PROCESS AND MANUFACTURING SYSTEM

Description

[0001] The present invention relates to a method comprising the following steps: rolling test of toothed components and tooth measurement of at least a subset of the toothed components. The invention further relates to a manufacturing system.

[0002] In modern vehicles that are partially or fully electrically powered, the transmission noise is no longer masked by the sound of a combustion engine during electric driving. Transmission noises are therefore more clearly audible and can be perceived as disturbing by vehicle occupants.

[0003] It is standard practice to subject all manufactured gears to a rolling test and / or noise test on a rolling test rig. If a gear exhibits unusual noise, its measurement is performed on a coordinate measuring machine or gear measuring machine. Additionally, gears are measured on a random sample basis using the gear measuring machine.

[0004] The time-limiting factor of the procedure outlined above is the measurement time of the gear measuring machine, which often operates purely tactilely. Measuring the relevant gear parameters, including the waviness analysis important for noise behavior, requires up to 20 minutes using a tactile measuring system on a gear measuring machine, depending on the component geometry. It is evident that, due to this measurement time, not all components can be measured tactilely during series production.

[0005] Hybrid gear measuring machines employ both optical and tactile measuring devices for coordinate measurement. While the use of optical measuring devices can reduce measuring time compared to purely tactile systems, a complete measurement of all relevant parameters still requires significantly more measuring time than the cycle time of the gear cutting machine would dictate. The terms "measuring time" and "measuring duration" are used synonymously in this text.

[0006] Despite the aforementioned challenges regarding measurement time, there is a constant demand for further improved quality control with regard to the noise behavior of gears. This can be achieved, for example, by increasing the scope of measurement, i.e., the number of parameters measured on a gear, and also by increasing the sample size, i.e., the number of gears measured, up to and including measuring all manufactured gears.

[0007] If tactile gear measuring systems are used for gear measurement, the aforementioned measures result in a further significant increase in measurement time. Even the use of a hybrid gear measuring machine does not achieve the desired result for the example of measuring all manufactured gears. The measurement time for the parameters "pitch," "profile," "flank," and "waviness," including the acquisition of auxiliary parameters such as the axis position, and loading the hybrid gear measuring machine, is approximately 2-3 minutes. However, the machine cycle time sometimes dictates an available measurement time of less than 60 seconds. This means that although hybrid measurement can significantly reduce measurement time, it is still far from meeting the machine cycle time.

[0008] Against this background, the present invention addresses the technical problem of providing a method for machining geared components that enables improved noise control. Furthermore, a manufacturing system is to be described.

[0009] DE 10 2021 107888 A1 discloses a method for hard finishing of a gear tooth or profile of a workpiece with a rolling test and a gear tooth measurement.

[0010] The technical problem described above is solved by the features of the independent claims. Further embodiments of the invention are described in the dependent claims and the following description.

[0011] According to the invention, a method is described comprising the following steps: rolling test of geared components and gear measurement of at least a subset of the geared components. The method is characterized in that the measurement requirement and the scope of the gear measurement are determined component-specifically depending on the result of the rolling test.

[0012] This means that, for a given component, it is first determined, based on the result of the rolling test of that component, whether or not it will be measured using gear measurement – ​​in other words, the measurement requirement is determined. Determining the measurement requirement is therefore a yes / no decision, whereby the component is either submitted for gear measurement or not.

[0013] If a measurement is required, determining the scope of the gear measurement primarily concerns defining the parameters to be measured on the component, such as pitch, runout, or similar characteristics. Investigations by the applicant have shown that certain dynamic anomalies or deviations of the gear teeth, measured using rolling tests, can be attributed to specific geometric deviations of the gear teeth. The term "scope" therefore does not refer to a dimension in the sense of a geometric circumference of the component, but rather to the specification or compilation of the test characteristics or parameters to be measured on this component – ​​i.e., the measurement task.

[0014] If, for example, the rolling test reveals that the dynamic anomalies of the gear teeth result not from waviness of the tooth flanks but from a pitch error, the time-consuming waviness measurement can be omitted for the component in question. In other words, based on the results of the rolling test, those geometric parameters can be identified, and the measurement task can be limited to these component-specific geometric parameters that are relevant for noticeable dynamic deviations of the gear teeth.

[0015] This reduces the overall measurement time, as only the component-specific measurement scope is carried out in the gear measurement for each component that requires measurement.

[0016] It may therefore be provided that a complete set of measurement parameters is defined for the gearing of the components to be manufactured, which includes all those parameters for gear measurement that cover all relevant geometric deviations for this gearing, such as the parameters: pitch, runout, wobble, flank shape, profile shape, angular deviations in profile and flank direction, tooth thickness deviation, surface waviness or topography deviations and the like.

[0017] Furthermore, it can be provided that a component-specific set of measurement parameters is selected, which is a selection or subset of this complete set of measurement parameters, whereby at least one parameter or several parameters of this complete set of measurement parameters are not part of the component-specific set of measurement parameters. In this way, each component can be measured as needed with the shortest possible measurement time, whereby only the component-specific parameters are measured.

[0018] In other words, the measurement task for gear measurement can be optimized for a specific component based on the results of the rolling test of that component. In particular, the measurement task for gear measurement can be reduced for a specific component starting from the complete set of measurement parameters.

[0019] The term "complete set of measurement parameters" has been introduced here solely for ease of understanding. For example, every gear measuring machine has a specific range of functions that can be accessed for each gear to be measured. Therefore, even without defining a "complete set of measurement parameters," it is readily possible to adapt the scope of the measurement to the specific component by selecting from the available functions of the gear measuring machine. This also results in a component-specific measurement scope, where, for example, a pitch measurement without waviness measurement is performed for one component based on the rolling test, while waviness measurement is performed for a second component based on the rolling test.Defining a pool of specific parameters that may be useful for gear measurement, from which component-specific selections can then be made, may therefore have been carried out as a preparatory step in the process, but is in no way essential for the success or execution of the process in question.

[0020] It may be stipulated that a rolling test is performed on each component. In this case, the rolling test is referred to as a 100% inspection. This means that every component is subjected to the rolling test after its hard finishing.

[0021] According to one embodiment of the procedure, the number of components for which the rolling test is performed is greater than the number of components for which the gear measurement is performed. Therefore, the gear measurement is not a 100% inspection. This means that not every component is subjected to gear measurement after its hard finishing.

[0022] It may be stipulated that for a component whose rolling test result meets the specified quality requirements of the rolling test, no measurement is required and no gear measurement is carried out, and that for a component whose rolling test result does not meet the specified quality requirements of the rolling test, a measurement is required and a gear measurement is carried out.

[0023] According to one embodiment of the procedure, deviations determined by means of the rolling test are provided as an order spectrum, whereby individual orders and / or order ranges of the order spectrum are assigned test characteristics of the gearing, such as runout errors; wobble; pitch errors of the first order and / or higher orders; surface waviness, flank shape errors or the like.

[0024] The orders are defined in a known manner, in particular as multiples of the rotational speed. Order analysis refers to the analysis of rotational frequencies and their multiples, with the order spectrum as the result of such an analysis. In other words, it involves the transformation of a frequency analysis from a temporal plane to a rotational plane. The first order corresponds, in particular, to the rotational frequency during the rolling test, the second order to twice the rotational frequency of the rolling test, and so on. Order spectra can, for example, refer to the rotational speed or frequency of the geared component, the rotational speed or frequency of the master gear, the tooth engagement frequency, or similar parameters. Order spectra can therefore be converted into one another without any loss of information.

[0025] It may be possible to determine, based on dominant orders of the order spectrum, those test characteristics or parameters of the gearing to be measured that are measured in the gearing measurement, specific to the component.

[0026] According to one embodiment of the procedure, it is provided that, in particular based on dominant orders, a conclusion can be drawn about a need for correction for certain test characteristics or parameters to be measured, so that, starting from the rolling test, it is possible to conclude that certain gear defects are present, in particular that certain geometric gear defects are present.

[0027] It may be stipulated that no gear measurement will be carried out for those test characteristics or parameters to be measured for which no dominant frequencies have been determined in the rolling test.

[0028] The quality requirements for rolling test can include absolute or relative limit values ​​for amplitudes of one or more frequencies of the order spectrum.

[0029] It can be provided that a first region of the order spectrum is an indicator for a first gear deviation and that a second region of the order spectrum is an indicator for a second gear deviation different from the first gear deviation, wherein orders belonging to the first region are smaller than orders belonging to the second region and wherein an anomaly of an order in the first region triggers a measurement requirement for the first gear deviation and an anomaly of an order in the second region triggers a measurement requirement for the second gear deviation.

[0030] According to one embodiment of the method, it can be provided that a first region of the order spectrum is an indicator for division errors and that a second region of the order spectrum is an indicator for waviness deviations, wherein orders belonging to the first region are smaller than orders belonging to the second region, and wherein an anomaly of an order in the first region triggers a measurement requirement for a division measurement, and an anomaly of an order in the second region triggers a measurement requirement for waviness.

[0031] It can be provided that a single order of the order spectrum is an indicator for a gear deviation assigned to that single order, and that a further single order of the order spectrum is an indicator for a second gear deviation, different from the first, assigned to that further single order, wherein the single order is different from the further single order, and wherein an anomaly of the single order triggers a measurement requirement for the gear deviation assigned to that order, and an anomaly of the further single order triggers a measurement requirement for the further gear deviation assigned to that further single order.

[0032] According to one embodiment of the method, corrections for hard finishing are determined based on the results of the rolling test and / or the results of the gear measurement. This can be a known method whereby correction values, e.g., for axis positions or feed rates, are determined for the hard finishing process based on measured deviations of the gear teeth in order to compensate for the measured deviations.

[0033] It may be stipulated that, for each component, an end-of-line test is performed after gear measurement using an end-of-line test bench, where the end-of-line test bench is, in particular, a gearbox test bench, or that, for each component, the end-of-line test of the gear is performed after rolling testing and without prior gear measurement using the end-of-line test bench. It may be stipulated that each gear is fed to and tested on the end-of-line test bench. In this way, the end-of-line test bench can be described as providing 100% inspection.

[0034] The rolling test is not an end-of-line test, but a separate process step independent of the end-of-line test, which is carried out on a separate rolling test bench independent of the end-of-line test bench.

[0035] The rolling test differs from the end-of-line test, for example, in that the gear being tested is not mounted in a gearbox housing during the rolling test. In contrast, during the end-of-line test, the gear being tested is mounted in a gearbox housing to test its fully assembled state, specifically with the corresponding mating gear that will be installed with the gear in its final assembly. This results in a further difference between the end-of-line test and the rolling test, as the gear being tested is run against a master gear during the rolling test, and not against the actual gear as it will be installed in its final assembly.

[0036] It may be provided that the geared components are hard-machined before the rolling test, with the hard-machining being carried out using a gear-cutting machine.

[0037] Hard finishing can be a machining process with a geometrically undefined cutting edge.

[0038] Hard finishing can be a grinding process. Hard finishing can be a single-part or a continuous-part grinding process. Hard finishing can be a gear grinding process or a profile grinding process. The grinding tool for the grinding process can be a grinding worm or a grinding wheel. The grinding tool for the grinding process can be a dressable grinding tool or a non-dressable grinding tool. Preferably, hard finishing can be a continuous gear grinding process with a dressable grinding worm.

[0039] Hard finishing can include gear honing.

[0040] Hard finishing can include gear lapping.

[0041] Hard finishing can include one or more machining steps selected from the steps "grinding", "honing" or "lapping".

[0042] The gear cutting machine can be a gear grinding machine. The gear grinding machine can have a dressing unit with a dresser for dressing a dressable grinding tool.

[0043] The gear cutting machine can be a gear lapping machine.

[0044] The gear cutting machine can be a gear honing machine.

[0045] According to one design of the procedure, the rolling test is to be carried out using the rolling test bench.

[0046] The result of the rolling test can include a turning error analysis.

[0047] The rolling test can be a single-flank rolling test. The test bench for the rolling test can be a test bench for single-flank rolling tests.

[0048] Single-flank rolling test is characterized by the fact that the gear under test and a master gear of the test rig, which rolls with the gear under test, have a fixed center distance from each other. During the test, the master gear and the gear under test are in single-flank contact with each other. The gear under test may be driven by a motor. The master gear is braked accordingly, in particular by another motor, to set a test torque and speed, or to set a test torque and speed profile. A rotary accelerometer and an incremental angle measuring system may be arranged on a drive shaft of the gear under test. Geometric deviations of the gear under test produce measurable errors in the rotational transmission and the rotational acceleration.Vibration sensors can also be used.

[0049] The results of the single-flank rolling test can include, for example: runout, rolling deviation, runout error, tooth-to-tooth amplitude, maximum rolling deviation, transmission error and dynamic backlash, noise behavior, surface defects.

[0050] The rolling test can be a double-flank rolling test. The test rig for the rolling test can also be a double-flank rolling test rig. The double-flank rolling test is characterized by the fact that the gear being tested and a master gear of the test rig, which rolls against the gear being tested, have a variable center distance from each other. During the test, the master gear and the gear being tested are in double-flank contact with each other. A force is applied to press, for example, the master gear, which is mounted on an axially movable shaft, into double-flank contact with the gear being tested with a defined force. Geometric deviations of the gear being tested produce measurable axial displacements of the shaft of the master gear, which is held on a test slide. Position sensors, rotary encoders, accelerometers, and vibration sensors can be used for measurement.

[0051] The results of the double-flank rolling test can include, for example: center distance, concentricity, rolling jump, rolling deviation, two-ball dimension, noise behavior.

[0052] According to one embodiment of the method, the gear measurement is carried out using a coordinate measuring machine. The coordinate measuring machine can be a gear measuring machine.

[0053] The methods of rolling inspection with turning error analysis, or more specifically, single-flank rolling inspection and double-flank rolling inspection, are state of the art and well known. The core of the invention is not the rolling inspection itself, or the single-flank rolling inspection or the double-flank rolling inspection, but rather the use of the results of such a rolling inspection, in particular the single-flank rolling inspection or the double-flank rolling inspection, to determine the measurement requirements and scope for a gear measurement specific to the component. The invention therefore relates in particular to rolling inspection-controlled measurement, whereby the term "rolling inspection-controlled" refers to the recognition of the measurement requirements and scope, and the measurement process itself is not controlled by the rolling inspection. It can therefore also be referred to as rolling inspection-triggered gear measurement, since the results of the rolling inspection trigger the component-specific measurement in the process chain.The measurement requirements and scope for component-specific gear measurement can be determined based on the results of the rolling test.

[0054] The gear measuring machine can have a rotary table for holding and rotating a gear to be measured around a rotational axis of the gear.

[0055] The gear measuring machine can have a tactile measuring device. The tactile measuring device can have a probe with a stylus ball, which is designed to be brought into contact with the gear teeth to be measured. The tactile measuring device can have several interchangeable probes, each probe having a stylus ball of a different diameter. The tactile measuring device can operate according to the measuring principle or the switching principle.

[0056] The gear measuring machine may have an optical measuring device. This optical measuring device may be an optical distance sensor, for example a confocal chromatic sensor, a laser distance measuring system, or the like.

[0057] The invention further relates to a manufacturing system comprising a rolling test stand for rolling testing of toothed components; a gear measuring machine for measuring toothed components; and a control device, wherein the control device is configured to control the manufacturing system for carrying out a method according to the invention.

[0058] The manufacturing system may include a gear cutting machine for the hard finishing of toothed components.

[0059] The invention will now be explained in more detail with reference to an exemplary embodiment shown in a drawing. The drawing schematically depicts: Fig. 1 a flow diagram of a method according to the invention; Fig. 2 a result of a rolling test; Fig. 3 a gear measuring machine; Fig. 4 a pitch measurement; Fig. 5 a flank, profile and waviness measurement; Fig. 6 a gear grinding machine; Fig. 7 hard finishing as continuous rolling grinding with a dressable grinding worm; Fig. 7 a test stand for single-flank rolling testing; Fig. 9 a test stand for double-flank rolling testing; Fig. 10 an end-of-line test stand; Fig. 11 a manufacturing system according to the invention.

[0060] Fig. 1 shows a flowchart of a process according to the invention. The process according to Fig. 1 The process is repeated in series production according to the invention for each toothed component to be machined and is described below by way of example and schematically for a toothed component.

[0061] According to the invention, in a process step (A) a hard finishing of a toothed component is first carried out.

[0062] The toothed component supplied to process step (A) has been pre-toothed and hardened prior to hard finishing.

[0063] Pre-cutting can be carried out, for example, by milling, in particular by gear hobbing. It is understood that, according to alternative embodiments, other methods for pre-cutting can also be used, in particular machining processes with geometrically defined cutting edges, such as skiving or the like.

[0064] In process step (B), a rolling test of the geared component is performed after hard finishing. Depending on the result of the rolling test, the measurement requirements and scope of the gear measurement are determined for the geared component on a component-specific basis.

[0065] If the rolling test according to procedure step (B) has shown that a measurement is required, a gear measurement is carried out for the toothed component in a procedure step (C), in accordance with the scope determined in the rolling test.

[0066] After the gear measurement, the geared component is subjected to an end-of-line test according to a process step (D).

[0067] If process step (B) shows that no measurement is required, no gear measurement is performed on the toothed component; instead, after the rolling test, the toothed component is directly subjected to the end-of-line test according to process step (D). The end-of-line test can be omitted according to alternative embodiments of the invention.

[0068] From the schedule according to Fig. 1 It can be seen that a rolling test is performed for each geared component. Furthermore, an end-of-line test is performed for each geared component. However, not every geared component undergoes gear measurement.

[0069] As mentioned in the introduction to this text, gear measurement is the most time-consuming of the described process steps. Therefore, based on the results of the rolling test, a decision is first made as to whether the geared component even needs to undergo gear measurement, and if so, to what extent this gear measurement must be carried out, i.e., which test characteristics or parameters to be measured actually need to be recorded on the geared component.

[0070] In a mass production process, which follows a procedure for each toothed component according to Fig. 1 It is therefore specifically intended that the number of toothed components for which the rolling test is carried out is greater than the number of toothed components for which the gear measurement is carried out.

[0071] Fig. 2 Figure (B) shows an exemplary and schematic representation of the result of the rolling test according to procedure step (B). A measured rotational error in µrad is plotted against the orders. The orders are defined in a known manner as multiples of the rotational speed. Order analysis refers to the analysis of rotational frequencies and their multiples. In other words, it involves the transformation of frequency analysis from a temporal plane to a rotational plane. The first order corresponds to the rotational frequency during the rolling test, the second order to twice the rotational frequency of the rolling test, and so on. The deviations determined by the rolling test are thus provided as an order spectrum, with orders corresponding to multiples of the rotational frequency during the rolling test. Test characteristics can be assigned to individual orders or order ranges of the order spectrum.geometric deviations of the toothing of the toothed component can be assigned.

[0072] Abnormalities observed during rolling tests that occur within order range I are, for example, due to pitch errors in the gear teeth of the geared component. Order range I extends, for example, from the first order to approximately the 160th order.

[0073] Defects in the rolling test that occur in order range II are, for example, due to deviations in the profile or flank of the toothing of the geared component. Order range II extends, for example, from approximately the 160th order to the 430th order.

[0074] Abnormalities observed during rolling tests that occur in order range III are, for example, due to waviness in the tooth flanks of the gear teeth of the toothed component. Order range III extends, for example, from order 290 to beyond order 500.

[0075] The specified values ​​for the extent of the order ranges are merely examples to illustrate the procedure according to the invention.

[0076] To provide an initial example of evaluating a component-specific order spectrum, it is assumed that anomalies or dominant orders for a first component occur exclusively in order range I, while the order amplitudes in ranges II and III are completely unremarkable for this first component. From this, it can be deduced that, for example, no time-consuming measurement of the tooth flank waviness is necessary for this first component, since the dominant orders determined during the rolling test clearly indicate pitch errors, and there are no issues regarding deviations in the waviness range.

[0077] Therefore, this first geared component requires measurement because dominant orders in order range I were detected, indicating a pitch error. The gear teeth of the first component must therefore be measured according to procedure step (C). However, the scope of measurement for this first component can be limited to a pitch measurement, for example, since the results of the rolling test do not indicate any abnormalities, such as those concerning the waviness of the tooth flanks.

[0078] In a second example, concerning the analysis of the order spectrum of a second geared component, it may occur that dominant orders appear in both order range I and order range III, indicating deviations in the pitch and implying critical values ​​on the tooth flank surfaces. Therefore, the order analysis can also determine that a measurement is required for this second component, meaning a gear measurement must be performed. In this case, the scope of measurement is expanded compared to the first component described above, as, in addition to the pitch measurement, the waviness of the tooth flanks must also be measured for the second component.

[0079] If a measurement requirement has been identified, the scope of the measurement can therefore be defined in a component-specific manner by determining, based on the analysis of the order spectrum, which geometric deviations of the gearing of the component in question cause the relevant dominant orders according to the analysis of the order spectrum.

[0080] In addition to the aforementioned classification categories I, II and III, individual classifications can also be specifically assigned to certain test characteristics or specific geometric deviations of the gearing in question.

[0081] The first order of the order spectrum according to the rolling test describes the runout error of a gear, where the associated first-order rotational error is denoted here by IV. The second order of the order spectrum according to the rolling test corresponds to the wobble of the gear, where the associated second-order rotational error is denoted here by V.

[0082] A classification range, designated VI, extends from the third order of the rolling test to the first tooth engagement order, with dominant orders within this classification range indicating periodically occurring pitch errors.

[0083] A classification area designated VII comprises those orders of the rolling test that cannot be assigned to any intervention frequencies or their harmonic or harmonic sidewalls, whereby these orders can also be collectively referred to as ghost orders.

[0084] The individual dental intervention orders according to the first, second, third and fourth dental intervention orders are designated here by VIII.

[0085] The numbers IX denote areas that relate to sidebands of the harmonic intervention frequencies, which are modulated by periodic division deviation.

[0086] Tooth engagement orders of the fifth tooth engagement order or higher are designated with X and are usually due to waviness of the surface of the flanks.

[0087] It is therefore evident that some information about the geometric deviations of the gear teeth of a given geared component can already be derived from an analysis of the order spectrum of the rolling test. According to the invention, a rolling test-controlled measurement requirement is now determined based on this information, i.e., the time-consuming measurement of the gear geometry is limited to the measurements that are actually necessary.

[0088] Furthermore, this also means that no gear measurement will be carried out if no abnormalities are found during the rolling test of a geared component that would necessitate a gear measurement.

[0089] The analysis of the rolling error pattern can be based on predefined quality requirements or characteristics. For example, absolute or relative limit values ​​for the amplitudes of the rotational error can be specified for the order ranges and / or for individual orders, whereby exceeding a relevant limit value triggers a measurement requirement for the correspondingly assigned test characteristic.

[0090] Specifically, it may be stipulated, for example, that the first-order rotational error during the rolling test may not exceed 20 µrad, 40 µrad, or 60 µrad. If this value is exceeded, as is the case here according to Fig. 2 If the example shown is the case, then there is a need to measure the division and the concentricity.

[0091] For the second-order rotational error, i.e., the wobble, such a limit value for the permissible rotational error can be lower. For example, it may be stipulated that the second-order rotational error may be a maximum of 10 µrad or 20 µrad, so that a measurement is required for the example shown in Fig. two, since the second-order rotational error here is approximately 55 µrad.

[0092] Thus, limit values ​​for permissible rotational error can be specified for the various order ranges or for the various individual orders, the exceeding of which triggers a measurement requirement for one or more test characteristics of the gearing assigned to the respective order range or order.

[0093] Such limit values ​​can also be defined relatively, for example by forming a ratio of the rotational errors of different orders, or by normalizing the rotational error for certain orders and comparing it to a limit value defined with respect to the normalized rotational error.

[0094] Orders for which a predefined limit is exceeded can also be referred to as dominant orders of the order spectrum. Alternatively, it can also be said that certain orders or order ranges exhibit anomalies or are conspicuous if the analysis of the order spectrum of the rolling test reveals that a predefined limit is exceeded.

[0095] Based on the results of the rolling test and / or the results of the gear measurement, corrections for hard finishing can be determined. These corrections can include, for example, corrected axis movements or correction values ​​for axis movements for hard finishing, or corrections for specific manufacturing parameters such as depth of cut, feed rate, or the like.

[0096] Fig. 3 Figure 100 shows a gear measuring machine for gear measurement. A component BT is subsequently shown partly as a helical gear and partly as a spur gear. Component BT merely serves as a placeholder for any type of toothed component. It is understood that the method according to the invention can be applied independently of the tooth shape or the specific design of the toothed component.

[0097] The gear measuring machine 100 is a coordinate measuring machine that has a rotary table 102 for holding and rotating the component BT about a rotary axis C. The gear measuring machine 100 has an optical measuring device 104 for optical gear measurement and a tactile measuring device 108 with a measuring probe 110 for tactile gear measurement. The gear measuring machine 100 can therefore be described as a hybrid coordinate measuring machine, since it enables both tactile and optical measurement.

[0098] If a measurement requirement has been identified according to a rolling test, the corresponding gear measurement takes place on an exemplary in Fig. 3 The gear measuring machine shown is 100.

[0099] Fig. 4 Figure 108 shows, by way of example and schematic, the measurement of a pitch P on the toothed component BT. Here, flanks F of component BT are measured using the optical measuring device 104 or the tactile measuring device 108. The measurement of the pitch P is carried out, in particular, at the level of the pitch circle T of the toothed component BT.

[0100] Fig. 5 Figure 1 shows an exemplary and schematic representation of a component BT designed as a helical gear. To detect waviness, a measuring grid G ​​is defined along a width B and a height H to measure the entire tooth flank F. This measuring grid G ​​is scanned using tactile or optical measurement to capture measuring points on the tooth flank corresponding to the grid. The result of such a waviness measurement is shown in an exemplary and schematic representation in Figure 2. Fig. 5 shown on the right-hand side, with deviations plotted over the height and width of the tooth flank in question.

[0101] Fig. 6 Figure 200 shows an exemplary and schematic representation of a gear grinding machine 200. The gear grinding machine 200 has a workpiece spindle for holding a workpiece BT to be machined and a tool spindle 204 for holding a grinding tool, wherein the grinding tool 206 is designed as a dressable grinding worm. The gear grinding machine 200 has controlled machine axes, as is known, to perform relative movements for grinding the toothed component BT. The corresponding degrees of freedom of movement, or machine axes, are designated X, Y, Z, A, B, and C, with axes C2 and B2 being assigned to a dressing device 208 for dressing the grinding tool 206. Axis Z1 is used for clamping shaft-shaped components.

[0102] Fig. 7 The figure shows, by way of example and schematically, the dressable grinding worm 206 during the grinding machining of the toothed component BT.

[0103] Fig. 8 Figure 3 shows an exemplary and schematic test stand 300 for single-flank rolling testing. The test stand 300 has a master gear 302 that engages with the toothed component BT under test for rolling. The center distance a1 between a shaft 303, which carries the master gear 302, and a shaft 308, which carries the toothed component BT, is constant. Furthermore, devices or rolling testing machines are known that are suitable for both single-flank and double-flank rolling testing, such as the rolling testing machine marketed by the applicant under the name R300. Such machines are suitable, for example, for single-flank rolling testing, structure-borne noise and rotational acceleration testing, and double-flank rolling testing.

[0104] A torque and speed for testing the toothed component BT are set via drives 310 and 306. Measured values ​​are acquired using sensors 304, 312, 314 and 316, which can be angle encoders, rotary accelerometers and vibration or noise sensors.

[0105] Fig. 9 Figure 400 shows an exemplary and schematic test rig 400 for double-flank rolling testing. A master gear 410 is mounted on a shaft 416, which is held on a loadable slide 404 that is displaceable relative to a support structure 402. The master gear is spring-loaded and pressed towards the toothed component BT to create a defined contact in the double-flank contact between the master gear 410 and the toothed component BT. The center distance a2 between the shaft 416 and a shaft 412, on which the toothed component BT is held, is variable. A drive 414 is assigned to the shaft 412 for rotating the shaft 412. Sensors 406 and 408 are also provided for measuring changes in the center distance a2. Reference numeral 28 represents another sensor 28 that can perform an angle measurement and / or a rotational acceleration measurement and / or a vibration measurement.

[0106] Fig. 10 Figure 500 shows an exemplary and schematic end-of-line test bench 500, in which the toothed component BT is mounted in a gearbox housing 502. Bearings 508 and 510, corresponding to the installed state, are provided for both the toothed component BT and a corresponding mating gear 512. Drives 504 and 506 are provided to set the desired speeds and torques for testing the toothed component BT. The gearbox housing and the toothed component 512, or the mating gear 512, may be part of the gearbox actually delivered. Alternatively, the housing 512 may simply be a housing that is structurally identical to the housing in which the toothed component BT is received in its fully assembled state. This also applies to the associated mating gear 512. The end-of-line test bench 500 can also be referred to as a gearbox test bench.

[0107] Fig. 11Figure 600 shows an exemplary and schematic representation of a manufacturing system 600, comprising a gear cutting machine 200 for hard finishing toothed components BT, a rolling test stand 300 or 400 for rolling testing toothed components BT, a gear measuring machine 100 for measuring toothed components BT, and an end-of-line test stand 500. The manufacturing system 600 also has a control unit 602, the control unit being configured to control the manufacturing system 600 for carrying out the method described above according to the invention.

[0108] Accordingly, the control unit 602 automatically determines whether a measurement is required after the rolling test of the toothed component, so that the toothed component BT, if a measurement is required, is fed to the gear measuring machine 100 and measured there to a component-specific defined extent, or, if no measurement is required, can be fed directly to the end-of-line test stand 500 after the rolling test.

[0109] Based on the results of the gear measurement using the gear measuring machine 100, corrections for the gear grinding machine 200 can be derived. Similarly, corrections for the gear grinding machine can be determined based on the results of the rolling test.

Claims

1. Method, having the method steps of: - rolling test of toothed components; and - gearing measurement of at least a subset of the toothed components; characterized in that - a measurement requirement and a scope of the gearing measurement are determined on a component-specific basis in dependence on a result of the rolling test.

2. Method according to claim 1, characterized in that a rolling test is carried out for each toothed component.

3. Method according to claim 1 or 2, characterized in that a number of the toothed components for which the rolling test is carried out is greater than a number of the toothed components for which the gearing measurement is carried out.

4. Method according to one of the preceding claims, characterized in that for a toothed component whose result of the rolling test meets specified quality requirements of the rolling test, there is no need for measurement and no gearing measurement is carried out, and in that for a toothed component whose result of the rolling test does not meet the specified quality requirements of the rolling test, there is a need for measurement and a gearing measurement is carried out.

5. Method according to one of the preceding claims, characterized in that deviations determined by means of the rolling test are provided as an order spectrum, wherein individual orders and / or order ranges of the order spectrum are assigned test features of the gearing, such as runout errors; wobble; pitch errors of the first order and / or higher orders; surface waviness, errors of the flank shape or the like.

6. Method according to claim 5, characterized in that those test characteristics of the gearing which are measured in the gearing measurement are determined component-specifically on the basis of dominant orders of the order spectrum.

7. Method according to claim 6, characterized in that for those test characteristics for which no dominant orders have been determined in the rolling test no gearing measurement is carried out.

8. Method according to claim 4 and according to one of claims 5, 6 or 7, characterized in that the quality requirements of the rolling test have absolute or relative limit values for amplitudes of one or more orders of the order spectrum.

9. Method according to one of claims 5-8, characterized in that a first range of the order spectrum is an indicator for a first gearing deviation and in that a second range of the order spectrum is an indicator for a second gearing deviation which is different from the first gearing deviation, wherein orders associated with the first range are smaller than orders associated with the second range and wherein an abnormality of an order in the first range triggers a measurement requirement for the first gearing deviation and an abnormality of an order in the second range triggers a measurement requirement for the second gearing deviation, in particular, a first range of the order spectrum is an indicator for pitch errors and in that a second range of the order spectrum is an indicator of deviations of the waviness, wherein orders associated with the first range are smaller than orders associated with the second range and wherein an abnormality of an order in the first range triggers a measurement requirement for a pitch measurement and an abnormality of an order in the second range triggers a measurement requirement for a waviness; and / or in that a single order of the order spectrum is an indicator for a gearing deviation assigned to this single order and in that a further single order of the order spectrum is an indicator for a second gearing deviation different from the first gearing deviation and assigned to this further single order, wherein the single order is different from the further single order and wherein an abnormality of the single order triggers a measurement requirement for the gearing deviation assigned to this order and an abnormality of the further single order triggers a measurement requirement for the further gearing deviation assigned to this further single order.

10. Method according to one of the preceding claims, characterized in that corrections for the hard finishing process are determined on the basis of the results of the rolling test and / or the results of the gearing measurement.

11. Method according to one of the preceding claims, characterized in that an end-of-line test is carried out for a respective toothed component after the gearing measurement by means of an end-of-line test bench, wherein the end-of-line test bench is in particular a gear test bench, or the end-of-line test of the gearing is carried out for a respective toothed component after the rolling test and without preceding gearing measurement by means of the end-of-line test bench.

12. Method according to one of the preceding claims, characterized in that - the rolling test is performed using the rolling test bench; and - the gearing is measured using a coordinate measuring machine.

13. Method according to one of the preceding claims, characterized in that - the toothed components are hard-finished before the rolling test, wherein the hard finishing is carried out using a gear cutting machine.

14. Production system (600), - having a rolling test bench (300, 400) for testing toothed components; - having a gear measuring machine (100) for measuring toothed components; characterized in that the production system (600) has a control device (602), wherein the control device is set up to control the production system for carrying out a method according to one of the preceding claims 1-13.

15. Production system according to claim 14, characterized by - a gear cutting machine for the hard finishing of toothed components.