Title of Invention

BANJO BOLT INSPECTION EQUIPMENT AND A SYSTEM FOR MONITORING HOLES OF BANJO BOLTS

Abstract

A system for inspecting and/or segregating banjo bolts, said system comprising of. (i) A spindle capable of being rotated using a motor; (ii) A rotary encoder mounted on a bottom side of the spindle; (iii) Two photo electric sensors or lasers fitted on to an adjustable bracket with an included angle of 90°C; (iv) A fixture directly mounted on top side of the spindle for receiving the banjo bolt for inspection; (v) An air cylinder with end sensing or displacement sensor to monitor the presence or absence of axial hole on the banjo bolt; (vi) A gripper system with a rotary cum linear air cylinder combination for unloading inspected banjo bolt; (vii) A dumber system to segregate accepted or rejected banjo bolts; (viii) A central system with high speed pulse counter for receiving total output from the rotary encoder; and (ix) A man machine interface unit (MMI) which provides interface between operator and the central system.

Full Text

A SYSTEM FOR INSPECTING AND/OR SEGREGATING BANJO BOLTS AND A PROCESS THERREOF Field of invention The present invention relates to the method for eliminating missing of (i) radial holes (ii) axial hole in a banjo bolt and a system to perform the method. The system is a combination of high intensity diffusive type sensors and a rotary encoder. This can be further developed for checking the presence/absence of a hole on a cylindrical member. Also it can be used on any manufacturing device where light sensor/rotary encoder co-relation exists. Background and priori art Basically holes are drilled in Banjo bolts by using bench drilling machine manually. Due to this following problems are encountered. 1. Blank without holes mixes with good products. 2. Missing operation i.e. missing of axial / radial holes again mixes with good products 3. Broken drills or burrs inside drilled holes and drilled holes will be partially blocked. 4. Partial hole depth Also there were lots of mix up problems in plating and before packing. Banjo bolts are used in lubrication of engines. The mixing of aforesaid bad products with good products results in cease of engine and thereby customer complaints. The operation sequence of drilling is as follows: • A suitable fixture to hold the component for axial hole drilling. • Axial hole drilling • A suitable fixture to hold the component for radial hole drilling. • Radial hole drilling • Deburring operation Today the auto manufacturers are introducing automated assembly lines. Parts are directly fed into the assembly line without any incoming inspection and human involvement. Hence parts have to be defect free and have consistent quality. Any mixing of defective parts i.e. without hole (blanks), with partially completed operations entering into the automated assembly line may cause stoppage and severe damage of assembly line. Customers insist on defect free supplies that can be directly fed to assembly line without any incoming inspection also, maintaining just in time inventory, no scope for rejection and segregation. This necessitates a final quality check by sorting of banjo bolt before despatch to provide the guarantee of 100% defect free supply as expected by the customer. Objects of invention The main object of the present invention is to provide a banjo bolt inspection system which is capable of eliminating banjo bolts having no hole, missing or partially completed holes or of holes filled with broken drill bit etc. and hence avoid mixing of bad products in accepted ones. Another object of the present invention is to provide a method for scanning the hole through out 360° of the rotation of the fixture with respect to an encoder. This will eliminate parts with broken drilling bits trapped inside the hole. Yet another object of the present invention is to inspect the banjo bolts and determine the hole tolerance so that banjo bolts having under size/over size holes can be eliminated. Summary of invention The present invention relates to a banjo bolt inspection system which is capable of eliminating banjo bolts with missing holes, undersize/oversize holes, holes having broken drill bit trapped inside them. The system is a combination of rotating encoder and photo electric sensors. This system has been developed for checking presence /absence of hole in a banjo bolt and can be extended on any manufacturing device where rotating encoder/photo electric or laser sensor co-relation exists. Particularly, the present invention provides an off line inspection system for monitoring banjo bolts mounted on a rotating spindle by scanning the banjo bolt using a photo electric light beam/ laser so that 100% okay products are obtained prior to dispatch. tailed description of the invention accordingly, the present invention relates to a system for inspecting and/or segregating injo bolts, said system comprising of a spindle capable of being rotated using a motor; a tary encoder mounted on a bottom side of the spindle; two photo electric sensors or users fitted on to an adjustable bracket with an included angle of 90°C; a fixture directly lounted on a top side of ■the spindle for receiving the banjo bolt for inspection; an air linder with end sensing/displacement sensor to monitor the presence or absence of axial ole on the banjo bolt; a gripper system with a rotary cum linear air cylinder combination -r unloading inspected banjo bolt; a dumber system to segregate accepted/rejected banjo olts; a central system with high speed pulse counter for receiving total output from the otary encoder; and a man machine interface unit (MMI) which provides interface etween operator and the central system. In an embodiment of the present invention, the motor is a DC brushless motor. In another embodiment of the present invention, the motor has variable speed drive and receives 22" V, 3-phase AC input. In yet ano ler embodiment of the present invention, the rotary encoder is capable of generating 024 pulses per revolution and 5V TTL output. In still fur er embodiment of the present invention, the rotary encoder is capable of giving abs. te positioning to the central system. In a furthe nbodiment of the invention, the photo electric sensor provides beam diameter less than 1 m for better scanning. In anoth embodiment, the central system includes a programmable logic controller which in t ; includes a CPU, one or more input/output modules and a high speed pulse counter cr gured to receive 5V TTL output from the rotary encoder. In yet another embodiment, the system provides an off-line inspection mechanism. In still further embodiment, the said system inspects the banjo bolts for the presence of any defect and the said system inspects the banjo bolts for (1) no holes, (2) partial holes, (3) displaced holes, (4) holes with broken drill bits inside, (5) undersized holes, (6) oversized holes (7) holes having high/low tolerance and any other defects of the banjo bolt. In a further embodiment, the said system segregates the banjo bolts having defects from the banjo bolts having no defect. In yet another embodiment of the present invention, there is provided a process for inspecting and/or segregating banjo bolts, said process comprising the steps of mounting the banjo bolt onto a spindle and fixture assembly capable of being rotated at a predetermined speed, rotating the fixture through at least 360° at a predetermined speed such that the banjo bolt is also rotated, scanning the banjo bolt for detecting any defects during the rotation and optionally, demounting the banjo bolt from the fixture and segregating the banjo bolt into defective banjo bolts and non-defective banjo bolts depending upon the results obtained in step (c). In a still further embodiment, the spindle and fixture assembly is rotated using a motor, the motor is a DC brushless motor and the motor has variable speed drive and receives 220 V, 3-phase AC input. In yet other embodiment of the present invention, the banjo bolt is scanned using a rotary encoder assembly. In still another embodiment, the rotary encoder is capable of generating 1024 pulses per revolution and 5V TTL output. In yet another embodiment of the present invention, the defects in the banjo bolt are detected by a central system. In another embodiment of the present invention, the rotary encoder is capable of giving absolute positioning to the central system. In yet another embodiment, the central system is configured to receive details regarding absolute positioning of the banjo bolt from the rotary encoder. Brief description of the accompanying drawings: Fig.l shows flow diagram of the inspection system-setting cycle. Fig.2 shows flow diagram for continuous running. Fig. 3 shows the total system. Fig.4 shows the concept of hole inspection. Fig. 5 shows the schematic diagram of the complete system. Fig.6 shows the equipment of banjo bolt inspection system. The working of the Banjo inspection system is as follows: i) Place the component into the fixture with A/F driving and press the cycle start Button ii) CPU sends signal to the drive and spindle rotation starts at 30 rpm (max.) iii) After first scanning of the hole , PLC will wait for next hole signal from the machine, then spindle rotation stops iv) Unloading gripper grips the component, lift up and rotates to 90°C and drops into chute, v) Same time signal is sent to dumper to open/close, vi) Gripper goes back to its home position, vii) Next cycle starts after pre-determined time delay through an external timer. Figure5 shows the schematic diagram of the complete system. The system contains 3 sections namely, manual system, Mechanical system and Pneumatic system. The pneumatic system consists of filters, direction control valves and flow control valves. The mechanical system comprises photo electric sensor for sensing the defects in the banjo bolts, a motor, spindle and fixture assembly to position the bolt, which has to be inspected. The pneumatic system and mechanical system are connected through pneumatic pipes. It also comprises a rotary encoder, which co ordinates the positioning of the bolt to be examined and sends these information to the central processing unit. The manual system consists of a programmable logic array, which is operated by a manual operator. The manual system coordinates the pneumatic and mechanical system. The banjo bolt inspection system of the present invention will be capable of sensing included angle variation due to defects in the hole (or no hole) by using high beam vs encoder arrangement. This combination of the system with a central processing unit and MMI will ensure that parts delivered to accepted bin will confirm to specialization and 100% defect free. Bad parts will get segregated providing scope for analysis and improvement. All systems used for detecting bad parts in inspection process used either a light sensor/laser and rotating encoder in conjunction and develops a relation between rotation of the spindle with respect to a linear displacement sensor (in this case light beam), based on which the product evaluation and subsequent rejections are done. This system uses a combination of rotational position and distance by means of light beam to segregate parts in inspection to ensure zero defect and can be used on any manufacturing/inspection operation where a co-relation exists between linear distance and rotational position. Case Study: Product: M73780 M10xl 0x 23 Banjo Bolt 2 holes (Radial), One hole (axial) Setting cycle for radial hole: • Adjust photo electric sensor slide and rotate the spindle and check the included angle in MMI. • As per calculation the included angle = 30 degrees. • The value recorded by MMI = 28° (This is mainly due to centering error while placing the component on to the fixture and hole diameter variation). • Set the limit in MMI: Lower: 25° Upper: 32° • Found that any component enters less than 25° and more than 32° is rejected. • Found that component which gives less than 25° is due to burrs blocked the hole partially and some dust lodged inside the hole. Setting Cycle for axial hole: • The axial tool and cylinder reed switch is set for particular depth of the axial hole. • If the axial hole depth is less or more from specified limit is found to be rejected. • In some of the bolts, axial holes have not crossed the radial hole and duly rejected by the system due to length variation. Engine will be ceased if such bolts enters in engine lubrication circuit. ADVANTAGES: The present invention provides 100% defect free products. The present invention solves the problem of mixing of bad products with good products thereby resulting in cease of engine and customer complaints. WE CLAIM: 1. A system for inspecting and/or segregating banjo bolts, said system comprising of: (i) A spindle capable of being rotated using a motor; (ii) A rotary encoder mounted on a bottom side of the spindle; (iii) Two photo electric sensors or lasers fitted on to an adjustable bracket with an included angle of 90°C; (iv) A fixture directly mounted on top side of the spindle for receiving the banjo bolt for inspection; (v) An air cylinder with end sensing or displacement sensor to monitor the presence or absence of axial hole on the banjo bolt; (vi) A gripper system with a rotary cum linear air cylinder combination for unloading inspected banjo bolt; (vii) A dumber system to segregate accepted or rejected banjo bolts; (viii) A central system with high speed pulse counter for receiving total output from the rotary encoder; and (ix) A man machine interface unit (MMI) which provides interface between operator and the central system. 2. The system as claimed in claim 1, wherein the motor is a DC brushless motor. 3. The system as claimed in claim 1, wherein the motor has variable speed drive and receives 220V, 3-phase AC input. 4. The system as claimed in claim 1, wherein the rotary encoder is capable of generating 1024 pulses per revolution and 5 V TTL output. 5. The system as claimed in claim 1, wherein the rotary encoder is capable of giving absolute positioning to the central system. 6. The system as claimed in claim 1, wherein the photo electric sensor provides beam diameter less than 1 mm for better scanning. 7. The system as claimed in claim 1, wherein the central system includes a programmable logic controller. 8. The system as claimed in claim 1, wherein the programmable logic controller includes a CPU, one or more input/output modules and a high speed pulse counter configured to receive 5V TTL output from the rotary encoder. 9. The system as claimed in claim 1 wherein the system provides an off-line inspection mechanism. 10. The system as claimed in claim 1 wherein said system inspects the banjo bolts for (1) no holes, (2) partial holes, (3) displaced holes, (4) holes with broken drill bits inside,(5)under sized holes, (6) oversized holes (7) holes having high/low tolerance and any other defects of the banjo bolts. 11. The system as claimed in claim 1, wherein said system segregates the banjo bolts having defects from the banjo bolt having no defect. 12. A method for inspecting and /or segregating banjo bolts, said method comprising the steps of: a. mounting the banjo bolt onto a spindle and fixture assembly capable of being rotated at a predetermined speed; b. rotating the fixture at least 360° at a predetermined speed such that the banjo bolt is also rotated; c. scanning the banjo bolt for detecting any defects during the rotation and optionally; d. demounting the banjo bolt from the fixture and segregating the banjo bolt into defective banjo bolts and non defective banjo bolts depending upon the results obtained in step (c). 13. The method as claimed in claim in claim 12, wherein the spindle and fixture assembly is rotated using a motor. 14. The method as claimed in claim 12, wherein the motor is a DC brushless motor. 15. The method as claimed in claim 12, wherein the motor has variable speed drive and receives 220V,3-phase AC input. 16. The method as claimed in claim 12, wherein the banjo bolt is scanned using a rotary encoder assembly. 17. The method as claimed in claim 12, wherein the rotary encoder is capable of generating 1024 pulses per revolution and 5V TTL out put. 18. The method as claimed in claim 12, wherein the defects in the banjo bolts are detected by a central system. 19. The method as claimed in claim 12, wherein the central system is configured to receive information regarding absolute positioning of the banjo bolt from the rotary encoder. 20. A system for inspecting and/or segregating banjo bolts substantially as herein described with reference to the accompanying drawings. 21. A method for inspecting and/or segregating banjo bolts substantially as herein described with reference to the accompanying drawings.

Documents:

0124-mas-2002 claims-duplicate.pdf

0124-mas-2002 claims.pdf

0124-mas-2002 correspondence-others.pdf

0124-mas-2002 correspondence-po.pdf

0124-mas-2002 description (complete)-duplicate.pdf

0124-mas-2002 description (complete).pdf

0124-mas-2002 description (provisional).pdf

0124-mas-2002 drawings.pdf

0124-mas-2002 form-1.pdf

0124-mas-2002 form-13.pdf

0124-mas-2002 form-19.pdf

0124-mas-2002 form-26.pdf

0124-mas-2002 form-3.pdf

0124-mas-2002 form-4.pdf

0124-mas-2002 form-5.pdf