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宁波研发园A区2栋12B17
聚贤街道,鄞州区,宁波市,浙江中国
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周六 to 周日: 9:30AM - 10:30PM
1、 Industry pain points
The engine block of a car is the core component with the most complex structure, the most processing steps, and the highest precision requirements in the powertrain. Typical cast iron or aluminum alloy cylinder processing involves more than 200 processes, among which the machining and inspection of precision hole systems are the key control nodes of the entire process
1.Main bearing hole: It is usually composed of 5-7 semi-circular holes forming a straight line, with a diameter range of about Ø 60~Ø 90mm, a diameter tolerance of H6~H7 level (i.e. ± 10~15 μ m), and a coaxiality requirement of ≤ Ø 0.02mm.. This is the core benchmark for crankshaft operation, which directly determines the NVH performance and lifespan of the engine;2. Cylinder bore: Inner diameter of approximately Ø 70~Ø 100mm, roundness requirement ≤ 5 μ m, cylindricity ≤ 8 μ m, surface roughness Rz ≤ 3 μ m. Before honing the cylinder bore, it is necessary to accurately measure the bore diameter and cylindricity after precision boring to control the honing allowance;3.Crankshaft hole: The hole diameter is about Ø 50~Ø 70mm, forming a complete circular hole after assembly with the bearing cover. Itspositional and dimensional consistencydirectly affects the rotational resistance torque of the crankshaft..
The five major measurement pain points currently faced by engine cylinder block machining are:
2、 Key measurement requirements
| Requirement dimension | Specific requirements |
| ——— | ——— |
| Aperture measurement range | Ø 3~Ø 200mm, covering all hole systems |
| repeatability accuracy | ≤ 0.5 μ m (high-resolution probe) |
| Resolution | ≤0.2μm， Meet the measurement requirements of small tolerance zones |
| Maximum number of sensors | ≥ 6, supports porous simultaneous detection scheme |
| communication method | Wireless (machining center multi station/turntable/truss manipulator) |
| Protection rating | IP68 / IP69K， Resistant to high-pressure cutting fluid erosion |
| Measuring needle length | Ø 3mm small holes are available → Ø 200mm large holes are all covered |
Typical testing items:
3、 Recommended products and parameter table
3.1 Marposs WRG60 (Marposs Corporation)
WRG60 is a wireless transmitter module (non independent probe) designed by Marposs for large-size/mass processing. It needs to be used in conjunction with Marposs MIDA series electronic gauge heads/aperture gauges (such as M8 modules) and has ultra-high resolution and multi-sensor compatibility capabilities.
| parameter item | Specification |
| ——- | —— |
| Resolution | 0.15 μm |
| Sensing Technology | strain gauge |
| communication method | radio |
| Maximum number of sensors | 8 (M8 connectors) |
| Needle interface | M8 multi-channel |
| Protection rating | IP68 |
| transmission distance | Maximum 15m (suitable for gantry and large machine tools) |
| Applicable aperture | Ø 3~Ø 200mm (with different probe configurations) |
Core advantages:
3.2 Renishaw OMP60 (Renishaw Corporation)
OMP60 is the flagship product of Renishaw’s optical transmission probe, widely used in automotive powertrain production lines.
| parameter item | Specification |
| ——- | —— |
| 2 σ repeatability accuracy | 0.25 μm |
| Sensing Technology | strain gauge |
| communication method | Infrared (modulated, 360 ° optical coverage) |
| Needle measurement system | LP2 / LP2DD |
| Protection rating | IP68 / IP69K |
| Optional battery | Lithium battery (ultra long endurance) |
Core advantages:
3.3 Blum BG60 (Blum Company)
BG60 is a “super large aperture measurement system” designed by Bog to solve the pain points of measuring large apertures such as engine cylinder blocks.
| parameter item | Specification |
| ——- | —— |
| Resolution | 0.15 μm |
| Applicable aperture | 3 ~ 200 mm |
| Needle measurement technology | Double touch/multi-point touch |
| communication method | Infrared/wired |
| Maximum measuring needle travel | 200mm |
| customization | Customized measuring needles can be made according to the customer’s aperture range |
Core advantages:
4、 Configuration plan
Plan A: Precision measuring line for main bearing hole of cast iron cylinder body
“`Machine tool: horizontal machining center (with B-axis rotary worktable)+truss mechanical arm for loading and unloadingProbe: Marposs WRG60 radio transmitter+MIDA electronic gauge head (0.15 μ m resolution)Measuring needle: Customized multi touch finger measuring needle (compatible with 7-hole main bearing hole scheme)Communication: The radio receiver is installed on the top of the machine tool“`
Detection process:1. After precision boring the main bearing holes, WRG60 is inserted into each main bearing hole (5-7 holes are drilled in one go, with 4 points of contact per hole for about 15 seconds)2. The measurement data includes:diameter of each hole+coaxiality of 5-7 holes+straightness(automatically calculated)3. Upload data to MES system and generate SPC control chart for main bearing hole4. If the coaxiality exceeds the tolerance, automatically trigger the machine tool tilt compensation (requires cooperation with Fanuc/Siemens macro program interface)
The core value of WRG60: 0.15 μ m high resolution combined with a porous measurement scheme that can be completed in one go, compresses the online measurement time of the entire main bearing hole to less than 15 seconds, matching the production line rhythm requirements of 60-90 seconds..
Plan B: Aluminum alloy cylinder body cylinder hole online full inspection line
“`Machine tool: horizontal boring machine or pentahedral machining centerProbe: Renishaw OMP60 (infrared, 0.25 μ m)Measuring needle: LP2DD extended type+customized measuring needle arm (suitable for different cylinder diameters)Communication: Renishaw OMI-2T infrared receiver“`
Detection process:1. After precision boring the cylinder hole, measure the upper, middle, and lower sections of each cylinder using OMP60 (4-8 detection points per section, approximately 25 seconds for 4-cylinder engines and 35 seconds for 6-cylinder engines)2. The macro program automatically calculates the average aperture, roundness, and cylindricity of each cylinder3. The roundness data is transmitted to the honing process as the basis for setting the honing allowance4. Conduct spot checks after honing (1 out of every 10 pieces) to verify the final quality of the cylinder bore
The core value of OMP60: As the most widely used online probe in the automotive industry, Renishaw OMP60 has the highest maturity of its macro program ecosystem.. The OMP60 macro program of mainstream CNC systems such as Fanuc, Siemens, Mitsubishi, etc. is a standard configuration that can be installed and used immediately, without the need to write measurement logic by oneself.
Plan C: Multi variety cylinder body flexible production line (full coverage of main bearing holes, cylinder holes, and crankshaft holes)
“`Machine Tool: Flexible Machining Unit (FMC) with Tray Exchange SystemProbe: Blum BG60 (0.15 μ m resolution, 3-200mm full range)Needle Set: BG60 Needle Replacement System (Main Bearing Hole Needle x 1/Cylinder Hole Needle x 3/Crankshaft Hole Needle x 1)Tool setter: Blum LaserControl LC50 DIGILOG (0.2 μ m)“`
Detection process(supports quick switching between 2-4 models):1. Tray in place → Identify workpiece model (RFID/Focas interface)2. Automatically call the measurement program of the corresponding model3. BG60 needle changing system automatically switches measuring needles based on workpiece characteristics:-Cylinder bore measurement: Replace the large-diameter three touch finger measuring needle-Main bearing hole measurement: Replace the multi hole straightness dedicated measuring needle-Measurement of crankshaft hole: Replace the standard double touch finger measuring needle4. All measurements are completed in about 30-40 seconds (6-cylinder machine), and the data is automatically classified and archived to the corresponding model
The core value of BG60: By using a probe system to complete all aperture measurement tasks, it significantly reduces the number of measuring heads occupied in the machine tool magazine (usually saving 2-3 tool positions), which is particularly important for flexible machining units with tight magazine capacity..
5、 Selection suggestions
1.Batch production line for a single model (with an annual output of over 100000 units)→ The Marposs WRG60 multi-sensor aperture measurement integrated system (0.15 μ m resolution, equipped with Marposs MIDA electronic gauge head, supporting simultaneous sampling of 8 sensors+8 sensors) is the optimal choice. Multiple sensors can complete multi parameter measurement in one probe, with the highest efficiency;2.Multi variety co linear flexible production line→ Blum BG60 (full range coverage 3-200mm) is equipped with a needle changing system, with one set of probes covering all hole systems, reducing tool magazine occupation and tool changing time;3. The equipment requires extremely high precision (coaxiality of the main bearing hole<Ø 0.015mm). The 0.15 μ m resolution of Marposs WRG60 or Blum BG60 is a necessary condition;4.For factories that already have a Renishaw product ecosystem (tool setter+other probes)→ OMP60 (0.25 μ m) is preferred, with good ecological compatibility, reusable macro programs and receivers, and the lowest comprehensive integration and maintenance costs;;5.The production line has a high degree of automation (truss loading and unloading+unmanned operation)→ The wireless solution (RMP version of WRG60 or OMP60) is superior to the infrared solution, avoiding the interruption of measurement caused by the obstruction of infrared signals by mechanical arms/workpieces.
Data source:
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The technical parameters of this article are based on the official product manuals and technical specifications of Renishaw, Marposs, and Blum. Part of this article is based on the maintenance and service data organized by Ningbo Jiangce Technology. Please refer to the official manual of the corresponding model for specific configuration and compatibility. This article does not constitute a disparagement or comparative conclusion of any third-party product, and the third-party software/systems mentioned in the article are compatibility statements. If you need professional repair services, please contact Ningbo Jiangce Technology Co., Ltd.