Gear Runout Compensation via Sinusoidal Axis Adjustment
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Solution Overview
Problem
Current methods for compensating tooth spacing errors in gear manufacturing machines are inadequate in addressing spindle and workholding runout, leading to significant tooth spacing errors due to random spindle orientation and varying workholding fixture positioning, which are not effectively captured or reduced by existing compensation techniques.
Innovation Solution
A method involving axial and radial runout measurements at specific positions, converted into sinusoidal functions, is executed during machining of each individual tooth slot to compensate for runout, allowing for precise adjustments to the machine axis orientations, thereby improving tooth spacing accuracy.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional spacing error compensation methods are used, then tooth spacing errors can be partially addressed, but spindle and workholding runout errors remain uncorrected and adversely affect compensation results
Solution Approach 1:
The patent performs preliminary runout measurement and calculation of compensation values before actual gear machining. The work spindle runout is measured using a measuring instrument, and compensation values are pre-calculated based on these measurements. This preliminary action ensures that when machining begins, the compensation parameters are already determined, allowing the spacing error compensation method to effectively counteract both spacing errors and runout errors, thereby improving both tooth spacing accuracy and consistency of compensation results.
2Manufacturing precision
If absolute spindle orientation is used for compensation, then spacing errors can be compensated, but random spindle runout orientation prevents accurate compensation
Solution Approach 1:
The patent implements a feedback mechanism where the actual spindle runout is measured and used to adjust compensation values. The measuring instrument provides feedback on the true spindle orientation and runout characteristics, which are then used to calculate accurate compensation values. This closed-loop feedback approach ensures that compensation is based on actual measured conditions rather than assumed orientations, thereby improving both tooth spacing accuracy and measurement precision despite random spindle runout orientation.
3Adaptability or versatility
If workholding fixture is repositioned between measurements and machining, then setup flexibility is improved, but runout characteristics change making compensation invalid
Solution Approach 1:
The patent requires that runout measurement and compensation value calculation be performed before any machining operations, and that the workholding fixture remain in its final positioned state throughout both measurement and machining. This preliminary measurement approach ensures that the runout characteristics measured are exactly those present during machining, maintaining validity of compensation values while still allowing setup flexibility as long as the fixture is not repositioned between measurement and machining operations.
Data Source
AI summary
A method of determining axial and/or radial runout due to workholding equipment and compensating for such runout during machining of a gear wherein axial and/or radial runout compensations are executed during the machining of each individual tooth slot.