Automated In-Machine Runout Inspection for SX1 Differential Case
Problem Overview
In the SX1 differential-case process, as-cast runout is currently checked manually inside the machine. The activity is operator-dependent, consumes inspection/cycle time and can introduce measurement variation or allow abnormal parts to be missed. Performing the check inside the machine also creates ergonomic and safety concerns. The challenge is to develop an automated in-machine or integrated runout inspection solution that measures the as-cast component consistently, identifies abnormal runout and provides an immediate decision without manual measurement intervention.
Industrial Context & Background
Metrology Automation / Machine Integration / Quality 4.0
Technical Requirements
1) Suitable for SX1 differential-case geometry and machine environment
2) Measure runout without affecting machining accuracy
3) Configurable specification limits
4) Automatic OK/NG indication/interlock where feasible
5) Maintain part/date-time/measurement traceability
6) Robust against coolant, chips, vibration and shop-floor conditions
Suggested Technology Stack: Displacement/Runout Sensors; In-Process Metrology; PLC/CNC Integration; Data Acquisition; Analytics
Expected Solution & Prototype
1) Runout measurement accuracy and repeatability compared with the approved reference method
2) % parts inspected automatically without manual measurement
3) Inspection time per part and cycle-time impact quantified
4) Automatic OK/NG classification against configurable runout limits
5) Missed-abnormal-part and false-reject rates measured during validation
6) Reduction in operator intervention and exposure inside the machine quantified
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