Current Volume 9
Abstract
This paper describes the design and development of Automatic Bore Gauge (ABG) Testing Machine for precision inspection of electric vehicle (EV) motor bearing bores. Dimensional accuracy of bearing bores is one of the key factors influencing Noise, Vibration and Harshness (NVH) performance in EV drivetrains. With the low noise floor of an EV, dimensional deviations at the micron level can be noticeable. Conventional manual bore gauges are not sufficiently repeatable for tight EV bearing tolerances, with operator-dependent repeatability in the range of ±5 µm. The proposed interdisciplinary system includes a cast iron structural frame, a precision spindle assembly with angular contact bearings, a double action pneumatic linear actuator for controlled probe insertion, an RM RV 3115 recirculating ball linear guide rail, and an LVDT (Linear Variable Differential Transformer) displacement sensor as the main measurement element. Pneumatic actuation is controlled by a solenoid directional control valve coupled to a motor controlled pressure regulator interfaced to a Programmable Logic Controller (PLC) and a NEMA 17 stepper motor with DRV8825 driver provides an accurate 360° rotational sweep of the bearing under test. The embedded control system collects LVDT data for the entire circumferential sweep and determines the minimum diameter (Dmin), maximum diameter (Dmax), average diameter (Davg), and ovality (Δ = Dmax - Dmin). Each bearing is categorized as Good, Rework, or Scrap. The pneumatic actuator force validation results in a safety margin of greater than 7:1 on the carriage operating load.Use of guide rail is less than 1.5% of rated dynamic capacity. The system provides better measurement repeatability to ±1 µm, reduces inspection time from ~25 s (manual) to 6s and eliminates operator induced variation. The system architecture encompasses a provision for IoT based real time data monitoring and traceability.
Keywords
Automated Bore Gauge, Precision Bearing Inspection, LVDT, Stepper Motor Control, PLC/Embedded Control System, Industrial Automation, Dimensional Measurement, Mechatronics System
Citations
IRE Journals:
Dr. Pranjal. A. Jog, Dr. Govind Waghmare, Aarohi Pathak, Aditya Patil, Avani Pathak; Devraj Patil "Development of Bore Gauge System for Bearing Inspection with integration of IOT" Iconic Research And Engineering Journals Volume 9 Issue 11 2026 Page 3656-3668 https://doi.org/10.64388/IREV9I11-1717680
IEEE:
Dr. Pranjal. A. Jog, Dr. Govind Waghmare, Aarohi Pathak, Aditya Patil, Avani Pathak; Devraj Patil
"Development of Bore Gauge System for Bearing Inspection with integration of IOT" Iconic Research And Engineering Journals, 9(11) https://doi.org/10.64388/IREV9I11-1717680
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