Abstract:
Apparatus and methods for aligning and/or installing reluctor rings on a crankshaft. In at least one preferred embodiment, apparatus having at least first and second alignment mechanisms for aligning a reluctor ring in a correct phased position on a crankshaft. In at least one additional embodiment, methods for installing a reluctor ring in a correct phase orientation on a crankshaft utilizing an alignment tool.

Description:
FIELD OF THE INVENTION  
       [0001]     This invention relates to tools for aligning and/or installing reluctor rings on a crank shaft. In at least one preferred embodiment, this invention relates to a tool having at least first and second alignment mechanisms for aligning a reluctor ring in a correct phased position on a crankshaft.  
       BACKGROUND OF THE INVENTION  
       [0002]     In the field of automotive repair there is an occasional need for the removal and reinstallation of a reluctor ring. The reluctor ring is typically attached to the crankshaft for the purpose of controlling cylinder timing. In a conventional automotive engine, the reluctor ring provides information about the rotational position and speed of the crankshaft in order to signal the need and/or timing of a spark in appropriate cylinders (i.e. to trigger ignition thereof). In such electronic ignition systems the current of a sensor circuit, in conjunction with the reluctor ring, is intermittently broken by the teeth rotating on the crankshaft mounted reluctor ring. This, in turn, provides the necessary information for correctly timed cylinder ignition.  
         [0003]     Replacement of the reluctor ring may be necessitated, or at least recommended, in various circumstances. For example, when repairing or reconditioning a crankshaft, the reluctor ring is often damaged upon its removal. Damage to a reluctor ring can occur in other circumstances as well and/or it may become necessary to periodically clean debris from between the reluctor ring and crankshaft. Circumstances in which reluctor rings are damaged are not uncommon since the reluctor ring is traditionally a relatively weak structure that is highly susceptible to warping or breakage e.g. such as during removal.  
         [0004]     A difficulty encountered in the reassembly of the crankshaft and reluctor ring is the alignment of the reluctor ring with respect to the crankshaft. In particular, the alignment of the ring is critical for the engine to start and ignite properly i.e. because the rotational position of the reluctor ring determines the timing of cylinder ignition, and, when improperly installed, the engine will not start. Since typical factory installed reluctor rings do not contain a notch or reference for indexing crank angle degrees, and because it is difficult to adjust the rotational orientation of a reluctor ring once installed (e.g. because they are typically press-fit or heat-fit onto a crankshaft) there exists a need for a reluctor ring alignment and installation tool which simplifies reluctor ring installation processes.  
         [0005]     In view of the above drawbacks in the prior art, there exists a need for apparatus and/or methods, or combination thereof, which overcome, or at least ameliorate, the above drawbacks. It is a purpose of this invention to fulfill these needs in the art, as well as other needs which will become apparent to the skilled artisan once given the above disclosure.  
       SUMMARY OF THE INVENTION  
       [0006]     Generally speaking, this invention addresses the above drawbacks by providing:  
         [0007]     a tool for installing a reluctor ring on a crankshaft comprising:  
         [0008]     a tool body;  
         [0009]     a first alignment mechanism;  
         [0010]     a second alignment mechanism located spaced apart from the first alignment mechanism;  
         [0011]     wherein the first and second alignment mechanisms are so located and spaced, one with respect to the other, such that when a preselected crankshaft reference aperture is aligned with the first alignment mechanism and a preselected reluctor ring reference aperture is aligned with the second alignment mechanism, the reluctor ring is in a substantially correct phase orientation for installation on the crankshaft.  
         [0012]     In an alternative embodiment there is provided:  
         [0013]     a method of installing a reluctor ring on a crankshaft in a correct phased orientation for calibrating ignition timing utilizing a reluctor ring installation tool comprising:  
         [0014]     a tool body;  
         [0015]     a first alignment mechanism;  
         [0016]     a second alignment mechanism located spaced apart from the first alignment mechanism;  
         [0017]     wherein the first and second alignment mechanisms are so located and spaced, one with respect to the other, such that when a preselected crankshaft reference aperture is aligned with the first alignment mechanism and a preselected reluctor ring reference aperture is aligned with the second alignment mechanism, the reluctor ring is in a substantially correct phase orientation for installation on the crankshaft; and  
         [0018]     wherein the method comprises:  
         [0019]     placing a reluctor ring having a central aperture over a crankshaft end such that the crankshaft end resides within the central aperture;  
         [0020]     placing the reluctor ring installation tool over the crankshaft end such that the reluctor ring is located substantially between a portion of the crankshaft and the tool, aligning the first alignment mechanism with a preselected crankshaft reference aperture;  
         [0021]     aligning the second alignment mechanism with a preselected reluctor ring reference aperture;  
         [0022]     wherein, when the first and second alignment mechanisms are aligned with the preselected crankshaft reference aperture and the preselected reluctor ring reference aperture, respectively, the reluctor ring is in a substantially correct phase orientation for engine ignition timing.  
         [0023]     In at least one embodiment of the subject invention, it is an object to simplify and/or make more efficient the installation of a reluctor ring on a crankshaft. In another embodiment, it is an object of the invention to provide a device that simplifies the rotational alignment and installation of a reluctor ring on a crankshaft through the use of at least two alignment mechanisms (e.g. pins or dowels) in cooperation with a tool body.  
         [0024]     In still further embodiments of the subject invention, it is an object to provide a reluctor ring installation tool in which at least one, or both, of the alignment mechanisms are configurable in a plurality of spatial orientations thereby to allow the installation tool to be used with a plurality of reluctor ring and/or crankshaft types. In a preferred embodiment, at least one of the alignment mechanisms is user locatable in at least two dimensions, but more preferably in at least three dimensions. In still further preferred embodiments, both alignment mechanisms are user adjustable at least axially, but more preferably at least axially and spatially one with respect to the other.  
         [0025]     In still additional embodiments, it is an object to provide a method of installing a reluctor ring, employing an installation tool, which is more time efficient, accurate, and less prone to error. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0026]      FIG. 1  is a three-dimensional perspective view of one embodiment of a reluctor ring installation tool according to the subject invention illustrated in the environment in which it finds utility in preparation for aligning a reluctor ring on a crankshaft.  
         [0027]      FIG. 2  is a three-dimensional perspective view of the embodiment of the invention illustrated in  FIG. 1  shown, in use, aligning a reluctor ring on a crankshaft.  
         [0028]      FIG. 3  is a top view of the embodiment of the reluctor ring installation tool illustrated in  FIG. 1 .  
         [0029]      FIG. 4  is a profile view of the reluctor ring installation tool illustrated in  FIG. 3  with certain parts shown in x-ray for clarity.  
         [0030]      FIG. 5  is a three-dimensional perspective view of a reluctor ring installation tool having positionally adjustable alignment mechanisms.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0031]     For a more complete understanding of the present invention and advantages thereof, reference is now made to the following description of various illustrative and non-limiting embodiments thereof, taken in conjunction with the accompanying drawings in which like reference numbers indicate like features.  
         [0032]     With reference initially to  FIG. 1 , therein is illustrated an exemplar embodiment of a reluctor ring installation tool according to the subject invention. As illustrated, tool  1  generally comprises a tool body  3  in combination with a first alignment mechanism  5  and a second alignment mechanism  7 , each provided for accomplishing or performing reluctor ring “phase” alignment (i.e. the angular alignment of the reluctor ring on a crankshaft) during reluctor ring installation on crankshaft  101  (as will be described in more detail below). In the embodiment as shown, tool body  3  is constructed from a cylindrical tube which, in preferred embodiments, is configured to have a cylindrical opening  4  via which the tool can be placed on the cylindrical end of a crankshaft. First alignment mechanism  5  is located, preferably at least partially, within, or in proximity to, cylindrical opening  4  (e.g. attached to tool body  3  via cross member  9 ), and second alignment mechanism  7  is, in the illustrated embodiment, located on an exterior surface of tool body  3  (e.g. attached thereto via flange  11 ).  
         [0033]     In  FIG. 1 , tool  1  is illustrated oriented above crankshaft  101  and reluctor ring  103  for sake of clarity. Although shown as such, it is understood, for example, that during actual reluctor ring installation when utilizing tool  1 , reluctor ring  103  is in cooperative communication with tool  1  with alignment mechanism  7  engaged thereto. Further details regarding reluctor ring installation in correct angular phase orientation will, of course, be provided in more detail below.  
         [0034]     Referring now to  FIG. 2 , this figure illustrates a perspective view of a preferred embodiment of the disclosed invention when it is engaged to both crankshaft  101  and reluctor ring  103 . Although not necessary, it may be seen, in this embodiment, that tool body  3  has an inner diameter just larger than the outer diameter of the crankshaft portion to which it is mounted so that it can engage crankshaft  101  in a preferably close fitting manner. In this regard, it is desirable to ensure that the tolerance of the “fit” relationship be reduced to a minimum, in this embodiment (if possible), thereby to improve the ability of the tool to be stable on the crankshaft end (e.g. so that alignment integrity is not compromised).  
         [0035]     Alignment mechanisms  5  and  7 , in preferred embodiments, are pins or dowel like rods which are specifically sized to fit in pre-selected, particularly dimensioned apertures located on crankshaft  101  and reluctor ring  103 . In further preferred embodiments, the alignment mechanisms are adjustable axially within apertures  13  and  15  (see  FIG. 3 ) in which they reside thereby to allow length tailorability of the alignment mechanisms. Such tailorability is useful, in some embodiments, by enabling the effective length of the alignment mechanisms (e.g. the length to which they extend downwardly) to be adjusted so that engagement with respective crankshaft alignment reference apertures (e.g. reference aperture  102 ) and reluctor ring alignment reference apertures (e.g. reference aperture  104 ) is possible to permit proper use of the tool. In this regard, alignment mechanisms  5  and  7  and apertures  13  and  15  are preferably threaded so that the length of the alignment mechanism can be adjusted by simply “threading” or “unthreading” the alignment mechanisms to whatever degree or length is desired. Alternative means for adjustability are, of course, contemplated.  
         [0036]     Turning now to  FIGS. 3 and 4 , therein is illustrated top and profile views of an embodiment of tool  1  with  FIG. 3  best showing an example relative radial positioning of each alignment mechanism. Furthermore, the means by which alignment mechanisms  5  and  7  are connected to tool body  3  are illustrated in x-ray detail in these figures (e.g. via cross bar  9  and flange  11 , respectively, such parts being positionally adjustable in some embodiments, as discussed below).  
         [0037]     In addition to the above described features and configurations, in further alternative embodiments, additional and/or alternative structures which permit radial adjustability of first and second alignment mechanisms  5  and  7  are contemplated. In this regard, it is recognized that different automotive manufacturers will typically manufacture reluctor rings and/or crankshafts with different dimensions and/or configurations and, therefore, a reluctor ring installation tool which accounts for such differences is desired. In view of these differences inherent among different brands of reluctor rings and crankshafts, in at least one embodiment of tool  1 , one or both of first and second alignment mechanisms  5  and  7  are adjustable radially about the circumference of tool body  3 , thereby to accommodate potential alternate locations of reluctor ring and crankshaft alignment reference apertures  102  and  104  (e.g. in certain embodiments such as illustrated in  FIG. 5 , cross member  9  can be manually rotated to effect such radial adjustability with flange  11  being rotatable in a similar fashion). In still further embodiments, alignment mechanisms  5  and  7  are adjustable in further spatial dimensions, including horizontally, vertically, and various combinations thereof. Moreover, in yet additional alternative embodiments in which tool body  3  is not tubular or cylindrical, other mechanisms for providing spatial adjustability are, of course, contemplated.  
       EXAMPLE  
       [0038]     Notwithstanding the above features, the embodiment of tool  1  illustrated in  FIGS. 1 and 2  is specifically configured for use with certain General Motors™ engine parts, including those installed on General Motors™ Generation III Engines including the 4.8 L, LR4, 5.3/LM7, 5.7 LS1, and 6.0 LQ4. In this regard,  FIGS. 1 and 2  illustrate a tool  1  in which the spatial orientations and dimensions of first and second alignment mechanism  5  and  7  are optimized for installation and phase calibration of such General Motors™ engine parts. In this regard, it is noted that crankshaft  101  and reluctor ring  103  each include a uniquely sized and located aperture for which alignment mechanisms  5  and  7  have been specifically located and configured.  
         [0039]     As such, in order to install reluctor ring  103  on crankshaft  101 , tool  1  is simply oriented such that alignment mechanism  7  registers with uniquely sized reference aperture  104  (an 8 mm aperture), and so that alignment mechanism  5  registers with aperture  102  (a 11 mm aperture located on the flywheel flange). If it is necessary to adjust the length of alignment mechanisms  5  and  7  so that sufficient engagement with the reference apertures is possible, such adjustments can be made at this time. Once properly aligned, reluctor ring  103  can be press fit (i.e. friction fit) onto the crankshaft end or heated (e.g. to approximately 450° F.) and then installed thereon to cool. If the alignment mechanisms are properly registered with the respective, matching reference apertures, the reluctor ring will be installed in the correct phase orientation, and proper ignition timing will result.  
         [0040]     Although the above described exemplar embodiments are particularly efficacious for their described purposes, it is understood, of course, that other embodiments and configurations can be employed utilizing the same principles as delineated above. For example, tool body  3  need not be cylindrical or tubular, and instead may be comprised of a simple framework carrying first and second alignment mechanisms for registration with the reference apertures. Furthermore, alternatives to the dowel-type alignment mechanisms can be employed and/or other alignment reference structures on the crankshaft and/or reluctor ring used.  
         [0041]     Once given the above disclosure, many other features, modifications, and improvements will become apparent to the skilled artisan. Such other features, modifications, and improvements are therefore considered to be part of this invention, the scope of which is to be determined by the following claims: