Background

A leading manufacturer of large diesel engines was experiencing significant issues with their surface finish measurements. The problem arose during the use of a bar surface finish gauge to measure critical engine components, such as the inside of the piston bore.

Problem Statement

Despite utilizing an isolated table for their measurements, the plant continued to face problems due to excessive vibration. This persistent vibration negatively impacted the precision of their measurements, which are crucial for ensuring the quality and performance of their diesel engines.

Specific Issues

1. Surface Finish Measurement Inaccuracy: The vibrations affected the accuracy of the surface finish measurements, which are vital for assessing the quality of the engine components.
2. High Precision Requirements: Navistar's measurement tasks required extremely high precision, including:
   • Surface Finish: Measuring below micron levels.
   • Micro Balance: Measuring weight differences down to millionths of a gram.
   • Microscopic Analysis: Using high-power microscopes with magnifications of up to 100,000 times, where even minor vibrations can blur the image and compromise the results.

Solution Exploration

The client considered implementing a specialized tabletop platform equipped with active vibration cancellation technology. This system works by detecting incoming vibrations and generating an equal and opposite force to cancel them out, akin to how noise-canceling headphones operate.

1. Active Vibration Cancellation: The proposed platform could provide the necessary stability for highly sensitive measurements by actively counteracting external vibrations.
2. Cost and Feasibility: Although the platform was expensive, priced at around $12,000, it was a crucial investment for maintaining measurement accuracy.

Additional Considerations

• Demonstration and Testing: To ensure the platform's effectiveness, it was suggested to bring a demo unit to their facility. This hands-on demonstration would allow Navistar to test the platform with their equipment, such as microscopes and surface finish gauges, directly addressing their vibration issues.
• Comparison with Existing Solutions: The existing isolated table was already a significant investment, but it was not sufficient to eliminate all vibrations. The new active cancellation platform promised a more robust solution.

Conclusion

The persistent vibration issues at our client highlighted the critical need for precise vibration measurement and mitigation solutions. By considering advanced technologies like active vibration cancellation, the client aimed to enhance the accuracy of their measurements, ensuring the high quality and reliability of their diesel engines. This case study underscores the importance of addressing environmental factors, such as vibration, to achieve the stringent precision required in modern metrology and manufacturing processes.