Gear Rolling Test Guided Measurement for Faster Noise Control
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Solution Overview
Problem
Existing methods for noise control in gearings are time-consuming due to the need for comprehensive tactile or hybrid measurements, which are not compatible with the cycle time of gear cutting machines.
Innovation Solution
A method where the rolling test of toothed components determines the measurement requirement and scope on a component-specific basis, allowing for targeted gearing measurements that only include necessary parameters, thereby reducing overall measurement time.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If comprehensive tactile or hybrid measurements are performed on all toothed components, then noise control quality is improved, but measurement time increases significantly making it incompatible with production cycle time
Solution Approach 1:
The patent applies partial measurement by performing comprehensive tactile or hybrid measurements only on selected toothed components based on rolling test results, rather than measuring all components. The measurement scope is adjusted dynamically - components showing deviations in rolling tests undergo full measurement, while others receive reduced measurement, thus reducing overall measurement time while maintaining noise control quality for problematic components
Solution Approach 2:
The patent changes the measurement parameters dynamically based on rolling test results. The measurement scope, depth, and type are adjusted as parameters according to the specific needs identified during rolling tests. This adaptive parameter adjustment allows the measurement process to focus resources on components that actually require detailed analysis, resolving the contradiction between comprehensive quality control and production speed
2Measurement precision
If the scope of measurement parameters is increased to cover all relevant geometric deviations, then noise control precision is improved, but measuring time increases beyond machine cycle limits
Solution Approach 1:
The patent segments the measurement parameters into different categories and applies them selectively. Based on rolling test results, only the relevant segments of measurement parameters are activated for each component. For example, if rolling tests indicate pitch errors, only pitch-related parameters are measured in detail, while other parameters receive minimal or no measurement, thus maintaining precision where needed while accelerating the overall process
Solution Approach 2:
The measurement scope and parameters are made dynamic rather than static. The system continuously adapts the measurement plan based on real-time rolling test feedback. This dynamic adjustment allows the measurement process to expand or contract its scope according to actual component quality, ensuring comprehensive measurement when needed while maintaining high productivity when components are within tolerance
3Reliability
If all manufactured gearings are measured using tactile systems, then complete quality control is achieved, but the process becomes too time-consuming for series production
Solution Approach 1:
The patent performs preliminary rolling tests on all toothed components before subjecting them to comprehensive tactile measurement. This preliminary action screens out components that are likely to pass quality checks, allowing the production process to proceed without time-consuming detailed measurements for these components. Only components showing abnormalities in the preliminary rolling tests undergo full tactile measurement, thus maintaining complete quality control for problematic items while preserving series production efficiency
Data Source
AI summary
A method having the following steps: rolling test of toothed components; and gearing measurement of at least a subset of the toothed components; wherein a measurement requirement and a scope of the gearing measurement are determined on a component-specific basis as in dependence on a result of the rolling test.