The automotive industry is undergoing a transformation marked by vehicle electrification and increasing demands for dimensional accuracy. In this context, powertrain systems are the pivotal element of every vehicle, whether they are electric or internal combustion ones.
Modern powertrains are a complex integration of mechanical and electronic components working together to convert energy from fuel or electricity into the mechanial power needed to propel vehicles. These systems include essential elements such as the engine, transmission housings, driveshafts, differential, and axles, all of which demand extremely tight tolerance to guarantee efficiency, safety, and reliability.
Increasing technological complexity has led to ever-stricter precision requirements. A modern internal combustion engine, with advanced components such as direct injection, turbocharing, and variable valve timing, requires dimensional tolerances at the micron scale (up to 0.013-0.025 mm!).
In parallel, the rise of EVs introduces new challenges with components like rotors, stators, and electric transmssion systems needeing specific quality controls.
QUALITY CONTROL CHALLENGES IN POWERTRAIN
Hence, quality control of powertrains poses multiple technical challenges that require advanced and state-of-the-art solutions.
For example, engine blocks require precise inspections for cylinder diameter, cylindricity, positional tolerances, and perpendicularity. Any minimal deviation from nominal specification can compromise engine or transmission performance or reduce vechiale safety.
Cylinder heads add another level of complexity, with inspection requirements including intake and exhaust port diameters, positional tolerances, perpendicularity, and precise spark plug hole placement. Traditional manual control methods fall short for managing the geometric sophistication and modern production volumes.
Crankshafts and camshafts require multidimensional controls, including measurement of main and rod journal diameters, cylindricity, concentricity, surface roughness, and phase angles. These critical components must operate with extreme precision to ensure engine balance and minimize vibration and noise.
Transmissions and axle components present further difficulties with gears that requires profile controls, center distances, helix angles, and form tolerances. Modern transmission systems, including those for electric vehicle need NVH (Noise, Vibration, Harshness) controls with precise measurements for acoustic optimization.
TOUCHDMIS AND POWERTRAIN METROLOGY: A COMPREHENSIVE SOLUTION
TouchDMIS marks a paradigm shift in CMM software, introducing a fully touch-based interface that simplifies user experience. Designed for shop-floor environments, TouchDMIS is not an adaption of legacy metrology software, but a solution build from the ground up for maximum productiviy and usability.
Interface is drawn up to provide maximum productivity for both experts and novice users, featuring floating windows and visible function buttons for quick access to main functions.
The software automatically suggest next measuring steps, minimizing learning time to just a few hours and delivering productivity benefits. This is especially advantageous in automotive environments where fast setup and operational simplicity are critical for maintaining the production workflow.
TouchDMIS implements all major international metrology standards, including DMIS ISO 22093, ISO 2768 for tolerance, ISO 10303 for CAD import, and ISO 10360 for CMM calibration. This compliance ensures seamlsess integration with existing quality process and complete measurement traceability in the automotive production environment.
Let’s explore the benefits of TouchDMIS in the powertraing metrology!
CAD integration and auto-generated measuring path
One of distincitve feature of TouchDMIS in automotive is its advanced CAD integration that simplifies CMM programming. The software nativaley supports STEP and IGES formats, with options for direct import from leading automotive CAD systems. This removes the need to manually recreate measurement geometries, slashing programming times.
The auto-generated measuring path is a major advantage for powertraing component inpsecion. TouchDMIS automatically calculates the most efficient path based on part geometry and feature type, considering accessibility and collision avoidance.
Moreover, CAD module enables program creation from the part’s CAD model, without needing the real CMM. This is helpful in automotive, where machines can be free to measure other parts while programs for new pieces are developed meantime. Full 3D visualization allows identification of potential collisions pre-execution, ensuring operational safety.
Real-time reporting and automotive traceability
TouchDMIS reporting system meets the rigorous traceability requirements of the automotive sector. The software generated automatic 3D graphica reports, combining measurement data with CAD visualization for immediate insight into deviations and critical areas.
Real-time reporting drastically reduces time-to-report, a critical parameter in automotive where quality department decision must be quick to keep the production on track.
The integration with advanced MES/ERP software guarantees a full data-driven production, ensuring that SPC is always monitored.
5-axes and scanning support
5-axes probe head like Renishaw® PH20 and REVO with continuous scanning in TouchDMIS accelerates access to complex powertrain geometries, increases data density for form GD&T, and stablizes accuracy at speed.
Infine head positioning reduces stylus changes and fixturing complexity, reaching multiple features in one setup on crankshafts, housing, gears, and rotor/stators, while continuous scanning capture roundness, cylindricity, profile, and runout in a single pass for stronger SPC and PPAP evidence.
REVOLUTIONING AUTOMOTIVE QUALITY CONTROL
TouchDMIS is a game-changer when it comes to controlling powertrain quality in automotive, as it combines a user-friendly interface and advanced metrology tools to meet industry standards. Its ease of use, CAD integration, automated pathing, and reporting options make it a cornerstone for digital transformation and manufacturing efficiency.
As automotive shifts towards electrification, autonomy, and sustainability, TouchDMIS provides the technological foundation to assure future powertrain component quality. Modern architecture and international standards compliance guaranteee long-term value and future-proof compatibility.
TouchDMIS adoption means not just upgraded shop-floor with a simple metrology software, but a jump to a smarter, more efficient and sustainable automotive quality control.
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