I. Industry Background and Measurement Challenges
As core precision components in engines and transmission systems, camshafts and double-lobe camshafts are slender shaft parts with irregular profiles, multi-lift surfaces, and phase-sensitive characteristics. They are widely used in the automotive, general machinery, and aerospace industries. Key parameters such as cam lift curves, profile accuracy, angular phase, base circle diameter, concentricity, and runout directly determine the operational efficiency, stability, and service life of powertrain systems.
The core measurement challenges for these parts differ significantly from those of ordinary shafts:
1. Complex contours: Cam surfaces are non-circular and asymmetrical, with multi-lift surfaces that undergo continuous, gradual changes. Traditional equipment struggles to fully capture contour data, resulting in insufficient profile fitting accuracy.
2. Parameter Interdependence: Cam lift, profile, phase angle, base circle diameter, coaxiality, and runout must all be measured simultaneously with micron-level precision; errors in a single parameter can easily lead to system-wide failures.
II. Solution: DSMY Series Optical Shaft Measuring System
Addressing the measurement challenges of camshafts and double-lobe camshafts, the DSMY Series Optical Shaft Measurement System features optical non-contact scanning and a multi-sensor fusion system. It is specifically designed to provide high-precision, high-efficiency, and comprehensive measurement solutions for non-circular profile shaft components, effectively resolving the measurement bottlenecks of traditional equipment.
1) Core Equipment Configuration
Multi-sensor fusion system: Equipped with a 25-megapixel high-resolution industrial area-scan camera, a wide-field-of-view high-resolution telecentric lens, and an adjustable-intensity telecentric transmission light source. With a horizontal resolution of 5,120 pixels, multiple rotational scans combined with a contact probe can complete the data acquisition of the entire cam surface profile within seconds.
High-Precision Measurement: An integrated optical measurement system, combined with a rotary axis, achieves a resolution of 0.0001 mm, balancing non-contact, high-efficiency measurement with precise inspection of special features.
Stable chassis design: The chassis and frame are constructed from high-quality granite, with a thermal expansion coefficient of only 4.6×10⁻⁶/°C—significantly superior to steel and aluminum. This prevents micron-level measurement errors caused by temperature fluctuations, ensuring high rigidity and thermal stability for reliable 24-hour continuous measurement.
III. Implementation Results
1. Breakthrough in Accuracy: Micron-level measurement accuracy enables precise identification of minute defects on cam surfaces. Profile fitting error is ≤0.5 μm, and the repeatability of pure optical phase angle measurements reaches ±0.05°, meeting the stringent tolerance requirements of high-end manufacturing.
2. Efficiency Improvement: The measurement cycle per part is reduced to seconds, significantly improving efficiency compared to traditional coordinate measuring machines (CMMs). It supports 100% full inspection of batch workpieces, substantially reducing labor costs.
3. Intelligent Management: Data is automatically stored, and standard PDF inspection reports can be generated with a single click, featuring tamper-proof protection; supports data export in multiple formats. Can integrate with MES systems to provide real-time feedback on production deviations, significantly reducing the defect rate.
IV. Industry Applications and Value
This solution has been widely adopted in the automotive and automotive parts, general machinery, aerospace, and medical device industries for batch quality inspection and high-end manufacturing of camshafts and double-lobe camshafts. Whether for camshafts in internal combustion engines, irregular-shaped camshafts in new energy transmission systems, or small double-lobe camshafts in precision aviation instruments, this equipment enables high-precision measurement of all parameters.
Compared to traditional measurement solutions, the DSMY series of optical shaft measurement systems addresses the challenges of measuring non-standard profile shaft components through three core advantages: high precision, high efficiency, and intelligence. It provides enterprises with a path to upgrade from "sampling inspection" to "full inspection and control," helping to enhance product quality and market competitiveness.
