Meshing Sensor Calibration for Thermally Stable Gear Machining
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Solution Overview
Problem
In precision machining of pre-toothed workpieces, existing meshing sensors face challenges in maintaining consistent spatial positioning due to thermal expansion and varying response behaviors, leading to inaccuracies in material removal during machining.
Innovation Solution
A machine tool with a calibration device that includes a calibration piece and a sensor controller to determine and adjust the spatial position of the meshing sensor relative to the workpiece spindle, allowing for precise positioning and calibration of the meshing sensor by moving it along the calibration piece in axial, radial, and tangential directions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the meshing sensor is positioned away from the workpiece spindle due to machine design constraints, then the machine structure is more feasible, but the spatial position of the meshing sensor changes due to thermal expansion, reducing measurement precision
Solution Approach 1:
The patent applies preliminary action by performing calibration of the meshing sensor before actual machining operations. The calibration device determines the spatial position of the meshing sensor relative to the workpiece spindle and stores calibration data that compensates for positional deviations. This preliminary calibration ensures that even though the sensor position may change due to thermal expansion during operation, the system has pre-established reference data to maintain measurement precision during subsequent machining.
2Adaptability or versatility
If the meshing sensor is made movable relative to the workpiece spindle to improve positioning flexibility, then the adaptability of the system is improved, but the reproducibility of meshing sensor positioning becomes more difficult
Solution Approach 1:
The patent implements feedback by using the calibration device to continuously or periodically determine the actual spatial position of the movable meshing sensor relative to the workpiece spindle. The system compares the current position with the calibrated reference position and uses this feedback information to compensate for positional deviations. This allows the meshing sensor to remain movable for adaptability while maintaining positioning reproducibility through active compensation based on real-time position detection.
3Productivity
If different meshing sensors are used to replace defective sensors, then the system maintains operational continuity, but the response behavior varies between sensors, reducing measurement consistency
Solution Approach 1:
The patent applies parameter changes by determining the specific response behavior characteristics of each individual meshing sensor during calibration. The calibration device measures parameters such as the switching region shape and location for each sensor and stores these as unique calibration data. When a sensor is replaced, the new sensor undergoes the same calibration process to establish its specific parameters. This allows the system to maintain operational continuity with different sensors while ensuring measurement consistency by adapting to each sensor's unique response characteristics through parameter-specific calibration.
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
Ensures accurate positioning of the meshing sensor, reducing material removal inaccuracies and enhancing the reproducibility of the meshing process, thereby improving the precision and consistency of machining operations.
Implementation Method 1
contactless meshing sensors are used for meshing, which work on an inductive or capacitive basis and determine the position of the tooth flanks
Implementation Method 2
contactless meshing sensors are used for meshing, which work on an inductive or capacitive basis and determine the position of the tooth flanks
Data Source
AI summary
A machine tool for machining pre-toothed workpieces has a workpiece carrier, a workpiece spindle with a workpiece spindle housing and a workpiece spindle shaft. The machine tool has a meshing sensor, a calibration piece, and a sensor controller which is designed to perform the following procedure: Moving the meshing sensor relative to the workpiece spindle into a calibration position in which the meshing sensor is located at the calibration piece 10; determining a response behavior of the meshing sensor by the sensor controller moving the meshing sensor relative to the calibration piece and meanwhile receiving sensor calibration signals of the meshing sensor, and moving the meshing sensor into a workpiece measuring position in which the meshing sensor is located at the workpiece, the workpiece measuring position depending on the determined response behavior.