Optical Gear Measurement Filtering Flank Groups
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Solution Overview
Problem
Existing optical and tactile measuring systems produce incompatible measurement results due to differences in accuracy and interaction with components, making it difficult to compare optical and tactile measurements of gear toothing.
Innovation Solution
A method involving an optical measuring system that filters and groups measuring points into flank groups, models profile segments, and determines geometric parameters, allowing for improved accuracy and comparability with tactile measurements by masking out irrelevant points and using higher-order mathematical functions for modeling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tactile measurement methods are used to measure gear toothing, then high measurement precision is achieved, but the measurement time becomes very long
Solution Approach 1:
The patent replaces the mechanical tactile measurement system with an optical measurement system. The optical system uses light to detect tooth flank geometry without physical contact, eliminating the need for probe insertion and retraction operations. This substitution enables continuous rotation of the gear during measurement, dramatically reducing measurement time while maintaining accuracy through optical detection of surface profiles.
Solution Approach 2:
The patent implements continuous measurement action by allowing the gear to rotate continuously during the measurement process. Unlike tactile methods that require stopping to insert and retract probes, the optical system maintains continuous operation, constantly detecting tooth profiles as the gear rotates. This continuous useful action eliminates idle time and achieves both high precision and short measurement duration.
2Productivity
If optical measurement systems are used to measure gear toothing, then measurement time is significantly reduced, but measurement precision and comparability with tactile measurements deteriorate
Solution Approach 1:
The patent applies preliminary action by pre-calibrating the optical measurement system with reference measurements taken using tactile methods. Before performing production measurements, the system establishes reference profiles and measurement parameters based on high-precision tactile data. This preliminary calibration ensures that subsequent optical measurements are comparable to tactile standards while maintaining the speed advantages of optical detection.
Solution Approach 2:
The patent changes measurement parameters by adjusting optical system settings such as focal length, aperture, and detection angle to optimize both precision and speed. The system dynamically modifies these parameters during measurement to maintain high accuracy across different tooth geometries and positions, ensuring that optical measurements achieve tactile-level precision while retaining rapid measurement capability.
3Measurement precision
If optical measuring systems measure surface profiles, then they detect into surface structures due to small focal diameter, but this leads to detection of dust and particles that are not detected by tactile systems
Solution Approach 1:
The patent extracts and separates the detection of harmful factors (dust and particles) from the primary measurement function. The system identifies and filters out measurements caused by dust particles through analysis of measurement characteristics such as unexpected depth variations, inconsistent reflection patterns, or positions that do not correspond to actual tooth geometry. This extraction allows the system to maintain high surface detection precision while eliminating false readings from contaminants.
Solution Approach 2:
The patent introduces an intermediary filtering layer in the data processing stage that distinguishes between valid surface features and harmful contaminants. The intermediary algorithm analyzes measurement patterns, comparing detected features against expected tooth geometry models and statistical variations. This intermediary processing layer acts as a mediator that allows the optical system to detect fine surface structures while filtering out dust and particle interference that would otherwise corrupt the measurements.
Data Source
AI summary
A method includes the steps providing a component that has toothing with a predetermined nominal geometry; providing a measuring device that has an optical measuring system; and measuring the toothing of the component by the optical measuring system, wherein measuring points are detected. The method further includes the steps of evaluating the measuring points, wherein the evaluation of the measuring points has at least the following steps: grouping the measuring points into flank groups by filtering; modeling profile segments from the measuring points of the flank groups, wherein each flank group is assigned a profile segment; and determining one or more geometric parameters of the toothing on the basis of the profile segments.