Data-Driven Decisions Through In-Process Test

Engine Manufacturing

SHORT BLOCK ASSEMBLY LINE HEAD SUB ASSEMBLY LINE

DATA COLLECTION,
ON, MANAGEMENT A
AND ANALYSIS
REPAIR BAY MANAGER
Using QualityWorX, collects
Crank Torque to Turn information about the parts at

Here the crank is rotated for the

10 Q10 repair station. Associates test
and operation step failures to
first time, usually at low speeds defects and repairs. Provides
(60-120 RPM). Breakaway torque statistical data to enable
and torque vs. angle signatures defect avoidance.
find defects such as contaminated
Valve Key Verification
main bearings, debris, wrong fit,
insufficient lubrication or bent cranks. H20 Q400
A slider assembly and laser scans Collect and store data for each test. Generate
valve stem heights. Valve stem
profile vs. position signature captures reports on production quality or specific parts.
incorrect valve type, damaged Analyze information to identify the root causes of
valves, missing or wrongly inserted
collets. issues affecting yield, to optimize manufacturing
test cycles, management limits and more.

Cup Plug Leak Test

Valve Seat Leak Test
30 H30
Verify seal integrity of cup plug
Measure air leakage when the
pressed into the block. Air mass flow
head is sealed and pressurized.
or pressure decay vs. time signatures
Air pressure decay vs. time or mass
find issues such as improper cup plug
flow signatures for each cylinder
position, missing, misaligned,
spot bent valves, debris under
deformed or undersized cup plug.
valve, damaged/missing valve
and valve seat.
Cold Test Hot Test
PISTON SUB ASSEMBLY LINE General end of line functional cold test for the
engine. Crank torque, intake vacuum, exhaust
Monitor engine parameters during a hot
test for 2-4 minute cycle. Oil pressure,
pulses, fuel rail leak, fuel injector pressures, oil vibration, RPM and cylinder drop out,
Keycheck Verification pressure, ignition system voltage/current and vacuum ignition, throttle position sensor,
P10 P20 H40 other signatures detect defects such as low
vacuum, bad oil pump, EGR valve functionality,
CAM position sensor, temperature, MAP
sensor, ECM module signatures find
Scan head profile of valve keepers
incorrect engine timing, leaking fuel rail, issues such as low vacuum cylinder
using a laser to verify presence and
damaged fuel injection, knock sensors, balance and power contribution, idle
Incremental Torque Piston Ring Verification proper assembly. Laser distance
missing/damaged gaskets, spark height and stability, oil pressure, fuel system or
Scans the ring stack using a vs. position on head signatures
(Piston Insertion) width resistance etc. gasket problems.
stepper motor and laser gage, find missing, off-location or angled
50 or machine vision. Ring edge valve keepers.
Additional test(s): Additional test(s):
Measure crank torque sequentially profile vs. height signatures Long Block Verification Valve Lash Coolant Cavity 210a – Mechanical 220a – Idle Stability
after each piston (or pair of pistons) find upside down rings,
Measure torque and combustion and Tappet Check Leak Test 210b – Oil System 220b – Misfire Test
is inserted into the block. Breakaway damaged rings, and more. 210c – Fuel System 220c – Bearing Test
torque vs. time and torque vs. angle
Roller Finger cylinder pressure as the crank is
Verify the tappet clearance Verifies coolant cavity integrity using a 210d – Ignition 220d – Sensor Tests
rotated 720º. Torque vs. angle and
over 360º signatures detect piston Follower Verification pressure vs. angle (1 per cylinder)
and timing using linear pressurized air test. Pressure decay vs. 210e – EGR Valve 220e – I/O Test
defects, main and conrod bearing
problems and abnormal drag friction.
H50 signatures detect low compression,
digital probes. Monitoring of
the cam and crank shaft is
time or mass flow signatures find missing,
leaking or damaged components (frost
210f – Sensor
210g – Vibration (NVH)
220f – Vibration (NVH)

Camshaft is rotated 360º while mis-assembled chains, head

required to verify proper plugs, gaskets), mis-assembled
measuring torque to turn. Torque installation problems, incorrect engine
valve timing of tappet components or improper run
vs. angle signatures detect missing timing, soft lash adjusters, and more.
activity. down torques.
rockers, off-location and missing
Piston Type Verification roller fingers, cam cap too tight,
60 Piston Sub Assembly
debris in bearings, reversed bearings,
insufficient lubrication and/or bent
Use a laser and slide assembly to Oil Gallery Crank and Cam Dowel Press Monitor valves.
scan the piston profile. Catch defects Dual lasers account for gap and
Plug Leak Test Seal Press Monitors the pressing force to insert
such as incorrect piston type, scan the piston to verify ring integrity. engine-to-transmission locator
orientation, and damaged piston(s). Piston edge profile vs. position signatures Uses slides and rubberized Monitors pressing forces as the
Crankshaft Seal and Cam Seal dowels. Force vs. distance signatures
catch missing oil ring(s) (rail, expander), contact boots for a leak test on
are pressed into the front cover. find missing, damaged, unseated
upside down compression, scraper ring each oil plug. Multi-channel air
Identifies missing or misaligned seal, dowels, under or oversized holes.
mass flow or pressure decay vs.
(1.4° bevel), wrong and/or extra ring.
time signatures find missing, damaged components, seal not fully
seated, under or oversized parts,
210
damaged or loose plugs and
crossed threads. and more.

70 80 90 100 110 130 140 Q20 160 165 170 175 180 210

210 220 220 220

DATA COLLECTOR
Using QualityWorX, collect
all the manufacturing process
Short Block Verification Short Block Vibration Crank Seal and Liquid Gasket Verification Fuel Rail Helium Leak Test
Cam Seal Leak Test Monitors the dispensing process while beads,
data, including signatures,
and store it in a single database, Oil Cavity Leak Test Helium is injected as a tracer
Q30
Crank is rotated and the torque and air pressure measured while Rotate crank for several seconds and measure by serial number and other
injecting pressurized air into the oil gallery with all other oil holes block vibration. Vibration vs. angle with Verifies sealing integrity of Crankshaft Seal swirls or drops of liquid gasket are applied. Measures oil cavity integrity using and the concentration is
and Cam Seal. Air mass flow or pressure Pressure vs. time and flow vs. time signatures parameters. Data is then a pressurized air test. Pressure measured. Pressure decay
plugged. Torque vs. angle and air back pressure vs. angle frequency analysis (FFT with order tracking) available for analysis and
signatures find missing control or main bearings, incorrect fit, signatures catch missing conrod bearings. decay vs. time signatures find improper seal catch air bubbles, incorrect/blocked nozzles, decay vs. time or mass flow vs. time signatures find small
position, missing or misaligned seal, rolled, cut too little or too much sealant, and more. traceability. signatures catch missing, leaking leaks, missing, damaged,
debris, reversed caps, blocked oil passages and bore lubrication. REPAIR BAY
or deformed seal and under or oversized parts. or damaged components (oil
gallery, drain plugs), casting
mis-assembled components.
MANAGER FINAL ASSEMBLY LINE
porosity, mis-assembled
components or improper run
down torques. Using QualityWorX,
collects information about
the parts under repair.
Associates test and
operation step failures
to defects and repairs.
Provides statistical data to
enable defect avoidance.

BLOCK MACHINING LINE CRANK MACHINING LINE

Thread Verification Head Leak Test
Checks the integrity of threaded
holes in blocks, heads or cranks.
Eddy vs. thread depth signatures
Use pressurized leak tests to verify the
block/head casting integrity. Air pressure
decay vs. time, or mass flow signatures
Harness the combined power of in-process testing
are used to find missing threads,
wrong pitch, shallow, undrilled or
find blow holes, missing cup plugs,
casting porosity, cracks, and more. and data analytics on your production line with Sciemetric.
damaged holes, and more.
Cylinder Liner Test Crank Reluctor Wheel
M10 M30 Visit www.sciemetric.com or email [email protected].
Verify assembly by measuring Use a laser and encoder to verify reluctor notch
press force as the combustion
cylinder inserts are installed to
symmetry and depth. Depth vs. angle signatures find
defects such as improper spacing or bad machining.
HEAD MACHINING LINE M40 M50 M55 M60 M20
catch loose or tight inserts,
damaged/cracked and not fully Valve Seat and Guide Cup Plug and
bottomed out liners.
Monitor the insertion force as valve Dowel Press Monitoring
seats and/or guides are pressed into Measure cup plug and dowel pin insertion
the cylinder head. Force vs. distance force to find missing, damaged, or
signatures find defects such as unseated cup plugs and dowel pins, and
missing/damaged seats, unseated
Cup Plug Press Crank Oil Hole Verification seats, and under or oversized holes.
under or oversized holes.
LEGEND
M20 M35 Key test application Machining line
Measure cup plug insertion Verifies integrity of crank oil holes by Spark Plug Tube Press
through force vs. depth pushing air through the crank hole testing Ensure that spark plug tubes are Short block assembly line Final assembly line
signatures to catch defects such for any blockages. Back pressure vs. flow pressed with proper force, to the proper
as missing or damaged cup signatures find missing holes, passage depth. Press monitor finds defects such
plugs, unseated plugs, and way debris, broken drill bits and more.
Head sub assembly line Sample QualityWorX station
as wrong tube diameter, bad machining
an under or oversized hole. of the head with an under or oversized
Piston sub assembly line
spark plug tube hole.

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