Optical Gear Oversize Measurement with Plausibility Validation
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Solution Overview
Problem
Current methods for measuring the oversize of gear tooth flanks during hard fine machining are inefficient, leading to long measuring times and non-productive periods, which reduce the profitability of the grinding process due to measurement inaccuracies and the need for frequent idle strokes during grinding operations.
Innovation Solution
The method involves using an optical distance sensor to measure the position of the tooth flank with a light beam aligned perpendicular to the axis of rotation, incorporating a plausibility check to validate measured values and shifting the sensor if necessary to ensure accurate measurements, allowing for faster and more precise determination of oversize situations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a probe with integrated measuring sensors is used to measure the oversize distribution, then measurement precision is improved, but measuring time increases significantly
Solution Approach 1:
The patent replaces the mechanical probe-based measurement system with an optical measurement system using a laser beam. This substitution eliminates the need for physical contact and integrated sensors in the grinding machine, enabling non-contact measurement that is both precise and significantly faster, thus resolving the contradiction between measurement precision and measuring time
Solution Approach 2:
The patent employs periodic scanning of the laser beam across the tooth flanks using rotational movement of the gear wheel or positioning mechanisms. This periodic scanning allows rapid acquisition of multiple measurement points along the tooth flank profile, dramatically reducing measurement time while maintaining precision through systematic data collection
2Adaptability or versatility
If the light beam is directed at an acute angle to the tooth flank surface, then measurement coverage is improved, but measurement accuracy deteriorates due to reduced measurement sharpness
Solution Approach 1:
The patent employs dynamic adjustment of the light beam angle through movable positioning systems. The angle of incidence can be adjusted and optimized for different measurement locations on the tooth flank, allowing the system to adapt to various geometric conditions while maintaining measurement accuracy. This dynamic capability enables both good coverage and precision by selecting optimal angles for each measurement point
3Reliability
If measured values are subjected to strict plausibility checks, then measurement reliability is improved, but processing time increases
Solution Approach 1:
The patent performs plausibility checks during the measurement process itself rather than after data collection is complete. By continuously validating measured values against expected ranges and geometric constraints in real-time, the system can immediately identify and discard implausible measurements, reducing the overall processing time while ensuring reliability
Solution Approach 2:
The patent implements feedback mechanisms where measured values are continuously monitored and compared against plausibility criteria. When values fall outside expected ranges, the system provides feedback to adjust measurement parameters or reject the data point, creating a closed-loop validation process that ensures reliability without requiring extensive post-processing time
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 approach significantly reduces measurement time while ensuring accuracy by discarding implausible values and using interpolation or extrapolation, thereby minimizing idle strokes and enhancing the efficiency of the grinding process.
Implementation Method 1
the position of the surface of the tooth flank provided with allowance is determined by means of optical distance measurement by a distance sensor, in that a light beam from the distance sensor is directed onto the surface
Data Source
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AI summary
The invention relates to a method for measuring the allowance (1) of a gear (2), wherein the gear (2) has a toothing (4) with a number of teeth (5) on its outer and/or inner circumference, wherein the teeth (5) have an allowance (1) on their tooth flanks (6) compared to the finished machined geometry (7), wherein the position of the surface (8) of the tooth flank (6) provided with allowance (1) is determined by means of optical distance measurement from a distance sensor (9) by directing a light beam (10) from the distance sensor (9) onto the surface (8), and wherein the light beam (10) is directed onto the surface (8) such that it is perpendicular to the axis of rotation (3) (N) or parallel to this direction (P).In order to perform the most reliable measurement possible, the invention provides that the measurement of the position of the surface (8) is initially carried out such that the light beam (10) is aligned in a direction (N) that is perpendicular to the axis of rotation (3), wherein a value for the position of the surface (8) of the tooth flank (6) determined by the distance sensor (9) is subjected to a plausibility check before use to determine whether the value lies within an expected range, and wherein, in the event that implausible measured values are present or expected, the optical distance measurement is carried out in a position in which the light beam (10) is shifted by a defined distance (a) parallel to the direction (N) that is perpendicular to the axis of rotation (3).