1. 1 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Cylinder Bore Inspection Engineering Research Center for Reconfigurable Manufacturing Systems

2. 2 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Project Background NCU (residual boring marks after honing of cylinders) detection requested by power train. Applicable scattering phenomenon observed in laboratory. Defect detection: Go/No-Go vs. conventional metrology. Project Goal Detection of non clean-up (NCU) of residual boring marks after honing of cylinder bores. Cycle time of 20 seconds required.

3. 3 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Laser Scattering from Machined Surfaces Laser light normally incident on a machined surface is scattered preferentially in a plane perpendicular to the machining marks. The physical phenomenon used to distinguish between boring and honing:

4. 4 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Cylinder Surface Scatter, not just reflection. Different pattern for boring vs. honing. Direction of scattered laser light varies with boring vs. honing.

5. 5 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Probe Assembly Slip Ring

6. 6 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Manufactured Probe LaserPrism MirrorDetector Slip Ring

7. 7 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Typical Data Data collected with Labview Plots generated with Matlab NCU Detection Properly Honed

8. 8 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Honing Problem Detection Different honing patterns at the top and bottom of the cylinder Axial stripes along the cylinder wall.

9. 9 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Alternate Detectable Conditions Coarse Honing Fine and Coarse Boring

10. 10 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Full Scale Prototype Goals Technology transfer to industry. Demonstrate parallel probe operation. Demonstrate survivability and maintainability of probes in a factory environment. Accelerate implementation in ERC member company plants.

11. 11 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Full Scale Prototype Requirements Inspect one bank of V blocks, all cylinders of straight 4 blocks. Demonstrate parallel operation. Easily reconfigurable. Inspect blocks from different manufacturers- straight 4,V-6, and V-8. Minimum cost.

12. 12 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Machine Specifications

13. 13 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Prototype Layout as in the Request for Proposal (RFP) Vibration absorbing pads Motion stage Probe rotation mechanism Probes Block Table Inspection station computer Environmental shield Base Support structure Fork lift holes

14. 14 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Full Scale Prototype Configuration as Requested by End-Users

15. 15 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Completed Prototype Station installed week of 9-17-07. Station and probes are operational.

16. 16 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering System Communication PC 5 PC 1PC 2PC 3PC 4 Rotary encoder Cylinder tool Rotary encoder Cylinder tool Rotary encoder Cylinder tool Rotary encoder Cylinder tool Linear encoder Gehring PC Gehring machine head UM system

17. 17 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Future Work Optimization of parallel detection at the ERC. Factory implementation of prototype system. Possible detection of rough hone or boring stages. A probe to measure dimensional variation and detect NCU is being developed.

18. 18 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering A new probe is being developed. Probe centering in a cylinder will be easily determined using this probe. Probe uses different detector, electronics, optics and software. New probe will measure dimensional variation as well as check surface finish.

19. 19 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Dimension sensing probe Scatter from surface is imaged onto detector by lens. Image position changes with distance from probe to surface. Detector is position sensitive. Slip Ring Bore Surface Mirror Lens Detector Laser

20. 20 NSF Engineering Research Center for Reconfigurable Manufacturing Systems University of Michigan College of Engineering Questions?