JP4165207B2 - Disk rotor cooling hole inspection system - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to an apparatus for inspecting a cooling hole of a disc rotor (brake disc rotor) in a vehicle disc brake, and in particular, the arrangement of cooling holes, which is essential for a ventilated type disrotor, has an irregular pitch. The present invention relates to a cooling hole inspection apparatus that can accurately determine the suitability of the degree of opening of each cooling hole based on the difference in pitch.
[0002]
[Prior art]
The heat load on the cast iron disc rotor in the disc brake tends to increase gradually due to the increase in weight and performance improvement due to the safety measures of automobiles, and ventilated type disrotors with excellent heat dissipation are often used as countermeasures. This ventilated type disrotor has a large number of radial cooling holes (bench holes) along the circumferential direction along the radial direction, and all of the cooling holes are cast sand, burrs, and meat. It is important for stabilizing the rotation balance, improving the cooling performance during braking, and preventing squealing that no so-called foreign matters such as the above are adhered, that is, a predetermined opening area is secured.
[0003]
Therefore, for example, in addition to a method of visually inspecting the presence or absence of foreign matter in the cooling hole for each of the machined disk rotors, the inner peripheral surface of the disk rotor is imaged by an imaging means as described in Patent Document 1. An automated inspection of the inner peripheral surface of the disk rotor is known.
[0004]
[Patent Document 1]
JP-A-6-331554 (FIG. 1)
[0005]
[Problems to be solved by the invention]
The number of cooling holes per ventilated type disrotor is as many as 36-50, and the cooling holes themselves are long and difficult to look inside. It is easy to overlook the presence of foreign matter at a certain position, and there is a limit to improving the inspection accuracy and thus the reliability of the inspection result. In addition, it is difficult to quantitatively evaluate the adhesion state of foreign substances by visual inspection, and there is a drawback that the suitability determination result is likely to vary due to individual differences, and this also cannot improve the inspection result. .
[0006]
Further, in the optical automatic inspection technique described in Patent Document 1, even though the inner peripheral surface of the disrotor itself can be inspected, the inspection up to the elongate cooling hole cannot be performed at all. The inspection eventually has to rely on visual inspection.
[0007]
In addition, some ventilated disrotors are regularly arranged with unequal pitches as cooling hole arrangements from the standpoint of preventing noise during braking, that is, the size of the cooling holes (effective opening area) is changed regularly. Regardless of whether it is a visual inspection or an automatic inspection, it is difficult to accurately discriminate between the size of the unequal pitch cooling holes and the presence or absence of foreign matter, and there is still room for improvement. ing.
[0008]
The present invention has been made paying attention to such a problem, and in particular, it is possible to distinguish between the size of cooling holes of unequal pitch and the presence or absence of foreign matter, and even when cooling holes having different sizes are mixed. It is an object of the present invention to provide a cooling hole inspection apparatus that automatically and accurately determines whether or not a cooling hole is appropriate and improves the inspection accuracy.
[0009]
[Means for Solving the Problems]
According to the first aspect of the present invention, there is a disc rotor in which a plurality of radial cooling holes along the radial direction of the disc rotor are regularly formed at irregular pitches along the circumferential direction. A device for individually inspecting a plurality of types of cooling holes having different degrees of opening, and a light emitting portion is provided on either the inlet side or the outlet side of the cooling hole which is an opening on the inner and outer peripheral sides of the disk rotor. With the light receiving part facing each other, a light beam is emitted from the light emitting part toward the light receiving part, and the disk rotor is rotated while the disk rotor is continuously rotated about its axis. At least intermittent light transmission time is continuously measured, and the presence or absence of a cooling hole with an inappropriate opening degree is determined by performing a predetermined calculation using a signal processing device based on the measured light transmission data. It has become to so that.
[0010]
The signal processing apparatus picks up the measured light transmission data of the same kind of cooling holes from the light transmission patterns for each period, with a light transmission pattern based on the arrangement of a plurality of types of regular cooling holes as one period. After calculating the average value of the measured light transmission data for each type of cooling hole, add the preset tolerance to the average value and calculate the reference value for each type of cooling hole individually. The measurement light transmission data and the reference value are compared for each type, and the suitability of the degree of opening of the corresponding cooling hole is individually determined.
[0011]
The above tolerance is set in advance based on past empirical rules and the like.
[0012]
Therefore, according to the first aspect of the present invention, when a plurality of types of cooling holes having different opening degrees (effective opening areas) are mixed by disposing the cooling holes at unequal pitches, one disk rotor is provided. If the number of types of cooling holes with different sizes to be included and the tolerance of each cooling hole are set in advance, the size of the disk rotor can be varied by simply rotating the disk rotor around its axis. Appropriateness determination of the degree of opening of each cooling hole can be performed individually.
[0013]
【The invention's effect】
According to the first aspect of the present invention, even when a plurality of types of cooling holes having different opening degrees (effective opening areas) are mixed due to the unequal pitch of the arrangement of cooling holes, As a result, it is possible to automatically and accurately determine whether or not the cooling hole is appropriate, and the reliability of the determination result can be greatly improved, and the burden on the operator can be reduced.
[0014]
DETAILED DESCRIPTION OF THE INVENTION
1 and subsequent drawings show a preferred embodiment of a cooling hole inspection apparatus according to the present invention, and in particular, (A) and (B) of FIG. 1 show an overall schematic configuration thereof.
[0015]
As shown in FIGS. 1A and 1B, there are a work carry-in conveyor 2 and a work carry-out conveyor 3 on both sides of the gantry 1, and the table 1 is rotated by a table drive unit 4 at the center of the gantry 1. A horizontal rotary table 5 is disposed. The disk rotors 6 conveyed by the work loading conveyor 2 by the pre-packing method are transferred one by one onto the rotary table 5 and used for the inspection of the cooling holes 16 as will be described later. It is carried out by the work carry-out conveyor 3. A centering chucking mechanism 7 and a work feeding mechanism 8 are disposed above the rotary table 5. The chucking mechanism 7 functions to position the disk rotor 6 together with the rotary table 5 so that the disk rotor 6 rotates stably while centering the disk rotor 6 transferred on the rotary table 5 before starting the inspection. do. The work feeding mechanism 8 takes out the inspected disk rotor 6 from the rotary table 5 and transfers it to the work carry-out conveyor 3 side, while rotating the next disk rotor 6 to be inspected from the work carry-in conveyor 2. It plays the role of transferring on the table 5.
[0016]
As shown in FIGS. 2 and 3, on the rotary table 5 side, the fixed position light emitting unit 11 and the light receiving sensor as the light receiving unit are opposed to each other in the radial direction across the disk portion of the disk rotor 6. 12 are arranged opposite to each other. The light beam (linear irradiation light) B emitted from the light emitting unit 11 is set so as to be directed to the light receiving sensor 12.
[0017]
As shown in FIG. 4 in addition to FIGS. 2 and 3, the disk rotor 6 to be inspected is provided with a large number of radial partition walls 15 between the inner side sliding plate 13 and the outer side sliding plate 14 in the disk portion. In addition, the space between the partition walls 15 and 15 is formed as cooling holes (bench holes) 16, 16... Having a substantially rectangular cross section, and the boss portion 18 having a hat cross section integrally with the outer side sliding plate 14. Is formed. Therefore, when the disk rotor 6 is rotated in the state of FIGS. 2 and 3, when the light beam B passes through the cooling holes 16, 16... When the partition 15, 15... Passes through the light beam B, light is blocked between the light emitting unit 11 and the light receiving sensor 12, and light transmission and light blocking are intermittent as long as the disk rotor 6 rotates continuously. Will be repeated. Then, the output from the light receiving sensor 12 is taken into the signal processing device 17 in FIG. 1, and is counted and temporarily stored as a light passing time and a light blocking time, as will be described later.
[0018]
3 and 4, in the case of the disk rotor 6 in which the pitches of the cooling holes 16, 16... Are equal, the shape of each cooling hole 16, 16. Since the opening areas (effective cross-sectional areas) are all equal, the light passing time when each cooling hole 16, 16... Passes through the light beam B and when each partition wall 15, 15. The relationship with the shading time is constant at any position. When the light passing time is counted and compared with a preset reference value, for example, as shown in FIG. Since the light passing time in the cooling hole 16 is shortened (light shielding time is lengthened), it can be determined that “foreign matter is attached”. Actually, the light passing time includes individual dimensional variations of the disk rotor 6, surface roughness of the casting surface, eccentric error at the time of chucking by the chucking mechanism 7, and the like. Considering this point, a reference value to be compared with the light transmission time is allowed to have a tolerance in advance, and the comparison results in “existence / absence of foreign matter in cooling hole 16”, that is, “disc rotor depending on whether foreign matter is attached”. 6 ”is determined.
[0019]
On the other hand, as shown in FIGS. 6 to 8, in the case of unequal pitch cooling holes in which the arrangement pitch of the cooling holes 16, 16... Is positively changed with regularity (in the examples of FIGS. However, the three cooling holes 16a, 16b, 16c that gradually decrease in opening area are set as a set, and the pitch of the cooling holes 16, 16,... The disc rotor based on the presence or absence of foreign matter adhesion as shown in FIG. 5 cannot be inspected unless the reference value has a tolerance exceeding the size difference in advance. It becomes impossible to determine the suitability of 6.
[0020]
Accordingly, in the case of unequal pitch cooling holes, the suitability of the disc rotor 6 is determined based on the presence or absence of foreign matter by the following measures.
[0021]
For example, when the disc rotor 6 having the unequal pitch cooling holes shown in FIGS. 6 to 8 is rotated under the same state as FIGS. 2 and 3, light transmission and light shielding may occur depending on the arrangement of the cooling holes 16 a to 16 c. Repeated intermittently with regularity, as shown in FIG. 9 (A), it is output as measured light shielding data that is substantially constant, like the long and short measured light transmission data 9a, 9b, 9c, 9d, 9e. In this case, when attention is paid to the measured light transmission data 9a, 9b, 9c, 9d, 9e,..., Data 9c, 9f, 9i,. It is impossible to identify whether the optical data 9c, 9f, 9i,..., Etc. are the result of light shielding by the adhering foreign matter as shown in FIG. 5 or the light transmitted through the smallest regular cooling hole 16c. Since the measured light transmission data 9a, 9b, 9c, 9d, 9e... Includes data 9a, 9d, 9g,... Having a relatively long light transmission time, the measured light transmission data 9a, It is impossible to identify whether 9d, 9g, etc. are the result of light passing through the hole due to the lack of thickness or the light passing through the regular cooling hole 16a.
[0022]
Therefore, in the case of the disc rotor 6 having the unequal pitch cooling holes 16a, 16b, 16c, the arrangement of the cooling holes 16a, 16b, 16c has regularity even if the pitch between the cooling holes 16a, 16b, 16c is not uniform. Focusing on this, the circuit configuration of the signal processing device 17 in FIG. 1 includes a counting unit 21, a data storage unit 22, a setting unit 23, a calculation unit 24, a determination unit 25, and the like as shown in FIG. Then, the measured light transmission data 9a, 9b, 9c, 9d, 9e,...
[0023]
More specifically, the regularity of the arrangement of the unequal pitch cooling holes 16a, 16b, and 16c refers to the size of the cooling holes 16a, 16b, and 16c in one set of three types as shown in FIGS. Since the six rotors gradually increase or decrease in the rotation direction, and the relationship between the three cooling holes 16a, 16b, and 16c is one cycle, the rotation is periodically repeated in the rotation direction of the disk rotor 6. The measured light transmission data 9a, 9b, 9c, 9d, 9e,... Of the cooling holes 16a, 16b, 16c read (counted) as time data by the counting unit 21 are temporarily or temporarily stored in time series together with the measured light shielding data. The data is stored in the storage unit 22 (step S1 in FIG. 11), and the measured light transmission data 9a, 9b, 9c, and 9d in the 1, 2, 3,. 9e ... first the actual communication light data respectively grouped into second measured through light data and third measured through light data ... and for each cycle of.
[0024]
For example, in FIG. 9, 9a, 9b, and 9c are the first cycle, 9d, 9e, and 9f are the second cycle, and 9g, 9h, and 9i are the third cycle (however, the first measured light transmission in the first cycle is The data need not be the measured light transmission data of the cooling hole 16a having the largest size, and may be the measured light transmission data of the second largest cooling hole 16b or the measured light transmission data of the smallest cooling hole 16c. ), Group A of measured light transmission data 9a, 9d, 9g..., Group B of measured light transmission data 9b, 9e, 9h..., And group C of measured light transmission data 9c, 9f, 9i. In the above (step S2), the average value of each of the groups A to C, that is, the same kind of cooling holes 16a, 16a..., 16b, 16b. It calculates an average value of the optical data as follows (step S3). Each of the groups A to C is nothing but a group of the cooling holes 16a, 16b, and 16c having the same size. Further, n is a known number of periods of one disk rotor having three kinds of cooling holes 16a, 16b, and 16c as one period, and is previously shown together with the number of kinds “3” of the cooling holes 16a, 16b, and 16c. 10 setting units 23 are set.
[0025]
Average value of group A Aa = (9a + 9d + 9g ...) / n
Average value Bb of group B = (9b + 9e + 9h...) / N
Average value Cc of group C = (9c + 9f + 9i ...) / n
Similarly, as the processing in the calculation unit 24, the preset tolerances ± x are added to the average values Aa, Bb, Cc of the groups A to C, and the reference values Aa ± x for the groups A to C are added. , Bb ± x, Cc ± x are obtained (step S4). The tolerance ± x is set in advance in the setting unit 23 in FIG. 10 based on empirical rules in consideration of the dimensional variation of the disk rotor 6 that is a cast product, the surface roughness of the casting surface, and the like as described above. (For example, about ± 0.1 to 0.2 mm).
[0026]
Thus, if the reference values Aa ± x, Bb ± x, and Cc ± x for each of the groups A to C are obtained, the measured light transmission data of each of the groups A to C is determined by the determination unit 25 as the reference value of the corresponding group. In comparison with, the appropriateness determination is performed and the determination result is output (steps S5 and S6). For example, in the case of group A, it is determined whether or not the measured light transmission data 9a, 9d, 9g,... Are within the range of Aa−x to Aa + x, and the measured light transmission data 9a, 9d, 9g,. If any of them deviates from the range of Aa−x to Aa + x, it is determined that the light transmission data is excessive or insufficient due to adhesion of foreign matters or lack of thickness as shown in FIG. Conversely, if any of the actually measured light transmission data 9a, 9d, 9g,... Falls within the range of Aa−x to Aa + x, “OK (pass)” is determined.
[0027]
Thereafter, the disc rotor 6 determined as “NG” is marked to be “NG” product, or sorted and collected so as not to be mixed with “OK” product.
[0028]
As described above, according to the present embodiment, even in the disk rotor 6 in which the pitches of the cooling holes 16a, 16b, and 16c are different from each other with regularity, the cooling holes 16a, 16a, Appropriateness of the opening degree of 16b, 16c can be determined automatically and accurately.
[0029]
In the embodiment described above, the suitability of each cooling hole 16a, 16b, 16c is determined based on the measured light transmission data. However, instead of the measured light transmission data, the measured light shielding data in FIG. 9 is used. It is also possible to determine whether the cooling holes 16a, 16b, and 16c are appropriate.
[Brief description of the drawings]
1A and 1B are diagrams showing a schematic configuration of a cooling hole inspection apparatus according to the present invention, in which FIG.
FIG. 2 is an enlarged cross-sectional view of a main part of FIG.
FIG. 3 is a horizontal sectional view of FIG. 2;
FIG. 4 is a perspective view of a disk rotor having cooling holes with an equal pitch.
FIG. 5 is an explanatory diagram showing a foreign matter adhesion state in FIG. 3;
FIG. 6 is a perspective view of a disk rotor having cooling holes with unequal pitches.
7 is a development view of the cooling hole in FIG. 6 on the opening side.
8 is a horizontal cross-sectional view of the main part of FIG.
9A and 9B are diagrams showing a processing procedure of an inspection output signal in a disk rotor provided with unequal pitch cooling holes in FIG. 6, and FIG. 9A is a diagram showing a relationship between a light passing time and a light blocking time in addition to a cycle; FIG. 5B is an explanatory diagram showing a relationship between an actually measured light passing time and a reference value that is a sum of an average value and a tolerance.
10 is a block circuit diagram showing a configuration of the signal processing device of FIG. 1. FIG.
FIG. 11 is a flowchart showing a processing procedure in the signal processing apparatus.
[Explanation of symbols]
5 ... Rotary table 6 ... Disc rotor 11 ... Light emitting unit 12 ... Light receiving sensor (light receiving unit)
16, 16a, 16b, 16c ... cooling hole 17 ... signal processing device 21 ... counting unit 22 ... data storage unit 23 ... setting unit 24 ... calculation unit 25 ... determination unit B ... light beam

Claims (2)

Multiple types of cooling with different degrees of opening due to the difference in pitch of the disk rotor in which a large number of radial cooling holes along the radial direction of the disk rotor are formed regularly and at irregular pitches along the circumferential direction A device for individually inspecting holes,
The light emitting part is faced on one of the inlet side and the outlet side of the cooling hole, which is the opening on the inner and outer peripheral sides of the disk rotor, and the light receiving part is faced on the other side. While irradiating with a light beam,
While continuously rotating the disk rotor about its axis as the center of rotation, continuously measure at least intermittent light transmission time accompanying the rotation of the disk rotor,
Based on the measured light transmission data, by performing a predetermined calculation in the signal processing device, the presence or absence of a cooling hole whose opening degree is not appropriate is determined,
In the above signal processing device,
A light transmission pattern based on the arrangement of a plurality of types of regular cooling holes is defined as one period, and measured light transmission data of the same kind of cooling holes is picked up from the light transmission patterns for each period, and each type of cooling hole is selected. After calculating the average value of the measured light transmission data, the reference value for each type of cooling hole is calculated individually by adding a preset tolerance to the average value,
A cooling hole inspection device for a disk rotor, wherein the measured light transmission data and a reference value are compared for each type of cooling hole, and the suitability of the degree of opening of the corresponding cooling hole is individually determined. . The signal processor is
A light transmission pattern based on the arrangement of a plurality of types of regular cooling holes is defined as one period, and measured light transmission data of the same kind of cooling holes is picked up from the light transmission patterns for each period, and each type of cooling hole is selected. Means for grouping into measured light transmission data;
After calculating an average value of the measured light transmission data for each group, a means for individually calculating a reference value for each group by adding a preset tolerance to the average value, and for each group, Means for comparing the measured light transmission data and the reference value to determine the suitability of the degree of opening of the corresponding cooling hole;
The cooling hole inspection device for a disk rotor according to claim 1, comprising:

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