MACHINE DEDICATED FOR DIMENSION MEASURING AND USG TESTING OF IRON CASTINGS - 8 CHANELS

The machine is designed for dimensional inspection and spheroidization testing of cast iron castings.

Intended Use

The machine is used to inspect the geometry and verify the cast iron structure of the steering knuckles being tested. It features six interchangeable nests, each dedicated to a specific reference. Parts are unloaded automatically, with OK and NOK parts separated into dedicated containers.

How It Works

Automatic cycle sequence:

• manual loading of the part by the operator and cycle start;
• movement of the nest to the ultrasonic testing position;
• visual inspection of the riser and ear distortion. Precise dimensional inspection of the part using Gefran sensors;
• ultrasonic measurement;
• movement of the nest to the unloading position;
• marking of the OK part;
• automatic unloading of OK or NOK parts.

Machine Design

TOOL / PART NEST

The machine is equipped with six tools dedicated to each reference. The tools are coded using a Harting connector and consist of a contour block matching the part outline, locating supports, and sensors that check the correct position of the part in the nest.

UT SPHEROIDIZATION INSPECTION MODULE

The inspection zone consists of a structure fitted with seven probe modules driven by pneumatic cylinders. The modules are equipped with springs that ensure proper probe pressure against the part surface. A suitable dose of oil is supplied to the heads through a hose in each machine cycle. Before the spheroidization inspection, the parts are clamped by a cylinder.

EAR DISTORTION AND MISRUN INSPECTION MODULE

For some references, an additional inspection of ear presence and distortion is carried out using a checking module equipped with a properly matched inspection element. For the same reference, misrun defects are checked using an IX-80 laser sensor.

LUG DISTORTION INSPECTION MODULE

The module is equipped with GEFRAN PY-3-C-025 contact sensors driven by pneumatic cylinders. Depending on the selected reference, the module is retooled by adjusting the sensor positions relative to the part. The sensors inspect lug distortion for references 50565282 and 50565283. In addition, these sensors verify the correct positioning of the steering knuckle in the nest.

UNLOADING MANIPULATOR

After inspection, parts that pass the test are drilled using a pneumatic drill and transferred to the OK parts container, while NOK parts are transferred without drilling to the container on the other side.

OIL DOSING SYSTEM

The DRAGON X pump by Dropsa supplies oil under pressure to a manifold fitted with dosing units. Downstream of the dosing elements, solenoid valves shut off individual probe modules depending on the inspected reference. The Dropsa pump is equipped with a liquid level sensor. If the oil level is low, a corresponding message is displayed on the operator panel. In such a case, the oil should be refilled.

Benefits for the Customer / User

• verification of correct casting in ductile iron, minimizing the risk of part cracking during operation;
• precise inspection of casting shape and dimensions in critical areas;
• one machine for multiple applications – handling 6 different references;
• marking / drilling of OK castings to simplify production flow management;
• reduced operator workload thanks to automatic unloading of OK and NOK parts.