Hard Fine Gear Machining With Sensor-Based Quality Screening
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Solution Overview
Problem
Current methods for hard-fine machining of gears, especially in electromobility, face challenges in ensuring high-quality production while being cost-effective, as they lack efficient real-time monitoring and detection of noise abnormalities, leading to potential systematic errors and increased costs due to delayed detection of defects.
Innovation Solution
Implementing a two-stage quality checking process using sensors and machine control during machining, followed by further measurement on additional devices, such as transmission test benches, to monitor vibration signals and detect deviations from tolerance limits, enabling early detection of incorrect machining and reducing the need for external measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If real-time monitoring with sensors and machine control is implemented during machining, then measurement precision and early detection of deviations are improved, but device complexity increases
Solution Approach 1:
The machine control system is designed to serve multiple functions: it not only controls the machining process but also records process signals, performs preliminary evaluation of measurement data, and triggers alarms or notifications when deviations are detected. This multi-functionality reduces the need for separate dedicated monitoring devices, thereby improving measurement precision without proportionally increasing device complexity.
Solution Approach 2:
A sensor system acts as an intermediary between the machining process and the machine control system. These sensors capture process signals (such as vibration, temperature, or acoustic emissions) and transmit them to the control system for evaluation. This intermediary layer enables precise real-time monitoring while keeping the core machining equipment relatively simple.
2Manufacturing precision
If comprehensive quality checking is performed during and after machining, then manufacturing precision is improved, but productivity decreases
Solution Approach 1:
The system performs preliminary evaluation of measurement data during the machining process itself, before the workpiece is fully completed. By detecting deviations early and triggering alarms or notifications in real-time, the system enables immediate corrective actions without waiting for post-machining inspection. This preliminary quality checking ensures manufacturing precision while minimizing interruptions to productivity.
Solution Approach 2:
The machine control system continuously monitors process signals and measurement data, comparing them against predefined tolerance limits. When deviations are detected, the system provides immediate feedback through alarms or notifications, allowing operators to adjust the machining process in real-time. This closed-loop feedback mechanism maintains high manufacturing precision without requiring extensive post-processing inspection, thus preserving productivity.
3Measurement precision
If external measuring devices are used for quality verification, then measurement precision is improved, but loss of time increases
Solution Approach 1:
The patent combines the measuring device with the hard fine machining machine, integrating both functions into a single unified system. This allows measurement and machining to occur in close proximity, enabling seamless transition between operations and eliminating the need to transport workpieces between separate machines. The integrated system maintains high measurement precision while significantly reducing the time loss associated with external measurement processes.
Solution Approach 2:
The system performs preliminary measurement and evaluation during the machining process itself, rather than waiting until after machining is complete. By detecting deviations early and providing real-time feedback, the system eliminates the need for extensive post-machining inspection, thereby reducing the time loss associated with external measuring devices while maintaining measurement precision.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach allows for real-time monitoring and early detection of machining errors, reducing production costs by identifying and addressing noise abnormalities directly within the machining process, ensuring higher quality and efficiency in gear production.
Implementation Method 1
A particularly relevant signal to be recorded is the vibration during gear grinding; this can be detected by a sound or acceleration sensor.
Data Source
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AI summary
The invention relates to a method for the hard fine machining of teeth or of a profile of a workpiece (1) by means of a hard fine machining tool (2) in a hard fine machining machine (3), wherein the workpiece (1) is clamped on a workpiece spindle and is machined by means of the hard fine machining tool (3). According to the invention, in order to be able to ensure a high degree of inspection of produced workpieces while nevertheless working as economically as possible, during or after the machining of the workpiece (1) in the hard fine machining machine (3) at least one signal is captured by means of at least one sensor (4) or a machine controller (5) and is stored in the machine controller (5), in the machine controller (5) the measured signal or at least one variable derived therefrom is compared with stored reference data so as to check whether the measured signal or the at least one variable derived therefrom lies within a predefined tolerance, and, if the measured signal or the at least one variable derived therefrom lies at least partly outside the predefined tolerance, the workpiece (1) is measured by means of an additional measuring device (6) after the machining of the workpiece (1).