Gear Cutting Rolling Test Correlation Using Rotation-Based Data
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Solution Overview
Problem
Existing methods struggle to efficiently compare rolling test results with data from a gear cutting machine due to non-comparable time references, making it difficult to determine correlations between gear deviations and machine deviations.
Innovation Solution
Record axis and sensor data from the gear cutting machine in relation to the component's rotation, convert the data into rotation-related formats using FFT, and compare these with rotation-related measurement data from the rolling test to identify direct correlations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If axis data and sensor data from the gear cutting machine are recorded in time reference format, then the data can be easily captured during machining, but the data cannot be directly compared with rolling test results due to incompatible reference systems
Solution Approach 1:
The patent transforms the reference system parameter of the data from time-based to rotation-based by using the component rotation angle as the independent variable. This parameter change enables direct comparison between machining data and rolling test results, as both can now be expressed in terms of rotational position rather than time.
Solution Approach 2:
The patent introduces rotation angle as an intermediary variable that bridges the time reference systems of the gear cutting machine and the rolling test bench. By converting both data sets to rotation-based references, the rotation angle serves as a common mediator that enables meaningful comparison between the two different measurement systems.
2Measurement precision
If rolling test results are recorded in relation to component rotation, then gear deviations can be accurately measured, but correlations with machine deviation data become difficult to determine due to different reference systems
Solution Approach 1:
The patent changes the reference parameter from time to rotation angle for the machine data, matching the rotation-based reference already used in rolling test results. This parameter alignment simplifies the correlation analysis by eliminating the need for complex time-synchronization and reference transformation procedures.
3Productivity
If both data sets use different reference systems (time vs. rotation), then each can be recorded independently, but direct correlation between gear deviations and machine deviations cannot be established
Solution Approach 1:
The patent transforms the machine data from time reference to rotation reference, creating a unified parameter system that preserves correlational information while maintaining the independence of data collection processes. This allows both data sets to be independently recorded yet directly correlated through the common rotation-based reference frame.
Data Source
AI summary
A gear cutting method includes: machining of a gearing of a component by a gear cutting machine, wherein during the machining, axis data of at least one machine axis of the machine, are recorded and/or wherein sensor data of a sensor of the machine, are recorded during the machining; providing the recorded axis data in relation to one revolution of the component as rotation-related axis data and/or providing the recorded sensor data in relation to one revolution as rotation-related sensor data; rolling test of the toothed component by a rolling test bench, wherein measurement data of the test are provided in relation to one revolution during the test as rotation-related measurement data; comparing the axis and/or sensor data with measurement data of the test to determine correlations between gear deviations according to measurement data of the test and machine deviations according to the axis and/or sensor data.