Gear Measurement Scope Based on Rolling Test Results
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Solution Overview
Problem
Existing gear measurement methods in modern vehicles are time-consuming, particularly when using tactile or hybrid gear measuring machines, failing to meet the cycle time requirements for comprehensive noise control and quality assurance in series production.
Innovation Solution
A method that determines measurement requirements and scope based on the results of a rolling test, selectively measuring specific geometric parameters of gear teeth to optimize measurement time, reducing unnecessary measurements by identifying and addressing dynamic anomalies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tactile gear measuring machines are used for comprehensive gear measurement, then measurement precision is improved, but measurement time increases significantly
Solution Approach 1:
The measurement process is segmented into two distinct stages: first, a rapid rolling test is performed on all gears to identify defective components, and second, only the defective gears identified in the first stage undergo comprehensive tactile measurement. This segmentation eliminates the need to perform time-consuming tactile measurements on all gears, thereby significantly reducing overall measurement time while maintaining measurement precision for defective components.
Solution Approach 2:
Instead of performing complete tactile measurements on all gears (excessive action), the method applies partial measurement only to the subset of gears that fail the rolling test. This partial action approach focuses measurement resources only where needed, reducing total measurement time while ensuring that all potentially defective gears receive thorough inspection.
2Productivity
If hybrid gear measuring machines are used to reduce measurement time, then measurement speed is improved, but measurement precision and scope are compromised
Solution Approach 1:
The measurement strategy is divided into two segments: a fast rolling test using hybrid measurement technology for initial screening of all gears, followed by comprehensive tactile measurement using precise tactile sensors only for defective gears. This segmentation allows the system to leverage the speed advantage of hybrid measurement for the majority of components while reserving high-precision tactile measurement for the small subset of defective gears, thereby achieving both high productivity and measurement precision.
3Reliability
If comprehensive measurement of all gear parameters is performed, then quality control is improved, but productivity decreases due to extended measurement time
Solution Approach 1:
A preliminary rolling test is performed on all gears before comprehensive measurement. This preliminary action quickly identifies defective components, allowing the system to skip time-consuming comprehensive measurements for functional gears. The preliminary test acts as a filter that protects subsequent detailed measurement processes from being applied unnecessarily, thereby maintaining high productivity while ensuring quality control through targeted comprehensive measurement of only defective gears.
Solution Approach 2:
Comprehensive measurement is applied partially only to defective gears identified by the rolling test, rather than excessively applying it to all gears. This partial application of comprehensive measurement maintains quality control for defective components while avoiding the productivity loss that would result from measuring all gears comprehensively, thus resolving the contradiction between reliability and productivity.
Data Source
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AI summary
Method comprising the following steps: rolling test of toothed components; and gear measurement of at least a subset of the toothed components; wherein a measurement requirement and a scope of the gear measurement are determined component-specifically depending on a result of the rolling test.