Gear Machine Tool Tooth Space Detection for Pre-Toothed Blanks

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing machine tools struggle to reliably detect the positions of teeth and gaps in pre-toothed workpieces during soft machining due to coarse tolerances that exceed the measurement range of contactless sensors typically used in hard fine machining.

Innovation Solution

A mechanical resistance element is used to engage with the tooth spaces of pre-toothed workpieces, providing measurable mechanical resistance that is indirectly detected using the machine tool's existing resources, such as drive current and vibration sensors, allowing for the determination of tooth positions without requiring additional sensors.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If contactless sensors are used to detect tooth spaces in pre-toothed blanks, then the measurement method is non-contact and suitable for hard fine machining, but the measurement precision is insufficient due to coarse tolerances of pre-toothed blanks exceeding the sensor measuring range

Engineering Contradiction:

Improvetooth space detection precisionVSAvoidapplicability to pre-toothed blanks with coarse tolerances

Core Design Contradiction:

Measurement precisionVSAdaptability or versatility

Solution Approach 1:

The patent replaces contactless optical/electrical sensors with a mechanical detection system. A mechanical measuring element with a defined measuring profile is inserted into the tooth spaces and engages with the tooth flanks through mechanical contact. This mechanical engagement provides measurable resistance or force signals that accurately detect tooth space positions even when tolerances are coarse, thereby substituting the inadequate contactless sensing method with a mechanically-based detection approach suitable for pre-toothed blanks.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The mechanical measuring element acts as an intermediary between the detection system and the pre-toothed blank. It physically engages with the tooth flanks and translates the geometric relationships into measurable mechanical signals (resistance, force, or position changes). This intermediary mechanism bridges the gap between the coarse tolerances of pre-toothed blanks and the detection requirements, enabling accurate tooth space identification without directly measuring the blank itself with high-precision sensors.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Measurement precision

If a mechanical resistance element is inserted into tooth spaces to detect positions, then detection accuracy for pre-toothed blanks is improved, but the device complexity increases due to the need for additional mechanical components

Engineering Contradiction:

Improvetooth space detection precisionVSAvoidcomplexity of detection device

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The mechanical measuring element is designed to perform multiple functions: it serves as both the detection probe for tooth space identification and as a centering tool for aligning the workpiece. By combining these functions into a single component, the patent reduces the need for separate centering devices and measurement probes, thereby limiting the increase in device complexity while maintaining improved detection accuracy for pre-toothed blanks.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Ease of manufacture

If existing machine tool resources are used to indirectly detect mechanical resistance, then additional sensors are avoided and cost is reduced, but the detection method requires sophisticated signal processing of existing sensor data

Engineering Contradiction:

Improveretrofit cost and complexityVSAvoidsignal processing complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The machine tool's existing drive system and motors serve dual purposes: they not only drive the mechanical measuring element but also function as the detection sensors. The drive current, torque, or power consumption of the motor that moves the measuring element provides direct information about mechanical resistance and tooth space positions. This self-service approach eliminates the need for additional dedicated sensors and reduces retrofit costs, as the existing drive electronics and control systems are utilized for detection purposes.

Inventive Principle:

Principle #25Self-service

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 method enables accurate and cost-effective detection of tooth spaces and teeth in pre-toothed workpieces, suitable for retrofitting existing machine tools, enhancing their capability to align gear cutting tools precisely.

Implementation Method 1

Methodology Applied

Scientific EffectMechanical resistance: Friction

Implementation Method 2

indirectly detected using the machine tool's existing resources, such as drive current and vibration sensors

Methodology Applied

Scientific EffectVibration: Vibration

Implementation Method 3

the pre-toothed workpiece rotates while the mechanical resistance element is displaced from tooth mesh to tooth mesh

Methodology Applied

Scientific EffectRotation:

Data Source

PatentUS20250312859A1Machine tool and method

Publication Date: 2025.10.09 KLINGELNBERG AG

AI summary

A machine tool for the production of gearings, having a workpiece spindle, having a tool spindle and having a device for finding tooth spaces of a pre-toothed workpiece held on the workpiece spindle, wherein the device for finding tooth spaces has a mechanical resistance element for insertion into the tooth spaces of the pre-toothed workpiece.