The particularly demanding rounding of the oil bores on the connecting rod and main bearing is performed by a robot. The solution consists of two separate robot cells with a modular design that can be easily adapted to individual requirements and integrated into existing production lines.

All components of the cells - from the pick-up table to the robot - are mounted on a platform and completely enclosed. The two cells each occupy only around twelve square meters of production space and can be linked via a loading gantry, for example, and loaded automatically via a roof hatch. Manual loading using lifting gear is also possible.

The two cells each occupy only approx. 12 square meters of production space. (Image: Indat Robotics)

Crankshafts up to a shaft length of 1,200 millimetres and a weight of 150 kilograms can be machined. In the first cell, the cheeks in the cut run-out, which are created during the preceding turning/milling process, and the oil bores in the bore waste are deburred. Once the shaft has been placed on the appropriate prisms, it is clamped and centered using a tailstock and headstock. Both can be precisely positioned via a servo drive. Radial alignment is performed by an alignment unit, which brings the first pin bearing of the crankshaft into the zero degree position. A rotary drive then turns the shaft into the respective position for deburring, which is carried out by the robot with the appropriate tools. An automatic changing system ensures that the different deburring tools can be changed quickly and in line with the process. An integrated set-up station, which is accessible from the outside, also enables worn tools to be changed without interrupting the ongoing process.

The workpiece is then transferred to the second cell, where finishing takes place. Here, the robot uses various milling and brushing tools to round off the oil holes and remove the burrs on the balancing holes. The exact position of the oil bores on the connecting rod and main bearing is determined with the help of a camera. This ensures precise rounding with an accuracy of plus/minus 0.1 millimeters. All the tools required in this process area are stored as a double set in a tool rack. Worn tools can also be removed and replaced here without interrupting the process. After this process, the workpiece is ready for installation and can be preserved and packaged for transportation. sw