A gear honing adaptive tooth alignment control method

Abstract

The present application belongs to the technical field of gear precision machining, and discloses a self-adaptive gear alignment correction control method for gear honing, which comprises the following steps: step A, clamping the workpiece by a clamping device and moving to the coaxial matching position of the secondary gear alignment mechanism, then clamping the workpiece center by an axial centering point after releasing the clamping mechanism to eliminate the clamping gap and radial runout; step B, touching and identifying the phase feature of the workpiece tooth part by a switch probe to determine the initial meshing phase and complete the coarse gear alignment matching with the standard meshing wheel; step C, collecting the workpiece rotation angle and tooth part phase signal in real time by using a ring encoder, calculating the phase deviation compensation amount based on the phase compensation model by the numerical control system, and realizing the high-precision meshing alignment of the workpiece and the honing wheel through closed-loop adjustment. The present application eliminates the clamping error and single-piece phase deviation through three-level collaborative control, and significantly improves the gear honing precision and product consistency.

Description

Technical Field

[0001] This invention belongs to the field of precision gear machining technology, and relates to an adaptive tooth alignment control method for honing. Background Technology

[0002] Internal meshing high-strength honing is the final forming process in the precision machining of high-end gearbox parts for automobiles, construction machinery, and other applications. In the field of gear precision machining, honing, with its unique internal meshing generating motion principle, can achieve micron-level precision shaping on the tooth surface, making it a key process to ensure gear transmission accuracy, smoothness, and low noise. The cutting allowance in honing is typically only a few micrometers to tens of micrometers. This extremely small machining allowance characteristic determines that it imposes extremely stringent requirements on the meshing phase matching accuracy between the workpiece and the honing wheel.

[0003] During gear honing, the meshing phase matching accuracy between the workpiece and the honing wheel directly determines the distribution of the tooth surface contact area, the magnitude of tooth profile error, the level of tooth direction accuracy, and the smoothness and noise reduction effect of gear transmission. Even a small deviation in the meshing phase can lead to serious consequences such as tooth surface contact area misalignment, local stress concentration, and increased transmission noise. Therefore, tooth alignment accuracy is a core control element to ensure the quality of gear honing, and its accuracy level directly affects the overall transmission performance and service life of the gearbox.

[0004] In the internal gear honing process, the workpiece and the honing wheel form a pair of internal gears, and the meshing phase relationship between them follows a strict transmission ratio constraint. There is a theoretical correspondence between the rotation angle φ1(k) of the standard meshing wheel and the rotation angle φ2(k) of the workpiece, based on the tooth ratio N1 / N2. However, due to geometric errors such as radial runout in the workpiece, the actual phase relationship needs to be superimposed with a phase compensation term caused by radial runout on top of the theoretical transmission ratio. The component of radial runout along the tooth surface normal direction causes a positional deviation of the workpiece tooth profile in the meshing line direction. This deviation is closely related to the workpiece end face pressure angle αt and exhibits a periodic distribution characteristic on the Z teeth of the workpiece in one revolution. Therefore, accurately measuring the radial runout value of each tooth of the workpiece and converting it into a meshing phase compensation amount is the core mathematical problem for achieving adaptive tooth alignment.

[0005] Currently, the existing honing techniques for tooth alignment mainly suffer from the following technical problems and shortcomings: Firstly, the traditional fixed-datum positioning method relies on a pre-set mechanical datum to determine the meshing phase position of the workpiece. However, due to differences in previous processing steps, heat treatment deformation, damage from impacts during transport, and human factors during clamping, each workpiece inevitably exhibits its own unique phase deviation and installation eccentricity error. The fixed-datum positioning method cannot perceive or compensate for these individual differences in each workpiece, resulting in a systematic deviation between the actual meshing phase and the theoretical meshing phase. This leads to misalignment between the workpiece and the honing wheel, uneven removal of tooth surface allowance, and over-cutting or under-cutting in localized areas.

[0006] Secondly, while manual gear setting can accommodate individual workpiece characteristics to some extent, its accuracy is highly dependent on the operator's experience and skill level. Manual gear setting has inherent drawbacks such as poor consistency, low efficiency, and significant susceptibility to human factors. Different operators have different standards for judging tooth characteristics and different operating techniques, resulting in significant fluctuations in gear setting quality between different shifts. This instability is further amplified in mass production, making it difficult to meet the stringent requirements of modern gear manufacturing for consistent product precision.

[0007] Third, existing technologies, whether using fixed-datum positioning or manual assistance, lack mathematical models and calculation methods to quantitatively convert workpiece geometric errors (such as radial runout) into meshing phase compensation quantities. Because a precise mapping relationship between radial runout and meshing phase deviation has not been established, even if radial runout is detected in the workpiece, it cannot be accurately converted into phase compensation commands usable by the CNC system, resulting in insufficient compensation accuracy.

[0008] Fourth, existing technologies lack a systematic control method capable of adaptively sensing the phase characteristics of individual workpieces and automatically performing deviation detection and closed-loop correction. Because it is impossible to accurately measure and dynamically compensate for the actual phase of each workpiece, overcutting will cause a decrease in tooth surface strength and a shortened service life, while undercutting will result in substandard tooth profile accuracy and increased transmission noise, ultimately leading to quality problems such as unstable gear machining accuracy and poor product consistency. Summary of the Invention

[0009] In view of this, the purpose of the present invention is to solve the above problems and provide an adaptive tooth alignment control method for honing.

[0010] To achieve the above objectives, the present invention provides the following technical solution: An adaptive tooth alignment control method for honing includes the following steps: Step A, workpiece clamping and precise positioning: The workpiece spindle clamps the gear workpiece to be processed through the clamping device, drives the workpiece to move to the coaxial mating position of the secondary gear setting mechanism, and then releases the clamping mechanism of the workpiece spindle. The workpiece is then center-clamped with an axial center to make the end face of the workpiece and the positioning end face of the tooling fit tightly together, eliminating the workpiece clamping gap and radial runout. Step B, Coarse Tooth Alignment and Phase Reference Detection: The control system drives the workpiece spindle to rotate at low speed. The phase characteristics of the workpiece teeth are detected by a fixed switch probe to determine the initial meshing phase of the workpiece and complete the coarse tooth alignment between the workpiece and the standard meshing wheel. Step C, Precision Phase Acquisition and Adaptive Closed-Loop Adjustment: A ring encoder mounted on the workpiece spindle is used to acquire the workpiece's rotation angle and tooth phase signals in real time. The phase data is fed back to the CNC system, which calculates the phase deviation compensation amount based on the following phase compensation model:

[0011] In the formula: For the workpiece corner, Here, k is the standard meshing gear rotation angle, k is the number of teeth rotating on the workpiece, and d is the workpiece pitch circle diameter. The pressure angle of the workpiece end face. Z represents the radial runout measurement value of the i-th tooth position of the workpiece, where Z represents the number of teeth on the workpiece, N1 is the number of teeth on the standard meshing gear, and N2 is the number of teeth on the workpiece. The CNC system integrates the phase deviation compensation amount with the real-time phase data of the ring encoder, outputs compensation control commands, drives the workpiece spindle to perform rotation angle correction, and achieves high-precision matching of the meshing phase between the workpiece and the honing wheel through closed-loop adjustment.

[0012] Furthermore, in step A, after the axial center clamps the workpiece at the center, it ensures that the workpiece and the workpiece spindle have rotational coaxiality and positioning rigidity, providing a mechanical reference guarantee for subsequent gear alignment.

[0013] Furthermore, in step B, the switch probe performs tactile detection and identification of the phase characteristics of the tooth groove or tooth surface of the workpiece to quickly determine the initial engagement phase of the workpiece.

[0014] Furthermore, after completing the coarse tooth matching, ensure that the workpiece enters a safe and correct meshing preparation state to avoid meshing interference and collision.

[0015] Furthermore, in step C, the ring encoder is a high-resolution encoder that acquires the precise rotation angle and tooth phase signal of the workpiece in real time and feeds back the real-time phase data to the CNC system.

[0016] The beneficial effects of this invention are as follows: 1. This invention achieves a tight fit between the workpiece end face and the tooling positioning end face by axial center clamping, eliminating clamping gaps and radial runout. This ensures the coaxiality of the workpiece and the workpiece spindle's rotation and positioning rigidity, providing a reliable mechanical reference for subsequent tooth alignment. A switching probe is used to detect the phase characteristics of the workpiece teeth, directly detecting the actual characteristics of a single workpiece. This adapts to phase differences between different workpieces, quickly completing coarse tooth matching with the standard meshing wheel and avoiding meshing interference and collision risks. A precise mathematical model for the radial runout to meshing phase deviation is established, solving the technical problem of the lack of a quantitative conversion relationship between radial runout and meshing phase in existing technologies. A ring encoder is used to collect the workpiece rotation angle and tooth phase signals in real time and feed them back to the CNC system at high speed. Combined with the phase compensation model, compensation control commands are automatically generated to drive precise rotation angle correction of the workpiece spindle, continuously maintaining the ideal meshing state between the workpiece and the honing wheel throughout the honing process.

[0017] 2. This invention forms a complete control link from mechanical reference establishment to coarse phase identification and fine phase closed-loop correction through three-level coordinated control: precise mechanical positioning, coarse phase detection by the switch probe, and fine phase acquisition and phase compensation model by the ring encoder. Each level eliminates clamping error, single-piece phase deviation and dynamic meshing error, significantly improving the accuracy, stability and product consistency of honing.

[0018] Other advantages, objectives, and features of the invention will be set forth in part in the description which follows, and in part will be apparent to those skilled in the art from the following examination, or may be learned from practice of the invention. The objectives and other advantages of the invention can be realized and obtained through the following description. Attached Figure Description

[0019] To make the objectives, technical solutions, and advantages of the present invention clearer, the preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings, wherein: Figure 1 This is a schematic diagram of the adaptive tooth alignment control method for honing in this invention.

[0020] Reference numerals: 1-Clamping device; 2-Workpiece; 3-Axial center; 4-Switch probe; 5-Standard meshing wheel; 6-Ring encoder. Detailed Implementation

[0021] The following specific examples illustrate the implementation of the present invention. Those skilled in the art can easily understand other advantages and effects of the present invention from the content disclosed in this specification. The present invention can also be implemented or applied through other different specific embodiments, and various details in this specification can be modified or changed based on different viewpoints and applications without departing from the spirit of the present invention. It should be noted that the illustrations provided in the following embodiments are only schematic representations of the basic concept of the present invention. Unless otherwise specified, the following embodiments and features can be combined with each other.

[0022] The accompanying drawings are for illustrative purposes only and are schematic diagrams, not actual pictures. They should not be construed as limiting the invention. To better illustrate the embodiments of the invention, some parts in the drawings may be omitted, enlarged, or reduced, and do not represent the actual product dimensions. It is understandable to those skilled in the art that some well-known structures and their descriptions may be omitted in the drawings.

[0023] In the accompanying drawings of the embodiments of the present invention, the same or similar reference numerals correspond to the same or similar components. In the description of the present invention, it should be understood that if terms such as "upper," "lower," "left," "right," "front," and "rear" indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, they are only for the convenience of describing the present invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, the terms used to describe positional relationships in the drawings are only for illustrative purposes and should not be construed as limiting the present invention. For those skilled in the art, the specific meaning of the above terms can be understood according to the specific circumstances.

[0024] Example 1 like Figure 1 As shown, the present invention provides an adaptive gear alignment control method for honing, which achieves adaptive and high-precision meshing alignment between the workpiece and the honing wheel in internal meshing high-force honing through three-level coordinated control: precise mechanical positioning, coarse phase detection by a switch probe, fine phase acquisition by a ring encoder, and a phase compensation model based on radial runout.

[0025] The specific implementation steps are as follows: Step A: Workpiece clamping and precise positioning The workpiece spindle clamps the gear workpiece 2 to be processed via clamping device 1 and drives the workpiece to move to the coaxial engagement position of the secondary gear alignment mechanism. After the workpiece spindle reaches the designated position, the clamping mechanism of the workpiece spindle is released, and at this time, the axial center 3 is used to center-tighten the workpiece. The clamping force applied by the axial center 3 makes the end face of the workpiece fit tightly with the positioning end face of the tooling, thereby completely eliminating the clamping gap and radial runout that may exist in the workpiece during the clamping process, ensuring that the workpiece and the workpiece spindle have high rotational coaxiality and positioning rigidity, and providing a stable and reliable mechanical reference guarantee for subsequent gear alignment operations.

[0026] Step B: Coarse tooth alignment and phase reference inspection After precise positioning is achieved, the control system drives the workpiece spindle to rotate at a low speed. During the workpiece rotation, the phase characteristics of the tooth grooves or tooth surfaces of the workpiece are detected and identified by a fixedly installed switch probe 4. The switch probe 4 can quickly and accurately detect the actual tooth phase position of the workpiece and quickly determine the initial meshing phase of the workpiece. Based on this, the coarse tooth matching between the workpiece and the standard meshing wheel 5 is completed. After the coarse tooth matching is completed, the workpiece enters a safe and correct meshing preparation state, thereby avoiding meshing interference and collisions during the subsequent fine tooth matching process.

[0027] Step C: Fine phase acquisition and adaptive closed-loop adjustment After coarse gear alignment, a ring encoder 6 mounted on the workpiece spindle is used for fine phase acquisition. The ring encoder 6 is a high-resolution encoder that acquires the precise rotation angle and tooth phase signal of a single workpiece in real time, and feeds back the real-time phase data to the honing machine CNC system through a high-speed signal transmission channel.

[0028] After receiving the real-time phase data from the ring encoder 6, the CNC system performs adaptive phase correction based on the meshing transmission relationship between the workpiece and the standard meshing wheel and the actual radial runout measurement of the workpiece, according to the following phase compensation model: The theoretical phase relationship between the workpiece and the standard meshing wheel is:

[0029] Considering the influence of the actual radial runout of the workpiece on the meshing phase, a phase compensation term is superimposed on the theoretical transmission ratio relationship:

[0030] In the formula: For the workpiece corner, Here, k is the standard meshing gear rotation angle, k is the number of teeth rotating on the workpiece, and d is the workpiece pitch circle diameter. The pressure angle of the workpiece end face. Z represents the radial runout measurement value of the i-th tooth position of the workpiece, Z represents the number of teeth of the workpiece, N1 is the number of teeth of the standard meshing gear, and N2 is the number of teeth of the workpiece.

[0031] The physical meaning of this compensation model is: the radial runout of each tooth position of the workpiece. Through end face pressure angle The sinusoidal relationship is projected and converted into positional deviation along the meshing line. The deviations of Z teeth per revolution are summed, averaged, and multiplied by the compensation coefficient kd to obtain the comprehensive phase compensation amount. The CNC system integrates the compensation amount with the real-time feedback data from the ring encoder 6 to accurately calculate the deviation between the actual phase of the workpiece and the target phase, and automatically outputs compensation control commands to drive the workpiece spindle for precise angle correction.

[0032] Through the aforementioned real-time closed-loop adjustment mechanism, the meshing phase between the workpiece and the honing wheel is always kept in a high-precision matching state throughout the honing cutting process, ultimately achieving stable and reliable adaptive tooth alignment between the workpiece and the honing wheel.

[0033] In the above embodiments, the positional relationships and functions of each component are as follows: Clamping device 1 is mounted on the workpiece spindle and is used to clamp workpiece 2 and drive the workpiece to the coaxial engagement position of the secondary gear-aligning mechanism; Axial center 3 is mounted on the secondary gear-aligning mechanism and is coaxially mounted with the workpiece spindle, and is used to center-clamp and position the workpiece; Switch probe 4 is fixedly mounted at the detection position between the workpiece and the standard meshing wheel 5, and is used to perform tactile identification of the phase characteristics of the workpiece teeth; Standard meshing wheel 5 is used to perform coarse gear alignment with the workpiece; Ring encoder 6 is mounted on the workpiece spindle and is used to collect the workpiece rotation angle and phase signal in real time; The honing machine CNC system is connected to the ring encoder 6 and is used to receive phase data, calculate the compensation amount based on the phase compensation model, and output control commands.

[0034] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. 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 be made to the technical solutions of the present invention without departing from the spirit and scope of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for adaptive tooth alignment control in honing, characterized in that, Includes the following steps: Step A, workpiece clamping and precise positioning: The workpiece spindle clamps the gear workpiece to be processed through the clamping device, drives the workpiece to move to the coaxial mating position of the secondary gear setting mechanism, and then releases the clamping mechanism of the workpiece spindle. The workpiece is then center-clamped with an axial center to make the end face of the workpiece and the positioning end face of the tooling fit tightly together, eliminating the workpiece clamping gap and radial runout. Step B, Coarse Tooth Alignment and Phase Reference Detection: The control system drives the workpiece spindle to rotate at low speed. The phase characteristics of the workpiece teeth are detected by a fixed switch probe to determine the initial meshing phase of the workpiece and complete the coarse tooth alignment between the workpiece and the standard meshing wheel. Step C, Precision Phase Acquisition and Adaptive Closed-Loop Adjustment: A ring encoder mounted on the workpiece spindle is used to acquire the workpiece's rotation angle and tooth phase signals in real time. The phase data is fed back to the CNC system, which calculates the phase deviation compensation amount based on the following phase compensation model: In the formula: For the workpiece corner, Here, k is the standard meshing gear rotation angle, k is the number of teeth rotating on the workpiece, and d is the workpiece pitch circle diameter. The pressure angle of the workpiece end face. Z represents the radial runout measurement value of the i-th tooth position of the workpiece, Z represents the total number of teeth sampled on the workpiece, N1 is the number of teeth of the standard meshing gear, and N2 is the number of teeth of the workpiece. The ring encoder is a high-resolution encoder that acquires the precise rotation angle and tooth phase signal of the workpiece in real time and feeds back the real-time phase data to the CNC system. The CNC system integrates the phase deviation compensation amount with the real-time phase data of the ring encoder, outputs compensation control commands, drives the workpiece spindle to perform rotation angle correction, and achieves high-precision matching of the meshing phase between the workpiece and the honing wheel through closed-loop adjustment.

2. The adaptive tooth alignment control method for honing according to claim 1, characterized in that, In step A, after the axial center clamps the workpiece, it ensures that the workpiece and the workpiece spindle have rotational coaxiality and positioning rigidity, providing a mechanical reference guarantee for subsequent gear alignment.

3. The method according to claim 1, characterized in that, In step B, the switch probe performs tactile detection and identification of the phase characteristics of the tooth groove or tooth surface of the workpiece to quickly determine the initial engagement phase of the workpiece.

4. The method according to claim 3, characterized in that, After completing the coarse tooth matching, ensure that the workpiece enters a safe and correct meshing preparation state to avoid meshing interference and collision.

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