Fewer Microns = Greener Energy

In ongoing efforts to improve efficiency and reduce the CO2 footprint of their fossil fuel engines, engine manufacturers are shaving microns off the tolerances of rotating components such as camshafts and crankshafts.

“Over the years, critical geometric dimensional tolerances for camshafts and crankshafts have been significantly tightened to improve engine life, reduce fuel consumption, and lower emissions,” says Addison D. Cole, CEO of Adcole. « Over the past 25 years, the roundness tolerances of crankshafts have been reduced from eight microns to three microns. The green cars of the future will have high-performance, small engines with very low emissions. As a result, production tolerances will be further tightened, which should lead to the adoption of Adcole technology by engine component manufacturers. »

More than 500 car manufacturers and automotive suppliers use Adcole’s automated inspection rooms for quality control of camshafts and crankshafts. Founded in 1957, the company has manufacturing facilities in Massachusetts and Florida and offices around the world. Nearly 60% of the company’s business comes from automotive OEMs and manufacturers of agricultural and construction equipment, outboard motors, and other small engine manufacturers. The remaining 40% of Adcole’s business comes from the aerospace hardware industry.

“Adcole equipment has given its customers a technical advantage in terms of accuracy and compatibility with other Adcole meters,” Cole said in an earlier interview with Automotive Industries. “Our larger customers use Adcole meters in their powertrain development labs, factory rooms, or on the production floor. The companies know that their production costs are low, but their end users get a quality product.”

The company has more than half a century of experience in designing and manufacturing specialized machines for measuring engine components. It also makes digital sun angle sensors for space satellites, primarily for the US, European, and Japanese aerospace industries. Adcole’s customer list includes General Motors, Ford, BMW, VW, Chrysler, Toyota, Fiat, Nissan, Renault, Hyundai, Volvo, Suzuki, Caterpillar, Daimler, BMW, Honda, Cummins, FAW, Tata, MAN, John Deere, SAIC, FAW, Dong Feng, and ThyssenKrupp.

One of Adcole’s leading products for the automotive industry is the ADCOLE 1310 High Speed Camshaft Inspection Gage. It is an end-of-line machine that measures up to 200 parts per hour for rise and chatter mark detection. This fully automatic gauge uses individual measuring heads for each cam lobe and cam follower, with a resolution of 0.1 micron, taking one data point every 1/10 degree or 3600 data points per revolution.

In early 2011, Adcole announced that it would soon launch the Adcole Model 1200-10 crankshaft meter, aimed at manufacturers of diesel, marine, and locomotive engines for crankshafts up to 4.5 meters in length. It is also suitable for oilfield and power generation applications. The product features a proprietary ball bearing shaft with a runout of <0.25 μm for measuring crankshafts up to 4.5 meters in length, with a swing diameter of 560 mm, weighing 2.050 kg.

By using a laser interferometer in combination with a contact follower with a stroke of 330 mm, this precision measuring gauge can measure 3,600 data points on pendulum blocks for roundness and straightness with an accuracy of 0.5 μm. Equipped with a 50 cm touch screen and a Windows-based operating system for ease of use and output flexibility, the Adcole Model 1200-10 crankshaft measuring machine can perform a complete measurement of the crankshaft within 15 minutes. Built on a base of structural steel head boxes with a large 60 cm thick surface plate weighing 7 tons, this robust machine weighs 22 tons, according to the company.

Automotive Industries spoke with J. Brooks Reece, vice president at Adcole, and asked him to tell us more about some of the unique features of the Adcole Model 1200-10.

Reece: Only Adcole makes such a large crankshaft with sub-micron accuracy. To achieve this performance, Adcole had to devise ways to handle the weight, stroke, and length of the component. Specifically, the granite surface plate is twice as heavy as that used in the 3.3-meter gauge. The spindle support has been made stronger and the technique for mounting it on the granite has been redesigned.

A spindle motor drive has been developed to control the rotation start and stop of such a heavy component. The tailstock is fully programmable with joystick control and includes a video monitor to ensure that the center of the tailstock is properly aligned. For added safety, a pneumatic system has been added that pushes air through the head and the centers of the loose head to sense whether the part is loaded correctly. Design changes have also been made to the vertical shaft drive and to the laser interferometer measuring system that is the trademark of the well-known Adcole Model 1200.

AI: How would you describe Adcole as an innovator?

Reece: We have always believed that our customers should have the most accurate gage possible. This means that more process tolerances can be reserved for the process. For example, if a measurement takes 10% or more of the component tolerances, there will be less tolerance production and a greater chance of good components being rejected. Adcole produces the most accurate gauges in its class, and our customers benefit from a strategic advantage.

AI: Tell us about Adcole’s ongoing development of advanced measurement solutions for crankshafts and camshafts.

Reece: All of the largest automotive and large diesel engine manufacturers depend on Adcole. Over the years, our customers have asked us to develop special measuring functions for their latest designs. In some cases, our customers have asked us to develop a new machine from scratch. One of our largest customers in the United States asked us to build a surface finishing machine that could automatically perform the measuring sequence. This was the first automatic roughness machine for crankshafts for the industry. Another unique aspect of this machine was its ability to measure the main and journal journals in each quadrant, which is essential for minimizing engine noise and increasing engine life. Our customers are increasingly choosing to use our products for both form and roughness measurements for camshafts and crankshafts.

AI: How does your R&D and subsequent product development reflect the growing demand for greener solutions?

Reece: Adcole measures rotating components that are essential to engine power and fuel economy. As a result, these same components influence clean exhaust emissions. Global vehicle production is expected to rise from the current level of 75 million vehicles to 100 million vehicles over the next five years. As China and India each add 100 million vehicles to their roads, infrastructure will be invested in highways and bridges.

During this expansion phase, attention will be focused on fuel consumption and emissions by the market and regulators. As in the past, Adcole will continue to contribute to improving engine performance and reducing production costs.

Original article published by Automotive Industries Magazine