A high-speed precision heavy-duty gear tooth profile dynamic modification processing device and dynamic modification method

Abstract

The application provides a high-speed precise heavy-duty gear tooth profile dynamic modification processing device and dynamic modification method, and belongs to the technical field of gear processing. The heavy-duty adaptive clamping mechanism is fixedly installed in the middle part of a rack assembly. The high-speed precise driving mechanism is in transmission connection with the heavy-duty adaptive clamping mechanism and a dynamic modification executing mechanism respectively. The dynamic modification executing mechanism is slidingly assembled on the upper part of the rack assembly. The multi-dimensional detection mechanism is fixedly arranged at the position of the corresponding processing area of the rack assembly. The cooling and dustproof mechanism is arranged on the periphery of the processing area. The central control system is in electrical signal connection with the heavy-duty adaptive clamping mechanism, the high-speed precise driving mechanism, the dynamic modification executing mechanism, the multi-dimensional detection mechanism and the cooling and dustproof mechanism respectively. The high-speed precise heavy-duty gear tooth profile dynamic modification processing device and dynamic modification method solve the problems of static modification, insufficient rigidity of clamping and driving, limited tool adjustment and offline detection lag of the existing modification device.

Description

Technical Field

[0001] This invention relates to the field of gear processing technology, and in particular to a high-speed, precision, heavy-duty gear tooth profile dynamic modification processing device and dynamic correction method. Background Technology

[0002] High-speed, precision, and heavy-duty gears are core components of transmission systems in high-end equipment such as aerospace, high-speed trains, and heavy machine tools. The machining accuracy of their tooth profiles directly affects transmission efficiency, vibration and noise, load-bearing capacity, and service life. Under actual operating conditions, gears are affected by multiple factors, including dynamic loads, temperature field changes, and assembly errors, which can easily lead to stress concentration on the tooth surface and contact area misalignment, resulting in increased vibration, tooth wear, fatigue tooth breakage, and other failures. Tooth profile modification is a key process for improving meshing performance and enhancing heavy-duty reliability. However, existing modification machining equipment is insufficient to meet the integrated machining requirements of high speed, precision, and heavy load.

[0003] Current gear profile modification devices generally suffer from several significant drawbacks: First, they mostly employ static, preset parameters for fixed-path machining, failing to detect dynamic errors such as tool wear, workpiece deformation, and temperature drift in real time. The modification amount is poorly adapted to actual working conditions, easily leading to insufficient modification failing to alleviate stress concentration, or excessive modification causing decreased overlap and increased vibration. Second, the clamping and driving rigidity is insufficient, resulting in transmission clearance, low positioning accuracy, and unstable clamping. Under high-speed and heavy-load conditions, this easily causes workpiece runout and motion errors, making it difficult to adapt to different specifications of heavy-duty gears. Third, the tool attitude adjustment capability is limited, failing to achieve multi-dimensional, high-precision dynamic compensation. Tool wear cannot be corrected in real time, making it difficult to guarantee modification quality. Fourth, they generally employ offline detection and delayed adjustment modes, failing to form a closed-loop control system of machining-detection-correction, resulting in significant error accumulation, delayed response, and low machining efficiency and stability.

[0004] To address the aforementioned pain points, this invention proposes a high-speed, precision, heavy-duty gear tooth profile dynamic modification processing device to achieve real-time detection, closed-loop control, and dynamic compensation, thereby meeting the high-precision, high-efficiency, and high-reliability modification processing requirements of gears in high-end equipment. Summary of the Invention

[0005] The purpose of this invention is to provide a high-speed precision heavy-duty gear tooth profile dynamic modification processing device and dynamic correction method, which solves the problems of existing gear modification devices that use static modification, insufficient clamping and driving rigidity, limited tool adjustment, and offline detection lag, making it impossible to achieve real-time dynamic compensation and closed-loop control, and thus difficult to meet the processing requirements of high-speed precision heavy-duty gears.

[0006] To achieve the above objectives, the present invention provides a high-speed, precision, heavy-duty gear tooth profile dynamic modification machining device, comprising a high-rigidity frame assembly, a heavy-duty adaptive clamping mechanism, a high-speed precision drive mechanism, a dynamic modification execution mechanism, a multi-dimensional detection mechanism, a cooling and dust prevention mechanism, and a central control system; the heavy-duty adaptive clamping mechanism is fixedly installed in the middle of the frame assembly, the high-speed precision drive mechanism is connected to the heavy-duty adaptive clamping mechanism and the dynamic modification execution mechanism respectively, the dynamic modification execution mechanism is slidably mounted on the upper part of the frame assembly, the multi-dimensional detection mechanism is fixedly arranged at the corresponding processing area position of the frame assembly, the cooling and dust prevention mechanism is covered on the periphery of the processing area, and the central control system is electrically connected to the heavy-duty adaptive clamping mechanism, the high-speed precision drive mechanism, the dynamic modification execution mechanism, the multi-dimensional detection mechanism, and the cooling and dust prevention mechanism respectively.

[0007] Preferably, the frame assembly includes a base, a column, a crossbeam, and shock-absorbing pads; the column is vertically fixed to the upper part of the base, the crossbeam is horizontally fixed to the top of the column, shock-absorbing pads are provided at the bottom of the base, high-precision linear guide rails are mounted on the crossbeam, and a worktable support is fixed in the middle of the base.

[0008] Preferably, the heavy-duty adaptive clamping mechanism includes a rotary table, a three-jaw centering chuck, an adaptive clamping assembly, and a clamping force detection unit; the rotary table is mounted on a table support via crossed roller bearings, the three-jaw centering chuck is fixed to the top of the rotary table, the adaptive clamping assembly is located on the top of the rotary table and cooperates with the three-jaw centering chuck to clamp the workpiece, and the clamping force detection unit is signal connected to the three-jaw centering chuck and the adaptive clamping assembly respectively.

[0009] Preferably, the high-speed precision drive mechanism is divided into a rotary drive assembly and a linear drive assembly; the rotary drive assembly is installed inside the worktable support and is connected to the rotary worktable for transmission, and adopts a double gear backlash-free meshing structure in conjunction with a harmonic reducer for transmission; the linear drive assembly is mounted on the linear guide rail of the crossbeam and is fixedly connected to the dynamic shaping actuator, and adopts a linear servo motor in conjunction with a preloaded ball screw for drive.

[0010] Preferably, the dynamic shaping actuator includes a mounting base, a multi-axis adjustment platform, a shaping tool assembly, and a tool wear detection unit; the mounting base is fixed to the lower part of the linear drive assembly, the multi-axis adjustment platform is fixed to the lower part of the mounting base, the shaping tool assembly is installed at the bottom of the multi-axis adjustment platform, and the tool wear detection unit is fixed to the side of the shaping tool assembly and connected to the central control system signal.

[0011] Preferably, the multi-dimensional detection mechanism includes a tooth profile accuracy detection unit, a temperature detection unit, and a vibration detection unit; the tooth profile accuracy detection unit is aligned with the workpiece tooth surface in a non-contact manner, the temperature detection unit is arranged near the tool and the workpiece respectively, and the vibration detection unit is fixedly installed on the rotary table and the housing of the dynamic shaping actuator.

[0012] Preferably, the cooling and dustproof mechanism includes a cooling component and a transparent dustproof cover; the nozzles of the cooling component are aligned with the machining cutting area, and the dustproof cover completely covers the machining area, enclosing the heavy-duty adaptive clamping mechanism, the dynamic shaping execution mechanism, and the multi-dimensional detection mechanism.

[0013] A method for dynamic correction of the tooth profile of high-speed, precision, heavy-duty gears includes the following steps: The multi-dimensional detection mechanism synchronously and at high frequency collects data on tooth profile morphology, tool wear, temperature, vibration, and clamping status, and transmits them to the central control system; The central control system processes and analyzes the data to classify and locate errors. The central control system calculates correction parameters based on the type and magnitude of the error, and controls the dynamic shaping actuator, high-speed precision drive mechanism, adaptive clamping mechanism, and cooling component to perform compensation actions respectively. After correction, the test is performed again for verification. If the error does not meet the standard, the correction is repeated until the accuracy requirements are met.

[0014] Preferably, error compensation includes: controlling the multi-axis adjustment platform to perform three-axis micro-displacement compensation for tool wear and geometric deviation; adjusting cooling parameters and performing trajectory thermal error compensation in conjunction with thermal deformation error; adjusting drive speed and motion trajectory in real time for vibration error; and automatically adjusting clamping force and displacement for clamping deviation.

[0015] Preferably, the central control system stores correction parameters and processing data in real time, and continuously optimizes the correction strategy through a self-learning algorithm to form a closed-loop control process of processing-detection-correction-feedback.

[0016] Therefore, the present invention employs the above-mentioned high-speed precision heavy-duty gear tooth profile dynamic modification processing device and dynamic correction method, and the technical effects are as follows: 1. Significantly improved overall machine rigidity and clamping stability: Adopting a high-rigidity frame and shock-absorbing structure, combined with adaptive clamping and force position detection, it effectively avoids workpiece deformation and runout, meeting the requirements for stable processing under high-speed and heavy-load conditions.

[0017] 2. Backlash-free transmission and significantly improved positioning accuracy: By using a dual-gear backlash-free drive, a harmonic reducer, and a precision linear servo, transmission backlash is eliminated, achieving micron-level rotation and positioning accuracy, thus reducing machining errors at the source.

[0018] 3. Achieve multi-dimensional real-time detection and dynamic tool compensation: Integrate tooth profile, temperature, vibration and tool wear detection, and with the three-axis fine adjustment platform, it can compensate for dynamic errors online, solving the problems of poor accuracy and low adaptability of traditional static shaping.

[0019] 4. Closed-loop dynamic shaping, improving efficiency and quality simultaneously: The "detection-analysis-correction" online closed loop enables real-time dynamic shaping and error self-elimination, resulting in higher shaping accuracy, improved processing efficiency, and stronger versatility and reliability. Attached Figure Description

[0020] Figure 1 This is a schematic diagram of the overall structure of a high-speed, precision, heavy-duty gear tooth profile dynamic modification processing device according to the present invention. Figure 2 This is a schematic diagram showing the connection between the heavy-duty adaptive clamping mechanism and the rotary drive assembly of the present invention; Figure 3 This is a schematic diagram of the dynamic shaping actuator of the present invention; Figure 4 This is a schematic diagram of the installation of the multi-dimensional detection mechanism of the present invention; Figure 5 This is a control logic block diagram of the central control system of the present invention.

[0021] Figure Labels 1. Base; 2. Column; 3. Crossbeam; 31. Linear guide rail; 4. Worktable support; 5. Rotary worktable; 51. Crossed roller bearing; 6. Three-jaw centering chuck; 61. Jaw; 62. Pressure sensor; 7. Adaptive clamping assembly; 71. Clamping cylinder; 72. Clamping block; 73. Displacement sensor; 8. Clamping force detection unit; 9. Rotary drive assembly; 91. Drive gear; 92. Driven gear; 93. Auxiliary meshing gear; 10. Linear drive assembly; 101. Slider; 11. Mounting base; 12. Multi-axis Adjustment platform; 121, X-axis adjustment module; 122, Y-axis adjustment module; 123, Z-axis adjustment module; 124, grating ruler; 13, shaping tool assembly; 131, high-speed electric spindle; 132, shaping tool; 133, tool chuck; 14, tool wear detection unit; 141, laser displacement sensor; 15, tooth profile accuracy detection unit; 151, laser profilometer; 152, detection bracket; 16, temperature detection unit; 17, vibration detection unit; 18, cooling assembly; 181, cooling pump; 182, nozzle. Detailed Implementation

[0022] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0023] Unless otherwise defined, the technical or scientific terms used in this invention shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains.

[0024] Example 1 like Figures 1 to 5As shown in the overall structure, this embodiment discloses a high-speed, precision, heavy-duty gear tooth profile dynamic modification machining device. The device consists of a frame assembly, a heavy-duty adaptive clamping mechanism, a high-speed precision drive mechanism, a dynamic modification execution mechanism, a multi-dimensional detection mechanism, a cooling and dust prevention mechanism, and a central control system. The components are arranged in an orderly manner in space and are electrically coordinated to jointly complete the high-speed, precision, heavy-duty, and dynamic modification machining of the gear tooth profile. It realizes a closed-loop control of machining-detection-correction-re-detection, which significantly improves the tooth profile accuracy, load-bearing capacity, and operational stability.

[0025] The frame assembly, serving as the foundation for the entire machine, employs a one-piece casting process combined with artificial aging to fully eliminate casting internal stress, ensuring no deformation or vibration during long-term high-speed, heavy-load machining. The base 1 features a rectangular, thick-walled structure with evenly distributed shock-absorbing pads at the bottom. These pads utilize a high-damping rubber and metal composite structure to absorb cutting vibrations generated during machining and external ground vibrations, preventing vibration transmission to the rotary table 5 and the dynamic shaping actuator, thus ensuring shaping accuracy. Two vertical columns 2 are fixed to the base 1. Columns 2 have a hollow rectangular cross-section with multiple internal reinforcing ribs to enhance bending and torsional rigidity, ensuring the crossbeam 3 does not sway during high-speed movement. The crossbeam 3 is horizontally fixed to the top of the columns 2, and a high-precision linear guide rail 31 is mounted on the crossbeam 3. The linear guide rail 31 is a high-rigidity roller guide rail used to support and guide the dynamic shaping actuator in smooth linear motion. The base 1 has a fixed worktable support 4 in the middle. The top of the worktable support 4 is a high-precision machining plane, which is used to install a heavy-duty adaptive clamping mechanism to ensure that the rotation center of the rotary worktable 5 is matched with the tool center of the dynamic shaping actuator after installation.

[0026] The frame assembly has high overall rigidity and stability. The shock-absorbing pads can effectively isolate vibration. The linear guide rail 31 has low motion resistance and high positioning accuracy, providing a stable and reliable installation benchmark for all subsequent precision moving parts. It avoids shaping errors caused by insufficient rigidity and excessive vibration from the structural source, and meets the basic requirements for high-speed precision heavy-duty gear processing.

[0027] The heavy-duty adaptive clamping mechanism is used to achieve rapid centering, stable clamping, and adaptive tightening of heavy-duty gears of different specifications and weights, avoiding clamping deformation, loosening, or workpiece eccentricity, and ensuring machining accuracy under high-speed rotation. The rotary table 5 is mounted on the table support 4 via high-precision crossed roller bearings 51. The crossed roller bearings 51 can simultaneously withstand radial, axial, and overturning moments, exhibiting extremely high rotational accuracy and minimal backlash, ensuring that the gear does not experience radial runout or axial movement during rotation. A three-jaw centering chuck 6 is fixed at the top center of the rotary table 5. The jaws 61 are made of hard alloy with anti-slip textures on the surface, ensuring no slippage under high clamping force and preventing damage to the gear end face and inner hole. A pressure sensor 62 is embedded inside the jaws 61 to collect the clamping force in real time, preventing excessive clamping force from deforming thin-walled parts of the gear, or insufficient clamping force from causing workpiece swaying during high-speed rotation.

[0028] The rotary table 5 is also equipped with an adaptive clamping assembly 7, which consists of a clamping cylinder 71, a clamping block 72, and a displacement sensor 73. The clamping cylinder 71 provides a stable and adjustable clamping force, and the clamping block 72 is made of soft, wear-resistant material, making flexible contact with the gear end face during clamping. The displacement sensor 73 detects the clamping displacement in real time to determine whether the gear is properly clamped and whether there is any eccentricity or tilting. The clamping force detection unit 8 is electrically connected to the pressure sensor 62 and the clamping cylinder 71, and collects clamping force and displacement signals in real time. It automatically adjusts the pressure of the clamping cylinder 71 according to the gear specifications, material, and weight to achieve adaptive clamping control: when the clamping force is detected to be too small, the clamping force is automatically increased; when the clamping force is detected to be too large, the clamping force is automatically decreased; and when the displacement is abnormal, an alarm is issued to ensure that heavy-duty gears of different modules and outer diameters can be clamped stably with high precision, without deformation or loosening.

[0029] The heavy-duty adaptive clamping mechanism combines three-jaw centering with side clamping, along with real-time clamping force detection and closed-loop adjustment, to completely solve the problems of insufficient rigidity, uncontrollable clamping force, and easy workpiece deformation caused by traditional clamping mechanisms. It can be adapted to the clamping needs of various specifications of heavy-duty gears in aerospace, high-speed trains, heavy machine tools and other fields.

[0030] The high-speed precision drive mechanism is divided into a rotary drive assembly 9 and a linear drive assembly 10, which respectively realize the high-precision rotation of the gears and the high-precision linear movement of the profile-modifying actuator. It eliminates transmission backlash throughout the entire process, improves transmission rigidity, and meets the dual requirements of high speed and high precision. The rotary drive assembly 9 is installed inside the worktable support 4 and consists of a servo motor, a harmonic reducer, a drive gear 91, a driven gear 92, and an auxiliary meshing gear 93. The servo motor provides stable power output, and the harmonic reducer achieves a high speed ratio reduction, significantly increasing output torque and reducing speed, ensuring low-speed, high-torque rotation of the rotary worktable 5. The drive gear 91 and driven gear 92 mesh with each other, and the auxiliary meshing gear 93 forms a dual-drive meshing structure, completely eliminating gear meshing backlash and fundamentally avoiding reversing backlash, impact, and motion lag, enabling the rotary worktable 5 to achieve extremely high rotational accuracy.

[0031] The linear drive assembly 10 is mounted on the crossbeam 3 and consists of a linear servo motor, a ball screw, and a slider 101. The linear servo motor directly drives the ball screw to rotate. The slider 101 cooperates with the ball screw and moves along the linear guide 31. The bottom of the slider 101 is fixedly connected to the dynamic shaping actuator, realizing high-speed, stable, and high-precision linear feed of the shaping tool 132. The ball screw adopts a high-precision ground screw and is equipped with a preload structure to eliminate axial backlash and ensure feed positioning accuracy and repeatability.

[0032] The high-speed precision drive mechanism combines double-gear backlash-free transmission with high-precision lead screw linear drive to achieve high-precision, high-rigidity, and backlash-free transmission of rotary and linear motion. This solves the defects of traditional devices, such as large transmission backlash, weak rigidity, and easy runout and error accumulation at high speeds, providing a precise motion basis for dynamic tooth profile modification.

[0033] The dynamic profile modification actuator is the core component for achieving multi-dimensional, high-precision, and dynamic profile modification of the tooth profile. It can respond to correction commands from the central control system in real time, quickly fine-tune the tool posture, and compensate for tool wear, thermal deformation, and motion errors. The dynamic profile modification actuator is fixed to the bottom of the slider 101 of the linear drive assembly 10 via the mounting base 11 and moves linearly along the crossbeam 3 with the slider 101. A multi-axis adjustment platform 12 is installed below the mounting base 11. The multi-axis adjustment platform 12 adopts a three-axis precision stacked structure, including an X-axis adjustment module 121, a Y-axis adjustment module 122, and a Z-axis adjustment module 123. Each axis is driven by a servo motor, and a closed-loop position feedback is achieved in conjunction with a precision transmission mechanism and a grating ruler 124. The grating ruler 124 detects the actual displacement of each axis in real time, ensuring extremely high adjustment accuracy. It can make minute, rapid, and precise adjustments to the spatial position of the profile modification tool 132, and compensate for various dynamic errors that occur during the machining process in real time.

[0034] A profile trimming tool assembly 13 is installed below the multi-axis adjustment platform 12, consisting of a high-speed electric spindle 131, a profile trimming tool 132, and a tool chuck 133. The high-speed electric spindle 131 has a wide speed range, meeting different cutting speed requirements from roughing to finishing. The profile trimming tool 132 uses a diamond-coated tool, which has extremely high wear resistance, high cutting edge precision, and long service life, making it suitable for high-speed, precision, heavy-duty gear tooth surface trimming. The tool chuck 133 has high clamping rigidity and good concentricity, ensuring that the tool does not run out of space under high-speed rotation. A tool wear detection unit 14 is installed on the side of the profile trimming tool assembly 13, consisting of a laser displacement sensor 141 and a data processing module. The laser displacement sensor 141 detects the tool edge wear in real time without contact, and the data processing module transmits the wear signal to the central control system. When the wear reaches a preset threshold, the system automatically triggers wear compensation, finely adjusting the tool position through the multi-axis adjustment platform 12 to offset the trimming error caused by wear and ensure continuous stability of the tooth profile accuracy.

[0035] The dynamic shaping actuator enables multi-dimensional adjustable tool posture, real-time wear detection and automatic compensation, breaking through the limitations of traditional shaping devices with fixed tool posture, delayed compensation and inability to dynamically correct. It enables the shaping process to be optimized in real time according to the machining status, significantly improving shaping consistency and accuracy.

[0036] Multi-dimensional detection mechanisms are used to collect key status data in real time and synchronously throughout the entire processing process, providing comprehensive, accurate, and real-time data support for dynamic correction, and realizing the transformation from "passive processing" to "active perception and intelligent correction".

[0037] The multi-dimensional detection mechanism includes a tooth profile accuracy detection unit 15, a temperature detection unit 16, and a vibration detection unit. The tooth profile accuracy detection unit 15 is mounted on the side of the column 2 via a detection bracket 152. The height of the detection bracket 152 is adjustable, allowing the laser profilometer 151 to accurately align with the gear tooth surface. The laser profilometer 151 uses high-frequency sampling to collect the actual tooth profile shape in real time, compares it with the preset theoretical tooth profile, and calculates key geometric errors such as tooth tip shaping error, tooth root shaping error, and tooth surface bulging error, providing direct basis for trajectory correction. The temperature detection unit 16 consists of an infrared temperature sensor and a temperature acquisition module. The infrared temperature sensor is positioned near the shaping tool 132 and the gear to be processed, respectively, to non-contactly detect the tool temperature, tooth surface temperature, and ambient temperature of the processing area in real time, identifying thermal deformation errors caused by frictional heat generation and changes in ambient temperature, providing data for thermal error compensation.

[0038] The vibration detection unit consists of vibration sensors and a vibration analysis module. The vibration sensors are mounted on the rotary table 5 and the mounting base 11 of the dynamic shaping actuator, respectively, to collect machining vibration signals in real time. The system determines whether the vibration originates from tool vibration, workpiece runout, transmission clearance, or structural resonance, and calculates the impact of vibration on tooth profile accuracy, providing a basis for optimizing machining speed and trajectory. The multi-dimensional detection mechanism achieves simultaneous acquisition of multi-source data on tooth profile geometric error, temperature drift, vibration state, and clamping state. The data is comprehensive, real-time, and has a high sampling frequency, fully reflecting the machining state and providing a solid foundation for the central control system to make rapid and accurate dynamic correction decisions.

[0039] The cooling and dustproof mechanism controls the machining temperature, suppresses thermal deformation, and prevents chips and dust from entering precision components, ensuring long-term stable operation and extending the service life of the device. The cooling assembly 17 is a vibration detection unit; 18 consists of a cooling pump 181, cooling pipes, and nozzles 182. The cooling pump 181 provides coolant at a stable pressure, and the cooling pipes are strategically arranged along the frame to guide the coolant to the machining area. The nozzles 182 are atomizing nozzles, with adjustable spray direction, angle, and flow rate, ensuring precise spraying of coolant to the cutting area and gear surface machining zone, quickly removing cutting heat, reducing tool and gear temperatures, suppressing thermal deformation, and simultaneously flushing away chips to prevent them from scratching the gear surface. The dust cover, made of transparent acrylic glass, is installed above the machining area on the frame, completely enclosing core precision components such as the heavy-duty adaptive clamping mechanism, dynamic profile control mechanism, and multi-dimensional detection mechanism, effectively preventing dust, coolant splashes, and chips from entering critical parts such as guide rails, bearings, and sensors. The dust cover has an openable inspection door on one side, which facilitates workpiece loading and unloading, tool replacement and daily maintenance. The transparent material allows operators to observe the processing status in real time.

[0040] The cooling and dustproof mechanism combines precise cooling with fully enclosed dustproofing to effectively reduce thermal errors, protect precision components, and improve the processing environment. This allows the device to maintain high precision and stability during long-term continuous processing, meeting the needs of long-term industrial production.

[0041] The central control system serves as the core of the entire machine's command, employing an industrial-grade controller in conjunction with a touchscreen, data storage module, and communication module. This enables multi-dimensional data acquisition, error source analysis, dynamic correction calculation, coordinated control of actuators, and full-process data traceability, forming a complete closed-loop control system of "real-time detection - error analysis - dynamic correction - command execution - effect feedback." The touchscreen facilitates human-machine interaction, allowing input of process parameters such as gear parameters, trimming amount, trimming curve, spindle speed, feed rate, clamping force range, and accuracy thresholds. It displays the machining status, error curves, detection data, and correction information in real time. The data storage module stores machining parameters, historical error data, correction strategies, and operating condition curves, supporting data playback, querying, and export for quality traceability and process optimization. The communication module supports high-speed Ethernet communication, enabling interface with host computers and digital workshop systems for remote monitoring, program uploading, and data management.

[0042] The dynamic correction method implemented by the central control system is carried out in its entirety according to the following steps: During the machining process, the tooth profile accuracy detection unit 15, tool wear detection unit 14, temperature detection unit 16, vibration detection unit, and clamping force detection unit 8 simultaneously collect data at high frequency, including tooth profile morphology, tool wear, tool and gear temperature, whole machine vibration signal, clamping force and clamping displacement, etc. All data are uploaded to the controller in real time.

[0043] The controller processes and analyzes the collected data, classifying errors into four main categories: tooth profile geometric error, temperature drift error, vibration-induced error, and clamping state error. It further traces and locates the source of the error, determining whether it originates from tool wear, transmission clearance, thermal deformation, workpiece runout, or assembly deviation. It distinguishes between compensable and non-compensable errors, and promptly issues alarms for non-compensable errors.

[0044] The controller automatically calculates the optimal correction parameters based on the error type, magnitude, source, and current processing status. To address tool wear and geometric deviations, the multi-axis adjustment platform 12 is controlled to perform micro-compensation on the X, Y, and Z axes to correct the tool posture. To address thermal deformation errors, the cooling flow rate and spray position are adjusted in tandem, while thermal error trajectory compensation is performed simultaneously. To address vibration errors, the speed and trajectory of linear and rotary drives are adjusted in real time to suppress resonance and vibration. To address clamping deviations, the pressure and displacement of the clamping cylinder 71 are automatically adjusted to ensure stable gear centering.

[0045] The controller converts the correction parameters into control commands and synchronously sends them to the multi-axis adjustment platform 12, rotary drive assembly 9, linear drive assembly 10, adaptive clamping assembly 7, and cooling assembly 17 vibration detection unit 18. Each actuator responds quickly and works in coordination to achieve real-time elimination of errors.

[0046] After correction, the multi-dimensional inspection agency immediately collects new data to verify the effect. If the error still exceeds the threshold, the correction process is restarted until the accuracy requirements are met. The data storage module continuously records the parameters and effects of each correction. The controller continuously optimizes the correction strategy through a self-learning algorithm, resulting in faster response speed, higher correction accuracy, and stronger stability in subsequent processing.

[0047] The central control system and dynamic correction method completely change the traditional static shaping mode, realize dynamic closed-loop correction in the whole process, multiple dimensions, and real time, solve common problems in the industry such as difficulty in balancing the shaping amount, unreasonable contact area, stress concentration, and large vibration and noise, and significantly improve the final shaping accuracy, processing efficiency and gear service performance.

[0048] Therefore, this invention employs the aforementioned high-speed precision heavy-duty gear tooth profile dynamic modification machining device and dynamic correction method. Based on a high-rigidity cast frame, it achieves deformation-free centering clamping of the gear through a heavy-duty adaptive clamping mechanism. A high-speed precision drive mechanism with double gear backlash elimination ensures rotation and feed accuracy. Relying on a three-axis adjustable dynamic modification actuator in conjunction with real-time tool wear detection, and combined with multi-dimensional online detection of tooth profile accuracy, temperature, and vibration, the central control system completes multi-source data acquisition, error source analysis, and dynamic compensation calculation, forming a "machining-detection-correction-feedback" closed-loop control. It can compensate for tool wear, thermal deformation, vibration, and clamping errors in real time, achieving high-precision dynamic modification of the tooth profile, significantly improving gear meshing accuracy, load-bearing capacity, and operational stability, and is suitable for gear machining needs under high-speed and heavy-duty working conditions in aerospace, high-speed trains, heavy machine tools, and other fields.

[0049] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and not to limit them. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can still be made to the technical solutions of the present invention, and these modifications or equivalent substitutions cannot cause the modified technical solutions to deviate from the spirit and scope of the technical solutions of the present invention.

Claims

1. A high-speed, precision, heavy-duty gear tooth profile dynamic modification machining device, characterized in that, It includes a high-rigidity frame assembly, a heavy-duty adaptive clamping mechanism, a high-speed precision drive mechanism, a dynamic shaping actuator, a multi-dimensional detection mechanism, a cooling and dustproof mechanism, and a central control system. The heavy-duty adaptive clamping mechanism is fixedly installed in the middle of the frame assembly. The high-speed precision drive mechanism is connected to the heavy-duty adaptive clamping mechanism and the dynamic shaping actuator respectively. The dynamic shaping actuator is slidably mounted on the upper part of the frame assembly. The multi-dimensional detection mechanism is fixedly arranged in the corresponding processing area of ​​the frame assembly. The cooling and dustproof mechanism is covered on the periphery of the processing area. The central control system is electrically connected to the heavy-duty adaptive clamping mechanism, the high-speed precision drive mechanism, the dynamic shaping actuator, the multi-dimensional detection mechanism, and the cooling and dustproof mechanism respectively.

2. The high-speed precision heavy-duty gear tooth profile dynamic modification machining device according to claim 1, characterized in that, The frame assembly includes a base, columns, crossbeams, and shock-absorbing feet; the columns are vertically fixed to the upper part of the base, the crossbeams are horizontally fixed to the top of the columns, shock-absorbing feet are installed at the bottom of the base, high-precision linear guides are mounted on the crossbeams, and a worktable support is fixed in the middle of the base.

3. The high-speed precision heavy-duty gear tooth profile dynamic modification device according to claim 2, characterized in that, The heavy-duty adaptive clamping mechanism includes a rotary table, a three-jaw centering chuck, an adaptive clamping assembly, and a clamping force detection unit. The rotary table is mounted on a table support via crossed roller bearings. The three-jaw centering chuck is fixed to the top of the rotary table. The adaptive clamping assembly is located on the top of the rotary table and cooperates with the three-jaw centering chuck to clamp the workpiece. The clamping force detection unit is connected to the three-jaw centering chuck and the adaptive clamping assembly via signals.

4. The high-speed precision heavy-duty gear tooth profile dynamic modification machining device according to claim 1, characterized in that, The high-speed precision drive mechanism is divided into a rotary drive assembly and a linear drive assembly. The rotary drive assembly is installed inside the worktable support and is connected to the rotary worktable for transmission. It adopts a double gear backlash-free meshing structure and a harmonic reducer for transmission. The linear drive assembly is mounted on the linear guide rail of the crossbeam and is fixedly connected to the dynamic shaping actuator. It adopts a linear servo motor and a preloaded ball screw for drive.

5. The high-speed precision heavy-duty gear tooth profile dynamic modification machining device according to claim 1, characterized in that, The dynamic shaping actuator includes a mounting base, a multi-axis adjustment platform, a shaping tool assembly, and a tool wear detection unit. The mounting base is fixed to the lower part of the linear drive assembly, the multi-axis adjustment platform is fixed to the lower part of the mounting base, the shaping tool assembly is installed at the bottom of the multi-axis adjustment platform, and the tool wear detection unit is fixed to the side of the shaping tool assembly and connected to the central control system.

6. The high-speed precision heavy-duty gear tooth profile dynamic modification machining device according to claim 1, characterized in that, The multi-dimensional detection mechanism includes a tooth profile accuracy detection unit, a temperature detection unit, and a vibration detection unit. The tooth profile accuracy detection unit is aligned with the workpiece tooth surface in a non-contact manner. The temperature detection units are arranged near the tool and the workpiece, respectively. The vibration detection unit is fixedly installed on the rotary table and the housing of the dynamic shaping actuator.

7. The high-speed precision heavy-duty gear tooth profile dynamic modification machining device according to claim 1, characterized in that, The cooling and dustproof mechanism includes a cooling component and a transparent dustproof cover; the nozzles of the cooling component are aligned with the machining cutting area, and the dustproof cover completely covers the machining area, enclosing the heavy-duty adaptive clamping mechanism, the dynamic shaping execution mechanism, and the multi-dimensional detection mechanism.

8. A method for dynamic correction of high-speed, precision, heavy-duty gear tooth profiles, based on the high-speed, precision, heavy-duty gear tooth profile dynamic profile modification processing device according to any one of claims 1-7, characterized in that, Includes the following steps: The multi-dimensional detection mechanism synchronously and at high frequency collects data on tooth profile morphology, tool wear, temperature, vibration, and clamping status, and transmits them to the central control system; The central control system processes and analyzes the data to classify and locate errors. The central control system calculates correction parameters based on the type and magnitude of the error, and controls the dynamic shaping actuator, high-speed precision drive mechanism, adaptive clamping mechanism, and cooling component to perform compensation actions respectively. After correction, the test is performed again for verification. If the error does not meet the standard, the correction is repeated until the accuracy requirements are met.

9. The method for dynamic correction of high-speed precision heavy-duty gear tooth profile according to claim 8, characterized in that, Error compensation includes: for tool wear and geometric deviation, controlling the multi-axis adjustment platform to perform three-axis micro-displacement compensation; for thermal deformation error, linking and adjusting cooling parameters and performing trajectory thermal error compensation; for vibration error, adjusting drive speed and motion trajectory in real time; and for clamping deviation, automatically adjusting clamping force and displacement.

10. The method for dynamic correction of high-speed precision heavy-duty gear tooth profile according to claim 8, characterized in that, The central control system stores correction parameters and processing data in real time, and continuously optimizes the correction strategy through a self-learning algorithm to form a closed-loop control process of processing-detection-correction-feedback.

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