Bevel Gear Pairing and Assembly for Low-Noise Final Drives
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Solution Overview
Problem
Current methods for manufacturing and assembling bevel and hypoid gears in differentials often result in lower-than-desired first-time quality due to the trial-and-error nature of axle hypoid gear matching, leading to gear noise issues that affect vehicle perception and customer satisfaction.
Innovation Solution
A method involving the formation of ring and pinion gears with parameter determination, single-flank testing, and noise/vibration analysis to adjust the assembly process, including the selection of shims, to optimize gear engagement and reduce noise/vibration, involving processes like grinding, cutting, lapping, and assembly adjustments based on data-driven evaluations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If trial and error lapping with assembly based on pattern matching is used to match axle hypoid gears, then the assembly process can be completed, but the first-time quality levels are lower than desired and gear noise increases
Solution Approach 1:
The patent applies preliminary action by performing single-flank testing on individual gears before assembly to determine their specific parameters. This pre-characterization allows for data-driven matching decisions during assembly, eliminating the need for trial-and-error lapping and directly achieving high first-time quality levels.
Solution Approach 2:
The patent implements feedback by using noise/vibration analysis results from tested gear assemblies to refine and adjust the manufacturing processes. This closed-loop approach continuously improves manufacturing precision by learning from actual performance data and making targeted process adjustments.
2Ease of manufacture
If trial and error lapping is used for gear matching, then assembly can be completed, but gear noise and vibration increase affecting vehicle perception
Solution Approach 1:
The patent replaces the mechanical trial-and-error lapping system with an automated testing and data-driven selection system. Single-flank testers and noise/vibration analyzers objectively evaluate gear parameters, substituting subjective mechanical adjustment with precise measurement and data analysis to eliminate noise-generating mismatches.
Solution Approach 2:
The patent applies parameter changes by measuring and utilizing specific gear parameters (such as tooth profile deviations, contact patterns, and noise characteristics) to select optimal gear pairs. By changing from generic pattern matching to parameter-based selection, the system achieves lower noise and vibration while maintaining ease of manufacture through automated processes.
3Manufacturing precision
If comprehensive testing and evaluation processes are implemented for gear assemblies, then manufacturing precision and quality improve, but the manufacturing process complexity and time increase
Solution Approach 1:
The patent performs single-flank testing on individual gears before assembly, completing characterizations in advance. This preliminary action prevents the need for time-consuming trial-and-error adjustments during assembly, as gears are pre-sorted by their measured parameters, thereby maintaining high quality while reducing overall cycle time.
Solution Approach 2:
The patent segments the manufacturing process into distinct testing and evaluation stages: individual gear testing, pairing based on test results, and final assembly verification. This segmentation allows parallel processing of multiple gears through the testing phase, reducing total manufacturing time while maintaining comprehensive quality control through systematic evaluation at each stage.
Data Source
AI summary
A method for controlling a process for manufacturing a bevel gear includes forming, via a first process, a ring gear and determining a first set of parameters associated with the ring gear, and forming, via a second process, the pinion gear, and determining a second set of parameters associated with the pinion gear. The ring gear and the pinion gear are paired, and a single-flank test is executed on the paired ring gear and pinion gear to determine a third set of parameters. The paired ring gear and pinion gear are assembled into a final assembly, and an end-of-line noise/vibration analysis of the final assembly is executed. The noise/vibration analysis, the first set of parameters, the second set of parameters, and the third set of parameters are evaluated, and one of the first process, the second process, the pairing process, and the assembly process are adjusted based thereon.