Gear Backlash Measurement Using Electrical Circuit Interrupt
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Solution Overview
Problem
Measuring backlash in gears located in closed or confined spaces, such as a ring gear within an engine, is challenging due to the bulkiness and cumbersome nature of conventional measurement systems, which often require disassembly of engine components and rely on manual sensing.
Innovation Solution
An apparatus comprising a test gear mounted on a spindle with an encoder and interrupt unit that forms an electrical circuit with the specimen gear, allowing for accurate measurement of backlash without disassembling the engine, using the opening and closing of the circuit to initiate and stop measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If conventional measurement systems are used to measure backlash in confined spaces, then measurement capability is achieved, but the system becomes bulky and cumbersome
Solution Approach 1:
The measurement apparatus is nested within the engine housing structure, with the spindle and test gear assembly fitting into the confined space where the ring gear is located. The encoder is mounted on the engine housing rather than being a separate external device, allowing the measurement system to operate within the existing engine boundaries without requiring external bulky equipment
Solution Approach 2:
An electrical circuit serves as an intermediary between the test gear and the measurement system. The circuit includes a contact element on the test gear that makes electrical contact with a corresponding element on the engine housing, allowing precise detection of gear position and movement without requiring direct mechanical connection to external measurement devices
2Measurement precision
If conventional measurement systems are used in confined spaces, then backlash can be measured, but disassembly of engine components is required
Solution Approach 1:
The engine housing serves multiple functions: it contains the ring gear, provides structural support, and acts as the mounting base for the encoder and electrical contact elements. This multi-functionality eliminates the need for separate measurement fixtures or disassembly of engine components, as the existing engine structure is utilized for measurement purposes
Solution Approach 2:
The measurement system utilizes the engine's own structural elements (housing, ring gear teeth) as integral parts of the measurement apparatus. The ring gear teeth serve both their functional purpose of transmitting power and as the measurement target for backlash detection, eliminating the need for separate test fixtures or disassembly
3Measurement precision
If manual sensing methods are used for backlash measurement, then measurement can be performed, but handling difficulty increases
Solution Approach 1:
The manual mechanical sensing method is replaced with an electrical detection system. The electrical circuit between the test gear contact element and the engine housing provides automatic detection of gear position and movement, eliminating the need for manual sensing operations and reducing handling difficulty while maintaining measurement precision
Data Source
AI summary
An apparatus for measuring a backlash in a specimen gear is provided. The apparatus includes a test gear mounted on a forward portion of a spindle, the test gear is configured to mesh with the specimen gear and form an electrical circuit upon contact with the specimen gear. An encoder is rotatably connected to the spindle and configured to output a rotation angle of the spindle. An interrupt unit is configured to detect an opening and closing of the electrical circuit and generate one or more interrupt signals based on the opening and the closing of the electrical circuit. A measuring unit is operatively coupled to the encoder and the interrupt unit, the measuring unit is configured to start measurement, and stop measurement of backlash based on the interrupt signal.