The multiple numbers of mandrel 215 are located inside layout design of the automated piston ring installation system as shown in FIG.1.The said mandrel 215 are differentiated from each other on basis on inside and/or outside diameter of ring assemblies 216.
The said mandrel 215 provided with sensing unit 217 which is further connected to said ECU/PLC 114. The input data from said sensing unit 217 transferred to ECU/PLC 114 where each piston ring assembly 216 identified and differentiated with other piston ring assemblies available in logistics.
The ECU/PLC 113 for the automated apparatus for inserting at least one piston ring onto a piston assembly 111 hereinafter called Robot ECU/PLC as shown in FIG.1 (not shown in FIG.2) and Electronic/Programmable control unit 114 of said the automated piston ring installation system.
The ECU/PLC 114 receives input data from sensing unit 217 and 212. Further it gets processed and gives output data to Robot ECU/PLC 113.
The said Robot ECU/PLC 113 gives instruction to said gripper 214 mounted at arm of said automated apparatus 219 for inserting ring on piston assembly. The said gripper 214 pick said a piston assembly 213 from piston loading station 211 and place it on corresponding mandrel for inserting ring on piston assembly.
The said ECU/PLC 114 receives information related to outer and/or inner diameter of piston as well piston ring assemblies placed on each mandrel. Further ECU/PLC 114 gives this input data to Robot ECU/PLC 113. The said Robot ECU/PLC 113 give instructions to automated apparatus 219 which directs gripper 214 to pick said and place piston assembly at matching mandrel for inserting ring of appropriate inner and/or outer diameter.
The said mandrel 215 further provided with servo motor 220 which rotates a piston ring assembly 216 in upward direction about vertical axis in order to pop-up corresponding piston ring and further it is mounted on the piston assembly 213.
The said piston assembly 213 further moved to piston assembly unloading station 218, where piston assembly can be picked and placed to stock form piston assembly unloading station manually or in assistance with machine or both.
The said ECU/PLC 114 communicate information related to inserted ring and corresponding piston unique number with centrally managed parts logistic database for handling multiple variants of piston rings and piston assemblies.
The said ECU/PLC 114 also communicate information related to picked piston assembly and corresponding piston unique number with centrally managed parts logistic database for handling multiple variants of piston rings and piston assemblies.
In FIG. 3, shown is detailed view of mandrel 30. The sensor unit 311 is mounted on mandrel to identify and differentiate a piston ring with respect to other piston rings in logistics on basis of inner and/or outer diameter of piston ring.
In FIG.4, shown is prospective view of piston assembly loading station 40. The said piston assembly loading station provided with visual sensing unit 411 to identify and differentiate a piston assembly 412 with respect to other piston assemblies in logistics on basis of inner and/or outer diameter of piston assembly.
In FIG.5, shown is another view of mandrel 50. The mandrel is provided with servo motor 511 which rotates a piston ring assembly surrounded on mandrel in upward direction about vertical axis in order to pop-up corresponding piston ring and further it is mounted on the piston assembly.
The said servo motor 511 is controlled by ECU/PLC 114 as shown in FIG. 1.
The mandrel 50 is provided with multiple numbers of holes 513 on top portion of mandrel.
The mandrel 50 is provided with cone portion 512 which is placed on top portion of mandrel with the help of said holes 513. The mandrel 50 also provided with
With reference to FIG. 6, the gripper 60 is used to pick and place piston assembly 611 for inserting piston ring onto it with proper safety. The process of inserting ring is as follows:
1. Operator fills one type of rings (approx. 150 nos.) in each mandrel.
2. Operator will place the piston assembly at loading point. There is poka yoke by two pins so the component will always kept as required orientation.
3. Sensing unit scans the bottom marking 2D matrix on piston bottom face and a sensor for part presence.
4. An automated apparatus for inserting ring on piston assembly pick the component from loading station and kept at mandrel as per the requirement.
5. Ball screw mechanisms push the ring vertical upward and insert it in piston groove with the positional feedback servo system.
6. After insertion of rings the automated apparatus for inserting ring on piston assembly move to the unloading station.
7. Repeat cycle in automatically accordingly.
One of the objective of present invention is to improve the product quality and preventing the field failures likely to be arise due to manual ring insertion .In the present invention cater the existing variants as well as for future variants.
Further objective of present invention is providing the adaptability to interfacing with centrally managed logistic database for variants management by bills of material verification.

CLIAMS:

1. An automated piston ring installation system for automatically inserting piston ring onto piston with connecting rod assembly comprising:
? At least one piston assembly loading station for placing piston assembly
? At least one automated apparatus for inserting at least one piston ring onto a piston assembly
? At least one vision sensing unit for identification and differentiate piston assembly with respect to inner or outer diameter of piston assembly
? At least one servo motor driven mandrel mechanism for rotating mandrel in upward direction about the axis
? At least one colour or visual sensor for identification and differentiate at least one piston ring with another piston ring on basis of inner or outer diameter of piston ring assembly
? At least one electronic control system for communicating information related to loaded ring and corresponding piston unique number with centrally managed parts logistic database for handling multiple variants of piston rings and piston assemblies
? At least one electronic control system interfaced with parts logistic database for data management of assembled parts
? At least one piston assembly unloading station for removing piston assembly after insertion of ring onto piston assembly
? At least one electronic control system for automated apparatus for inserting piston ring onto a piston assembly and
? At least one outer protection cover.
2. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein piston assembly loading station for placing piston assembly located at anywhere inside outer protection cover.
3. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein an automated apparatus for inserting at least one piston ring onto a piston assembly is controlled through Electronic/Programmable control unit and located outside outer protection cover.
4. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein vision sensing unit for identification and differentiate piston assembly is located at piston assembly loading station.
5. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein servo motor is driven by electrical, battery or any other means.
6. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein visual sensor for identification and differentiate piston ring with another is located on mandrel.
7. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein parts logistic database collect real time data of each piston and piston ring available at work station.
8. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein piston assembly loading station for placing piston assembly located at anywhere inside outer protection cover.
9. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein an automated apparatus for inserting at least one piston ring onto a piston assembly is located at anywhere inside outer protection cover.

10. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein outer protection cover is made up from glass, steel, iron, fibre, plastic or combination of thereof or any other material.
11. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1, wherein Electronic/Programmable control unit may be independently incorporated on automated apparatus for inserting piston ring on piston assembly.
12. The automated piston ring installation system for automatically inserting piston ring to piston assembly claimed in claim 1 & 11, wherein Electronic/Programmable control unit of the automated piston ring installation system and automated apparatus for inserting piston ring on piston assembly communicate data to each other.
13. A process for the automated piston ring installation system for automatically inserting piston ring to piston assembly comprising:
? Identifying outer or inner diameter of piston assembly with the help of said visual sensor
? Picking piston assembly from piston assembly loading station with help of gripper mounted at arm of said automated apparatus for inserting ring
? Identifying outer or inner diameter of piston ring with the help of said colour sensor
? Placing piston assembly to insert ring with help of said gripper
? Mounting piston ring onto piston assembly with the help of said servo motor
? Unloading piston assembly at piston assembly unloading station and
? Communicating information related to loaded ring and corresponding piston unique number to centrally managed parts logistic database through control unit.