Optical Gear Mounting Distance Control
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Solution Overview
Problem
Existing gear finishing methods face challenges in accurately setting the mounting distance due to clamping errors and time-consuming measurement processes, particularly when dealing with variations in gear geometry and heat treatment distortions.
Innovation Solution
A system comprising optical sensors and a gear feature controller that measures distances from reference points on a gear's surface to determine stock removal amounts and calculate the mounting distance, enabling precise material removal and reducing clamping errors through non-contact measurements.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional clamping methods (pitch chuck three-jaw chucks, bore expansion collet, outside diameter expansion collet, outside diameter chuck) are used to hard machine the datum surface, then the gear can be positioned for machining, but clamping errors are imparted and accurate setting of the mounting distance is inhibited due to variations between gears and clamping location
Solution Approach 1:
The patent replaces mechanical clamping and measurement systems with optical sensing technology. Optical sensors non-contactingly measure the datum surface and tooth surfaces to determine mounting distance, eliminating mechanical clamping errors entirely. The system uses light-based measurement instead of mechanical contact, thereby substituting the mechanical system that causes clamping variability with an optical system that provides consistent, error-free measurements.
Solution Approach 2:
The patent creates a digital replica or model of the gear's actual geometry through optical scanning. The system captures the actual positions of the datum surface and tooth surfaces, creating a digital copy of the gear's features. This digital model is then used to calculate the precise mounting distance without physical clamping, allowing the system to compensate for any variations in the actual gear geometry.
2Manufacturing precision
If the over-ball contact technique is used to determine the amount of material to remove by measuring mounting distance at one or more locations, then the stock removal amount can be determined, but the process is time consuming and requires different measurement instruments for different gear tooth geometry
Solution Approach 1:
The patent implements a universal optical measurement system that can measure all gear types with the same instrumentation. The optical sensors and imaging system are configured to capture the complete gear geometry in a single setup, eliminating the need for different measurement instruments for different gear tooth geometries. The system adapts to various gear types through software processing rather than requiring physical instrument changes.
Solution Approach 2:
The patent combines multiple measurement functions into a single integrated optical system. Instead of using separate instruments for different measurement tasks (over-ball contact, mounting distance measurement, tooth geometry measurement), the system merges all these functions into one optical measurement platform that captures all necessary geometric data simultaneously through imaging and optical sensing.
3Manufacturing precision
If multiple measurement instruments and techniques are used to account for heat treatment distortions and variations in gear geometry, then measurement accuracy can be maintained, but the complexity of the measurement system increases and the process becomes more time consuming
Solution Approach 1:
The patent replaces complex mechanical measurement systems with optical sensing technology. Instead of using multiple mechanical instruments that require alignment, calibration, and manual operation, the system uses optical sensors and imaging devices that automatically capture geometric data. This substitution reduces system complexity while maintaining or improving measurement accuracy.
Solution Approach 2:
The system performs self-measurement and self-calculation of the mounting distance. The optical sensors automatically capture the gear geometry, and the controller independently calculates the mounting distance based on the captured images and measurements. This eliminates the need for complex manual measurement procedures and reduces the complexity of the overall measurement system.
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 solution allows for accurate and efficient determination of stock removal amounts, minimizing clamping errors and geometric defects, thereby improving the precision of gear finishing processes.
Implementation Method 1
The first optical sensor is operable to measure a plurality of first distances... The second optical sensor is operable to measure a plurality of second distances
Data Source
AI summary
The present disclosure is directed toward a system that includes a first optical sensor, a second optical sensor, and a gear feature controller. The first optical sensor measures a plurality of first distances measured from a first reference point to a surface provided between a pair of adjacent teeth among a plurality of teeth circumferentially distributed about a first side of a gear. The second optical sensor measures a plurality of second distances measured from a second reference point to a surface along a second side of the gear opposite the first side. The gear feature controller configured to determine a stock removal amount of the gear based on the first distances and the second distances.