Complete system for deburring and finishing car and truck crankshafts
Deburring is an essential step when it comes to manufacturing ready-to-install crankshafts for passenger cars and trucks. It is particularly demanding in terms of precision, which is why standard processes usually involve high investments and are not very versatile. iNDAT Robotics has now developed a complete robot-assisted solution for deburring and finishing crankshafts, which not only achieves a high degree of repeat accuracy but also processes small batch sizes at an affordable price. The particularly demanding task of rounding the oil holes on conrod and main bearings is taken over by a robot. Consisting of two separate modularly-designed robot cells, the system can be easily adapted to individual requirements and integrated into existing production lines.
All components making up the cells – from the picking table to the robot – are mounted on a platform and completely enclosed. The two cells each only occupy about 12 square meters of production space and can be linked via a loading gantry, for example, and loaded automatically via a roof hatch. The system can also be loaded manually with the aid of lifting gear.
Crankshafts with a shaft length of up to 1200 mm and a weight of 150 kg can be processed. In the first cell, the raised edges at the end of the cut formed during the preceding turning-milling process are deburred, as well as the oil holes at their intersections. After the shaft has been placed on the corresponding vee supports, it is clamped and located between a head- and tailstock. Both can be precisely positioned via a servo drive. Radial alignment is performed by an alignment unit, which brings the first conrod journal of the crankshaft into the zero degree position. A rotary drive then turns the shaft into position for deburring by the robot with the appropriate tools. An automatic changeover system ensures the rapid change of the various deburring tools required for the relevant process. An integrated tooling station, which is accessible from the outside, also allows worn tools to be changed without interrupting the ongoing process.
The crankshaft is then transferred to the second cell for finishing. Here, the robot uses various milling and brushing tools to round off the oil holes and remove burrs from the balancing holes. The exact position of the oil holes on the conrod and main bearing journals is determined with the aid of a camera. This ensures their precise rounding with an accuracy of +/- 0.1 mm.
All the necessary tools for this process are stored as a double set in a tool rack. Worn tools can also be removed and replaced without interrupting the process. The workpiece is now ready for installation and can be preserved and packed for transport.