Analysis of gear machining process by means of rolling inspection

Abstract

The invention relates to a method comprising the following method steps: machining a toothing of a component by means of a gear machining machine, during the machining of the toothing, acquiring axis data of at least one machine axis of the gear machining machine and / or acquiring sensor data of at least one sensor; providing the acquired axis data related to the rotation of the component as rotation-related axis data, and / or providing the acquired sensor data related to the rotation of the component as rotation-related sensor data; performing a rolling test on the toothed component by means of a rolling test bench, providing rolling test measurement data relating to a rotation of the component during the rolling test as rotation-related measurement data; the rotation-related axis data and / or the rotation-related sensor data are compared with the rotation-related measurement data of the rolling test in order to determine a correlation between the tooth deviation of the rotation-related measurement data according to the rolling test and the machine deviation of the rotation-related axis data and / or the rotation-related sensor data.

Description

Technical Field

[0001] The present invention relates to a method having the following method steps: machining the tooth portion of a component by means of a gear processing machine and performing a rolling inspection on the toothed component by means of a rolling inspection bench. Background Art

[0002] Due to the continuously increasing requirements for the quality of the tooth portion and especially its noise characteristics, in industrial mass production, at most 100% of all manufactured tooth portions are subjected to a rolling inspection on a rolling inspection bench. Herein, in particular, periodic deviations that have a negative impact on the noise characteristics of the tooth portion can be determined.

[0003] Furthermore, it is known that during the machining of the tooth portion, axis data or sensor data of the relevant gear processing machine are recorded in order to monitor the machine function, machine components, and the manufacturing process itself. Most of this data of the machine tool is obtained as a travel signal or a time signal.

[0004] For example, axis or drive or kinematic deviations of a gear processing machine may be reflected in the results of the rolling inspection because these deviations are partially transferred to the geometry of the manufactured tooth portion. The results of the rolling inspection are usually obtained in relation to the rotation of the component during the rolling inspection. The results of the rolling inspection cannot be directly compared with the analyzed data from the gear processing machine, so it is complex to determine the correlation between the results of the rolling inspection and the machine analysis data. Summary of the Invention

[0005] In this context, the technical problem underlying the present invention is to provide a method that enables an efficient comparison between the results of the rolling inspection and the analyzed data from the gear processing machine.

[0006] The technical problem described above is solved by the features of the independent claims. Other design solutions of the present invention are derived from the dependent claims and the following description.

[0007] According to a first aspect, the present invention relates to a method having the following method steps: machining the tooth part of a component by means of a gear processing machine, wherein during the machining of the tooth part, axis data of at least one machine axis of the gear processing machine is acquired, such as axis feed, axis acceleration, power consumption of the axis drive device or similar data, and / or, during the machining of the tooth part, sensor data of at least one sensor of the gear processing machine is acquired, and the sensors are, for example, a solid-borne sound sensor, an acceleration sensor, a distance sensor or the like; providing the acquired axis data related to the rotation of the component as rotation-related axis data, and / or providing the acquired sensor data related to the rotation of the component as rotation-related sensor data; performing a rolling inspection on the toothed component by means of a rolling inspection bench, wherein measurement data of the rolling inspection related to the rotation of the component during the rolling inspection is provided as rotation-related measurement data; comparing the rotation-related axis data and / or the rotation-related sensor data with the rotation-related measurement data of the rolling inspection in order to determine the correlation between the tooth part deviation according to the rotation-related measurement data of the rolling inspection and the machine deviation according to the rotation-related axis data and / or the rotation-related sensor data.

[0008] Since not only the measurement data of the rolling inspection but also the axis data and / or the sensor data of the gear processing machine are given in a rotation-related manner (i.e., related to the rotation of each component), the correlation can be directly explored. In this way, the errors or defects of the gear processing machine, such as an inaccurate axis, drive device, bearing or the like, can be directly inferred from the deviations measured in the scope of the rolling inspection.

[0009] Providing the axis data and / or the sensor data of the gear processing machine as data related to the rotation of the component enables, for example, a simplified comparison with the measurement data of the rolling inspection compared to a pure time reference of these data known in the prior art.

[0010] According to a design of the method, it can be provided that the rotation-related axis data is provided as an order spectrum, in particular by means of FFT. Here, the abbreviation FFT represents the fast Fourier transform in a known manner (English: fast fourier transformation). Here, the order is a multiple of the rotational speed of the component, so that the measured deviation or measurement value is depicted as the amplitude at each order.

[0011] According to a design of the method, it can be provided that the rotation-related sensor data is provided as an order spectrum, in particular by means of FFT. Here, the abbreviation FFT represents the fast Fourier transform in a known manner (English: fast fourier transformation). Here, the order is a multiple of the rotational speed of the component, so that the measured deviation or measurement value is depicted as the amplitude at each order.

[0012] It can be set that the results related to the rotation of the rolling test are provided as order spectra, in particular by means of the FFT. Here, the abbreviation FFT represents the fast Fourier transformation in a known manner (English: fast fourier transformation). Here, the order is a multiple of the rotational speed of the component, so that the measured deviation or the measured value is depicted as the amplitude at each order.

[0013] The order of the rolling test can be directly compared with the order of the axis data and / or the sensor data of the gear processing machine. If, for example, anomalies in the second or ninth order occur for the order spectrum of the rolling test and for the order spectrum of the axis data, a direct correlation can be assumed between the deviation of the axis data and the deviation of the rolling test. As long as the corresponding order of the axis data can be specifically assigned to a component of the gear processing machine, the error in the tooth profile for the tooth profiles to be manufactured subsequently can be reduced or eliminated by calibrating and / or maintaining the relevant component.

[0014] For example, it can be set that at least one order of one of the order spectra is assigned to a first component of the gear processing machine, such as a bearing, a drive or the like, and at least one further order of one of the order spectra is assigned to a second component of the gear processing machine different from the first component, such as a bearing, a drive or the like, wherein the defect of the first component and / or the second component is detected according to the amplitude of one of the orders.

[0015] The components of the gear processing machine are excited to vibrate during the machining of the tooth profile, in particular in the range of their natural frequencies, wherein the vibration excitation is carried out, for example, by periodically occurring machining forces and / or by the feed motion (i.e. the movement and in particular the acceleration of the controlled machine axes). Here, vibrations often occur which are multiples of the tooth meshing frequency, the tool spindle speed and / or the workpiece spindle speed. By means of the measures according to the invention, all the vibrations obtained which are related to the rotation of the workpiece or the component are now in particular given in order to enable a direct comparison with the results of the rolling test.

[0016] It can be set that the axis data and / or the sensor data are already recorded or stored as data related to the rotation of the component during their acquisition. Alternatively, it can be set that the axis data and / or the sensor data are recorded or stored, for example, with a time reference or related to the rotation of the tool, and are then transformed as data related to the rotation of the component. In particular, the transformation can be carried out automatically and computer-aided. The transformation can be carried out after averaging the data.

[0017] According to one design of the method, it can be set to take the average value of the axis data, where, in particular, the average value is taken for each rotation of each component. Alternatively or additionally, it can be set to take the average value of the sensor data, where, in particular, the average value is taken for each rotation of each component.

[0018] An acceleration sensor can be set as the sensor for acquiring sensor data, and the acceleration sensor is assigned to the workpiece spindle of the gear processing machine. Here, in particular, simultaneously with recording the sensor data of the acceleration sensor, the rotational position of the workpiece spindle is acquired. Here, the rotational position is the angular position of the workpiece spindle that carries the component during machining. By simultaneously acquiring the rotational position of the workpiece spindle, the sensor data of the acceleration sensor can be stored as data related to the rotation of the workpiece spindle. The measured values of the acceleration sensor can be averaged according to each rotation of the workpiece spindle.

[0019] According to one design of the method, it can be set to acquire the current consumption of the tool spindle (such as a grinding spindle) as axis data. During the recording of the current consumption of the tool spindle, the rotational position of the workpiece spindle can again be acquired simultaneously in order to acquire the current consumption related to the rotation of the workpiece spindle. The measured values of the current consumption can be averaged according to each rotation of the workpiece spindle. In particular, the periodic fluctuations of the current consumption of the workpiece spindle can be associated with the measured deviations of the rolling inspection. Brief Description of the Drawings

[0020] The present invention will be described in more detail below with reference to the drawings showing embodiments. It is schematically shown respectively:

[0021] Figure 1 A gear grinding machine is shown;

[0022] Figure 2 A grinding spindle with a toothed component to be ground is shown;

[0023] Figure 3 An inspection table for unilateral rolling inspection is shown;

[0024] Figure 4 The result of the rolling inspection is shown;

[0025] Figure 5 An inspection table for bilateral rolling inspection is shown;

[0026] Figure 6 The order spectrum of the rolling inspection of the axis data and the sensor data is shown;

[0027] Figure 7 A flowchart of the method according to the present invention is shown. Detailed Description of the Embodiment

[0028] Figure 1 A gear processing machine is shown, more precisely, a gear grinding machine 2. The gear grinding machine 2 has a tool spindle 4 for holding and rotating a grinding tool. The gear grinding machine 2 has a workpiece spindle 6 for holding and rotating a toothed member to be ground. The gear grinding machine has a dressing device 8 for dressing the grinding tool.

[0029] The tool spindle 4, which can also be referred to as a grinding tool spindle, is equipped with an acceleration sensor 14 for acquiring sensor data.

[0030] The gear grinding machine 2 has numerically controlled machine axes X, Y, Z, A, B, C, C2, B2 for performing translational and rotational relative movements in order to provide the required machining kinematics during gear machining or dressing. In addition, the gear grinding machine 2 has an axis Z1 with a movable center sleeve 12 for clamping a shaft or a mandrel.

[0031] Figure 2 Exemplarily and schematically, the tool spindle 4 and the workpiece spindle 6 are shown. The tool spindle has a dressable grinding worm 14 held therein, and the workpiece spindle 6 has a toothed member 16 to be ground held therein, and the tooth portion 17 of the toothed member is ground.

[0032] During the grinding process, the sensor data 18 of the acceleration sensor 10 is acquired as a time signal of the acceleration a with respect to time t. In addition, during the grinding process, the axis data 22 in the form of the current consumption I of the motor 20 for the rotational drive of the workpiece spindle 4 is acquired as a time signal of the current consumption I with respect to time t. The schematically shown curves should not be understood as real measurement data, but only as placeholders.

[0033] In addition, simultaneously with the sensor data 18 and the axis data 22, during the grinding process, the angular position of the workpiece spindle 6 is acquired by means of a rotation sensor 24 as additional axis data 26, more precisely, as the rotation angle φ with respect to time t.

[0034] Figure 3 Exemplarily, the schematic structure of an inspection bench 28 is shown, which is used to perform a unilateral rolling inspection on a corresponding toothed member 16.

[0035] The inspection bench 28 has a first drive device 30 and a second drive device 32. The first drive device 30 is arranged to drive a first shaft 34 on which the toothed member 16 to be inspected is mounted.

[0036] The second drive device 32 is used to brake a mating gear 36, which is mounted on a second shaft 26 coupled to the drive device 20.

[0037] The mating gear 36 is an externally toothed spur gear portion that meshes with the toothed portion of the component 16. By driving the toothed component 16 and simultaneously braking the mating gear 36, the rotational speed and torque can be adjusted during the inspection run. It goes without saying that the rotational speed curve and torque curve can also be adjusted. The axial distance a1 between the shafts 38 and 34 is constant.

[0038] The test bench 16 has a rotational sensor or an angle measurement system 40, a rotational acceleration receiver 42, and a structure-borne sound sensor 44.

[0039] Figure 4 Exemplarily and schematically, the measured rotational error F plotted in units of the rotation U of the gear 16 in [μm] is shown, that is, the result of the unilateral rolling test of the individual toothed component 16. From this, the values of, for example, the concentricity error Fr’, the tooth-to-tooth amplitude fi’, and the maximum rolling deviation Fi’ for the first order can be determined in a known manner.

[0040] Alternatively or additionally, a bilateral rolling test can be performed. The test bench 46 for the bilateral rolling test is exemplarily and schematically shown in Figure 5 In order to avoid repetition, the same reference numerals are assigned to the same features below.

[0041] The difference between the bilateral rolling test and the unilateral rolling test described above with reference to Figure 3 basically lies in that the axial distance a2 is not constant during the test. The mating gear 36 is mounted and supported on a movable carriage 48 by means of its shaft 38. The movable carriage 48 is supported on a stationary corresponding support 52 by means of a spring device 50.

[0042] By means of the spring device 50, the mating gear 36 is pressed into tooth contact with the toothed portion to be inspected of the component 16, wherein there is two-sided contact on the right and left sides of the toothed portion to be inspected of the component 16 in this tooth contact.

[0043] During the inspection, that is, during the rolling of the toothed component 16 and the mating gear 36, the mating gear 36 is pressed in the direction of the component 16 with a defined force.

[0044] The deviation is obtained based on the translational displacement of the movable carriage 34. A stroke receiver 54 and a vibration receiver 56 are assigned to the carriage 48 in order to receive measurement data. The results of the bilateral rolling test are, for example, rolling concentricity deviation, bilateral rolling deviation, and bilateral rolling runout.

[0045] Figure 6 Exemplarily and schematically shown above is the one made according to Figure 4The order spectrum determined from the measured rotational error. It is applicable that, here, it is only a schematic diagram and not real measured values. These orders correspond to multiples of the rotational speed of the component during the rolling inspection.

[0046] In Figure 6 the lower part of which is exemplarily and schematically shown the order spectrum generated from the axis data or sensor data according to Figure 3 Accordingly, in the example figure, the y-axis is labeled with both "acceleration" and "current consumption".

[0047] By comparing the dominant orders, an error or deviation of the gear cutting machine can be assigned to the measured deviation of the toothed component. For example, it can be seen that damage or wear of the bearings of the tool spindle of the gear cutting machine will directly cause, for example, a measurable rotational error of the second order of the toothed component. Since not only the results of the rolling inspection but also the axis data and / or the measurement data are given in relation to the rotation of the component, the association between the tooth deviation and the machine deviation can be directly identified in a simple manner.

[0048] Therefore, according to the present invention, a method can be provided, which has the following method steps:

[0049] (A) Machining the tooth part of the component 16 by means of the gear cutting machine 2, wherein, during the machining of the tooth part, axis data 22, 26 of the machine axes 4, 6 of the gear cutting machine 2 are acquired, and, during the machining of the tooth part, at least sensor data 18 of the sensor 10 of the gear cutting machine 2 are acquired;

[0050] (B) Providing the acquired axis data 22, 26 related to the rotation of the component 16 as rotation-related axis data 22, 26, and providing the acquired sensor data 18 related to the rotation of the component 16 as rotation-related sensor data, wherein the rotation-related axis data are provided as an order spectrum by means of FFT, and the rotation-related sensor data are provided as an order spectrum by means of FFT;

[0051] (C) Performing a rolling inspection on the toothed component by means of a rolling inspection table, wherein measurement data of the rolling inspection related to the rotation of the component during the rolling inspection are provided as rotation-related measurement data, wherein the rotation-related result of the rolling inspection is provided as an order spectrum by means of FFT;

[0052] (D) Comparing the rotation-related axis data and the rotation-related sensor data with the rotation-related measurement data of the rolling inspection in order to determine the association between the tooth deviation according to the rotation-related measurement data of the rolling inspection and the machine deviation according to the rotation-related axis data and the rotation-related sensor data.

[0053] List of reference numerals

[0054] 2 Gear processing machine

[0055] 4 Tool spindle

[0056] 6 Workpiece spindle

[0057] 8 Dressing equipment

[0058] 10 Acceleration sensor

[0059] 12 Center sleeve

[0060] 14 Grinding screw

[0061] 16 Component

[0062] 17 Tooth part

[0063] 18 Sensor data

[0064] 20 Driving device

[0065] 22 Axis data

[0066] 24 Rotation sensor

[0067] 26 Axis data

[0068] 28 Test bench for unilateral rolling inspection

[0069] 30 Driving device

[0070] 32 Driving device

[0071] 34 Shaft

[0072] 36 Mating gear

[0073] 38 Shaft

[0074] 40 Angle measurement system

[0075] 42 Rotational acceleration receiver

[0076] 44 Structure-borne sound sensor

[0077] 46 Test bench for bilateral rolling inspection

[0078] 48 Carriage

[0079] 50 Spring device

[0080] 52 Corresponding bracket

[0081] 54 Stroke receiver

[0082] 56 Vibration receiver

Claims

1. A method having the following method steps: - Machining the tooth part (17) of the component (16) by means of a gear cutting machine (2), wherein, During machining of the tooth portion (17), axis data (22, 26) of at least one machine axis (4, 6) of the gear cutting machine (2) is acquired, said axis data being, for example, axis feed, axis acceleration, power consumption of the axis drive or the like, and / or, during machining of the tooth portion (17), sensor data (18) of at least one sensor (10) of the gear cutting machine (2) is acquired, said sensors being, for example, solid - state acoustic sensors, acceleration sensors, distance sensors or the like; - Provide the acquired axis data (22, 26) related to the rotation of the component (16) as rotation - related axis data, and / or provide the acquired sensor data (18) related to the rotation of the component (16) as rotation - related sensor data; - Perform a rolling inspection on the toothed component (16) by means of a rolling inspection bench (3, 5), wherein measurement data of the rolling inspection related to the rotation of the component (16) during the rolling inspection is provided as rotation - related measurement data; - Compare the rotation - related axis data (22, 26) and / or the rotation - related sensor data (18) with the rotation - related measurement data of the rolling inspection in order to determine the correlation between the tooth deviation according to the rotation - related measurement data of the rolling inspection and the machine deviation according to the rotation - related axis data and / or the rotation - related sensor data.

2. The method according to claim 1, characterized in that the rotation - related axis data is provided as an order spectrum, in particular by means of FFT, and / or the rotation - related sensor data is provided as an order spectrum, in particular by means of FFT.

3. The method according to one of the preceding claims, characterized in that The rotation - related result of the rolling inspection is provided as an order spectrum, in particular by means of FFT.

4. The method according to claim 2 or 3, characterized in that, At least one order of one of the order spectra is assigned to a first component of the gear cutting machine, such as a bearing, a drive or the like, and at least one further order of one of the order spectra is assigned to a second component of the gear cutting machine different from the first component, such as a bearing, a drive or the like, wherein a defect of the first component and / or the second component is detected based on the amplitude of one of the orders.

5. The method according to any one of the preceding claims, characterized in that the axis data is averaged, in particular averaged per revolution of the component, and / or the sensor data is averaged, in particular averaged per revolution of the component.

6. The method according to one of the preceding claims, characterized in that, In order to acquire the sensor data (18), an acceleration sensor (10) is provided as the sensor (10), which is assigned to the tool spindle (4) of the gear cutting machine (2), wherein, in particular, the rotational position of the workpiece spindle (6) is acquired simultaneously with recording the sensor data of the acceleration sensor.

7. The method according to one of the preceding claims, characterized in that, The current consumption of the tool spindle (4) is acquired as axis data, wherein, in particular, the rotational position of the workpiece spindle (6) is acquired simultaneously with recording the current consumption of the tool spindle (4).

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