Optical Sensor Scanning Gear Shaft Flanks for Shape Deviation
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Solution Overview
Problem
Current methods for measuring shape deviations on transmission shafts, particularly worm shafts and gear wheels, are inadequate as they fail to efficiently assess microstructure and macro-shape deviations along the flank path, leading to suboptimal performance and increased wear and noise due to the limitations of tactile and coordinate measuring devices.
Innovation Solution
A non-contact measurement device utilizing an optical sensor with a rotary setup that scans the flank surface using scattered light distribution, allowing for continuous scanning of the flank path with high resolution and detection of surface defects, enabling precise measurement of roughness, waviness, and roundness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tactile roughness measuring devices with stylus are used, then transverse roughness can be measured at a few points, but the entire flank path cannot be scanned and longitudinal roughness and macro-shape deviations cannot be adequately measured
Solution Approach 1:
The patent replaces the mechanical stylus-based tactile measurement system with an optical measurement system that uses light sources and detectors to scan the flank surface. This substitution enables non-contact measurement across the entire flank path at high speed, eliminating the limitations of point-by-point mechanical scanning while maintaining measurement precision for both transverse and longitudinal roughness as well as macro-shape deviations
Solution Approach 2:
The patent transitions from one-dimensional point measurements to two-dimensional surface scanning by implementing an optical sensor array that captures spatial distribution of roughness and shape deviations across the entire flank path. This dimensional expansion allows simultaneous measurement of multiple parameters (transverse roughness, longitudinal roughness, waviness, roundness) along the complete flank trajectory
2Measurement precision
If coordinate measuring machines are used to measure macro-shape deviations, then shape and waviness can be detected, but the measurement process is time-consuming and expensive
Solution Approach 1:
The patent replaces slow mechanical coordinate measuring machines with a high-speed optical scanning system that uses light sources and detectors to rapidly capture macro-shape deviations. The optical system scans the entire flank path in seconds, providing accurate measurements of waviness, roundness, and other macro-shape features without the time and cost constraints of traditional coordinate measuring machines
Solution Approach 2:
The patent implements continuous scanning of the flank path by rotating the workpiece and moving the optical sensor along the flank trajectory. This continuous measurement process captures the entire flank surface without interruptions, enabling complete macro-shape analysis in a single rapid operation rather than through multiple discrete measurement points
3Quantity of substance
If traditional measurement methods are used, then discrete points can be measured, but the complete flank path with all surface defects cannot be comprehensively assessed
Solution Approach 1:
The patent replaces discrete point measurement with continuous optical scanning that captures the entire flank path. The optical sensor array records spatial distribution of surface features including craters, microcracks, and other defects along the complete flank trajectory, providing comprehensive surface assessment that mechanical point measurements cannot achieve
Solution Approach 2:
The patent implements a multi-functional optical measurement system that simultaneously measures multiple surface parameters including transverse roughness, longitudinal roughness, waviness, roundness, and surface defects. This universal measurement capability allows comprehensive assessment of the entire flank path in a single operation, eliminating the need for separate measurement processes for different surface features
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
Enables rapid and precise measurement of shape deviations along the flank path, detecting surface defects like craters and microcracks, thereby improving the accuracy and efficiency of transmission shaft metrology.
Implementation Method 1
an optical sensor which emits light onto the flank surface to be measured and detects the reflected light and evaluates its scattered light distribution
Implementation Method 2
a mirror module which directs the emitted radiation transversely to the longitudinal axis of the sensor onto the surface of the flank and deflects the reflected light in the direction of the detector line
Data Source
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AI summary
A device and method for non-contact measurement on gear shafts, particularly worm shafts, are described. An optical sensor (16) emits light onto the surface of the gear shaft's flank (12) to be measured, and the reflected scattered light distribution is evaluated to measure the shape deviation. A drive device (14) supporting the optical sensor (16) is moved parallel to the longitudinal axis (32) of the gear shaft (12) in synchronization with the rotation of the gear shaft (12), so that the optical sensor (16) continuously scans the flank of the gear shaft (12) along a predetermined section.