Gear Phase Detection Using Contact Sensing on Machine Tools
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Solution Overview
Problem
Machine tools lack the ability to accurately detect the phase of a gear held at a rotatable spindle axis, which is essential for post-treatment processes like burr removal and finishing, due to a lack of knowledge about the angles of tooth spaces or teeth in the circumferential direction.
Innovation Solution
A method and machine tool configuration that includes a controller with a contact sensor and a contactor to detect the phase of the gear by moving the contactor along specific angles and determining the contact points, allowing for precise detection of the phase without the need for additional measuring devices, and enabling post-treatment processes based on the detected phase.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If machine tools use conventional detection methods for gear phase, then additional measuring devices are required, but this increases device complexity and cost
Solution Approach 1:
The machine tool's existing contact sensor, originally designed for other measurement tasks, is repurposed to detect gear phase by detecting contact between the contactor and gear teeth. This allows the same device to perform multiple functions including dimensional measurement and phase detection, eliminating the need for dedicated measuring devices and reducing system complexity
Solution Approach 2:
The gear itself serves as the measurement reference by using its own tooth geometry to trigger the contact sensor. The gear's physical features (teeth and spaces) directly provide the measurement signal through contact detection, eliminating the need for external reference standards or complex measurement systems
2Manufacturing precision
If machine tools implement accurate gear phase detection, then post-treatment processes can be optimized, but machining time increases due to additional detection steps
Solution Approach 1:
The gear phase detection process is merged with the existing machining workflow by integrating the contact sensor detection into the tool path. The detection operations are combined with positioning movements already required for post-treatment, allowing phase detection to occur during normal machine operations without requiring separate dedicated detection time
Solution Approach 2:
The gear phase is detected before the post-treatment process begins, allowing the machining operations to be precisely positioned and executed in a single setup. This preliminary detection enables the subsequent high-precision post-treatment to proceed immediately without requiring additional adjustment or repositioning time
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 accurate detection of the gear phase, reducing machining time and eliminating the need for dedicated measuring devices, thereby improving the efficiency and cost-effectiveness of gear post-treatment processes.
Implementation Method 1
a contact sensor (150) and a contactor (152) to detect the phase of the gear by moving the contactor along specific angles and determining the contact points
Data Source
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AI summary
A method for detecting a phase on a gear (G) includes obtaining a first determination result indicating whether the gear (G) has been detected at a first detection position (dp1), which has a first angle (P1) in a circumferential direction of the rotation axis (A4). A second determination result different from the first determination result is obtained. The second determination result indicates whether the gear (G) has been detected at a second detection position (dp2), which has a second angle (P2) different from the first angle (P1) relative to a reference position (RL) in the circumferential direction. A third angle (P3), which is between the first angle (P1) and the second angle (P2), is obtained. A third determination result indicating whether the gear (G) has been detected at a third detection position (dp3) is obtained. The third detection position (dp3) has a third angle (P3) relative to the reference position (RL) in the circumferential direction. The first angle (P1) is replaced the third angle (P3) when the third determination result and the first determination result are identical to each other. The second angle (P2) is replaced the third angle (P3) when the third determination result and the first determination result are different from each other. The phase (P) on the gear (G) in the circumferential direction is detected based on an angle that is between the first angle (P1) and the second angle (P2).