Optical Gear Measurement Parameter Tuning for Faster Precision
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Solution Overview
Problem
Current optical measurement methods for workpieces with cyclically symmetrical geometry, such as gear wheels, lack the precision of tactile methods and are time-consuming, making them inefficient for quality monitoring and process adaptation.
Innovation Solution
A method that adapts optical measurement parameters based on specific geometrical and surface characteristics of the workpiece, including minimal and maximum radii, surface roughness, and other parameters, to enhance measurement accuracy and avoid collisions, using an optical measuring system with adjustable settings like trigger frequency, exposure time, and tilt angle.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If tactile measurement methods are used to achieve high measurement precision, then measurement accuracy is improved, but measurement time increases significantly
Solution Approach 1:
The patent replaces the mechanical tactile measuring probe with an optical sensor system. The optical sensor captures images of the workpiece surface, and through image processing and coordinate transformation, obtains measurement data without physical contact. This substitution eliminates the time-consuming mechanical sampling process while maintaining measurement capability through optical field detection.
Solution Approach 2:
The patent creates an optical copy (image) of the workpiece surface using an optical sensor. Instead of physically touching and sampling discrete points with a probe, the system captures a comprehensive optical image that represents the entire surface geometry, from which measurement data is extracted through digital processing.
2Productivity
If optical measurement methods are used to reduce measurement time, then productivity is improved, but measurement precision deteriorates compared to tactile methods
Solution Approach 1:
The patent applies parameter changes by introducing multiple correction factors (radial, axial, and tangential) that adjust the optical measurement data to match the true workpiece geometry. These parameter adjustments compensate for systematic deviations between the optical sensor coordinate system and the workpiece actual coordinate system, thereby improving measurement accuracy.
Solution Approach 2:
The patent implements a feedback mechanism where measurement data from the optical sensor is processed through coordinate transformation and correction algorithms. The system continuously refines the measurement results by applying corrections based on the relationship between the optical coordinate system and the workpiece reference coordinate system, ensuring high accuracy.
3Measurement precision
If multiple profile lines or flank lines are measured to acquire defined quality features, then measurement precision is improved, but measurement time increases by multiple times
Solution Approach 1:
The patent enables continuous measurement by capturing the entire workpiece surface in a single optical scan rather than sequentially sampling individual points or lines with a tactile probe. The optical sensor continuously records surface geometry information across the entire field of view, allowing all required profile and flank line measurements to be obtained simultaneously from the captured image.
Solution Approach 2:
The patent transitions from one-dimensional sequential point sampling (tactile method) to two-dimensional surface imaging (optical method). By capturing the workpiece surface as a 2D image, the system can extract multiple profile lines and flank lines simultaneously from different spatial locations, dramatically reducing measurement time while maintaining the ability to evaluate multiple quality features.
4Measurement precision
If optical sensor is positioned close to workpiece for accurate measurement, then measurement precision is improved, but risk of collision increases
Solution Approach 1:
The patent introduces a coordinate transformation intermediary that decouples the optical sensor position from the workpiece measurement coordinate system. The optical sensor can be positioned at a safe distance while the captured images are mathematically transformed to reference coordinates that accurately represent the workpiece geometry, eliminating the need for close positioning.
Solution Approach 2:
The patent applies parameter changes through coordinate system transformation and correction factors that allow measurements to be accurately referenced to the workpiece coordinate system regardless of the optical sensor's physical position. This enables the sensor to operate from a safe distance while maintaining measurement accuracy through mathematical correction.
Data Source
AI summary
Method for the optical measurement of at least one measurand on a workpiece, including:providing a workpiece to be measured, wherein the workpiece comprises a cyclically symmetrical geometry, such as a toothing or the like;specifying the at least one measurand on the workpiece;providing a measuring device having an optical measuring system for the contactless measurement of the measurand on the workpiece, wherein the optical measuring system has an optical sensor;measuring the at least one measurand on the workpiece using the optical measuring system;characterized byproviding at least one geometrical parameter of the workpiece to be measured; anddetermining at least one measurement parameter for carrying out the optical measurement on the basis of the at least one measurand on the workpiece and/or the at least one geometrical parameter of the workpiece to be measured.