Patent Application
20180283318
The embodiments disclosed herein are related to a system and method of assembling a component part of a motor vehicle.
An engine block includes an upper block and a lower block. Placed between the upper block and the lower block is a crankshaft that rotates within the assembled engine block. Upper main bearings that rest between the crankshaft and the upper block and lower main bearings that rest between the crankshaft and the lower block aid in rotation of the crankshaft. Failure to install the lower main bearings in the lower block properly during the assembly process may negatively impact performance of the engine. Therefore, there exists a need for a system and method to ensure proper installation of the lower main bearings in the lower block prior to assembly of the engine block.
The features and advantages described in the specification are not all inclusive and, in particular, many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims. Moreover, it should be noted that the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter.
According to one aspect, a system for installing a predetermined number of parts into a component includes a tray having a plurality of sections for receiving the predetermined number of parts, a plurality of proximity sensors, each of the proximity sensors associated with one of the sections in the tray for tracking the predetermined number of parts, a visual indicator for confirming movement of the predetermined number of parts into and out of the tray, and a light curtain for sounding an alarm if the component is moved to an installation position before the movement of the predetermined number of parts into and out of the tray is completed.
According to another aspect, a system for installing a predetermined number of bearings into a lower block of an engine includes a tray having a plurality of slots for receiving the predetermined number of bearings, a plurality of proximity sensors, each of the proximity sensors associated with one of the slots in the tray for tracking the predetermined number of bearings, a visual indicator for confirming movement of the predetermined number of bearings into and out of the tray, and a light curtain for sounding an alarm if the lower block is moved to an installation position for installation in the engine before the movement of the predetermined number of bearings into and out of the tray is completed to ensure all of the predetermined number of bearings are installed in the lower block.
According to yet another aspect, a method for installing a predetermined number of parts into a component includes the steps of providing a tray having a plurality of sections for receiving the predetermined number of parts, placing the predetermined number of parts into the sections of the tray, detecting the presence of the predetermined number of parts with a plurality of proximity sensors, each of the proximity sensors associated with one of the sections in the tray for tracking the predetermined number of parts, installing each of the predetermined number of parts into the component, and providing a visual indicator for confirming movement of the predetermined number of parts out of the tray.
The FIGS. depict various embodiments for purposes of illustration only. One skilled in the art will readily recognize from the following discussion that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles of the embodiments described herein.
With further reference to
Each of the slots 402 further includes a hole 404 which is sized to receive a proximity sensor 406 which detects whether a lower main bearing 302 is present in the slot 402. The proximity sensor 406 may be an inductive proximity sensor that operates under the electrical principle of inductance that is well known to those skilled in the art. An inductive-type proximity sensor 406, illustrated in
As illustrated in
The proximity sensors 406 are inserted into the holes 404 of each of the slots 402 from beneath the tray 400. Each of the holes 404 may have an angular shape to receive more securely a nut 600 on proximity sensor 406. In the illustrated embodiment in
Due to the presence of the proximity sensors 406 beneath the tray 400, along with the wires 602 that provide the electrical communication with the visual indicator 408, there is also a need to provide a cover 800, as illustrated in
As illustrated in
While the presence detection device is described as a light curtain 906 in the illustrated embodiment, other presence detection devices may also be used, such as an area scanner 914 like an optical scanners or laser scanners, or a pressure sensitive floor sensor or any other suitable method known to those skilled in the art.
A method 1000 of installing the lower main bearings 302 is now disclosed that is illustrated in the flowchart in
In the third step 1006, all of the lower main bearings 302 in the tray 400 are installed in the lower block 104. In step four 1008, if all of the lower main bearings 302 are removed from the tray 400, the visual indicator gives an install confirmation. If all of the lower main bearings 302 are not removed from the tray 400, an alternate step 1010 occurs, and if the assembly worker moves the lower block to the installation zone 904 through the light curtain 906, a fault occurs and an alarm will sound.
As shown in step 1012, to clear the fault, the lower block must be returned to the loading zone 902, and the method resets to step 1004 such that all of the lower main bearings 302 must be reloaded in the tray 400, and the third step 1006 is repeated. In the event that the fault is not cleared, and the method is not followed, the assembled engine block 100 may be flagged for further review.
In the case where all of the lower main bearings 302 are installed, and the visual indicator 408 indicates all of the lower main bearings 302 are out of the slots 402 in the tray 400, the assembly worker 912 may move on to step 1014 and pass through the light curtain 906 and assemble the lower block 104 to the engine block 100. Finally, in step 1016, the engine block 100 may be released to move on in the production cycle.
The system and method 1000 disclosed herein have been directed to the assembly of lower main bearings 302 into the lower block 104 of an engine block 100 for an engine for a motor vehicle. The system and method 1000, however, may be applied to any circumstance that requires the assembly of a predetermined number of parts into a component in a factory, and the embodiment illustrating the assembly of an engine block is merely illustrative.
Reference in the specification to “one embodiment” or to “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiments is included in at least one embodiment. The appearances of the phrase “in one embodiment” or “an embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
In addition, the language used in the specification has been principally selected for readability and instructional purposes, and may not have been selected to delineate or circumscribe the inventive subject matter. Accordingly, the disclosure of the embodiments is intended to be illustrative, but not limiting, of the scope of the embodiments, which is set forth in the claims.
While particular embodiments and applications have been illustrated and described herein, it is to be understood that the embodiments are not limited to the precise construction and components disclosed herein and that various modifications, changes, and variations may be made in the arrangement, operation, and details of the methods and apparatuses of the embodiments without departing from the spirit and scope of the embodiments as defined in the appended claims.
