Gear Tooth Machining Control for Independent Surface Modifications
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Solution Overview
Problem
Current gear machining technologies face challenges in approximating multiple tooth surface shape modification elements to target values, limiting design freedom and requiring lengthy trial-and-error processes to achieve ideal meshing under load, which affects noise reduction and gear performance.
Innovation Solution
A gear machining support device and system that synchronizes the rotation of the workpiece and machining tool, using a target modification amount storage unit and correction amount determination unit to adjust machining control elements, allowing for precise approximation of crowning, bias, helix angle, pressure angle, and tooth profile roundness to target values during the machining process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If the distance between centers of the center axis line of the machining tool and the center axis line of the workpiece is changed to modify the crowning, then the crowning modification amount is adjusted, but the bias is also modified at the same time in proportional relation, reducing the degree of freedom in design
Solution Approach 1:
The patent segments the control of modification elements by introducing multiple independent machining control elements (first machining control element for crowning, second machining control element for bias) instead of controlling them through a single distance parameter. This allows independent adjustment of crowning and bias modification amounts, resolving the coupling problem and increasing design freedom.
Solution Approach 2:
The patent changes the control parameters from a single distance between centers to multiple machining control elements with different functions. By modifying multiple parameters (positioning parameters and machining control elements) independently, the system achieves independent control over crowning and bias modification amounts, eliminating the proportional relationship constraint.
2Manufacturing precision
If trial and error machining is performed to achieve target modification amounts for multiple modification elements, then the tooth surface shape can be adjusted, but machining time is significantly increased
Solution Approach 1:
The patent performs preliminary calculation of the relationship between machining control elements and modification elements before machining. By pre-establishing the correlation and using calculated correction amounts, the system directly determines the optimal machining parameters without requiring trial-and-error iterations, significantly reducing machining time while maintaining precision.
Solution Approach 2:
The patent implements a feedback mechanism where the actual modification amounts are measured and compared with target modification amounts, and correction amounts are calculated based on the differences. This feedback loop enables precise adjustment of machining control elements to achieve target values directly, eliminating the need for repeated trial-and-error machining cycles.
3Ease of operation
If multiple modification elements are controlled through a single machining parameter, then the control process is simplified, but the ability to independently adjust each modification element is lost
Solution Approach 1:
The patent segments the control functions by assigning different machining control elements to different modification elements. The first machining control element controls crowning, the second controls bias, and the third controls helix angle, among others. This segmentation maintains operational simplicity through automated control while enabling independent adjustment of each modification element.
Solution Approach 2:
The patent creates a universal machining control system where multiple machining control elements work together under unified management. The control device coordinates multiple control elements to simultaneously achieve multiple modification targets, providing both simplicity in overall control and independence in individual element adjustment.
Data Source
AI summary
A gear machining support device supports machining when a tooth of a gear is machined on a workpiece by relatively moving the workpiece and a machining tool while synchronizing rotations of the workpiece and the machining tool around respective center axis lines thereof. The gear machining support device includes: a target modification amount storage unit configured to store target modification amounts of at least two of modification elements of a tooth surface shape of the tooth of the gear, the modification elements including crowning, bias, a helix angle, a pressure angle, and a tooth profile roundness; and a correction amount determination unit configured to determine a correction amount of a machining control element during a machining operation such that the at least two of modification elements approximate the respective target modification amounts stored in the target modification amount storage unit.