DESC:FORM 2
THE PATENTS ACT, 1970
(39 of 1970)
&
The Patent Rules, 2003
COMPLETE SPECIFICATION
(See sections 10 & rule 13)
1. TITLE OF THE INVENTION
AN AUTOMATIC LUBRICATION SYSTEM FOR INJECTOR SLEEVE BURNISHING OPERATION IN HORIZONTAL MACHINING CENTER (HMC) MACHINE
2. APPLICANT (S)
NAME NATIONALITY ADDRESS
BEML LIMITED IN BEML Soudha, No 23/1, 4th Main S.R. Nagar, Bengaluru- 560027, Karnataka, India.
3. PREAMBLE TO THE DESCRIPTION
COMPLETE SPECIFICATION

The following specification particularly describes the invention and the manner in which it is to be performed.

FIELD OF INVENTION:
[001] The present invention relates to the modification of fixture to adopt oil supply to the injector sleeve burnishing surface. The present invention in particular relates to the automatic lubrication system, modification of fixture to adopt lubrication & pressured air supply and method for injector sleeve burnishing operation in horizontal machining center (HMC) machine.
DESCRIPTION OF THE RELATED ART:
[002] For conical milling and burnishing operation of injector sleeve in Horizontal Machining Center (HMC) machine, Lubrication system has been modified and also made it automated through CNC programming, by utilizing electric driven oil pump and solenoid. The passage is made in the fixture with ‘V’ line input with two threaded adapters, one for connecting oil pipe line and another one for compressed air. Lubrication oil is supplied from fixture side and directed to tip of the tool, the sufficient oil at the machining area is ensured at the required time. Hence the burnishing operation can be carried out at the intended pressure of tool, by which the sealing of injector sleeve to the cylinder head and the surface finish will be proper. Since sufficient lubrication is ensured during machining operation, life of the tool also will get improved.
[003] Reference may be made to the following:
[004] Publication no. GB723593 relates to a device for introducing upper-cylinder lubricant into an engine comprising a reservoir 5, Fig. 1, a plate-like member 1, Fig. 2, matching in shape and size to and for connection between a carburetter and an induction manifold, not shown, a venturi tube mounted concentrically in a central opening in the member 1, a conduit 13, Fig. 1, connecting the upper region of the reservoir 5, above the level of the lubricant therein, to the venturi, and the reservoir 5 having an air intake passage 17 in the upper region thereof terminating in a nozzle 21, a tubular element 23 extends from adjacent the reservoir bottom and is provided with a jet 24 juxtaposed in ejector arrangement with the nozzle 21 so that during the passage of the fuel air fixture to the engine atomised lubricant is drawn into the latter, in quantities that are proportional to the mixture velocity, by creating an air flow through the reservoir 5 which atomises the lubricant drawn through the element 23 by the ejector arrangement. The reservoir 5, which is transparent and either depends from a cover 16 or an extension of the plate member, incorporates a baffle 25 which screens the bell mouths of conduits 13 from the nozzle 21 and jet 24; the passage 17 opens to atmosphere through a needle valve 9 and a filter 20 comprising oil-saturated steel wool, for example. A dual carburetter may be used so that the plate embodies two openings 2, Fig. 2 each of which may have two heated and concentric venturi tubes 26, 27 therein whilst a conduit 13 with a square or obliquely cut end opens into each of the inner venturi tubes 27. In a modification, the inner and/or outer venturi tubes incorporate spiral vanes and the conduits open in an offset manner into the tubes; two conduits may open into each inner venturi. In a further modification, lubricant from a separate tank 36, Fig. 6, enters the reservoir 34 through a float-actuated valve 35 in which reservoir is located a jet member 39 mounted upon a perforated element 40 whilst the air inlet nozzle 38 opens to atmosphere through a needle valve 9 and filter 19; the nozzle also communicates with atmosphere through a pipe 42, incorporating a needle valve 44, an exhaust gas heater 41 and a filter. The valve 9 may be closed when hot air is required to be drawn through the reservoir 34. The plate member 1b and reservoir 34 are connected by flanges 45 and bolts 46. In a final modification, the tank is separated from the reservoir, which latter has a depending baffle to prevent the draught inside the container from affecting the valve float.
[005] Publication no. IN1292/CHE/2004 relates to a two way CNC Horizontal Machining center used for machining the component in different setups. The two way CNC Horizontal Machining Center with trunnion mounted hydraulic fixture is the unique solution for engine blocks machining in a single set up. This fixture mounted on the central table allows accommodation of different models of engine blocks with their variants. It also facilitates machining on inclined faces of the engine block, in addition to machining four faces of the engine block in a single set up.
[006] Publication no. CN205111 discloses a hydraulically operated fixture automatic control system, including the metal dustcoat, the inside of metal dustcoat is provided with the electrical control unit, oil circuit electromagnetism valves, hydraulic power units, coolant liquid the control unit, flushing solenoid valve group, airtight detecting element and airtight detecting element valves, hydraulic power units connects oil circuit electromagnetism valves, the anchor clamps controller of oil circuit solenoid valve group link lathe, coolant liquid the control unit connects flushing solenoid valve group, the coolant liquid of flushing solenoid valve group link lathe, airtight detecting element connects airtight detecting element valves, the air supply of lathe is connected to airtight detecting element valves, oil circuit electromagnetism valves, hydraulic power units, coolant liquid the control unit, flushing solenoid valve group, airtight detecting element and airtight detecting element valves all with the electrical control unit connection, the the main control unit case of electrical control unit connection lathe, its automatic control that can realize anchor clamps, high precision, the easy control of clamp force just can greatly alleviate dependent manual operation intensity.
[007] Publication no. CN114505693 discloses a machining method for a movable guide rail locking structure of a hydrostatic guide rail, and belongs to the field of hydrostatic guide rails, and the machining method comprises the following steps that S1, a movable guide rail comprises an upper slide carriage, a left side component and a right side component, the left side component and the right side component are tightly pressed on the left side and the right side of a fixed guide rail through a pressing device respectively, and the left side component and the right side component are pressed to generate elastic deformation; S2, the upper slide carriage is fixedly connected with the left side component and the right side component through fixing pieces, and a movable guide rail is formed; and S3, the pressing device is removed, the left side component and the right side component are clamped on the left side and the right side of the fixed guide rail through clamping force formed by elastic deformation, relative movement of the fixed guide rail and the movable guide rail is limited, and when the throttler conveys high-pressure oil/gas into an oil cavity/gas cavity between the fixed guide rail and the movable guide rail, the fixed guide rail and the movable guide rail are closed. As the pressure of oil pressure/air pressure in the oil cavity/air cavity is larger than the clamping force of the left part and the right part, an oil film gap/air film gap is generated between the fixed guide rail and the movable guide rail, and the fixed guide rail and the movable guide rail can move relatively.
[008] Publication no. CN114043256 provides a gas-liquid parallel lubricating guide rail and a working method thereof. The gas-liquid parallel lubricating guide rail comprises a guide rail base body and a sliding table, the guide rail face of the sliding table is divided into two areas in the movement direction, one area is an oil lubricating area which adopts a traditional common sliding guide rail design, and the other area is a gas film lubricating unloading area which is provided with air inlet holes and a plurality of communicated air distribution grooves, the air inlet holes are communicated with the air distribution grooves, compressed air is introduced into the air film lubricating unloading area through the air inlet holes so as to form pressure air film lubricating and unloading, and an open groove is further formed between the two areas. According to the invention, the load can be effectively unloaded, so that the frictional resistance, the driving power and the energy consumption are reduced, meanwhile, the friction loss between the combination surfaces of the sliding table and the guide rail base body can be greatly reduced, the service life of the guide rail is greatly prolonged, and meanwhile, the power consumption of the motor is reduced, improvement is simple, the gas-liquid parallel lubricating guide rail can be widely popularized and used on a machine tool provided with a common sliding guide rail.
[009] Publication no. CN113958382 discloses an oil injection control system for an electronic air cylinder of a low-speed diesel engine. The oil injection control system comprises a Hall sensor used for measuring the number of pulses from a reference position to a current position, a first processing unit used for determining the rotating angle of a main engine crankshaft on the basis of the number of the pulses, a second processing unit used for determining the running position of a main engine piston on the basis of the rotating angle and generating a control instruction, and an air cylinder oil injector used for executing oil injection operation of different durations on the basis of the control instruction; the reference position is determined through an upper dead center sensor and a lower dead center sensor. The oil injection amount can be correspondingly controlled and adjusted according to the running position and different running states (such as forward running and reverse running) of the main engine piston, accurate control over the oil injection amount is achieved, the mechanical efficiency is improved, the service life of a cylinder sleeve is prolonged, the fuel consumption rate of a main engine and the maintenance cost of parts are reduced, and excellent practicability and economical efficiency are achieved.
[010] Publication no. WO2011091572 relates to a water channel structure for a cylinder head includes a first intake valve hole (11), a first exhaust valve hole (10), a second intake valve hole (14), a second exhaust valve hole (13) and a fuel injector sleeve (12), which are all placed on the cylinder head (21). The first intake valve hole, the first exhaust valve hole, the second intake valve hole and the second exhaust valve hole are placed around the fuel injector sleeve, and bolt holes (9), a fuel inlet hole (22) and oil return hole (15) are located on the cylinder head. A lower water channel (6) and an upper water channel (7) are placed in the cylinder head around the first intake valve hole, the first exhaust valve hole, the second intake valve hole, the second exhaust valve hole, an air inlet (17) and an air drain (18), the lower water channel is communicated with the upper water channel via a connection channel (23), a water inlet (16) connecting to the lower water channel is located at the bottom end of the cylinder head, and a water drain (19) connecting to the upper water channel is located at the top end of the cylinder head. A first communication hole (24) is located between the first exhaust valve hole and the second exhaust valve hole, the first communication hole connects one side of the lower water channel with the connection channel, and a second communication hole (25) is located between the first intake valve hole and the second intake valve hole, the second communication hole connects the other side of the lower water channel with the connection channel.
[011] Publication no. EP3285006 relates to the injector device (1) comprises an elongated body (2) with a leading edge (3) and a trailing edge (4), gas nozzles (7) and oil nozzles (8), an oil supply duct (10) housed within the elongated body (2) and connected to the oil nozzles (8), a gas supply duct (11) housed within the elongated body (2) and connected to the gas nozzles (7). The oil supply duct (10) is connected to the gas supply duct (11) only between one or more oil nozzles (8) and one gas nozzles (7), and the gas supply duct (11) is connected to the elongated body (2) only via bridges (13).
[012] Publication no. US2005087560 relates to the lubricating mixture of a lubricant and air is supplied to a cutting location by a lubricating tool with a spring biased piston dividing a cylinder into an air chamber and a lubricant chamber. The air chamber is connectable to a pressurized air source. The lubricant supply chamber is selectively connectable through a control valve to a lubricant source or to an exchangeable lubricant and air mixing attachment also connected to the pressurized air source. The attachment includes three flow restrictors. Two restrictors feed air and lubricant to a mixing area. One restrictor feeds the mixture to an output. Different sets of restrictors with different flow restricting characteristics provide an exact mixture dosage for satisfying any cutter lubricating requirement. It is merely necessary to replace one attachment by another attachment having different flow restricting characteristics.
[013] Publication no. IN202011044010 relates to adaptive minimum quantity lubricant (MQL) system is provided. The adaptive MQL system comprises a thermocouple, a temperature module, a solenoid valve, an air compressor, and a nozzle. The adaptive MQL system limits the temperature rise during machining process by application of intelligently controlled minimal amount of lubricant or cutting fluid only at the desired points in time. The system also helps in monitoring temperature during machining process by using a moving thermocouple. The adaptive MQL system is easily implementable on the shop floor. The adaptive MQL system is simple and cost effective. The adaptive MQL system helps in intermittent usage of the lubricant or cutting fluid and reduces unnecessary use of the lubricant, thereby reducing cost of lubrication. The present invention also provides the process for monitoring and controlling temperature during a machining operation. The process provided by the present invention is simple and cost-effective.
[014] Publication no. US73002 relates to a shaft tool with a machining section and a cylindrical shaft which comprises at least one internal coolant/lubricant duct which on its end facing away from the machining section comprises at least one orifice, wherein the shaft forms a conical fitting surface that encloses the orifice. A device comprising a shaft tool and a connection piece, the connection piece comprising a centric coolant/lubricant supply duct which exits in an apex region of an inner cone which accommodates in a positive-locking manner the conical fitting surface of the shaft tool, the conical fitting surface facing the inner cone.
[015] In general, in Horizontal Machining Center (HMC), the lubrication or coolant will be supplied from jig side via machining tool and it has to reach till tip of the tool (machining area) for sufficient cooling or lubrication, where temperature or friction will be more during machining operation. But during cone milling and burnishing operation of injector sleeve, the clearance between tool and the work piece (i.e., sleeve) will become very less or zero clearance, so the coolant or lubrication oil will not reach up to the tip of the tool or very less quantity will be reached there. Hence, the machining operation can not be carried out at intended pressure of tool, so the sealing of injector sleeve to the cylinder head and the surface finish will not be proper. Hence this will lead to coolant leak from cylinder head to the cylinder bore of an engine. Also, during every stage of machining operation, manually air will be blown to remove chips from the work piece and tool, this may lead to a safety concern or chances of skipping this process, which will lead to damage of work piece (ie sleeve) as well as tool
[016] In a direct injection internal combustion engine, the fuel injector will be mounted on the cylinder head. In some engine Injector sleeve will be adopted, to close the coolant port. Precise machining of injector sleeve is mandatory for better surface contact between sleeve and the injector, in order to avoid engine oil entry in to the combustion chamber and also to avoid combustion gas leak from the engine cylinder.
[017] In order to overcome above listed prior art, the present invention aims to provide an automatic lubrication system for injector sleeve burnishing operation in HMC machine. The invention provides fixture which adopts lubrication & pressured air supply and method for injector sleeve burnishing operation in horizontal machining center (HMC) machine. The fixture adopts oil supply to the injector sleeve burnishing surface.
OBJECTS OF THE INVENTION:
[018] The principal object of the present invention is to provide automatic lubrication system for injector sleeve burnishing operation in HMC machine.
[019] Another object of the present invention is to provide modified fixture for adopting oil and air supply; and automated control of lubrication oil supply and pressurized air, to enhance the machining process of injector sleeve burnishing operation.
SUMMARY:
[020] The present invention relates to an automatic lubrication system for injector sleeve burnishing operation in Horizontal Machining Center (HMC) machine. The invention provides fixture which adopts lubrication & pressured air supply and method for injector sleeve burnishing operation in horizontal machining center (HMC) machine. The present invention ensures the sufficient oil at the machining area at required time where lubrication oil is supplied from fixture side and directed to tip of the tool. The burnishing operation can be carried out at the intended pressure of tool, by which the sealing of injector sleeve to the cylinder head and the surface finish will be proper. Since sufficient lubrication is ensured during machining operation, life of the tool also will get improved. Hence, the number of injector sleeve burnishing operation with the same tool is increased to 4 times.
BREIF DESCRIPTION OF THE INVENTION
[021] It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are therefore not to be considered for limiting of its scope, for the invention may admit to other equally effective embodiments.
[022] Figure 1 shows an automatic lubrication system for injector sleeve burnishing operation according to the present invention;
[023] Figure 2 shows flowchart according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION:
[024] The present invention provides an automatic lubrication system for injector sleeve burnishing operation in Horizontal Machining Center (HMC) machine. The invention provides fixture which adopts lubrication & pressured air supply and method for injector sleeve burnishing operation in horizontal machining center (HMC) machine. The present invention ensures the sufficient oil at the machining area at required time where lubrication oil is supplied from fixture side and directed to tip of the tool. The burnishing operation can be carried out at the intended pressure of tool, by which the sealing of injector sleeve to the cylinder head and the surface finish will be proper. Since sufficient lubrication is ensured during machining operation, life of the tool also will get improved. Hence, the number of injector sleeve burnishing operation with the same tool is increased to 4 times.
[025] Also, the compressed air supply to the machining area is made automated, during end of every stage; pressurized air will be supplied to the machined area, where chips will be blown out from the work piece and the tool. This automated process results in improve in safety of the operator.
[026] For conical milling and burnishing operation of injector sleeve in Horizontal Machining Center (HMC) machine, Lubrication system has been modified and also made it automated through CNC programming, by utilizing electric driven oil pump and solenoid. The passage is made in the fixture with ‘V’ line input with two threaded adapters, one for connecting oil pipe line and another one for compressed air.
[027] Refer the fig 1, the injector sleeve (4) will be placed in the injector sleeve bore of the cylinder head (3). When the cylinder head along with injector sleeve is mounted on the fixture (5), the one end of oil/ air port (6) will be inline to injector sleeve and sealed with o–ring (6), to avoid oil slippage, when oil is supplied. The oil line (8) is controlled by the solenoid valve (11) and solenoid valve is operated by CNC unit of the machine. When the tool (2) is entering the injector sleeve, just before machining starts, solenoid valve will get actuated by the CNC unit and oil supply will get started. The draining oil will be collected to the two stage filter tray (14 & 15) which has paper filter and the filtered oil will re-circulated to the oil tank (13). The oil supply solenoid will be turned off by the CNC unit itself, once that machining stage is completed (fig 1).
[028] Then the compressed air line solenoid valve (10) will get actuated and supply the pressurized air for removing chips in the injector sleeve and the machining tool. The compressed air line solenoid valve is controlled by solenoid valve, which will in turn control by CNC unit of the machine.
[029] The modified fixture has two supply tubes, one for oil and another one for compressed air. And both the supply line is controlled by the solenoid valve, the solenoid valve is in-turn controlled by CNC unit. The program will switch ON the solenoid valve, which turn on the oil pump, exactly when the machining is about to takes place and will be switched OFF once the machining operation is done. During every stage, after machining, compressed air solenoid valve is actuated by the CNC unit and it will clean the machined area, to remove chips and debris. The solenoid valve will get switched OFF after certain seconds, controlled by the timer. The oil getting drained from the machining surface and work bench, will be collected back to the tank through filter paper at two stages (fig 2).
[030] Thus invention supplies lubricating oil automatically when the tool moved for machining with help of sensor and Solenoid till the machining completes as per the timer. It also supplies compressed air automatically with help of solenoid valve to clean the machined chips to ensure the proper machining.
[031] Numerous modifications and adaptations of the system of the present invention will be apparent to those skilled in the art, and thus it is intended by the appended claims to cover all such modifications and adaptations which fall within the true spirit and scope of this invention.
,CLAIMS:WE CLAIM:
1. A automatic lubrication system for injector sleeve burnishing operation in horizontal machining center (HMC) machine comprises-
a) the injector sleeve (4) placed in the injector sleeve bore of the cylinder head (3) and when the cylinder head along with injector sleeve is mounted on the fixture (5), the one end of oil/ air port (6) is inline to injector sleeve and sealed with o–ring (6), to avoid oil slippage, when oil is supplied;
b) the oil line (8) is controlled by the solenoid valve (11) and solenoid valve is operated by CNC unit of the machine.
2. The automatic lubrication system for injector sleeve burnishing operation, as claimed in claim 1, wherein when the tool (2) is entering the injector sleeve, just before machining starts, solenoid valve gets actuated by the CNC unit and oil supply will get started and draining oil is collected to the two stage filter tray (14 & 15) which has paper filter and the filtered oil will re-circulated to the oil tank (13), oil supply solenoid will be turned off by the CNC unit itself, once that machining stage is completed, the compressed air line solenoid valve (10) gets actuated and supply the pressurized air for removing chips in the injector sleeve and the machining tool.
3. The automatic lubrication system for injector sleeve burnishing operation, as claimed in claim 2, wherein the compressed air line solenoid valve is controlled by solenoid valve, which in turn control by CNC unit of the machine.
4. The automatic lubrication system for injector sleeve burnishing operation, as claimed in claim 1, wherein the fixture has two supply tubes, one for oil and another one for compressed air and both the supply line is controlled by the solenoid valve, which is in-turn controlled by CNC unit.
5. The automatic lubrication system for injector sleeve burnishing operation, as claimed in claim 1, wherein the system is switched ON the solenoid valve, which turn on the oil pump, exactly when the machining is about to takes place and is switched OFF once the machining operation is done and during every stage, after machining, compressed air solenoid valve is actuated by the CNC unit and it cleans the machined area, to remove chips and debris, the solenoid valve gets switched OFF after certain seconds, controlled by the timer and oil getting drained from the machining surface and work bench, is collected back to the tank through filter paper at two stages.