Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

Existing installations
Requirements strongly depend on
camshaft technology (e.g. conventional, built)
For gauging purpose:

dimensions (length, diameter)

rotational positions (index, camlobe profile)
form (run-out, roundness)
camlobe profile (confex profiles, in operation steps)
geometries

for detecting part type purpose:

for flexible productions, many different but similar shaft types
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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

ensures that correct cam shaft type is loaded

feature feature specification accuracy repeatability

lenght grinded 7 m < 5 m
turned 7 m < 10 m
rough 10 m < 16 m

diameter Grinded bearings, static 2 m < 2 m

Grinded bearings, dynamic 2 m < 2 m
Cam basic circle, dynamic 2 m < 1,5 m
Cam basic circle, static 2 m < 2 m

roundness Cam basic circle < 3 m < 2 m

Grinded bearings < 3 m < 2 m

runout Cam basic circle < 3 m < 3 m

Grinded bearings < 3 m < 2 m

camhight dynamic < 4 m

static < 5 m

cam angle of rotation < 0,06

cylindricity < 5 m < 3 m

Description of the nominal profile

Cam angle and cam profile form are determined with a known nominal profile of the cam. This nominal
profile may be available as a text file.

The nominal profile has the following format:

Example for a standard cam:

0.001 probe radius
360 number of angle steps
0 0 0
1 0.002 0
2 0.010 0
3 0.030 0
...
90 6.000 15
91 5,992 0 1st column: angle position
92 5,985 0 2nd column: distance from cam base circle
... 3rd column: marker
159 0.033 0
160 0.016 0

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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

161 0.007 0
162 0 0
...
358 0 0
359 0 0

1. Line: Radius of the probe

This line contains the radius of the probe for which the peak table has been provided.

Examples:

0.001 The nominal profile contains the actual contour trajectory

0 The nominal profile is created for a flat probe. The probing radius is therefore infinite.
3 The nominal profile refers to a spherical probe. The radius of the probe sphere is specified
here (e.g. 3 mm).

2. Line: Number of angle steps:

This line contains the number of angle steps.

The angle steps must always have the same size.

Examples:

360 at an angle step width of 1

720 at an angle step width of 0.5
1440 at an angle step width of 0.25

From 3rd line: contour points in polar co-ordinates

Every line contains a point in polar co-ordinates and possibly a marking.

1st column: The angle positions must be entered continuously
(in the example with an angle step width of 1 = 360 lines).
The starting angle need not necessarily be 0.
2nd column: Distance of the cam point from the cam base circle
3rd column: Marking for fitting process of the cam angle
Symmetrical automatic fitting (standard process) is used in the example. The cam peak is
marked with the marker 15.

The nominal profiles are created with ascending angles. The opening and closing side are determined
with a direction specification in the test characteristic.

Fig. 1 shows the dialog box for managing nominal profiles.

Fig. 2 contains the dialog box for processing the nominal profiles. The profile trajectory, the speed and
the acceleration are displayed graphically. The polar co-ordinates with the marking of the cam tip are
visible in the left-hand section. The markers are displayed in the graphic.
The used nominal profiles are part of the test program and are saved with it.

The nominal profile is loaded by the dialog box for managing nominal profiles. The "Import" button
loads the nominal profile file (e.g. S6401B.txt). The file is selected and a name assigned.
Conversely, the nominal profile file can be saved with the "Export" button.

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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

Fig. 1: Management of the nominal profiles

Determining the cam angle

The characteristic "rotation angle position cam profile fit" is used for this function. The cam angle is
calculated by fitting the nominal profile in the measured profile by the selected process.
The different processes are determined by markers in the nominal profile.
The following processes are possible:

Symmetrical automatic fitting (standard process)

The nominal profile of the cam is observed for the automatic fitting. First the maximum absolute
gradients before and after the cam peak are determined. The used range before the cam peak is
determined from the point of the maximum gradient to the point at which the gradient drops below 60%
in the direction of the cam peak. On the side after the cam peak, the range begins at 60% of the
maximum gradient and goes in the direction of the base circle to the point where the sum of the
gradients after the cam peak is equal to the sum before the cam peak. This process is suitable for
cams which have similar forms on the opening and closing sides.
This evaluation is activated by marker 15.

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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

Fig. 2: Processing the nominal profile

Symmetrical fitting with manually determined alignment angles

Five alignment angles before and 5 alignment angles after the cam peak are defined. In this
symmetrical process, rotational fitting takes place so that the sum of the form deviations over the
alignment angles before the cam peak is equal to the sum of the form deviations over the alignment
angles after the cam peak.
If this fitting is to be used, the markers 5 (at 5 points before the cam peak), 10 (at 5 points after the
cam peak) and marker 15 (cam peak) must be set.

Asymmetrical fitting

Five alignment angles can be defined before the cam peak. The fitting only takes place at these 5
angles.
To use the asymmetrical fitting, marker 5 (at five points before the cam peak) and marker 15 (cam
peak) must be set.

Bestfit process

Fitting the cam profile by the bestfit process. The whole profile is used for the fitting. Parts of the base
circle can be extracted with marker 18.
This fitting process is used when marker 17 is set. The beginning and end of the base circle segment
to be extracted are determined by two markers 18.

The following markers are possible:

5 alignment angles before cam peak
10 alignment angles after cam peak
15 cam peak
17 cam peak bestfit
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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

18 base circle

A valid nominal profile must always contain either marker 15 or 17.

The markers 5 and 10 are optional and only possible in connection with the marker 15. If no markers of
this type are set, the symmetrical automatic fitting process is executed.
The markers 18 are optional and only possible in connection with the marker 17. If the marker 17 is set
between 2 markers 18, only this segment is used for the fitting.
The permissibility of the markers is checked in the dialog box in figure 2. Wrong marker setting creates
an error message.

The characteristic "rotational angle position cam profile fit" ( fig. 3 ) must be selected from the test
characteristic group rotational position.
The reference position and the length position must be determined. The angle reference (reference
angle) must be determined. A part axis can be determined. With a defined part axis (reference part
axis), the rotation point of the cam is determined by this part axis. Otherwise the centre point of the
cam base circle is calculated for this.

Fig. 3: Characteristic rotation angle position cam profile fit

With the evaluation mode it is determined whether the fitting of the cam takes place at the position of
the cam peak or in the vicinity of the nominal dimension. If the "nominal dimension related" mode is
operated, the actual cam angle position should be near to the nominal dimension. Otherwise an error is
generated. This mode should also be used if a certain cam is to be selected for multiple cams.
In the parameter section "characteristic-specific settings", the nominal profile (e.g. S6401B) must be
selected.

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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

The direction of rotation is adapted according to the direction of rotation of the measuring machine.
This may be necessary when the direction of the nominal profile does not match the rotation direction
on the measuring machine.
The result of this measurement is a rotation angle position. The graphical representation may be either
the unfiltered cam contour (fig. 4) or the profile deviation of the measured cam of the nominal profile
after fitting (fig. 5).

Fig. 4: Measurement of the cam angle representation of the cam

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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

Fig. 5: Measurement of the cam angle

representation of the deviation from the nominal profile after the fitting

Measurement of the cam profile form

With the "profile form cam" test characteristic ( fig. 6 ) the contours of the measured cam data are
compared with a nominal profile.
The nominal profile described above is accessed here.
The characteristic "profile form cam" must be selected from the test characteristic group "profile form".
The reference position and the length position must be defined.

The nominal profile (e.g. S6401B) must be selected in the section "characteristic-specific settings".
The direction of rotation is adapted according to the direction of rotation of the measuring machine.
This may be necessary when the direction of the nominal profile does not match the rotation direction
of the measuring machine.
The "Other references" parameter determines whether other reference characteristics are used.
The following references are possible:
- without references
- axis reference
- axis reference and angle reference

The selection of reference characteristics activates the parameter group "reference characteristics".
With an axis reference, the cam profile is fit related to this axis. Otherwise the fit is performed by the
centre point of the cam base circle.
When using an angle reference, an angle position is specified for fitting the cam. Errors in the angle
position therefore lead to deviations in the profile form.
If no angle reference is specified the cam is fit in the optimum angle position related to the cam peak.
When measuring without references, the evaluation range can be limited by the "angle range cam"
parameter. Here, the evaluation range is located symmetrically around the cam peak. The cam form
deviation for the whole cam is calculated with value 0 for the cam angle range.
The result of this measurement is a profile form deviation, i.e. the distance between the maximum and
minimum deviation from the nominal contour. The graphic representation shows either the unfiltered
cam contour ( fig. 7 ) or the profile deviation ( fig. 8 ).
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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

Fig. 6: Characteristic profile form cam Fig. 7: Measurement of the profile form
representation of the cam

Fig. 8: Measurement of the profile form - representation of the profile form deviation

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Solution: OPTICLINE camshaft

Waveline Formline Gearline Gaugeline Opticline

01.11.2006

More than 25 successful installation until 2006

customer country units type year

Oswald GERMANY 1 CONTOUR 810 2002
Kuka GERMANY 1 CONTOUR 810 2002
FIAT ITALY 1 CONTOUR 810 2003
Hr GERMANY 1 CONTOUR 805 2002
Hr GERMANY 1 CONTOUR 810 2003
Schleicher GERMANY 1 CONTOUR AUTOMATIC 810 2003
Schleicher GERMANY 1 CONTOUR 805 2003
Schleicher GERMANY 1 CONTOUR 410 2004
VW Chemnitz GERMANY 1 CONTOUR 810 2004
HQM Chemnitz GERMANY 1 CONTOUR 810 2004
Neumayer GERMANY 4 CONTOUR 810 2004/2005
Neumayer GERMANY 2 CONTOUR 810 2004/2005
Audi Neckarsulm GERMANY 1 CONTOUR 814 2004
Mahle GERMANY 1 CONTOUR 805 2004
Mahle GERMANY 1 CONTOUR 810 2004
Mahle GERMANY 1 CONTOUR 810 2004
Thyssen Krupp Presta GERMANY 1 CONTOUR 805 2004
Thyssen Krupp Presta GERMANY 1 CONTOUR 810 2005
Dr. Schrick Remscheid GERMANY 1 CONTOUR 814 2004
Audi Gyr HUNGARY 1 CONTOUR 810 2005
Hirschvogel GERMANY 1 CONTOUR AUTOMATIC 810 2005
Linnemar USA 1 CONTOUR 810 2005
DaimlerCrysler Hamburg GERMANY 1 CONTOUR 810 2006
27

Major advantages

flexibel gauge for flexible productionsolution for offline and automated

measurementone gauge for dimensions, form and positionvery fast, results
within secondsvery accurateshopfloor hardened

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