Abstract: A rotor for an induction motor includes a rotor core having first and second ends and a plurality of conductor bars. Each conductor bar has a respective first end extending beyond the first end of said rotor core. Each first exposed end has a respective enclosed opening. The rotor also includes an end ring comprising a casting of material flowed between the respective first ends of the conductor bars and through the respective closed openings.

Abstract: A method for fabricating a rotor assembly includes assembling shorting end rings onto conductor bars through a steel laminate stack. The ends of the steel laminate stack are immersed into a bath containing molten metal.

Abstract: A method for calibrating a CNC machine comprises mounting a gauge to a table of the CNC machine and calibrating a probe to the gauge mounted on the CNC machine. A total deviation of the probe and an actual table center position from a nominal table center position for a coordinate system associated with the CNC machine are determined. A controller operatively connected to the CNC machine and the probe is programmed to compensate for the total deviation.

Abstract: A system and method for identifying the start location of the lead thread and the thread profile and quality in a threaded bore in a part, where the system and method can be used for determining the location of the lead thread in a threaded bore in a cylinder head for a spark plug in one non-limiting embodiment. The system includes a moveable table on which the part is mounted. The system also includes a probe having an optical assembly that is inserted in the threaded bore. A camera uses the optical assembly to generate images of the thread bore, where the images are image slices as the probe moves through the threaded bore. The image slices are unwrapped and then joined together to form a planer image to determine a start location of the lead thread, thread count, defects in the threaded bore and thread profile parameters.

Abstract: A stator for an electric motor includes a stator coil including a wire pair with respective ends that are joined with a ring. The ring is positioned around the wire pair and joined to the wire pair by a metal joining process.

Abstract: A system and method for inspecting a machined surface. The method includes acquiring optical information of the machined surface from a predefined orientation. Further, the method includes comparing one or more parameters of the optical information with a corresponding one or more reference parameters. Furthermore, the method includes assessing a quality of the machined surface based on the comparison.

Abstract: A method of detecting a gap between a valve seat insert and a port in a cylinder head may include heating the valve seat insert and the cylinder head and generating a thermal image of the valve seat insert and the cylinder head at an interface between the valve seat insert and corresponding port in the cylinder head housing the valve seat insert. The thermal image may be evaluated to determine the magnitude of a gap between the valve seat insert and the cylinder head based on a temperature at the interface between the valve seat insert and the cylinder head.

Abstract: A system and method for inspecting a machined surface. The method includes acquiring optical information of the machined surface from a predefined orientation. Further, the method includes comparing one or more parameters of the optical information with a corresponding one or more reference parameters. Furthermore, the method includes assessing a quality of the machined surface based on the comparison.

Abstract: A system and method for identifying the start location of the lead thread and the thread profile and quality in a threaded bore in a part, where the system and method can be used for determining the location of the lead thread in a threaded bore in a cylinder head for a spark plug in one non-limiting embodiment. The system includes a moveable table on which the part is mounted. The system also includes a probe having an optical assembly that is inserted in the threaded bore. A camera uses the optical assembly to generate images of the thread bore, where the images are image slices as the probe moves through the threaded bore. The image slices are unwrapped and then joined together to form a planer image to determine a start location of the lead thread, thread count, defects in the threaded bore and thread profile parameters.

Abstract: A method and system are provided for non-contact evaluation of a machined surface of a cast-metal part, including a vision-based porosity inspection station. A digital image of the machined surface is acquired, oriented and scaled to an XY coordinate system, filtered, and inverted. A second image is generated with known design surface features eliminated. Each pixel of the inverted digital image is XOR-compared with a corresponding pixel of the second image. Identified common surface features common to both images is analyzed statistically for conformance to a threshold. A defect is identified as any identified surface feature common to both images which exceeds the threshold. The system moves the part for further processing if a statistical analysis of defects indicates an acceptable component, and alternatively, removes the part from further processing if the analysis indicates a flawed component.

Abstract: An apparatus and method for machining a workpiece in a single-pass comprising a tool configured to produce a borehole when rotated and translated relative to the workpiece, a toolholder configured to fixedly secure and rotate the tool, and a bushing retractably coupled to the toolholder, so as to be shiftable between extended and fully retracted positions, and preferably biased towards the extended position, wherein said tool, toolholder, and bushing are cooperatively configured such that the bushing provides lateral support for the tool during the machining process.

Abstract: A system, method, and apparatus are provided for prioritizing the measurements made on manufactured parts while maintaining specified part quality standards. According to the method, system and apparatus, the process used by the CMM is modified so that the number of measurements made is reduced in accordance with the results of the analysis provided herein. A CMM apparatus is modified in accordance with the analysis results. A method for part measurement prioritization in a measuring system and method includes describing a set of features to be measured on a plurality of substantially identical parts, separating the set of features into sensitive features and non-sensitive features, dividing the non-sensitive features into a plurality of groups, and prioritizing the part measurements to measure the sensitive features and provide alternating measurements of the non-sensitive features.

Abstract: A system and method for machining a workpiece in a single-pass comprising a guide formation mechanism configured to produce a guide element, a combination tool configured to concurrently produce a pilot and finish borehole, and a tool holder for securing and rotating the tool, wherein the guide presents first and second hole sections having differing diameters, and the tool presents first and second cutting tool sections having differing diameters, and said first and second hole and tool sections are cooperatively configured.

Abstract: A multistage machining process includes a plurality of stations. Workpiece feature quality is predicted based on decomposition of the machining process into sources of variation, reticulation of the machining process into machining stations and error models that account for significant contributions to feature quality including from categorical sources of variation.

Abstract: An adjustable boring bar assembly is provided in which the cutting radius can be altered by predetermined increments simply by releasing and turning the bar within a sleeve of a hydraulic holder. The holder sleeve is slightly eccentrically located relative to the spindle axis, so that turning of the bar effectively changes the working radius of the cutting point. Slots on the holder, arrayed about the sleeve, are located at discrete angular positions to produce the desired radial increments. A pin on the boring bar disengages from one slot and re seats in another when the bar is released, withdrawn, turned, reinserted and re-gripped.

Abstract: A three-flute, three-tooth drill has a central peak on the central axis between three V-shaped teeth that provides improved cutting chisel edges. The rake faces, which produce the V-shaped cutting teeth, are setback of radial planes of the drill, and have a slight positive rake angle. Gashes are ground into the clearance faces in such a way as to produce the peak with three chisel edges, each of which curves radially out and merges into a straight cutting edge with no reversal in slope. Therefore, the chisel edges cut cleanly, due both to their positive axial rake, and due to the fact that there are no undercuts along their length in which chips could build up.

Abstract: A twist drill with a novel cutting and configuration is provided that has the center cutting capability of a two flute drill combined with the stability and accuracy of a four flute drill. The drill has four flutes and four lands, but only to complete cutting edges. The two complete cutting edges are formed by two complete lead facets that run all the way to the center axis of the drill, thereby also forming two chisel edges. The other two cutting edges terminate short of the center axis of the drill, each stopping at an intermediate gash located to either side of the chisel edges. The intermediate gashes interconnect the chip removal gashes that serve the four cutting edges, joining them in two pairs. A coolant passage exits each intermediate gash, near the chisel edges. Thus, as the drill center cuts, the chisel edge chips have a clear exit path into the intermediate gash and then out to one of the other chip removal gashes.

Abstract: The brazing seams that attach cutting edge wear inserts on a drill are protected against wear and erosion. The inserts are deliberately differentially sized so that the points where the brazing seams that attach them intersect the cutting edges are differentially spaced from the drill center line. Then, a notch is cut into each cutting edge just wide and deep enough to prevent the brazing seam from contacting the cut. Cutting is still complete, despite the notches, since they do not overlap.