EP0683012B1 - Metal rolling machine with opposite rows of claw units for machining a centered workpiece and method for rolling rotary grooves of a workpiece - Google Patents

Description

Field of the Invention

This invention relates to metal working, more specifically to a new and improved one Machine for rolling fillets of metal workpieces and onto one new and improved method for simultaneously rolling all or a number of Fillets of a workpiece such as the fillets of crank pins of an engine crankshaft.

Description of the prior art

Various machines and methods were used prior to the present invention around metallic workpieces such as Camshafts and crankshafts for internal combustion engines to consolidate and finish. Since many engines have been scaled down to Getting it into smaller vehicles is difficult to finish and the consolidation of the correspondingly reduced workpieces. For example it is very difficult to reduce the size of crankshafts with optimized effectiveness to consolidate, because the lengths of the crank pins are so small that only insufficient Space for a tool to simultaneously roll all fillets in one Rolling process is present.

Verfahren und Vorrichtung zum Feinwalzen und Festwalzen von mehrhübigen Kurbelwellen" eine Maschineneinheit und ein Verfahren zum Walzen von Zapfenhohlkehlen einer Kurbelwelle offenbart, um die Probleme zu lösen, die das gleichzeitige Walzen von benachbarten Kurbelzapfen mit der verfügbaren Ausrüstung ausschließen. In dieser Patentoffenbarung nehmen die Maschineneinheit und die Kurbelwelle eine erste relative Lage zueinander ein, so daß die Hohlkehlen eines ersten Satzes von nicht benachbarten Zapfen festgewalzt werden können. Daraufhin werden in einer zweiten relativen Lage der Maschineneinheit und der Kurbelwelle die Hohlkehlen eines zweiten Satzes von nicht benachbarten Zapfen festgewalzt. Mit einem derartigen Aufbau und einem derartigen Verfahren werden alle Hohlkehlen in zwei Etappen oder zwei Verfahrensschritten durch eine einzelne Maschine gewalzt.Prior to the present invention, such crank pins and main bearings for downsized crankshafts, as well as crankshafts for larger engines, have been fixed by various fillet rolling machines and processes. For example, in U.S. Patent 5,138,859 to Winkens, published August 18, 1992, for a

Method and apparatus for multi-stroke crankshaft rolling and deep rolling "discloses a machine unit and method for rolling crankshaft journal grooves to solve the problems that preclude the simultaneous rolling of adjacent crankpins with the available equipment. In this patent disclosure, the machine unit and the crankshaft is in a first relative position to one another so that the fillets of a first set of non-adjacent pins can be rolled in. Then, in a second relative position of the machine unit and the crankshaft, the fillets of a second set of non-adjacent pins are rolled in place Construction and such a process, all fillets are rolled in two stages or two process steps by a single machine.

Although such machines and processes are effective and work of high Generating quality, new and improved machines and processes are needed to higher standards for machine efficiency with high output and one long service life, which requires excellent parts such as Crankshafts of high Produce quality with fillets consolidated by deep rolling.

Co-pending U.S. Application No. 176,792, filed January 3, 1994 describes equipment, tools and processes for rolling Fillets of a workpiece with fillet claw arms on one side of a crankshaft are arranged in graduated sets, so that all journal fillets of a crankshaft can be rolled in one rolling process.

US 353 030 of April 22, 1994 to the applicant Aspects of this Invention.

The present invention relates to a machine and a method that are similar to those disclosed in copending application No. 176,792 However, technology continues to improve. They are suitable for a wide range of applications, in particular those in which simultaneous rolling of the fillets from opposite Sides of the crankshaft is necessary or desired.

It is important to say that the present invention solves the space problems that many have Facilities occur in which pendulum tools are needed to get close to roll adjacent or adjacent fillets that use bulky currently available equipment for side-by-side rolling difficult or even excludes.

In the invention, the opposite rows of fillet roller claw units moving towards and away from each other simultaneously between (1) one open position, in the unfinished crankshafts invited to the lathe finished workpieces can be unloaded from the lathe can, and (2) a closed position in which the fillet rolling tools in all or a number of the crankpin grooves, including the grooves of neighboring ones Crank pin and also engage in the main bearings so that they are rolled down at the same time and can be solidified.

This invention further relates to a method for simultaneously rolling the fillets a plurality of seats of an elongated engine crankshaft. This method is defined in claim 2.

The present invention will become apparent in the following detailed description and drawing shown, which shows the following:

Brief description of the drawing figures

Figure 1

Fig. 3 is a pictorial representation showing the outline of a preferred embodiment the fillet rolling machine and the method according to the present Invention describes;

Figure 2

is a sectional view, with some parts in solid lines that are substantially is cut along lines 2-2 of Figure 1 and shows how the Fillet rolling tools the fillets of neighboring, by webs of one Crankshaft separate crankpin rolls;

Figure 3

is a view similar to the view of Figure 2, the another embodiment of rolling tools, the fillets of neighboring, not of Roll webs separate crank pin seats;

Figure 3a

Figure 3 is a view similar to the views of Figure 2 and Figure 3 showing how the tool of Figure 3 is used to separate crank pins from webs to roll the crank of Figure 2;

Figure 3b

Figure 3 is a diagram showing the overlapping crank pins of Figure 3a;

Figure 4

is a diagrammatic side view of the tool of Figure 2, in the taken essentially along the lines of sight 4-4 of Figure 2;

Figure 5

Figure 3 is a diagrammatic front view of the machine of a preferred embodiment the fillet rolling machine of this invention, which the rows of the machine in a retracted position for loading or unloading the workpiece shows;

Figure 6

Figure 5 is a view similar to that of Figure 5, but with the rows in place 5 have been moved inwards to a processing position in which the Engage fillet rolling tools in the fillet of the crankshaft;

Figure 7

6 is a diagrammatic plan view of a section of the machine from FIG. 6, taken generally along lines of sight 7-7 of Figure 6;

Figure 8

Fig. 12 is a diagrammatic side view of part of the fillet rolling machine from Figures 5 and 6, generally along lines 8-8 from figure 6 taken.

Detailed description of the drawing figures

The drawing figures are discussed in more detail below. Figure 1 shows figuratively part of a machine 10 for rolling the fillets of the seats of a workpiece, which here as angularly offset and adjacent crank pin 12, 14 of an elongated Crankshaft 16 of an internal combustion engine are shown.

The crankshaft 16 is placed in a lathe 17 turning the workpiece or another Mechanism attached, the front end or the flange end 18 of the crankshaft in the chuck of the driving stick 20 and the opposite end on a centering mandrel 24 of the lathe tailstock is attached. The cane is selectable by one Motor 30 rotated so that the crankshaft 16 rotates about its axis of rotation 32.

The fillet rolling machine 10 has left and right side rows 36, 38, each one Have a plurality of oscillating claw units 40, 42. Every swinging claw unit consists of upper and lower claw arms 44, 46 (left side row of the claw units 40) and 48, 50 (right side row of claw units 42) which are rotatable between the inner and outer ends thereof are connected by pivot bolts 52, 54. The outer The ends of each pair of arms are functional through individually extendable and contractible pneumatic or hydraulic drive cylinders 56, 58 or other suitable Control actuators connected to the fillet rolls for rolling the Apply pressure to the fillets of the crank pins when expanding. Every drive cylinder has a piston with a connecting rod 60 or 62 which rotates with a lower one Arm is connected while the corresponding cylinder tube in a fork shoe 64th or 66 projects rotatably connected to a corresponding upper claw arm 44 or 48 is.

The inner ends of the upper and lower arms of each claw unit are directly aligned opposite and are with upper and lower tools 68, 70 or 72, 74 (Figure 2) for deep rolling of annular fillets 86, 88 and 90, 92 from angularly offset and adjacent crank pins 12, 14 of the crankshaft 16, which are formed by annular webs 94, 96 are separated. The lower tools 70, 74 are on the lower arms of the left and right claw units secured and have pairs of spaced backup rollers 98, 100, which engage and support the pin seats while their fillets be rolled. Such lower support tools are more detailed in the pending one U.S. Application No. 176,792.

Each left side pendulum claw unit 40 and each pendulum claw unit 42 the right side of a corresponding, on the left and right sides of movable upper frame 108, 110 rotatably attached and hanging from them Upper swing arm 104, 106 held, with the frame 108, 110 on a straight line Sliding mechanism or on carts 112, 114 (Figures 5 and 6) are attached run along front and rear horizontal support rails 116, 118. The rails 116 are in turn attached to a support beam 120 which is held by stands 122 which are fixed on the floor or a base plate 124. Actuators like hydraulic drive cylinders 126, 128 are functional with the left and right frame 108 and 110 connected and can be individually driven to the Frame and the associated rows of oscillating claw units that work are connected between a retracted layer (Figure 5) for loading and unloading the workpieces and a closed layer (Figures 6 and 7) for the To move the deep groove deep rolling process. After the crankshaft 16 in the claws of the Claw units have been inserted, each side is individually engaged with the seats brought so that the rollers 138, 140 of the tool 68 and the rollers 142, 144 of the Tool 72 engage the fillets under a predetermined read, which is optional e.g. by optionally changing the expansion force applied by cylinders 56, 58 can be changed.

The drive motor 30 is connected to the chuck of the drive stick 20 and can optionally for rotating driving of the crankshaft 16 about its axis 32. The pairs of clamping claws are for swinging operation on swing arms 104, 106 attached rotatably to the upper support structure provided by frames 108, 110 are attached. If the engine rotates the crankshaft for the deep rolling process, oscillate the arms on an arched path and the separate pairs of claws follow the circumference of the radially offset crank pin rotation axis 32 around the fillets to edit and roll this crank pin. The rolling pressure is determined by the expansion force the cylinder 56, 58 constructed. As is known in this field, this works Deep rolling of circular fillets to the metallic structure of the fillets to consolidate the fillets and the crankshaft.

Each of the upper arms 44, 46 on the left and right sides of the claw units worn upper tools 68 and 72 includes a housing that is releasably attached to the upper Claw of each arm is secured by fastening units 48, 150. Each case shows a support roller 152, 154, which is seated on needle bearings, which on centrally aligned, hubs 156, 158 attached between the housing side plates are held.

The hardened fillet rollers, e.g. rollers 138, 140 are for rotation about mutually inclined axes A, A 'on the lower sides of the tools by cages such as. Cages 160 and opposing adjustable screws 162 are adjustably attached. The cages have pockets 164 formed therein in which the rollers are made of hardened Steel or other suitable materials are arranged to be functional. These fillet rollers touch corresponding annular treads 166, 168 in the support rollers so that localized rolling loads are exerted on the fillets by the claw arms can. When the crankshaft is rotated by operating the lathe motor, touch the rollers roll the front pairs of grooves 86, 88 and 90, 92 of the adjacent tenons the crankshaft, so that the fillets are rolled and machined under pressure, when the crankshaft is turned.

The resulting from the rolling operation with the tools shown in Figure 2 Cross side loads are offset against each other because the rollers 138, 140 and Rollers 142, 144 in each of the tools have equal and opposite slopes exhibit. In the event that the crankshaft as shown in Figure 3 no webs between has the angularly offset pin 12 ', 14', only the fillets 86 ' and 92 'rolled. A ball bearing unit 170 with a cage is between the housing of the Tools 68 ', 72' are arranged and allows the deep rolling of the adjacent ones Pin grooves 86 'and 91' result in opposite side loads as described in the pending application 176,792 canceled against each other will. To move the sides of tools between the retracted and To facilitate the closed position, the storage unit 170 is one of the tools held and engages in the side of the other tool so that the rolling of the adjacent and opposite fillets caused side loads against each other To get picked up.

The diagram of Figure 3b shows the overlap (shaded connection area F) that between the adjacent and angularly offset crank pins 12 and 14 and on the inner Fillets 88 and 90 with webs occurs.

In order to strengthen this structure in an improved manner by rolling without the webs, e.g. To unnecessarily bend or move the webs 94 and 96, the grooves 86, 88 become and 90, 92 first rolled with the tool from FIG. 2, preferably with a changeable one Roll pressure, so that the sheet 12 '(dashed line) and 14' (solid Line) of overlapping with high pressure for deep machining and solidification of the inner Fillets 88 and 90 are rolled in these areas. The remaining arcuate Sections of the inner fillets are rolled at a lower pressure, which is sufficient is in order to leave the webs 94, 96 intact.

Accordingly, there is no overbending of the webs at this point. Below will be the outer grooves 86 and 92 are firmly rolled with the tool shown in FIG. 3a, with constant or variable pressure, so that the outer fillets 86th and 92 are completely rolled and consolidated. This procedure can also be reversed are, as shown in Figure 3a, the outer fillets first rolled and are fixed, and then the inner grooves 86 and 90 as described can be rolled with variable pressures.

In Figure 5, the machine is shown diagrammatically as a front view, with the Crankshaft 16 with radially offset pins inserted into the one arranged in the middle Lathe, and wherein the rows 36, 38 of the claw units from each other and from the crankshaft are moved away by the operation of the drive cylinders 126, 128, their cylinder tubes are attached to the stands 174, 176, which at their lower ends to the fixed Rails 116, 118 and these in turn are attached to the base plate 124.

Middle tool lifting sections 180, 182 of control or counterweight cylinders 184, 186 have fork shoes at their upper ends, which are rotatable on eyelets are attached, extending from the upper ends of the stands 190, 192 of the upper frame of the extend left and right rows of claw units and have lower ends, which are rotatably attached to upper claws 44 and 48 at 194, 196. The lifting sections can optionally be operated to open the claws of the claw units cause so that the crankshaft, which is fixed in the center lathe 16 is in the ranks of the claw units can be invited when the ranks move to the rolling position of Figure 6. The claws of the units are subsequently closed by expanding cylinders 56, 58 while the tool lifting sections 180, 182 of the control or regulation and counterweight units are overridden. The Accordingly, crank pins are gripped by the tools with a force that small but sufficient to keep the crankshaft from turning.

Then the actual rolling of the fillets by turning the crankshaft started by the motor 30, the one exerted by the rollers on the fillets Force up to the deep rolling force is increased by that of the cylinders 56, 58 the corresponding claw units force is increased. The rolling force can during of the rolling can be changed because the crankshaft is driven for as long as possible until the fillet rolling is finished. The claws and tools follow the circular one Sway the path of the corresponding pins to be rolled and the connected swing arms or swing back and forth along an arc to make a pendulum motion enable. The control or counterweight cylinders 186, 188 which are rotatable is secured between the upper support structure and the lower claw arms, one Stroke change section 196, 198, so that different crankshafts with different crank pin positions can be rolled. The cylinders 186, 188 point additional pneumatic spring counterweight sections 200, 202. The spring section is similar to a gas spring and is used for the gentle movement of the arms of the claw units while the fillets are being rolled.

Figure 7 is a top view of the left and right rows of pivot arms, shown in dashed lines Roll the staggered crankpin lines shown in the drawing. One notices, that with this arrangement to provide the rolling pressure on the claw units required cylinders can easily be used in the machine since the cylinders and the claw units for adjacent tenons are operable on opposite Sides of the crankshaft are attached. The left row is for rolling the one set of pegs and the right row is for rolling the one adjacent to the first set of pegs Set of pins provided. Accordingly, according to the invention is sufficient Space available for all fillets and, if desired, the main shaft bearings 210, 212, 214 to be rolled simultaneously in one machine. As best in the figures 7 and 8, the fillet roller claws of the claw units 216, 218, 220, similar to those disclosed, have tools like those in Figure 2 that are used for rolling the fillets of the main bearings can be used while the stud fillets be rolled.

Since a preferred embodiment of the invention has been shown and described, other embodiments will become apparent to those skilled in the art. Accordingly the invention is not limited to what has been shown and described, but by the following claims.

Claims (3)

1. A machine (10) for permanently hardening a ductile iron crankshaft (16) for a combustion motor, comprising a middle axis of rotation (32) and a plurality of crank-pin seats (12, 14), parallel to this axis of rotation (32) by simultaneous machining of the material of adjacent and mutually aligned grooves (86, 88, 90, 92) of cylindrical crank-pin seats (12, 14), with the machine (10) comprising: first and second mounts (108, 110), first and second rocker bars (104, 106), first and second pin tails functionally connecting the first and second rocker bars (104, 106) by the first and second mounts (108, 110); first and second claw units (40, 42) extending laterally from opposing sides of the crankshaft towards the crankshaft, with each claw unit (40, 42) comprising a lower claw (46, 50) and an upper claw (44, 48) as well as a pin tail (52, 54) which rotatably attaches the lower claw (46, 50) and the upper claw (44, 48), with each of the claw units (40, 42) comprising a tool mount for mounting the tools (68, 70, 72, 74) for simultaneous machining of the material of adjacent and mutually aligned grooves (86, 88, 90, 92) of the crank pin seats (12, 14) by rotating the crankshaft (16) around the axis of rotation (32), as a result of which the rocker bar (104, 106) supporting the respective claw unit (40, 42) rocks on the pin tail and swings at an angle while the claws (44, 48) of each of the claw units (40, 42) move around the respective crank pin seat (12, 14).
2. A process for simultaneous rolling of the grooves (86, 88, 90, 92) of a plurality of seats of an elongated crankshaft (16) of a combustion engine with an axis of rotation (32) and with a plurality of pairs of crank pin seats (12, 14) arranged side-by side, comprising the following process steps:

   a. Inserting one end of the crankshaft (16) into the chuck (20) of a motor-driven crankshaft turning machine (10) and inserting the other end into a support of the machine, so that the crankshaft (16) can be driven by the machine (10) around its axis of rotation (32);

   b. Arranging left and right rotary-groove rolling machines (36, 38) each comprising a plurality of pairs of elongated and rotatably connected lever arms (104, 106) on the left and right side of the crankshaft (16), so that the lever arms (104, 106) on the whole are aligned transversely to the axis (32) of the crankshaft (16) and so that the crankshaft (16) can be inserted into the turning machine (10);

   c. Moving the left and right rotary-groove rolling machines (36, 38) from their initial position towards the crankshaft (16) into a position in which the tools (68, 70, 72, 74) carried on the ends of the lever arms (104, 106) touch the pairs of crank pin seats (12, 14);

   d. Placing a load onto the crank pin seats (12, 14,) by the lever arms (104, 106) and the tool (68, 70, 72, 74);

   e. Driving the machine (10) for rotating the crankshaft (16) so that the tool (68, 70, 72, 74) rolls and concurrently machines the grooves (86, 88, 90, 92) of the majority of pairs of crank pin seats;

   f. Opening the lever arms (104, 106) and removing the rolled crankshaft (16) from the machine (10).
3. A process according to claim 2 for hard-rolling the grooves (86, 88, 90, 92) of a pair of overlapping and angularly-offset crank pins (12, 14) of a crankshaft (16) for a combustion engine, with the crank pins (12, 14) comprising pairs of interior crank pin grooves (88, 90) and exterior crank pin grooves (86, 92), with a stay (94, 96) in between, comprising the following process steps:

   Hard-rolling the interior grooves (88, 90) of each crank pin (12, 14) during which the angular area of overlap of the interior crank pin grooves (88, 90) is rolled at a higher pressure than the remaining angular sections, so as to optimise the integrity of the stays;

   Subsequent hard-rolling of the exterior grooves (86, 92) of the crank pin seats (12, 14) essentially at constant pressure for complete hardening of the exterior grooves (86, 92) and the crankshaft (16).

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