DESC:FIELD
The present disclosure relates to the field of industrial engineering.
BACKGROUND
During assembly of an engine, various assembly operations are performed on a cylinder block before the cylinder block is assembled within a vehicle. In a conventional shaft assembly operation, an operator needs to change the orientation of a heavy cylinder block in order to insert an idler shaft within the cylinder block. Further, the operator has to rotate the cylinder block before transferring the cylinder block for next assembly operation. The operator needs to perform the abovementioned activities a number of times in a day, which causes fatigue. In a conventional plug pressing operation, a welch plug is pressed on the cylinder block. An operator presses the plug using a hammer which may result in improper assembly of the plug on the cylinder block. In a conventional manual cylinder liner assembly operation, another operator inserts a cylinder liner within the cylinder block with help of a dolly. Further, yet another operator embosses an identifying mark, in a form of a number, on the cylinder block using a number punching unit.
The abovementioned operations are repetitive in nature, which causes heavy fatigue. Further the abovementioned operations are performed by different operators, thereby increasing the labour cost. The abovementioned operations are performed at different locations, thereby requiring more floor space. Additionally, such operations increases non-value adding activities such as transferring the cylinder block from one place to another, changing orientation of the cylinder block, and lifting the cylinder block numerous times in a day. Such non-value adding activities consume lot of time, thereby reducing the production of assembled cylinder blocks.
Therefore, there is felt a need for a workstation that is capable of performing multiple operations on a cylinder block at one location, and alleviates the abovementioned drawbacks associated with the conventional operations.
OBJECTS
Some of the objects of the present disclosure, which at least one embodiment herein satisfies, are as follows.
An object of the present disclosure is to provide a workstation that is capable of performing multiple assembly operations at a single place without changing orientation of a cylinder block.
Another object of the present disclosure is to provide a workstation for performing multiple assembly operations on a cylinder block that requires less labor and time, and causes less fatigue.
Yet another object of the present disclosure is to provide a workstation that eliminates tumbling of a cylinder block.
Yet another object of the present disclosure is to provide a workstation that eliminates need of manual pressing.
Still another object of the present disclosure is to provide a workstation that eliminates the requirement of separate work spaces for separate operations.
Other objects and advantages of the present disclosure will be more apparent from the following description, which is not intended to limit the scope of the present disclosure.
SUMMARY
The present disclosure envisages a workstation for performing multiple assembly operations on a cylinder block. The workstation comprises a support structure, a first hydraulic cylinder, a second hydraulic cylinder, at least one pneumatic cylinder, and a punching unit. The support structure is configured to securely hold the cylinder block. The first hydraulic cylinder has a first rod extendable therefrom. The first hydraulic cylinder is configured to insert a shaft within the cylinder block by pressing the shaft via the first rod. The second hydraulic cylinder has a second rod extendable therefrom. The second hydraulic cylinder is configured to press fit a plug on the cylinder block by pressing the plug on the cylinder block via the second rod. The at least one first pneumatic cylinder has a third rod extendable therefrom. The first pneumatic cylinder is disposed at an operative top surface of the holding structure, and is configured to press a cylinder liner against an operative inner surface of at least one cylinder of the cylinder block via the third rod, thereby assembling the cylinder liner with the cylinder block.
The punching unit is coupled to the support structure, and is configured to emboss an identifying mark on the cylinder block.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWING
A workstation for performing multiple assembly operations on a cylinder block, of the present disclosure, will now be described with the help of the accompanying drawing, in which:
Figures 1A, 1B, 1C and 1D illustrate different isometric views depicting various orientations of a cylinder block during assembly operations;
Figure 2 illustrates an isometric view depicting a conventional shaft assembly operation;
Figure 3 illustrates an isometric view depicting a conventional welch plug assembly operation;
Figure 4 illustrates an isometric view depicting a conventional liner assembly operation;
Figure 5 illustrates an isometric view depicting a conventional number punching operation;
Figure 6 illustrates a consolidated view depicting the conventional processes illustrated in figure 2 to figure 5;
Figure 7 illustrates an isometric view of a workstation for performing multiple assembly operations on a cylinder block, in accordance with an embodiment of the present disclosure; and
Figures 8A, 8B, 8C, and 8D illustrate isometric views depicting various assembly operations performed by the workstation of figure 7.
LIST OF REFERENCE NUMERALS
100 – Cylinder block
105 – Front face of cylinder block
110 – Side face of cylinder block
115 – Top face of cylinder block
120 – Rear face of cylinder block
125 – Plurality of cylinders
200 – Conventional shaft assembly operation
205 – Conveyor in conventional assembly operations
210 – Operator
215 – Vertical press machine
300 – Conventional plug assembly operation
305 – Trolley
310 – Location of a plug
400 – Conventional liner assembly operation
500 – Conventional number punching operation
505 – Number punching unit
510 – KBK arrangement
515 – Indenter
700 – Workstation of the present disclosure
701 – Conveyor of the workstation
702 – Support structure
703 – Base
704 – Frame
705 – First pneumatic cylinder
710 – Punching unit
715 – Second hydraulic cylinder
720 – First hydraulic cylinder
725 – Locating pin
730 – Cylinder liners
740 – Shaft
745 – First holder
750 – Plug
755 – Second holder
765 – Linear motion rails
770 – Second pneumatic cylinder
DETAILED DESCRIPTION
Conventionally, a plurality of assembly operations is performed on a cylinder block before the cylinder block is fitted in a vehicle. Figure 1A to figure 1D illustrate different orientations of a cylinder block 100 required for different assembly operations.
Figure 1A illustrates the cylinder block 100 with a front face 105 oriented for idler shaft assembly. Figure 1B illustrates the cylinder block 100 with a side face 110 oriented for number punching. Figure 1C illustrates the cylinder block 100 with a top face 115 oriented for liner pressing. Figure 1D illustrates the cylinder block 100 with a rear face 120 oriented for welch plug pressing. The cylinder block 100 includes a plurality of cylinders 125 configured on the top face 115 thereof.
Figure 2 illustrates a conventional shaft assembly operation 200. The cylinder block 100 is disposed on a conveyor 205 in horizontal position. An operator 210 has to lift the cylinder block 100 from the conveyor 205 and requires orienting the cylinder block 100 such that the front face 105 faces a top side of a vertical press machine 215. The vertical press machine 215 then presses the shaft within the cylinder block 100 at appropriate location. After completing the shaft assembly operation 200, the operator 210 has to again dispose the cylinder block 100 in horizontal position. However, in the shaft assembly operation, the operator 210 needs to lift and change the orientation of the massive cylinder block repeatedly in a day causing back ache and inducing fatigue. Further, separate space is required for the shaft assembly operation.
Figure 3 illustrates a conventional plug assembly operation 300. The cylinder block 100 is placed on a trolley 305. A welch plug is placed at a location shown by the reference numeral 310 on the rear face 120 of the cylinder block 100. The welch plug is securely disposed within a bore formed on the rear face 120 of the cylinder block 100 using a hammer. However, for the plug assembly operation 300, separate place is required. Further, as the plug assembly operation is performed manually using the hammer, the welch plug may get distorted due to improper hammering.
Figure 4 illustrates a conventional liner assembly operation 400. Another operator disposes a cylinder liner in each the cylinders 125. The cylinder liner is manually press fitted within the cylinders 125. The liner assembly operation, thus, induces fatigue due to its repetitive nature.
Figure 5 illustrates a conventional number punching operation 500. A number punching unit 505 is hanged on a light hanger assembly by KBK arrangement 510. An indenter 515 of the number punching unit 505 is kept substantially perpendicular to the side face 110 of the block 100 that is to be marked. However, if the number punching unit 505 is not kept perpendicular, there are chances of misalignment of the indenter 515 and the cylinder block 100 leading to a shift in the number punching position and clarity. For the operator to align the number punching unit 505 perpendicular to the side face 110 of the cylinder block 100 requires considerable skill, and is a tiresome job considering the number of times the operator has to do the task in a shift.
All the abovementioned operations are repetitive in nature causing fatigue from perspective of an operator. For every operation, as shown in figure 6, the orientation of the cylinder block 100 needs to be changed. The abovementioned operations are performed by different operators, thereby increasing the labour cost. The abovementioned operations are performed at different locations, thereby requiring more floor space. Additionally, such operations increases non-value adding activities such as transferring the cylinder block from one place to another, changing orientation of the cylinder block, and lifting the cylinder block numerous times in a day. Such non-value adding activities consume lot of time, thereby reducing the production of assembled cylinder blocks.
The present disclosure envisages a workstation that can perform multiple operations at a single place, and is operable by a single operator. The workstation, of the present disclosure, is now described with reference to figure 7 through figure 8D.
A workstation 700, of the present disclosure, comprises a support structure 702 having a base 703 and a frame 704. The frame 704 is attached to the base 703. The support structure 702 is configured to securely hold the cylinder block 100 therewithin. The support structure 702 is provided with a locating pin 725. The locating pin 725 facilitates alignment of the cylinder block 100 with the support structure 702.
The workstation 700 comprises a first hydraulic cylinder 720. The first hydraulic cylinder 720 has a first rod (not exclusively labelled in figures) extendable therefrom. The first hydraulic cylinder 720 is configured to insert a shaft 740 within the cylinder block 100. The first hydraulic cylinder 720 presses the shaft 740 within the cylinder block 100 via the first rod. The first hydraulic cylinder 720 is disposed on attached to the support structure 702 such that an axis of the first hydraulic cylinder 720 is collinear with a bore configured to receive the shaft 740 within the cylinder block 100. In an embodiment, the shaft 740 is an idler shaft.
The first hydraulic cylinder 720 comprises a first holder 745. The first holder 745 is attached to the free end of the first rod, and configured to hold the shaft 740 which is to be inserted within the cylinder block 100.
The workstation 700 further comprises a second hydraulic cylinder 715. The second hydraulic cylinder 715 has a second rod (not exclusively labelled in figures) extendable therefrom. The second hydraulic cylinder 715 is configured to press fit a plug 750 on the cylinder block 100 by pressing the plug 750 on the cylinder block 100 via the second rod. The cylinder block 100 has a bore (not shown in figures) configured on the rear face 120 to receive the plug 750 therewithin. The second hydraulic cylinder 715 is attached to the support structure 702 such that an axis of the second hydraulic cylinder 715 is collinear with an axis of the bore configured to receive the plug.
The second hydraulic cylinder 715 comprises a second holder 755 attached to the second rod. The second holder 755 is configured to hold the plug. In an embodiment, the plug 750 is a welch plug.
The first hydraulic cylinder 720 is disposed diametrically opposite to the second hydraulic cylinder 715, as locations of the shaft and the shaft are diametrically opposite to each other.
The workstation further comprises at least one first pneumatic cylinder 705. The first pneumatic cylinder 705 has a third rod (not shown in figures) extendable therefrom. The first pneumatic cylinder 705 is disposed at an operative top surface of the support structure 702, more specifically on the frame 704. The first pneumatic cylinder 705 is configured to press a cylinder liner 730 against an operative inner surface of at least one cylinder 125 of the cylinder block 100 via the third rod. The press fitting of the cylinder liner 730 assembles the cylinder liner 730 with the cylinder 125.
An axis of the first pneumatic cylinder is collinear with the axis of the cylinder 125.
In an embodiment, the workstation 700 comprises a plurality of first pneumatic cylinders 705. The number of first pneumatic cylinders 705 is determined as per the number of the cylinders 125 of the cylinder block 100. In an exemplary embodiment, the workstation 700 comprises four first pneumatic cylinders 705 for the cylinder block having four cylinders.
The workstation 700 further comprises a punching unit 710. The punching unit 710 is coupled with support structure 702. The punching unit 710 is configured to emboss an identifying mark on the cylinder block 100. In an embodiment, the identifying mark can be a numerical or a letter.
In an embodiment, an axis of the punching unit 710 is at a predetermined angle with respect to the axis of the cylinder 125.
The workstation 700 further comprises a second pneumatic cylinder 770 configured to release the cylinder block 100 after the assembly operations are completed.
In an operative configuration, an operator receives the cylinder block 100 from the conveyor 701. The operator then disposes the cylinder block 100 within the frame 704 of the support structure 702 such that the top side 115 of the cylinder block 100 faces the operative top side of the frame 704. Further, the operator places the shaft 740 on the first holder 745 such that the shaft 740 is loosely fitted on the first holder 745. Further, the first hydraulic cylinder 720 is actuated which inserts the shaft 740 within the bore provided to receive the shaft 740 within the cylinder block 100, thereby assembling the shaft 740 with the cylinder block 100. Further, the plug 750 is loosely fitted on the second holder 755. The second hydraulic cylinder 715 is actuated with press fits the plug 750 using the second rod. The cylinder liners 730 are disposed in each of the cylinders 125. The cylinder liners 730 are press fitted against the operative inner surface of the cylinders 125 using the first pneumatic cylinders 705.
Further, the fixture-type number punching unit 710 is mounted on linear motion rails 765 to achieve perpendicularity with a number punching face of the cylinder block 100. The punching unit 710 then embosses an identifying mark in the form of a numerical or a letter, on the cylinder block 100 at predetermined location.
The sequence of the abovementioned operations can be altered as per the requirement.
After completing the abovementioned operations, the cylinder block 100 is ejected from the workstation 700, automatically, through a pneumatic cylinder 770.
The workstation 700 of the present disclosure requires single operator as against multiple operators in conventional processes. Further, the workstation 700 occupies less space as multiple operations are performed at a single place. The workstation 700 causes less fatigue from the perspective of the operator and also reduces the non-value adding activities.

TECHNICAL ADVANCEMENTS
The present disclosure described herein above has several technical advantages including, but not limited to, the realization of a workstation that:
• is capable of performing multiple operations at a single place without changing orientation of a cylinder block;
• requires less labor and time, and causes less fatigue;
• eliminates tumbling of a cylinder block;
• eliminates need of manual pressing; and
• eliminates the requirement of separate work spaces for separate operations.
The disclosure has been described with reference to the accompanying embodiments which do not limit the scope and ambit of the disclosure. The description provided is purely by way of example and illustration.
The embodiments herein and the various features and advantageous details thereof are explained with reference to the non-limiting embodiments 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.
The foregoing description of the specific embodiments so fully revealed 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.
Throughout this specification the word “comprise”, or variations such as “comprises” or “comprising”, will be understood to imply the inclusion of a stated element, integer or step, or group of elements, integers or steps, but not the exclusion of any other element, integer or step, or group of elements, integers or steps.
The use of the expression “at least” or “at least one” suggests the use of one or more elements or ingredients or quantities, as the use may be in the embodiment of the disclosure to achieve one or more of the desired objects or results.
Any discussion of documents, acts, materials, devices, articles or the like that has been included in this specification is solely for the purpose of providing a context for the disclosure. It is not to be taken as an admission that any or all of these matters form a part of the prior art base or were common general knowledge in the field relevant to the disclosure as it existed anywhere before the priority date of this application.
The numerical values mentioned for the various physical parameters, dimensions or quantities are only approximations and it is envisaged that the values higher/lower than the numerical values assigned to the parameters, dimensions or quantities fall within the scope of the disclosure, unless there is a statement in the specification specific to the contrary.
While considerable emphasis has been placed herein on the components and component parts of the preferred embodiments, it will be appreciated that many embodiments can be made and that many changes can be made in the preferred embodiments without departing from the principles of the disclosure. These and other changes in the preferred embodiment as well as other embodiments of the disclosure will be apparent to those skilled in the art from the disclosure herein, whereby it is to be distinctly understood that the foregoing descriptive matter is to be interpreted merely as illustrative of the disclosure and not as a limitation.
,CLAIMS:WE CLAIM:

1. A workstation (700) for performing multiple assembly operations on a cylinder block (100), said workstation (700) comprising:
a support structure (702) configured to securely hold said cylinder block (100);
a first hydraulic cylinder (720) having a first rod extendable therefrom, said first hydraulic cylinder (720) configured to insert a shaft (740) within said cylinder block (100) by pressing said shaft (740) via said first rod;
a second hydraulic cylinder (715) having a second rod extendable therefrom, said second hydraulic cylinder (715) configured to press fit a plug (750) on said cylinder block (100) by pressing said plug (750) on said cylinder block (100) via said second rod; and
at least one first pneumatic cylinder (705) having a third rod extendable therefrom, said first pneumatic cylinder (705) disposed at an operative top surface of said support structure (702), and configured to press a cylinder liner (730) against an inner operative surface of at least one cylinder (125) of said cylinder block (100) via said third rod for assembling said cylinder liner (730) with said cylinder block (100).
2. The workstation (700) as claimed in claim 1, which comprises a punching unit (710) coupled to said support structure (702), and configured to emboss an identifying mark on said cylinder block (100).
3. The workstation (700) as claimed in claim 1, wherein said first hydraulic cylinder (720) is disposed diametrically opposite to said second hydraulic cylinder (715) on said support structure (702).
4. The workstation (700) as claimed in claim 1, wherein said first hydraulic cylinder (720) comprises a first holder (745) attached to said first rod, and configured to hold said shaft (740).
5. The workstation (700) as claimed in claim 1, wherein said second hydraulic cylinder (715) comprises a second holder (755) attached to said second rod, and configured to hold said plug (750).
6. The workstation (700) as claimed in claim 1, which comprises a locating pin (725) configured to facilitate alignment of said cylinder block (100) with said support structure (702).
7. The workstation (700) as claimed in claim 1, which comprises a second pneumatic cylinder (770) configured to release said cylinder block (100) from said support structure (702).
8. The workstation (700) as claimed in claim 1, wherein:
an axis of said punching unit (710) is at a predetermined angle with respect to an axis of said cylinder (125) of said cylinder block (100); and
an axis of said first pneumatic cylinder (705) is collinear with the axis of said cylinder (125) of said cylinder block (100).