Gear Cutting Apparatus Automation via Tooth Groove Calculation
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Solution Overview
Problem
Existing combined gear cutting apparatuses face inefficiencies due to manual adjustments and the need for large apparatus configurations, which can lead to inaccurate positioning and increased processing costs, especially when dealing with foreign substances like chips and requiring extensive sensing times.
Innovation Solution
A combined gear cutting apparatus with a workpiece drive portion, first and second processing portions, and a control portion that stores and calculates workpiece and tool information to synchronize the rotation and positioning of tools, eliminating the need for manual adjustments and sensing apparatuses by using encoded counters for precise tool and workpiece positioning.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If a touch sensor and proximity switch are employed for positioning the tooth surface, then the positioning operation can be automated and visual confirmation is not necessary, but the apparatus configuration becomes large and processing cost increases
Solution Approach 1:
The invention extracts and removes the proximity switch from the positioning system, keeping only the touch sensor. The control unit calculates tooth groove positions based on cutter rotation information without requiring a proximity switch, thereby simplifying the apparatus configuration while maintaining automated positioning capability.
Solution Approach 2:
The invention replaces the mechanical sensing approach (proximity switch detecting tooth tips) with a calculation-based approach. The control unit computes tooth groove positions using cutter rotation data and predetermined tooth pitch information, eliminating the need for complex mechanical sensing systems.
2Measurement precision
If a proximity switch is positioned close to the workpiece for accurate detection, then positioning precision improves, but the magnetic sensor is susceptible to foreign substances like chips and requires large apparatus configuration
Solution Approach 1:
The invention replaces the proximity switch (magnetic sensor) with a touch sensor combined with calculation-based positioning. The control unit determines tooth groove positions using cutter rotation information and predetermined tooth pitch, eliminating susceptibility to foreign substances while maintaining positioning precision.
Solution Approach 2:
The invention uses predetermined tooth pitch information (a digital copy of the gear geometry) to calculate actual tooth groove positions based on cutter rotation. This computational approach replicates the physical sensing function without requiring physical proximity to the workpiece, avoiding interference from chips and other foreign substances.
3Device complexity
If manual adjustment is performed for positioning the touch sensor and workpiece, then the apparatus configuration can be simplified, but working efficiency decreases due to complicated adjustment operations
Solution Approach 1:
The system performs self-positioning through automated control. The control unit calculates tooth groove positions based on cutter rotation information and automatically controls the positioning stage and cutter feed, eliminating the need for manual adjustment operations while maintaining simple apparatus configuration.
Solution Approach 2:
The control unit uses feedback from the touch sensor (detecting tooth groove depth) and cutter rotation information to automatically adjust and maintain precise positioning. This closed-loop control eliminates manual intervention while keeping the apparatus configuration simple.
Data Source
AI summary
A combined gear cutting apparatus includes a workpiece drive portion, a first processing portion holding and moving a first tool to a processing position for a workpiece, a second processing portion holding and moving a second tool to a processing position for the workpiece, and a control portion which includes a storage portion storing workpiece information indicating a configuration of the workpiece before first processing is performed, first tool information, second tool information and relative position information. The control portion includes a tooth groove configuration calculation portion calculating tooth groove configuration information of the workpiece based on the first tool information, the workpiece information and the relative position information obtained when the first processing is completed. The second tool is configured to move to a start position of second processing for the workpiece based on the tooth groove configuration information, the second tool information and the relative position information.