DESC: FIELD OF THE INVENTION
[001] The present subject matter relates to a horizontal machining center, specifically, to a multi-operation machining center for performing machining operations on a crankshaft.
BACKGROUND OF THE INVENTION
[002] Manufacturing of automotive components, such as crankshafts includes multiple operations. Conventionally, the crankshaft is manufactured by a forging process. Thereafter, various tasks such as end machining, end grinding, oil hole drilling, balancing etc. may be performed on the forged crankshaft, to obtain the final product. Further, each operation on the crankshaft is performed on dedicated machines. For example, end drilling operation, oil hole drilling operation, end grinding and balancing operations are performed on four to five different machines. Use of different machines results in increased setup time for each machining operation, more occupation of floor space, and increased material movement from one machine to another machine. Further, independent skilled labor is needed for performing operations on each of the machines.
SUMMARY OF THE INVENTION
[003] This summary is provided to introduce concepts related to a multi-operation machining center, and these concepts are further described below in the detailed description. This summary is not intended to identify essential features of the claimed subject matter, nor is it intended for use in determining or limiting the scope of the claimed subject matter.
[004] The present subject matter discloses a multi-operation machining apparatus to carry out various machining operations, such as End machining, Oil hole drilling, End Turning in lieu of End Grinding, Balancing, on a forged crankshaft. The machining operations are performed on a single multi-operation machining apparatus. Further, the task of End grinding may be replaced by the multi-tasking multi-operation machining apparatus with end turning task amounting to grinding tool cost saving.
[005] In accordance with the present subject matter, various machining tasks for manufacturing of the crankshaft may be performed by a single multi-operation machining apparatus in various stages. Thus, the present subject matter reduces the amount of setup time for each machining task, reduces floor space needed, reduces material movement from one machine to another machine. Also, the single multi-operation machining apparatus performing all the operations requires single skilled labor, amounting to cost efficient and effective machining operation by reducing the probability of human error.
BRIEF DESCRIPTION OF THE DRAWINGS
[006] FIG. 1 illustrates a side view of the multi-operation machining apparatus in accordance with an implementation of the present subject matter.
[007] FIG. 2a illustrates a side view of a fixture of the multi-operation machining apparatus, in accordance with an implementation of the present subject matter.
[008] FIG. 2b illustrates a top view of a fixture of the multi-operation machining apparatus, in accordance with an implementation of the present subject matter.
DETAILED DESCRIPTION OF THE DRAWINGS
[009] The following description is merely exemplary in nature and is not intended to limit the present disclosure, application, or uses.
[0010] According to this invention, there is provided a multi-operation machining apparatus.
[0011] In one embodiment, the multi-operation machining apparatus (100) comprises:
a spindle (110) to mount a machining tool, wherein the spindle imparts a motion to the machining tool along one of a X-axis, Y-axis, and Z-axis of the machning axis;
a fixture (104) to mount a crankshaft (108) and position the crankshaft (108);
a rotation table (106) to mount the fixture (104), to rotate the fixture (104) about the Z axis, and translate the fixture (104) along the X-axis; and
a balancing equipment (112) to perform a weight balancing operation on the crankshaft (108).

[0012] In one embodiment, the multi-operation machining apparatus (100) further comprises a robotic arm (114) to mount and dismount the crankshaft (108) from the multi-operation machining apparatus (100).

[0013] In one embodiment, the robotic arm (114) mount and dismount the crankshaft (108) from at least one of the fixture (104) and the balancing equipment (112).

[0014] In one embodiment, the fixture further comprises a main spindle (104-1) and a sub-spindle (104-2) each configured to hold an end of the crankshaft (108), wherein the main spindle (104-1) rotates the crankshaft (108).

[0015] In another aspect, there is provided a method of manufacturing a crankshaft (108) mounted on a fixture (104), the fixture (104) being mounted on a rotation table (106), the method comprising:
- positioning a gear end of the crankshaft (108) with respect to a spindle (110) and drilling a hole in the gear end of the crankshaft (108);
- rotating the rotation table (106) to align a flange end of crankshaft (108) and drilling a hole in the flange end of the crankshaft (108);
- rotating the rotation table (106) to align the crankshaft (108) perpendicular with respect to the spindle (110) and performing oil hole drilling operation;
- rotating the crankshaft (108) on the fixture and performing a turning operation on the crankshaft (108); and
- mounting the crankshaft (108) on a balancing equipment (112) to perform a weight balancing operation on the crankshaft (108).
[0016] In one embodiment, the oil hole drilling operation comprises actuating the spindle (110) to move the crankshaft (108) back and forth to form oil holes or rotating the crankshaft (108) by the spindle (110) to form oil holes.
[0017] Example embodiments will now be described more fully with reference to the accompanying drawings. The drawings described herein are for illustrative purposes only of selected embodiments and not all possible implementations, and are not intended to limit the scope of the present disclosure. It should be understood that throughout the drawings, corresponding reference numerals indicate like or corresponding parts and features.
[0018] Fig. 1 illustrates a side view of a multi-operation machining apparatus 100. The multi-operation machining apparatus 100 is capable of performing four different operations on a crankshaft 108. The four operations performed for the manufacturing of crankshaft 108 includes End drilling and tapping on the ends of the crankshaft 108, Oil hole and oil groove drilling, Turning operation at the ends of the crankshaft 108, and Balancing operation of the crankshaft 108. Further, the end drilling operation includes a step of drilling holes on a flange End and a gear End of the crankshaft 108. Generally, the end drilling operation is performed to allow the lubricants to pass through the crankshaft 108. Further, the oil hole and oil groove drilling is done on the body of the crankshaft 108 for oil to pass there through. Furthermore, the end turning operation is performed on the crankshaft 108 to smoothen the surface of the crankshaft 108. Finally, balancing operation is performed on the crankshaft 108 to ascertain if the mass of the crankshaft is equally balanced in the body of the crankshaft 108 as crankshaft 108 should rotate in balanced condition when assembled in engine.
[0019] In accordance with the present subject matter, the multi-operation machining apparatus 100 performs the above mentioned four operations on the crankshaft 108 before the crankshaft 108 is available for use. The multi-operation machining apparatus 100 may comprise a fixture 104, a rotating table 106, a spindle 110 having a drilling and turning tool, balancing equipment 112 and a robotic arm 114, in an implementation of the present subject matter.
[0020] In an example, an operator 102 may allow the robotic arm 114 to mount the crankshaft 108 on the fixture 104. The fixture 104 may be coupled to the rotating table 106. The rotating table 106 may rotate the fixture 104 and the crankshaft by 360 degrees, thus imparting a horizontal motion to the crankshaft, in accordance with the present subject matter. Further, the spindle 110 may be capable of imparting a motion to the drilling tool along X-axis, Y-axis, and Z-axis. Hence, the rotating table 106 and the spindle 110 may allow movement of the crankshaft 108 in horizontal as well as in vertical direction, as desired, for various operations to be performed.
[0021] In an implementation of the present subject matter, the drilling tools mounted on the spindle 110 may perform the operation of end drilling and oil drilling on the crankshaft 108 to form a passage for lubricant and oil.
[0022] In another implementation the robotic arm 114 may reduce operator’s intervention in the operation of the multi-operation machining apparatus 100, by performing the operation of mounting, dismounting and transporting the crankshaft 108 in different sections of the multi-operation machining apparatus 100 for the process of crankshaft manufacturing.
[0023] In accordance with the present subject matter, the balancing equipment 112 of the multi-operation machining apparatus 100 may determine if mass of the crankshaft 108 is evenly distributed along the body of the crankshaft 108. If as a result of determination uneven mass distribution is captured, the balancing equipment 112 may determine the position and extent of error and share the information with a controller that operates the spindle 110 to actuate the drilling tool. The drilling tool on the spindle 110 may perform a drilling operation to balance the mass of the crankshaft in an example. In an alternate example, a turning tool on the spindle 110, in conjunction with the spindle 110 may perform the end turning operation on the crankshaft 108.
[0024] Figure 2a and figure 2b illustrate a side view and a top view of the fixture 104, respectively. As disclosed in Fig. 1, the crankshaft 108 may be mounted by the operator 102, onto the fixture 104. The fixture 104 may rotate 360 degrees by motion of the rotating table 106, thus, allowing the crankshaft 108 to rotate and translate about the rotation table 106. Further, the fixture 104 may also include a main spindle 104-1 and a sub spindle 104-2 that may hold the crankshaft 108 onto the fixture 104 to stabilize the position of the crankshaft 108. Thus, a permutation and combination of the movement of fixture 104 and the spindle 104-1, 104-2 impart diverse orientations to the crankshaft 108 for different manufacturing operations, while keeping the movement of the crankshaft108.
[0025] In operation of the present subject matter, the operator 102 may fix the crankshaft 108 onto the fixture 104, and initiate the multi-operation machining apparatus 100 for performing various operations on the crankshaft. Upon initiation of the multi-operation machining apparatus 100, the spindles 104-1, 104-2 holds the crankshaft 108 firmly onto the fixture 104, in an embodiment of the present subject matter. Thereafter, the operator 102 confirms if a gear end of the crankshaft 108 is in line with the vertical drilling tool. After, ensuring that the gear end of the crankshaft is in line with the vertical drilling tool, the drilling tool is actuated to enable the drilling tool to come in contact with the crankshaft 108 on the fixture 104. Upon contact of the drilling tool with the crankshaft 108, the drilling tool drills through the gear end of the crankshaft to form the first hole on the gear end. After, drilling the hole in the gear end, the drilling tool is moved away from the crankshaft 108. Thereafter, the rotation table 106 rotates the fixture 104 by 180 degrees, such that the flange end of the crankshaft 108 is in line with the drilling tool. After, ensuring the alignment of the crankshaft 108, the drilling tool is actuated towards the crankshaft 108 to drill a hole on the Flange end of the crankshaft 108. Further, after drilling the hole on the flange end, the drilling tool actuates away from the crankshaft 108, marking the end of end drilling operation on the crankshaft 108. In an implementation, to form threads on the crankshaft 108, as a part of tapping operation, the spindle 110 is actuated.
[0026] In another implementation, for oil hole drilling operation, the fixture 104 may be rotated by 90 degrees such that the crankshaft 108 with the holes drilled on the ends, is aligned perpendicular to the spindle 110. After, ensuring that the crankshaft and the spindle 110 are aligned perpendicular to each other, the spindle 110 actuates, such that the crankshaft 108 is moved back and forth to form oil holes. The oil holes may be formed by the tool by diagonally forming holes along the body of the crankshaft 108. In an example, the crankshaft 108 may also be rotated by the spindle 110 in order to form oil holes.
[0027] In an implementation, upon completion of the oil hole drilling operation, the rotating table 106 rotates the fixture 104 such that the crankshaft rotates by 90 degrees. The rotation of the crankshaft 108 by 90 degrees aligns the crankshaft 108 perpendicular to the spindle 110. Simultaneously, the drilling tool is replaced by the turning tool. Thereafter, the main spindle 104-1 is actuated to rotate the crankshaft 108. Simultaneously, the spindle 110 is actuated to operate the turning tool to come in contact with the crankshaft ends. Further, for performing the turning operation the crankshaft 108 is held firmly on the fixture to smoothen the surface of the crankshaft 108. Since, the crankshaft 108 keeps rotating and the turning tool actuates, desired surface finish may be achieved without the need for grinding operation. Thus, the resources and time spent on the grinding operation are eliminated. The size of the turned diameter is verified by in-process gauge mounted inside the machine.
[0028] In accordance with the present subject matter, after successful completion of the turning operation, the robotic arm 114 dismounts the crankshaft 108 from the fixture 104 and the spindle 110 and mount the crankshaft 108 on the balancing equipment. The balancing equipment 112 may perform dynamic balancing of the mass of the crankshaft as disclosed in Fig. 1. Thereafter, the robotic arm 114 dismounts the crankshaft 108 from the balancing equipment and remounts the crankshaft on the fixture. Thereafter, the spindle 110 is actuated to drill into the crankshaft 108 at positions as determined by the balancing equipment to remove the mass from the crankshaft thereby balancing the crankshaft.
[0029] Finally, upon performing the four operations of end drilling, oil hole drilling, turning, and balancing of the crankshaft 108, the robotic arm 114 dismounts the crankshaft 108 and moves the completed crankshaft 108 out of production, in accordance with the present subject matter.
[0030] It is to be understood that the present invention is not limited to the embodiment described above, but encompasses any and all embodiments within the scope of the present subject matter.
,CLAIMS:We Claim:
1. A multi-operation machining apparatus (100) comprising:
a spindle (110) to mount a machining tool, wherein the spindle imparts a motion to the machining tool along one of a X-axis, Y-axis, and Z-axis of the machning axis;
a fixture (104) to mount a crankshaft (108) and position the crankshaft (108);
a rotation table to mount the fixture (104) to
rotate the fixture (104) about the Z axis, and
translate the fixture (104) along the X-axis; and

a balancing equipment (112) to perform a weight balancing operation on the crankshaft (108).

2. The multi-operation machining apparatus (100) as claimed in claim 1 further comprises a robotic arm (114) to mount and dismount the crankshaft (108) from the multi-operation machining apparatus (100).

3. The multi-operation machining apparatus (100) as claimed in claims 1 to 2, wherein the robotic arm (114) mount and dismount the crankshaft (108) from at least one of the fixture (104) and the balancing equipment (112).

4. The multi-operation machining apparatus (100), wherein the fixture further comprises a main spindle (104-1) and a sub-spindle (104-2) each configured to hold an end of the crankshaft (108), wherein the main spindle (104-1) rotates the crankshaft (108).

5. A method of manufacturing a crankshaft (108) mounted on a fixture (104), the fixture (104) being mounted on a rotation table (106), the method comprising:
positioning a gear end of the crankshaft (108) with respect to a spindle (110) and drilling a hole in the gear end of the crankshaft (108);
rotating the rotation table (106) to align a flange end of crankshaft (108) and drilling a hole in the flange end of the crankshaft (108);
rotating the rotation table (106) to align the crankshaft (108) perpendicular with respect to the spindle (110) and performing oil hole drilling operation;
rotating the crankshaft (108) on the fixture and performing a turning operation on the crankshaft (108); and
mounting the crankshaft (108) on a balancing equipment (112) to perform a weight balancing operation on the crankshaft (108)..

6. The method as claimed in claim 5, wherein the oil hole drilling operation comprises actuating the spindle (110) to move the crankshaft (108) back and forth to form oil holes or rotating the crankshaft (108) by the spindle (110) to form oil holes.

7. The method as claimed in claim 5, where the method comprises rotating the crankshaft 108 by 90 degrees to align the crankshaft 108 perpendicular to the spindle 110; simultaneously, replacing the drilling tool by the turning tool; actuating the main spindle 104-1 to rotate the crankshaft 108; simultaneously, actuating the spindle 110 to operate the turning tool to come in contact with the crankshaft ends; performing the turning operation by holding the crankshaft 108 firmly on the fixture to smoothen the surface of the crankshaft 108; dismounting the crankshaft 108 from the fixture 104 and spindle 110 by using robotic arm 114; mounting the crankshaft 108 on the balancing equipment to perform a weight balancing operation on the crankshaft (108); dismounting the crankshaft 108 from the balancing equipment by the robotic arm 114; remounting the crankshaft on the fixture; and actuating the spindle 110 to drill into the crankshaft 108 at positions as determined by the balancing equipment to remove the mass from the crankshaft thereby balancing the crankshaft.

Dated This 20th March 2019

Chirag Tanna
Of NOVOIP
Applicant’s Patent Agent