A Force-Sensor-Based Method to Eliminate Deformation of Large Crankshafts during Measurements of Their Geometric Condition

Abstract

This article describes an innovative method for eliminating deformation in large crankshafts during measurement of their geometric condition. The currently available techniques for measuring crankshaft geometry are introduced and classified according to their applicability and the method of measurement. The drawbacks of the methods have been identified and a solution to these problems has been proposed. The influence of the rigid support of a shaft on its deformation, and thus on the reduction in the accuracy of crankshaft geometry measurements, has also been investigated. The concept and main versions of the proposed measuring system with active compensation for shaft deflection, by means of actuators cooperating with force transducers monitoring the deflection of individual crank journals of a crankshaft being measured, have been presented and the flexible support control system has also been described. The problems relating to the operation of the control system have been furnished along with a way to solve them, including the issue of noise reduction in the signal from the force transducer and the influence of the controller parameters on the operation of the flexible support. The computer system that controls the flexible supports has been briefly characterized, and the performance of the prototype system and the model reference system has been compared. The results have shown that the system is able to effectively eliminate the deflection and elastic deformation of the crankshaft under the influence of its own weight.