Gear processing device and phase detection device

Abstract

To provide a gear machining device that is able to shorten a machining cycle time.SOLUTION: A control device 50 of a gear machining device 1 detects a phase of a first detection tooth of a first gear and a phase of a second detection tooth of a second gear by means of a sensor 40 and a rotation angle detector; calculates phases of teeth of the first gear other than the first detection tooth, based on the first detection tooth and a tooth pitch angle of the first gear; calculates phases of teeth of the second gear, other than the second detection tooth, based on the second detection tooth and a tooth pitch angle of the second gear, determines a reference pair in which a deviation angle between the phase of the tooth of the first gear and the phase of the tooth of the second gear is minimum; and performs a machining process after performing positioning by means of the phases of the reference pair as a machining start reference.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a gear machining device and a phase detection device. [Background technology]

[0002] Patent Documents 1 to 3 describe gear machining devices for machining a workpiece having multiple gear stages. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2015-89600 A [Patent Document 2] JP 2019-111610 A [Patent Document 3] JP 2018-138319 A Summary of the Invention [Problem to be solved by the invention]

[0004] In machining a gear, for example, after rough machining, the gear may be hardened and then finished. When performing the finish machining, a workpiece with teeth formed by rough machining is mounted on a workpiece spindle device, the tooth phase of the mounted workpiece is detected, and the workpiece and the gear cutting tool are positioned based on the detected tooth phase of the workpiece, and the workpiece is then finished.

[0005] When a workpiece has multiple gears, it is sometimes required that the deviation angle between the phase of any tooth of a first gear and the phase of any tooth of a second gear be within an allowable range. For this purpose, before finishing, a combination of teeth that minimizes the deviation angle is found, and then finishing is performed based on the combination of teeth.

[0006] Therefore, it is necessary to detect the phases of all the teeth of the first gear, detect the phases of all the teeth of the second gear, and find a combination that minimizes the deviation angle from the phases of all the teeth detected. In this case, since the phases of all the teeth of the first gear and the second gear are detected, it takes a lot of time before finishing can be performed. This causes a problem of a long machining cycle time.

[0007] The present invention has been made in consideration of the above problems, and aims to provide a gear cutting device that can shorten the processing cycle time, and a phase detection device for use in a gear cutting device or the like. [Means for solving the problem]

[0008] One aspect of the present invention is A gear machining device configured to machine at least one of a tooth surface of the first gear and a tooth surface of the second gear, the gear surface being a workpiece having a first gear with an equal tooth pitch angle and a second gear with a different number of teeth from the first gear and an equal tooth pitch angle, the gear machining device comprising: a gear cutting tool having a plurality of tool blades in a circumferential direction; a tool spindle device that rotatably holds the gear cutting tool; a workpiece spindle device that rotatably holds the workpiece and is provided with a rotation angle detector that detects a rotation angle; a moving device that moves the tool spindle device and the workpiece spindle device relatively; In a state where the workpiece is held by the workpiece spindle device and the workpiece is rotating, At a position on the workpiece facing the first gear in the radial direction The first gear in the workpiece Radial direction to the circumference distance At a position on the workpiece facing the second gear in the radial direction, The second gear Radial direction to the circumference Detect distance do A sensor; a control device that controls the moving device while synchronously controlling the rotation of the tool spindle device and the workpiece spindle device in order to machine gear teeth on the workpiece; Equipped with The control device includes: The sensor The radial distance between the sensor and the peripheral surface of the first gear detected by and the rotation angle detector of the workpiece spindle device Based on the detected rotation angle a first detection process for detecting a phase of a first detection tooth which is a part of all teeth of the first gear; The sensor The radial distance between the sensor and the peripheral surface of the second gear detected by and the rotation angle detector of the workpiece spindle device Based on the detected rotation angle a second detection process for detecting a phase of a second detection tooth which is a part of all the teeth of the second gear; executing a first phase calculation process for calculating a phase of a tooth of the first gear other than the first detection tooth based on the detected phase of the first detection tooth and a tooth pitch angle of the first gear stored in advance; execute a second phase calculation process to calculate a phase of a tooth of the second gear other than the second detection tooth based on the detected phase of the second detection tooth and a tooth pitch angle of the second gear stored in advance; executing a deviation angle calculation process to calculate deviation angles between the phases of the teeth of the first gear and the phases of the teeth of the second gear, based on the phases of all the teeth of the first gear obtained by the first detection process and the first phase calculation process and the phases of all the teeth of the second gear obtained by the second detection process and the second phase calculation process; executing a determination process for determining, as a reference set, the phase of the teeth of the first gear and the phase of the teeth of the second gear that minimize the deviation angle; a positioning process for controlling the tool spindle device and the workpiece spindle device in order to position the gear cutting tool and the workpiece using a tooth phase of the first gear and a tooth phase of the second gear constituting the reference set as a processing start reference; The gear cutting device performs a processing process to control the moving device while synchronously controlling the rotation of the positioned gear cutting tool and the workpiece in order to process at least one of the tooth surfaces of the first gear and the second gear.

[0009] Another aspect of the present invention is A phase detection device for an object having a first gear with an equal tooth pitch angle and a second gear with an equal tooth pitch angle different from the number of teeth of the first gear, the phase detection device determining, as a reference set, the tooth phases of the first gear and the tooth phases of the second gear that minimize deviation angles between the tooth phases of the first gear and the tooth phases of the second gear, In a state where the object is rotating At a position on the object that faces the first gear in the radial direction The first gear in the object Radial direction to the circumference distance and at a position on the object that faces the second gear in the radial direction. The second gear Radial direction to the circumference Detect distance do A sensor; a spindle device that rotatably holds the object and includes a rotation angle detector that detects a rotation angle; a processing device that determines the reference set based on the detection results of the sensor and the detection results of the rotation angle detector of the spindle device; Equipped with The processing device includes: The sensor The radial distance between the sensor and the peripheral surface of the first gear detected by and the rotation angle detector of the spindle device Based on the detected rotation angle a first detection process for detecting a phase of a first detection tooth which is a part of all teeth of the first gear; The sensor The radial distance between the sensor and the peripheral surface of the first gear detected by and the rotation angle detector of the spindle device Based on the detected rotation angle a second detection process for detecting a phase of a second detection tooth which is a part of all the teeth of the second gear; executing a first phase calculation process for calculating a phase of a tooth of the first gear other than the first detection tooth based on the detected phase of the first detection tooth and a tooth pitch angle of the first gear stored in advance; execute a second phase calculation process to calculate a phase of a tooth of the second gear other than the second detection tooth based on the detected phase of the second detection tooth and a tooth pitch angle of the second gear stored in advance; executing a deviation angle calculation process to calculate deviation angles between the phases of the teeth of the first gear and the phases of the teeth of the second gear, based on the phases of all the teeth of the first gear obtained by the first detection process and the first phase calculation process and the phases of all the teeth of the second gear obtained by the second detection process and the second phase calculation process; The phase detection device executes a determination process for determining, as the reference set, the phase of the teeth of the first gear and the phase of the teeth of the second gear that result in the smallest deviation angle. Effect of the Invention

[0010] According to the gear machining device of the above aspect, the first detection process detects the phase of a first detection tooth which is a part of all teeth of the first gear, and the second detection process detects the phase of a second detection tooth which is a part of all teeth of the second gear. In other words, the first detection process does not detect the phase of all teeth of the first gear, and the second detection process does not detect the phase of all teeth of the second gear. Therefore, the time required for detection can be significantly shorter than when all teeth are detected.

[0011] In the first detection process and the second detection process, the phases of all the teeth are not detected, so there are remaining teeth whose phases have not been detected. The phases of the remaining teeth not detected by the sensor are found by calculation in the first phase calculation process and the second phase calculation process. Specifically, the first phase calculation process calculates the phase of the teeth of the first gear other than the first detected tooth based on the phase of the first detected tooth and a tooth pitch angle of the first gear stored in advance. The second phase calculation process calculates the phase of the teeth of the second gear other than the second detected tooth based on the second detected tooth and a tooth pitch angle of the second gear stored in advance.

[0012] The first gear and the second gear have equal tooth pitch angles. Therefore, the tooth pitch angle can be easily calculated if the number of teeth is known. Furthermore, since the teeth of the first gear and the second gear are positioned at positions shifted by the respective tooth pitch angles, once the phase of one tooth is known, the phase of the remaining teeth can be easily calculated. Therefore, the time required to obtain the phase of all the teeth of the first gear and the phase of all the teeth of the second gear can be shortened. As a result, the processing cycle time can be shortened.

[0013] Also, like the gear machining device described above, the phase detection device of the above aspect can shorten the time required to obtain the phases of all the teeth of the first gear and the phases of all the teeth of the second gear, thereby shortening the time required to determine, as a reference set, the phases of the teeth of the first gear and the phases of the teeth of the second gear when the deviation angles between the phases of the teeth of the first gear and the phases of the teeth of the second gear are minimum. [Brief description of the drawings]

[0014] [Figure 1] FIG. 1 is a diagram illustrating an example of a gear machining device. [Diagram 2] This is a view of the workpiece and the tool viewed from a direction perpendicular to the rotation axis of the workpiece in the XZ plane. The dashed line showing the tool indicates the position after the workpiece has been subjected to gear machining. [Diagram 3] This is a view of the workpiece and the tool from the Y direction. The dashed line showing the tool indicates the position after gear machining has been performed on the workpiece. [Figure 4] FIG. 2 is a functional block diagram showing a partial configuration of the gear machining device. [Diagram 5] 4 is a flowchart showing a process performed by a control device. [Figure 6] FIG. 13 is a diagram showing a partial configuration of a gear machining device when a phase of a first detection tooth of a first gear of a workpiece is detected by a sensor as a first detection process of the control device. [Figure 7]FIG. 13 is a diagram showing an output waveform when a sensor detects the phase of a first detection tooth of a first gear of a workpiece in a first detection process of a control device. [Figure 8] 13 is a development view of a first detection tooth and a portion of the remaining teeth of a first gear of a workpiece detected by a sensor in a first detection process of the control device. FIG. [Figure 9] FIG. 11 is a diagram showing a partial configuration of the gear machining device when the phase of a second detection tooth on a second gear of the workpiece is detected by a sensor as a second detection process of the control device. [Figure 10] FIG. 11 is a diagram showing an output waveform when the phase of a second detection tooth on a second gear of the workpiece is detected by a sensor in the second detection process of the control device. [Figure 11] 13 is a development view of a second detection tooth and a portion of the remaining teeth of a second gear of a workpiece detected by a sensor in a second detection process of the control device. FIG. [Figure 12] 13A and 13B are diagrams showing waveforms of all teeth of a first gear and waveforms of all teeth of a second gear calculated in a first phase calculation process and a second phase calculation process of a control device. [Figure 13] FIG. 2 is a development view showing a reference set consisting of the tooth phase of the first gear and the tooth phase of the second gear that minimizes the deviation angle, and the teeth around it. [Figure 14] FIG. 2 is a diagram showing a partial configuration of the gear machining apparatus, illustrating a state in which the sensor is not used for detection. [Figure 15] 4 is a flowchart showing a processing process of the control device. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0015] (1. Configuration of gear machining device 1) The gear machining device 1 will be described with reference to Fig. 1. The gear machining device 1 is a device that generates a tooth profile (gear teeth) on the workpiece W by using the gear skiving cutter T by moving the workpiece W and a gear skiving cutter T relatively while rotating the workpiece W and the gear skiving cutter T as a gear cutting tool.

[0016] In this embodiment, the gear machining device 1 is a general-purpose machine tool, for example, a machining center. The machining center is configured to be tool replaceable, and is capable of machining according to the attached tool. For example, replaceable gear cutting tools include a gear skiving cutter T, a hob cutter, a shaper cutter, etc. By replacing with a hob cutter or a shaper cutter, the gear machining device 1 becomes a device that machines a tooth profile (gear teeth) on the workpiece W by hobbing or shaping.

[0017] Moreover, examples of replaceable tools other than gear cutting tools include end mills, milling tools, drills, turning tools, threading tools, grinding tools, etc. Note that a tool exchange device and a tool magazine that stores a plurality of tools are not shown in FIG.

[0018] In this embodiment, the machining center serving as the gear machining device 1 is basically a horizontal machining center. However, the gear machining device 1 can also be configured in other ways, such as a vertical machining center.

[0019] As shown in Fig. 1, the gear machining device 1 has, for example, three mutually orthogonal linear axes (X-axis, Y-axis, Z-axis) as drive axes. Here, the direction of the rotation axis of the gear skiving cutter T (equal to the rotation axis of the tool spindle) is defined as the Z-axis direction, and two axes perpendicular to the Z-axis direction are defined as the X-axis and Y-axis. In Fig. 1, the horizontal direction is the X-axis direction, and the vertical direction is the Y-axis direction.

[0020] Furthermore, the gear machining device 1 has one rotation axis (B axis) as a drive axis for changing the relative position between the workpiece W and the gear skiving cutter T. In this embodiment, the B axis is a rotation axis whose center of rotation is the Y axis direction. The gear machining device 1 also has a Ct axis as a rotation axis for rotating the gear skiving cutter T, and a Cw axis as a rotation axis for rotating the workpiece W.

[0021] In the gear machining device 1, the configuration for relatively moving the workpiece W and the gear skiving cutter T can be appropriately selected. For example, the gear machining device 1 may have an A-axis with the X-axis direction as the center of rotation instead of the B-axis. In the following, an example will be given of the gear machining device 1 in which the gear skiving cutter T is linearly movable in the Y-axis and Z-axis directions, the workpiece W is linearly movable in the X-axis direction, and the workpiece W is rotatable about the B-axis.

[0022] The gear machining apparatus 1 includes a bed 10, a workpiece holding device 20, a tool holding device 30, a sensor 40, and a control device 50. The bed 10 is installed on an installation surface and formed into a shape corresponding to the shapes of the workpiece holding device 20 and the tool holding device 30. In this embodiment, the bed 10 is, for example, rectangular. On the upper surface of the bed 10, a pair of X-axis guide rails 11 extending in the X-axis direction and a pair of Z-axis guide rails 12 extending in the Z-axis direction are formed.

[0023] The workpiece holding device 20 allows the workpiece W to move linearly in the X-axis direction and rotate about the B-axis and Cw-axis relative to the bed 10. The workpiece holding device 20 mainly includes an X-axis moving table 21, a B-axis rotating table 22, and a workpiece spindle device 23.

[0024] The X-axis moving table 21 is driven by a driving device such as a linear motor or a ball screw mechanism (not shown) to move in the X-axis direction while being guided by the X-axis guide rail 11 of the bed 10. The B-axis rotating table 22 is placed on the upper surface of the X-axis moving table 21 and moves in the X-axis direction together with the X-axis moving table 21. The B-axis rotating table 22 is also provided rotatably on the B-axis relative to the X-axis moving table 21. A rotating motor (not shown) is housed in the B-axis rotating table 22, and the B-axis rotating table 22 can rotate on the B-axis by driving the rotating motor.

[0025] The workpiece spindle device 23 is provided on the B-axis rotating table 22, and rotates about the B-axis integrally with the B-axis rotating table 22. The workpiece spindle device 23 rotatably holds the workpiece W. A rotation motor and a rotation angle detector, which will be described later, are provided in the workpiece spindle device 23, and the workpiece W can be rotated about the Cw-axis by being driven by the rotation motor. In this way, the workpiece holding device 20 enables the workpiece W to move in the X-axis direction relative to the bed 10, and to rotate about the B-axis and the Cw-axis.

[0026] In detail, the workpiece spindle device 23 includes a housing 23a and a spindle 23b. The housing 23a of the workpiece spindle device 23 is fixed to the B-axis rotating table 22, and the spindle 23b of the workpiece spindle device 23 is rotatably supported by the housing 23a. A workpiece W is attached to the tip of the spindle 23b. In other words, the workpiece W is cantilevered by the spindle 23b of the workpiece spindle device 23.

[0027] The tool holding device 30 mainly includes a column 31, a saddle 32, and a tool spindle device 33. The column 31 is driven by a driving device such as a linear motor or a ball screw mechanism (not shown) to move in the Z-axis direction while being guided by the Z-axis guide rail 12 of the bed 10. A Y-axis guide rail 31a is formed on a surface (left surface in FIG. 1) of the column 31 that extends in the vertical direction. The saddle 32 is driven by a driving device such as a linear motor or a ball screw mechanism (not shown) to move in the Y-axis direction while being guided by the Y-axis guide rail 31a of the column 31.

[0028] The tool spindle device 33 is provided on the saddle 32 and moves integrally with the saddle 32 in the Y-axis direction. The tool spindle device 33 holds the gear skiving cutter T. A rotary motor (not shown) is housed in the tool spindle device 33, and the tool spindle device 33 is capable of rotating the gear skiving cutter T about the Ct axis by driving the rotary motor. In this way, the tool holding device 30 holds the gear skiving cutter T so that it can move in the Y-axis and Z-axis directions relative to the bed 10 and can rotate about the Ct axis.

[0029] In detail, the tool spindle device 33 includes a housing 33a and a spindle 33b. The housing 33a of the tool spindle device 33 is fixed to the saddle 32, and the spindle 33b of the tool spindle device 33 is rotatably supported by the housing 33a. A gear skiving cutter T is attached to the tip of the spindle. In other words, the gear skiving cutter T is cantilevered by the spindle of the tool spindle device 33.

[0030] The sensor 40 is provided, for example, on the saddle 32. The sensor 40 is a sensor capable of detecting the distance to the teeth of the workpiece W when the workpiece W is held by the workpiece spindle device 23 and the workpiece W is rotating. The sensor 40 is preferably a non-contact distance sensor using, for example, an eddy current or a laser. However, a contact type sensor can also be used as the sensor 40. Since the sensor 40 is provided on the saddle 32, it moves integrally with the tool spindle device 33. The sensor 40 may also be provided so that the detection unit can be moved forward and backward.

[0031] The control device 50 includes an arithmetic processing device (processor) and a storage device, and controls each driving device by executing a machining program. That is, the control device 50 controls the rotation of the gear skiving cutter T, the rotation of the workpiece W, and the relative movement between the workpiece W and the gear skiving cutter T. The control device 50 controls each driving device while synchronously controlling the rotation of the workpiece spindle device 23 and the tool spindle device 33 in order to machine gear teeth on the workpiece W.

[0032] (2. Configuration of Gear Skiving Cutter T) The configuration of the gear skiving cutter T will be described with reference to Figures 2 and 3. The gear skiving cutter T includes a blade portion Ta and a shaft portion Tb.

[0033] The blade portion Ta has a plurality of tool blades in the circumferential direction. The axial end faces of the plurality of tool blades in the blade portion Ta form the rake faces, and the radial outer surfaces of the tool blades form the flank faces. In this embodiment, the circumscribing surface of the blade portion Ta, i.e., the surface connecting the radial outer surfaces of the tool blades, which are the flank faces, forms a conical surface. However, the circumscribing surface of the blade portion Ta can also be configured to form a cylindrical surface. The shaft portion Tb is integrally provided on the back side of the rake faces of the blade portion Ta and is provided coaxially with the blade portion Ta. The shaft portion Tb is attached to the spindle 33b (shown in FIG. 1) of the tool spindle device 33.

[0034] (3. Structure of Workpiece W) An example of the configuration of the workpiece W will be described with reference to Fig. 2. As shown in Fig. 2, the workpiece W has multiple stages of gears in the axial direction. In this embodiment, the workpiece W has two stages of gears, that is, a first gear W1 and a second gear W2. However, the workpiece W may have three or more stages of gears.

[0035] The first gear W1 has a uniform tooth pitch angle. The second gear W2 also has a uniform tooth pitch angle. The number of teeth of the first gear W1 is different from the number of teeth of the second gear W2. In this embodiment, as shown in FIG. 2, the first gear W1 has a larger diameter than the second gear W2, but the first gear W1 and the second gear W2 may have the same diameter.

[0036] (4. Gear skiving processing explanation) The state in which a tooth profile (gear teeth) is generated on a workpiece W by a gear skiving cutter T will be described with reference to Figs. 2 and 3.

[0037] In this embodiment, the gear machining device 1 is applied to a workpiece W on which a first gear W1 and a second gear W2 are formed in advance. The gear machining device 1 is configured to machine at least one of the tooth flank of the first gear W1 and the tooth flank of the second gear W2 that are formed in advance. In this embodiment, the gear machining device 1 machines the tooth flank of the first gear W1 that is formed in advance, and also machines the tooth flank of the second gear W2 that is formed in advance. For example, the gear machining device 1 performs finish machining on the tooth flank of the first gear W1 and the tooth flank of the second gear W2.

[0038] 2 and 3 show a case where gear skiving is performed on the tooth surface of the second gear W2 in the workpiece W by the gear skiving cutter T. The case where gear skiving is performed on the tooth surface of the first gear W1 by the gear skiving cutter T is substantially the same.

[0039] In gear skiving, as shown in Fig. 3, the rotation axis At of the gear skiving cutter T is set at an intersection angle θ with an axis parallel to the rotation axis Aw of the workpiece W. Also, as shown in Fig. 2, the rotation axis At of the gear skiving cutter T and the rotation axis Aw of the workpiece W are parallel to the XZ plane. As shown in Fig. 2, the center distance between the rotation axis At of the gear skiving cutter T and the rotation axis Aw of the workpiece W, that is, the distance in the Y-axis direction, is Da.

[0040] The workpiece W is rotated around the rotation axis Aw (Cw axis), and the gear skiving cutter T is rotated around the rotation axis At (Ct axis). While synchronizing the rotation of the workpiece W and the rotation of the gear skiving cutter T, the gear skiving cutter T is moved relative to the workpiece W in the direction of the rotation axis Aw of the workpiece W, thereby generating a tooth profile on the workpiece W. In gear skiving, each tooth groove portion of the workpiece W is machined only once by the gear skiving cutter T while the workpiece W rotates once.

[0041] In addition to the above-mentioned finishing, the present invention can also be applied to machining chamfers for synchromesh mechanisms to facilitate smooth shift changes in a vehicle's manual transmission. That is, the gear machining device 1 may machine chamfers for synchromesh mechanisms on the tooth flanks of the first gear W1 and the second gear W2 that have been formed in advance. Since the chamfers are formed on a portion of each tooth flank in the axial direction, the gear machining device 1 machines only a portion of the tooth flanks of the first gear W1 and the second gear W2.

[0042] (5. Functional block configuration of gear processing device 1) Next, functions of a portion of the configuration of the gear machining device 1 will be described with reference to Fig. 4. As shown in Fig. 4, the gear machining device 1 includes an X-axis moving device 61 that moves the workpiece W and the gear skiving cutter T relatively in the X-axis direction, a Y-axis moving device 62 that moves them relatively in the Y-axis direction, and a Z-axis moving device 63 that moves them relatively in the Z-axis direction.

[0043] In this embodiment, the X-axis moving device 61 is a driving device such as a linear motor or a ball screw mechanism for moving the X-axis moving table 21 in the X-axis direction relative to the bed 10. The Y-axis moving device 62 is a driving device such as a linear motor or a ball screw mechanism for moving the saddle 32 in the Y-axis direction relative to the column 31. The Z-axis moving device 63 is a driving device such as a linear motor or a ball screw mechanism for moving the column 31 in the Z-axis direction relative to the bed 10. Although not shown, the X-axis moving device 61, the Y-axis moving device 62, and the Z-axis moving device 63 are configured to include a driving circuit, a motor (linear motor or rotary motor), and a position detector (linear position detector or rotation angle detector), etc.

[0044] 4, the gear machining device 1 further includes a workpiece spindle device 23, a tool spindle device 33, and a rotation device 64. As described above, the workpiece spindle device 23 constitutes the workpiece holding device 20, and holds the workpiece W rotatably around the Cw axis. The workpiece spindle device 23 includes a drive circuit 23c, a rotation motor 23d, and a rotation angle detector 23e.

[0045] As described above, the tool spindle device 33 constitutes the tool holding device 30 and holds the gear skiving cutter T rotatably around the Ct axis. Although not shown, the tool spindle device 33 is configured to include a drive circuit, a rotation motor, and a rotation angle detector. The rotation device 64 is a moving device for changing the attitude of the workpiece W and the gear skiving cutter T. In this embodiment, the rotation device 64 includes a rotation motor for rotating the B-axis rotating table 22 about the B axis relative to the X-axis moving table 21. Furthermore, the rotation device 64 is configured to include a drive circuit, a rotation angle detector, and the like in addition to the rotation motor.

[0046] The sensor 40 detects the distance between the teeth of a first gear W1 preformed on the workpiece W while the workpiece W is rotating. However, the sensor 40 does not detect all the teeth of the first gear W1, but only some of the teeth of the first gear W1. The sensor 40 also detects the distance between the teeth of a second gear W2 preformed on the workpiece W while the workpiece W is rotating. However, the sensor 40 does not detect all the teeth of the second gear W2, but only some of the teeth of the second gear W2.

[0047] The control device 50 controls the sensor 40 to detect the distance between the sensor 40 and some of the teeth of the first gear W1 and the distance between the sensor 40 and some of the teeth of the second gear W2 while the workpiece W is rotating. To perform detection by the sensor 40, the control device 50 controls an X-axis moving device 61, a Y-axis moving device 62, and a Z-axis moving device 63 as moving devices, and further controls the workpiece spindle device 23.

[0048] The control device 50 detects the phase of some of the teeth of the first gear W1 and the phase of some of the teeth of the second gear W2 based on the detection result of the sensor 40 and the detection result of the rotation angle detector 23e of the workpiece spindle device 23. For example, the control device 50 makes the detection time of the sensor 40 correspond to the detection time of the rotation angle detector 23e. Then, the control device 50 detects the phase of some of the teeth of the first gear W1 and the phase of some of the teeth of the second gear W2 based on the distance detected by the sensor 40 and the rotation angle of the rotary motor 23d detected by the rotation angle detector 23e. Then, the control device 50 calculates information for machining the workpiece W based on the phase of some of the teeth of the first gear W1 and the phase of some of the teeth of the second gear W2.

[0049] In addition, the control device 50 controls the X-axis moving device 61, the Y-axis moving device 62, and the Z-axis moving device 63 as moving devices in order to machine the workpiece W, and further controls the workpiece spindle device 23, the tool spindle device 33, and the rotation device 64.

[0050] (6. Processing of the control device 50) The process (control method) of the control device 50 will be described with reference to Fig. 5 to Fig. 15. When the workpiece W is held by the workpiece spindle device 23 and the workpiece W is rotating, the control device 50 executes a first detection process (first detection step ST1) to detect the phase of a first detection tooth Wd1 (shown in Fig. 8), which is a part of all the teeth of the first gear W1, using the sensor 40 and the rotation angle detector 23e.

[0051] In order to execute the first detection process, the control device 50 first positions the workpiece W and the sensor 40 at the positions shown in Fig. 6. Here, as shown in Fig. 6, the sensor 40 includes a detection unit 41 and a support unit 42 that supports the detection unit 41. The detection unit 41 of the sensor 40 is, for example, a non-contact distance sensor such as an eddy current or laser. The support unit 42 of the sensor 40 has a base end provided on the saddle 32 and holds the detection unit 41 at its tip. The support unit 42 of the sensor 40 is provided so as to be movable forward and backward with respect to the saddle 32. As shown in Fig. 6, the control device 50 extends the support unit 42 of the sensor 40 to move the detection unit 41 of the sensor 40 forward.

[0052] 6, the control device 50 controls the X-axis moving device 61, the Y-axis moving device 62, and the Z-axis moving device 63 as moving devices so that the detection unit 41 of the sensor 40 faces the first gear W1 in the radial direction of the first gear W1. In other words, the detection unit 41 of the sensor 40 coincides with the axial position of the first gear W1 on the workpiece W, and the distance between the detection unit 41 of the sensor 40 and the first gear W1 is within the detectable range of the sensor 40.

[0053] Then, the control device 50 controls the workpiece spindle device 23 to rotate the workpiece W. At this time, the control device 50 sets the rotation angle of the workpiece W to an angle smaller than one revolution, rather than one revolution. Furthermore, the control device 50 acquires the detection result of the rotation angle detector 23e.

[0054] In the first detection process, the sensor 40 detects the distance of a first detection tooth Wd1 (shown in FIG. 8), which is a part of all the teeth of the first gear W1, while the workpiece W is rotating. At the same time, the rotation angle detector 23e detects the rotation angle of the rotation motor 23d. Then, the control device 50 obtains the detection time of the sensor 40 and the detection time of the rotation angle detector 23e in correspondence with each other. That is, the phase of the first detection tooth Wd1 is detected by the sensor 40 and the rotation angle detector 23e.

[0055] At this time, the output waveform H1, which is the detection result by the sensor 40, is as shown in Fig. 7. As shown in Fig. 7 and Fig. 8, the peak value in the detection value of the sensor 40 corresponds to the tooth bottom. In Fig. 7, the horizontal axis represents the rotation angle of the workpiece W obtained from the rotation angle detector 23e (corresponding to the rotation angle of the rotation motor 23d).

[0056] 7 and 8, the first detection process detects an angle range φd1 smaller than one revolution of the first gear W1. For example, the first detection process detects the phases of a plurality of first detection teeth Wd1 that are a portion of all the teeth of the first gear W1. For example, the first detection process detects the phases of the first detection teeth Wd1 for three teeth of the first gear W1.

[0057] For example, the first detection process detects the bottom phases of the first detection teeth Wd1 of multiple teeth. As shown in Fig. 7 and Fig. 8, in the first detection process, the sensor 40 detects bottom phases P1a, P1b, and P1c of the first detection teeth Wd1 of three teeth. The detection value of the sensor 40 is large for the bottoms located farther from the detection unit 41 of the sensor 40 and is small for the tips located closer to the detection unit 41.

[0058] The control device 50 may detect the phase of one first detection tooth Wd1 among all the teeth of the first gear W1 in the first detection process. In this case, in Fig. 7 and Fig. 8, only the root phase P1a of the one first detection tooth Wd1 is detected in the first detection process. The control device 50 may detect the tip phase of the first detection tooth Wd1 instead of the root phase in the first detection process.

[0059] 5, following the first detection process, the control device 50 executes a second detection process in which, while the workpiece W is being held by the workpiece spindle device 23 and rotating, the sensor 40 and the rotation angle detector 23e detect the phase of a second detection tooth Wd2, which is a part of all the teeth of the second gear W2 (second detection step ST2). Note that the second detection process may be executed before the first detection process.

[0060] In order to execute the second detection process, the control device 50 first positions the workpiece W and the sensor 40 at the positions shown in Fig. 9. As shown in Fig. 9, the control device 50 controls the X-axis moving device 61, the Y-axis moving device 62, and the Z-axis moving device 63 as moving devices so that the detection unit 41 of the sensor 40 faces the second gear W2 in the radial direction of the second gear W2. In other words, the detection unit 41 of the sensor 40 coincides with the axial position of the second gear W2 on the workpiece W, and the separation distance between the detection unit 41 of the sensor 40 and the second gear W2 is within the detectable range of the sensor 40. At this time, the control device 50 extends the support portion 42 of the sensor 40 to move the detection unit 41 of the sensor 40 forward, as shown in Fig. 9.

[0061] Then, the control device 50 controls the workpiece spindle device 23 to rotate the workpiece W. At this time, the control device 50 sets the rotation angle of the workpiece W to an angle smaller than one revolution, rather than one revolution. Furthermore, the control device 50 acquires the detection result of the rotation angle detector 23e.

[0062] In the second detection process, the sensor 40 detects the distance of a second detection tooth Wd2 (shown in FIG. 12), which is a part of all the teeth of the second gear W2, while the workpiece W is rotating. At the same time, the rotation angle detector 23e detects the rotation angle of the rotation motor 23d. Then, the control device 50 obtains the detection time of the sensor 40 and the detection time of the rotation angle detector 23e in correspondence with each other. That is, the phase of the second detection tooth Wd2 is detected by the sensor 40 and the rotation angle detector 23e.

[0063] At this time, the output waveform H2, which is the detection result by the sensor 40, is as shown in Fig. 10. As shown in Fig. 10 and Fig. 11, the peak value in the detection value of the sensor 40 corresponds to the tooth bottom. In Fig. 10, the horizontal axis represents the rotation angle of the workpiece W obtained from the rotation angle detector 23e (corresponding to the rotation angle of the rotation motor 23d).

[0064] In the second detection process, as shown in Fig. 10 and Fig. 11, an angle range φd2 smaller than one revolution of the second gear W2 is detected. For example, the second detection process detects the phases of a plurality of second detection teeth Wd2 that are a part of all the teeth of the second gear W2. For example, the second detection process detects the phases of the second detection teeth Wd2 for three teeth of the second gear W2.

[0065] For example, the second detection process detects bottom phases of the second detection teeth Wd2 of multiple teeth. As shown in Fig. 10 and Fig. 11, in the second detection process, the sensor 40 detects bottom phases P2a, P2b, and P2c of the second detection teeth Wd2 of three teeth. The detection value of the sensor 40 is large for the bottoms located farther from the detection unit 41 of the sensor 40 and is small for the tips located closer to the detection unit 41.

[0066] The control device 50 may detect the phase of one second detection tooth Wd2 among all the teeth of the second gear W2 in the second detection process. In this case, in Fig. 10 and Fig. 11, only the tooth root phase P2a of one second detection tooth Wd2 is detected in the second detection process. The control device 50 may detect the tooth tip phase of the second detection tooth Wd2 instead of the tooth root phase in the second detection process.

[0067] 5, following the second detection process, the control device 50 executes a first phase calculation process (first phase calculation step ST3). Note that the first phase calculation process may be executed after the first detection process and before the second detection process.

[0068] The first phase calculation process calculates phases P1d-P1g, ... (shown in the upper part of FIG. 12) of the teeth Wc1 (shown in FIG. 8) other than the first detection tooth Wd1 of the first gear W1 based on the phase of the first detection tooth Wd1 detected in the first detection process (ST1) and the tooth pitch angle Pit1 of the first gear W1 stored in advance. As described above, the first detection process (ST1) detects the phase of the first detection tooth Wd1 located in an angle range φd1 smaller than one revolution of the first gear W1. Therefore, the first phase calculation process (ST3) calculates phases P1d-P1g, ... of the remaining teeth Wc1 of the first gear W1 taking into account the phase of the first detection tooth Wd1.

[0069] In the first detection process described above, the phases P1a, P1b, and P1c of the first detection teeth Wd1 are detected. Therefore, in the first phase calculation process, first, a phase P1a' of a specific one of the first detection teeth Wd1 is calculated based on the phases P1a, P1b, and P1c of the first detection teeth Wd1 and the tooth pitch angle Pit1 of the first gear W1.

[0070] Since the first gear W1 is an equal-angle gear, the tooth pitch angle Pit1 of the first gear W1 can be calculated from the number of teeth of the first gear W1. For example, when the number of teeth of the first gear W1 is 31, the tooth pitch angle Pit1 is 11.612°. The tooth pitch angle Pit1 of the first gear W1 is stored in advance in the control device 50.

[0071] Then, the phase P1a' of one specific first detection tooth Wd1 is calculated, for example, according to equation (1). P1a'={P1a+(P1b-Pit1)+(P1c-2×Pit1)} / 3 ... (1)

[0072] The phase P1a' of one specific first detection tooth Wd1 obtained by formula (1) corresponds to an average value of the phases P1a, P1b, and P1c of the multiple first detection teeth Wd1. For example, the tooth pitch angle Pit1 of the first gear W1 before this processing may be shifted due to differences in the amount of deformation caused by heat treatment in the previous process. Therefore, by averaging using the phases P1a, P1b, and P1c of the multiple first detection teeth Wd1 as in formula (1), it is possible to average out the differences in deformation caused by heat treatment, etc.

[0073] Next, in the first phase calculation process, phases P1d-P1g,... of the teeth Wc1 of the first gear W1 other than the first detection tooth Wd1 are calculated based on the phase P1a' of the specific one first detection tooth Wd1 and the tooth pitch angle Pit1 of the first gear W1, as shown in the upper part of Fig. 12. The phases P1d-P1g,... of the teeth Wc1 can be obtained by sequentially adding the tooth pitch angle Pit1 to the phase P1a' of the specific one first detection tooth Wd1.

[0074] Here, in the first detection process, as described above, the phase P1a of only one first detection tooth Wd1 may be detected instead of the phases P1a, P1b, P1c of the multiple first detection teeth Wd1. In this case, in the first phase calculation process, phases P1d-P1g, ... of the teeth Wc1 of the first gear W1 other than the first detection tooth Wd1 may be calculated based on the detected phase P1a of the one first detection tooth Wd1 and the tooth pitch angle Pit1.

[0075] 5, the control device 50 executes the second phase calculation process following the first phase calculation process (second phase calculation step ST4). Note that the second phase calculation process may be executed after the second detection process, or may be executed before the first phase calculation process.

[0076] The second phase calculation process calculates phases P2d-P2j,... (shown in the lower part of FIG. 12) of the teeth Wc2 (shown in FIG. 11) other than the second detection tooth Wd2 of the second gear W2 based on the phase of the second detection tooth Wd2 detected in the second detection process (ST2) and the tooth pitch angle Pit2 of the second gear W2 stored in advance. As described above, the second detection process (ST2) detects the phase of the second detection tooth Wd2 located in an angle range φd2 smaller than one revolution of the second gear W2. Therefore, the second phase calculation process (ST4) calculates phases P2d-P2j,... of the remaining teeth Wc2 of the second gear W2 in consideration of the phase of the second detection tooth Wd2.

[0077] In the second detection process described above, the phases P2a, P2b, and P2c of the second detection teeth Wd2 are detected. Therefore, in the second phase calculation process, first, a phase P2a' of a specific one of the second detection teeth Wd2 is calculated based on the phases P2a, P2b, and P2c of the second detection teeth Wd2 and the tooth pitch angle Pit2 of the second gear W2.

[0078] Since the second gear W2 is an equal-angle gear, the tooth pitch angle Pit2 of the second gear W2 can be calculated from the number of teeth of the second gear W2. For example, if the number of teeth of the second gear W2 is 15, the tooth pitch angle Pit2 is 24°. The tooth pitch angle Pit2 of the second gear W2 is stored in advance in the control device 50.

[0079] Then, the phase P2a' of one particular second detection tooth Wd2 is calculated, for example, according to equation (2). P2a'={P2a+(P2b-Pit2)+(P2c-2×Pit2)} / 3 (2)

[0080] The phase P2a' of one specific second detection tooth Wd2 obtained by formula (2) corresponds to an average value of the phases P2a, P2b, and P2c of the multiple second detection teeth Wd2. For example, the tooth pitch angle Pit2 of the second gear W2 before this processing may be shifted due to differences in the amount of deformation caused by heat treatment in the previous process. Therefore, by averaging using the phases P2a, P2b, and P2c of the multiple second detection teeth Wd2 as in formula (2), it is possible to average out the differences in deformation caused by heat treatment, etc.

[0081] Next, in the second phase calculation process, phases P2d-P2j,... of the teeth Wc2 of the second gear W2 other than the second detection tooth Wd2 are calculated based on the phase P2a' of the specific second detection tooth Wd2 and the tooth pitch angle Pit2 of the second gear W2, as shown in the lower part of Fig. 12. The phases P2d-P2j,... of the teeth Wc2 can be obtained by sequentially adding the tooth pitch angle Pit2 to the phase P2a' of the specific second detection tooth Wd2.

[0082] Here, in the second detection process, as described above, the phase P2a of only one second detection tooth Wd2 may be detected instead of the phases P2a, P2b, P2c of the multiple second detection teeth Wd2. In this case, in the second phase calculation process, phases P2d-P2j, ... of the teeth Wc2 of the second gear W2 other than the second detection tooth Wd2 may be calculated based on the detected phase P2a of the one second detection tooth Wd2 and the tooth pitch angle Pit2.

[0083] 5, following the second phase calculation process, the control device 50 executes a deviation angle calculation process (deviation angle calculation step ST5). The deviation angle calculation process compares the phase of all teeth of the first gear W1 with the phase of all teeth of the second gear W2 to calculate deviation angles between the phase of each tooth of the first gear W1 and the phase of each tooth of the second gear W2.

[0084] Here, the phases of all the teeth of the first gear W1 are the phases P1a, P1b, P1c of the first detected tooth Wd1 obtained by the first detection process, and the phases P1d to P1g, . . . of the remaining teeth Wc1 obtained by the first phase calculation process.

[0085] 12, the deviation angle between the bottom phase P1d of the first gear W1 and the bottom phase P2e of the second gear W2, which is closest to the bottom phase P1d of the first gear W1, is ΔP1d. The deviation angle between the bottom phase P1g of the first gear W1 and the bottom phase P2j of the second gear W2, which is closest to the bottom phase P1g of the first gear W1, is ΔP1g. In this way, the deviation angles are compared between the closest teeth.

[0086] In addition, when the tip phase of the first gear W1 is obtained by the first detection process and the first phase calculation process, and the tip phase of the second gear W2 is obtained by the second detection process and the second phase calculation process, the deviation angle is the deviation angle between the tip phases. Also, the deviation angle between the tip phase of the first gear W1 and the root phase of the second gear can be used, or the deviation angle between the root phase of the first gear W1 and the tip phase of the second gear can be used.

[0087] As shown in Fig. 5, the control device 50 executes a determination process following the deviation angle calculation process (determination step ST6). In the determination process, the tooth phase of the first gear W1 and the tooth phase of the second gear W2 that provide the smallest deviation angle among the respective deviation angles are determined as a reference set. In Fig. 12, the deviation angle ΔP1g between the bottom phase P1g of the first gear W1 and the bottom phase P2j of the second gear W2 that is closest to the bottom phase P1g of the first gear W1 is smallest. Therefore, as shown in Figs. 12 and 13, the bottom phase P1g of the first gear W1 and the bottom phase P2j of the second gear W2 are the reference set.

[0088] In the case where the deviation angle of the tooth tip phase is obtained in the deviation angle calculation process, the determination process determines the reference set in which the deviation angle between the tooth tip phases is the smallest. Of course, in the case where the deviation angle between the tooth root phase of the first gear W1 and the tooth tip phase of the second gear W2 is obtained in the deviation angle calculation process, the determination process determines the reference set in which the deviation angle is the smallest.

[0089] 5, following the determination process, the control device 50 executes a positioning process (positioning step ST7). The positioning process controls the workpiece spindle device 23 and the tool spindle device 33 to position the gear skiving cutter T and the workpiece W using the tooth root phase P1g of the first gear W1 and the tooth root phase P2j of the second gear W2 constituting the reference set as processing start references.

[0090] Here, in the positioning process before starting processing, the support portion 42 of the sensor 40 is contracted and the detection portion 41 of the sensor 40 is retracted as shown in Fig. 14. In other words, when the workpiece W is processed by the gear skiving cutter T, the sensor 40 moves to a position where it does not interfere with the workpiece W.

[0091] As shown in Fig. 5, the control device 50 executes a machining process following the positioning process (machining step ST8). In the machining process, the gear skiving cutter T machines the tooth surface of the first gear W1 and the tooth surface of the second gear W2 of the workpiece W in accordance with a machining program. The machining order may be such that the first gear W1 is machined and then the second gear W2 is machined, or vice versa. However, there may be cases where only one of the tooth surface of the first gear W1 and the tooth surface of the second gear W2 is machined.

[0092] The processing (processing method) will now be described with reference to Fig. 15. The control device 50 determines whether the deviation angle in the reference set determined in the determination process is less than the allowable range (allowable range determination step ST11). As described above, the deviation angle in the reference set is the smallest deviation angle among the deviation angles between the bottom phases of the first gear W1 and the bottom phases of the second gear W2.

[0093] If the deviation angle of the reference set is less than the allowable range (ST11: Yes), the control device 50 performs machining on the tooth surface of the first gear W1 without performing correction, which will be described later (first gear machining step ST12). That is, in order to machine the tooth surface of the first gear W1, the machining process by the control device 50 controls the moving devices 61, 62, 63, and 64 while synchronously controlling the rotation of the positioned gear skiving cutter T and the workpiece W. In this manner, the tooth surface of the first gear W1 is machined.

[0094] Subsequently, when the machining of the first gear W1 is completed, the control device 50 machines the tooth surface of the second gear W2 without performing any correction described later (second gear machining step ST13). That is, in order to machine the tooth surface of the second gear W2, the machining process by the control device 50 controls the moving devices 61, 62, 63, and 64 while synchronously controlling the rotation of the positioned gear skiving cutter T and the workpiece W. In this manner, the tooth surface of the second gear W2 is machined.

[0095] On the other hand, if the deviation angle of the reference set is equal to or greater than the allowable range (ST11: No), the processing of the control device 50 calculates and sets a correction value (correction value setting step ST14). The correction here is a process for reducing the deviation angle of the reference set after processing. The correction value may be set for both the processing of the first gear W1 and the processing of the second gear W2, or may be set for the processing of either the first gear W1 or the second gear W2. For example, if the deviation angle is large, the correction value is set for both the first gear W1 and the second gear W2, and if the deviation angle is small, the correction value is set for either the first gear W1 or the second gear W2.

[0096] When a correction value is set for machining of the first gear W1, the control device 50 performs machining on the tooth surface of the first gear W1 while making corrections based on the correction values ​​(first gear machining step ST12). That is, the machining process of the control device 50 performs machining by making corrections to the workpiece spindle device 23 and the tool spindle device 33 so as to reduce the deviation angle in the reference set.

[0097] Subsequently, when a correction value has been set for machining of the second gear W2, when machining of the first gear W1 is completed, the control device 50 performs machining on the tooth surface of the second gear W2 while making corrections based on the correction value (second gear machining step ST13). That is, the machining process of the control device 50 performs machining by making corrections to the workpiece spindle device 23 and the tool spindle device 33 so as to reduce the deviation angle in the reference set.

[0098] Therefore, if the deviation angle in the reference set is equal to or exceeds the allowable range, the deviation angle in the reference set between the first gear W1 and the second gear W2 after machining is reduced by performing machining while correcting the deviation angle.

[0099] (7. Effects) According to the gear machining device 1 described above, the first detection process detects phases P1a, P1b, and P1c of the first detection tooth Wd1, which is a part of all the teeth of the first gear W1, and the second detection process detects phases P2a, P2b, and P2c of the second detection tooth Wd2, which is a part of all the teeth of the second gear W2. In other words, the first detection process does not detect the phases of all the teeth of the first gear W1, and the second detection process does not detect the phases of all the teeth of the second gear W2. Therefore, the time required for detection can be significantly shorter than when all the teeth are detected.

[0100] In the first and second detection processes, the phases of all the teeth are not detected, so there are remaining teeth Wc1 and Wc2 whose phases have not been detected. The phases P1d-P1g, ..., P2d-P2j, ... of the remaining teeth Wc1 and Wc2 that are not detected by the sensor 40 are found by calculation in the first and second phase calculation processes. Specifically, the first phase calculation process calculates the phases P1d-P1g, ... of the teeth Wc1 of the first gear W1 other than the first detection tooth Wd1 based on the phases P1a, P1b, P1c of the first detection tooth Wd1 and the tooth pitch angle Pit1 of the first gear W1 stored in advance. The second phase calculation process calculates the phases P2d-P2j, ... of the teeth Wc2 of the second gear W2 other than the second detection tooth Wd2 based on the second detection tooth Wd2 and the tooth pitch angle Pit2 of the second gear W2 stored in advance.

[0101] The first gear W1 and the second gear W2 have equal tooth pitch angles Pit1 and Pit2. Therefore, the tooth pitch angles Pit1 and Pit2 can be easily calculated if the number of teeth is known. Furthermore, since the teeth of the first gear W1 and the second gear W2 are shifted by the tooth pitch angles Pit1 and Pit2, once the phase of one tooth is known, the phase of the remaining teeth can be easily calculated. Therefore, the time required to obtain the phase of all the teeth of the first gear W1 and the phase of all the teeth of the second gear W2 can be shortened. As a result, the processing cycle time can be shortened.

[0102] In addition, the first phase calculation process uses the phases P1a, P1b, and P1c of the multiple first detection teeth Wd1 to calculate the phase P1a' of a specific one of the multiple first detection teeth Wd1. In this way, by using the phases P1a, P1b, and P1c of the multiple first detection teeth Wd1, the influence of the deviation of each phase P1a, P1b, and P1c can be reduced. For example, even if a difference in deformation occurs due to heat treatment or the like, the influence of the difference in deformation can be reduced by calculating the phase P1a' of the specific one first detection tooth Wd1. The same is true for the second phase calculation process.

[0103] In addition, in the processing, if the deviation angle of the reference set is equal to or greater than the allowable range, a correction is performed. By performing the correction in this manner, the deviation angle of the reference set after processing can be made to be less than the allowable range.

[0104] (8. Other Examples) The above has described the gear cutting device 1. Here, it is possible to extract only the process of determining the reference set in the gear cutting device 1 and grasp it as a phase detection device (1).

[0105] The phase detection device (1) determines the tooth phase of the first gear W1 and the tooth phase of the second gear W2, which are a reference set, for an object having a first gear W1 and a second gear W2. In other words, the phase detection device (1) determines the tooth phase of the first gear W1 and the tooth phase of the second gear W2, which have the smallest deviation angle, as a reference set.

[0106] The phase detection device (1) includes a sensor 40, a rotation angle detector 23e, and a processing device (50) which is a part of the above-mentioned control device 50. The processing by the processing device (50) is similar to the processing ST1 to ST6 (shown in FIG. 5) by the above-mentioned control device 50, and therefore the description thereof will be omitted.

[0107] The phase detection device (1) determines the tooth phase of the first gear W1 and the tooth phase of the second gear W2, which are a reference set, and can be applied to the gear machining device 1 as described above, and can also be applied to product inspection and the like, in addition to the gear machining device 1. In this case, the product inspection is, for example, an inspection for indicating the reference set when the tooth phase of the first gear W1 and the tooth phase of the second gear W2, which are a reference set, are indicated before shipment.

[0108] The phase detection device (1), like the above-described gear machining device 1, can shorten the time required to obtain the phases of all the teeth of the first gear W1 and the phases of all the teeth of the second gear W2. Therefore, it is possible to shorten the time required to determine, as a reference set, the tooth phases of the first gear W1 and the tooth phases of the second gear W2 when the deviation angles between the tooth phases of the first gear W1 and the tooth phases of the second gear W2 are minimum. [Explanation of symbols]

[0109] 1 Gear processing equipment, phase detection equipment 23 Workpiece spindle device 23e Rotation angle detector 33 Tool spindle device 40 Sensors 50 Control device, processing device 61~64 Mobile device ST1 First detection process ST2 Second detection process ST3 First phase calculation process ST4 Second phase calculation processing ST5 Angular deviation calculation processing ST6 Judgment process ST7 Positioning process ST8 Processing T Gear Skiving Cutter W Workpiece W1 First gear W2 Second gear Wd1 First detection tooth Wd2 Second detection tooth

Claims

1. A gear machining device configured to machine at least one of a tooth surface of a first gear and a tooth surface of a second gear, the gear surface being a workpiece having a first gear with an equal tooth pitch angle and a second gear with a different number of teeth from that of the first gear, the gear machining device comprising: a gear cutting tool having a plurality of tool blades in a circumferential direction; a tool spindle device that rotatably holds the gear cutting tool; a workpiece spindle device that rotatably holds the workpiece and is provided with a rotation angle detector that detects a rotation angle; a moving device that moves the tool spindle device and the workpiece spindle device relatively; a sensor that detects a radial distance to a peripheral surface of the first gear on the workpiece at a position radially opposed to the first gear on the workpiece while the workpiece is rotating with the workpiece spindle device holding the workpiece; and a sensor that detects a radial distance to a peripheral surface of the second gear on the workpiece at a position radially opposed to the second gear on the workpiece while the workpiece is rotating. a control device that controls the moving device while synchronously controlling the rotation of the tool spindle device and the workpiece spindle device in order to machine gear teeth on the workpiece; Equipped with The control device includes: a first detection process for detecting a phase of a first detection tooth, which is a part of all teeth of the first gear, based on the radial distance between the sensor and a peripheral surface of the first gear detected by the sensor and the rotation angle detected by the rotation angle detector of the workpiece spindle device; a second detection process is executed to detect a phase of a second detection tooth, which is a part of all teeth of the second gear, based on the radial distance between the sensor and the peripheral surface of the second gear detected by the sensor and the rotation angle detected by the rotation angle detector of the workpiece spindle device; executing a first phase calculation process for calculating a phase of a tooth of the first gear other than the first detection tooth based on the detected phase of the first detection tooth and a tooth pitch angle of the first gear stored in advance; execute a second phase calculation process to calculate a phase of a tooth of the second gear other than the second detection tooth based on the detected phase of the second detection tooth and a tooth pitch angle of the second gear stored in advance; executing a deviation angle calculation process to calculate deviation angles between the phases of the teeth of the first gear and the phases of the teeth of the second gear, based on the phases of all the teeth of the first gear obtained by the first detection process and the first phase calculation process and the phases of all the teeth of the second gear obtained by the second detection process and the second phase calculation process; executing a determination process for determining, as a reference set, the phase of the teeth of the first gear and the phase of the teeth of the second gear that minimize the deviation angle; a positioning process for controlling the tool spindle device and the workpiece spindle device in order to position the gear cutting tool and the workpiece using a tooth phase of the first gear and a tooth phase of the second gear constituting the reference set as a processing start reference; A gear machining device that performs a machining process by controlling the moving device while synchronously controlling the rotation of the positioned gear cutting tool and the workpiece in order to machine at least one of the tooth surfaces of the first gear and the second gear.

2. the deviation angle calculation process calculates deviation angles between each of the tooth tip phases of the first gear and each of the tooth tip phases of the second gear, 2. The gear machining device according to claim 1, wherein the determination process determines, as the reference set, a tooth tip phase of the first gear and a tooth tip phase of the second gear when a deviation angle between the tooth tip phase of the first gear and the tooth tip phase of the second gear is minimum.

3. the deviation angle calculation process calculates deviation angles between each of the tooth root phases of the first gear and each of the tooth root phases of the second gear, 2. The gear machining device according to claim 1, wherein the determination process determines, as the reference set, a bottom phase of the first gear and a bottom phase of the second gear when a deviation angle between the bottom phase of the first gear and the bottom phase of the second gear is minimum.

4. the first detection process detects a phase of the first detection tooth among all the teeth of the first gear; the second detection process detects a phase of one of the second detection teeth among all the teeth of the second gear; the first phase calculation process calculates a phase of a tooth of the first gear other than the first detection tooth based on a phase of the detected one of the first detection teeth and a tooth pitch angle of the first gear; The gear machining device according to any one of claims 1 to 3, wherein the second phase calculation process calculates a phase of a tooth of the second gear other than the second detection tooth, based on a phase of the detected one of the second detection teeth and a tooth pitch angle of the second gear.

5. the first detection process detects phases of a plurality of the first detection teeth among all the teeth of the first gear, the second detection process detects phases of a plurality of the second detection teeth among all the teeth of the second gear; The first phase calculation process includes: Calculating a phase of a specific one of the first detection teeth based on the first detection teeth and a tooth pitch angle of the first gear; calculating a phase of a tooth of the first gear other than the first detection tooth based on a phase of the specific first detection tooth and a tooth pitch angle of the first gear; The second phase calculation process includes: Calculating a phase of a specific one of the second detection teeth based on the second detection teeth and a tooth pitch angle of the second gear; 4. The gear machining device according to claim 1, wherein a phase of a tooth of the second gear other than the second detection tooth is calculated based on a phase of a specific second detection tooth and a tooth pitch angle of the second gear.

6. The processing step includes: Controlling the moving device while synchronously controlling the rotation of the positioned gear cutting tool and the workpiece in order to process the tooth surface of the first gear; The gear machining device according to any one of claims 1 to 5, wherein the moving device is controlled while synchronously controlling the rotation of the positioned gear cutting tool and the workpiece in order to machine the tooth surface of the second gear.

7. The processing step includes: When the deviation angle in the reference set is equal to or larger than an allowable range, a correction is made to the tool spindle device and the workpiece spindle device so that the deviation angle after machining is reduced, 7. The gear machining device according to claim 1, wherein, when the deviation angle calculated in the deviation angle calculation process is below an allowable range, machining is performed without performing the correction.

8. The gear cutting tool is a gear skiving cutter having a plurality of tool blades, each of which has an axial end surface as a rake surface and a radial outer surface as a relief surface. The gear cutting device according to any one of claims 1 to 7.

9. A phase detection device for an object having a first gear with an equal tooth pitch angle and a second gear with an equal tooth pitch angle different from the number of teeth of the first gear, the phase detection device determining, as a reference set, the tooth phases of the first gear and the tooth phases of the second gear that minimize deviation angles between the tooth phases of the first gear and the tooth phases of the second gear, a sensor that detects a radial distance to a peripheral surface of the first gear on the object at a position radially opposed to the first gear on the object while the object is rotating, and detects a radial distance to a peripheral surface of the second gear on the object at a position radially opposed to the second gear on the object; a spindle device that rotatably holds the object and includes a rotation angle detector that detects a rotation angle; a processing device that determines the reference set based on the detection results of the sensor and the detection results of the rotation angle detector of the spindle device; Equipped with The processing device includes: a first detection process for detecting a phase of a first detection tooth, which is a part of all teeth of the first gear, based on the radial distance between the sensor and a peripheral surface of the first gear detected by the sensor and the rotation angle detected by the rotation angle detector of the spindle device; a second detection process for detecting a phase of a second detection tooth, which is a part of all teeth of the second gear, based on the radial distance between the sensor and a peripheral surface of the first gear detected by the sensor and the rotation angle detected by the rotation angle detector of the spindle device; executing a first phase calculation process for calculating a phase of a tooth of the first gear other than the first detection tooth based on the detected phase of the first detection tooth and a tooth pitch angle of the first gear stored in advance; execute a second phase calculation process to calculate a phase of a tooth of the second gear other than the second detection tooth based on the detected phase of the second detection tooth and a tooth pitch angle of the second gear stored in advance; executing a deviation angle calculation process to calculate deviation angles between the phases of the teeth of the first gear and the phases of the teeth of the second gear, based on the phases of all the teeth of the first gear obtained by the first detection process and the first phase calculation process and the phases of all the teeth of the second gear obtained by the second detection process and the second phase calculation process; a phase detection device that executes a determination process to determine, as the reference set, the phase of the teeth of the first gear and the phase of the teeth of the second gear that result in the smallest deviation angle.

Images