Large internal combustion engine showcasing intricate details of its components.

Quality Assurance for Internal Combustion Engines

To ensure optimal integration and functionality of the overall system, rigorous quality assurance of individual components is essential. The quality of these components is critical in managing high loads during continuous operation, as well as facilitating rapid ramp-up times and transitions between operating modes. Key performance indicators such as operational smoothness, durability, and efficiency - specifically regarding fuel consumption and power output - are significantly impacted by component quality. Ensuring high standards in these areas is paramount for achieving superior system performance and reliability.

Cylinder blocks and heads

Challenges

The cylinder head and block form the engine's main structure, housing pistons, the crankshaft, and the camshaft and other essential components. Made from cast iron or aluminum alloy for strength and heat resistance, they provide the basic structure for all combustion-related components, including valves and fuel injectors.

Quality assurance challenges involve ensuring precise geometry to maintain structural integrity and proper fitment, achieving optimal surface roughness to minimize friction and wear, and accurately aligning bearings to support the crankshaft and other rotating components. Additionally, precise valve seating and features for lubrication and cooling are essential for proper functioning and sealing, while fuel injectors maintain efficient operation. Addressing these challenges is vital for ensuring the engine's efficiency, reliability, and longevity.
Solutions

To ensure precisely manufactured and durable cylinder blocks and heads, ZEISS offers a comprehensive range of solutions.

ZEISS CMMs enable the high accuracy measurement of machined parts and their complex geometries, GD&T requirements, tight tolerances as well as surface finish parameter. Optical 3D scanners, such as ZEISS ATOS 5, provide non-contact measurement solutions for capturing detailed surface data and geometric features for casting dies and casted parts. Microscopy solutions provide detailed imaging and analysis of material microstructure, composition and failure analysis and technical cleanliness,

ZEISS PiWeb is a data management and analysis software that supports efficient data collection, visualization, and reporting, enabling informed decision-making.

Pistons and connecting rods

Challenges

Pistons play a crucial role in converting chemical energy into mechanical motion. To achieve optimal performance, pistons must adhere to precise specifications that facilitate the transformation of linear motion into rotational motion, which is then transmitted through connecting rods to the crankshaft.

The technical challenges include dimensional accuracy to prevent wear and ensure efficient combustion, achieving the required surface finish to minimize friction and enhance sealing, and verifying the integrity of piston dimensions and rings. Additionally, precise alignment and balancing of connecting rods are necessary for smooth motion transfer and reduced stress on the crankshaft.
Solutions

The ZEISS portfolio offers a wide range of solutions to ensure effective quality assurance for pistons and connecting rods.

CMMs provide high-precision measurements to maintain dimensional accuracy. ZEISS X-ray and CT solutions enable non-destructive testing to examine internal structures for defects. Microscopy solutions of ZEISS enable high-resolution imaging and analysis for the precise examination of the microstructure and composition of the material.

ZEISS PiWeb integrates smoothly into the process workflow, providing efficient data management and analysis, with thorough documentation from initial production to end-of-life, supporting informed decisions.

Crankshafts and camshafts

Challenges

Crankshafts and camshafts are critical components in engine systems, playing essential roles in converting and controlling motion and combustion. The crankshaft transforms the linear motion of pistons into rotational motion, driving the vehicle's wheels or drive shafts for other machinery like electric generators. Meanwhile, the camshaft regulates the timing of the engine's intake and exhaust valves, ensuring synchronization with the crankshaft for optimal engine performance.

To maintain the efficiency and reliability of these components, precise measurement is crucial. ZEISS Industrial Quality Solutions offers advanced technologies to address the challenges associated with measuring crankshafts and camshafts.
Solutions

To prevent premature wear and vibrations on these forged parts, maintaining tight tolerances is essential.

Optical 3D metrology of ZEISS enables precise capture of geometries, dimensional parameters, and surface characteristics of dies and the forged camshafts and crankshafts. CMMs, such as the ZEISS PRISMO or MMZ family, are the solution to measure the final part with tight tolerances on form, profile, position, runout and other functional features. Complementing this, ZEISS microscopy solutions provide in-depth analysis of material properties and composition following forging and heat treatment, as well as assessments of technical cleanliness.

By seamlessly integrating into the workflow, ZEISS PiWeb enhances data management and analysis, streamlining collection, visualization, and reporting, while documenting the entire lifecycle from production to end-of-life.

Valves, fuel injectors, or carburetors

Challenges

Advanced measurement technologies in quality assurance are vital for ensuring the efficiency and reliability of engine components. Valves, fuel injectors, and carburetors each present specific metrological challenges for engine performance. Valves require precise dimensional accuracy and surface quality to ensure effective sealing and minimal wear. For fuel injectors, maintaining the exact nozzle geometry is essential to prevent leaks. Similarly, the correct dimensions of the mixing chamber and throttle valve in carburetors are also of great importance, along with the assessment of wear on moving parts.
Solutions

ZEISS CMMs enable the high accuracy measurement of valve seating and other critical features to ensure proper function and efficiency.

Optical 3D scanners offer non-contact measurement solutions, ideal for inspecting delicate components and capturing detailed surface data and geometric features for casted parts. High-resolution imaging from ZEISS microscopy solutions allow for a thorough examination of the material's microstructure and composition.

ZEISS PiWeb provides efficient data management and analysis, facilitating collection, visualization, and reporting, with comprehensive documentation from production through repair to end-of-life, aiding informed decisions.