Optical Roughness Probe with Virtual Skid for Gear Tooth Flanks

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Solution Overview

Problem

Existing roughness measuring probes face challenges in accurately measuring surface roughness on small-module gears and 3-dimensional structures due to issues like signal distortion, inability to penetrate tooth gaps, and limitations in guiding into corners or edges, leading to incomplete topography measurements.

Innovation Solution

A roughness measuring probe that incorporates an optical scanning device with a virtual skid, allowing for non-contact optical scanning and equidistant positioning, using a chromatic confocal sensor or triangulation principle to measure surface roughness without physical contact, enabling precise measurement of microscopic details on complex surfaces.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If a mechanical scanning process with a stylus tip is used to measure surface roughness, then measurement precision can be achieved, but the stylus tip is sensitive to uncontrolled movements and tends to wear out or be destroyed

Engineering Contradiction:

Improvesurface roughness measurement precisionVSAvoidstylus tip durability

Core Design Contradiction:

Measurement precisionVSReliability

Solution Approach 1:

The patent replaces the mechanical contact-based stylus tip with an optical scanning device that uses light to measure surface roughness. This substitution eliminates the mechanical contact that causes wear and vulnerability to uncontrolled movements, while maintaining measurement precision through optical detection methods.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces light as an intermediary between the measuring device and the surface. Instead of direct mechanical contact, light serves as the mediator to carry measurement information from the surface to the detector, eliminating the need for a physical stylus tip that can wear or break.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Adaptability or versatility

If existing sliding-shoe probes are used to measure tooth flanks, then macroscopic irregularities can be detected, but the probes cannot penetrate far into the tooth gaps of small-module gears or reach close to the tooth tip

Engineering Contradiction:

Improveability to measure tooth flanksVSAvoidaccess to tooth gap regions

Core Design Contradiction:

Adaptability or versatilityVSMeasurement precision

Solution Approach 1:

The patent replaces the bulky mechanical sliding-shoe probe with a compact optical scanning device. This substitution allows the measuring system to access confined spaces like tooth gaps and regions near tooth tips that are inaccessible to traditional mechanical probes, while maintaining the ability to detect both macroscopic and microscopic surface features.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Measurement precision

If a stylus tip with small tip radius is used to detect surface roughness, then measurement precision is improved, but the tip is relatively sensitive and tends to wear out or be destroyed

Engineering Contradiction:

Improvesurface roughness detection accuracyVSAvoidstylus tip vulnerability to damage

Core Design Contradiction:

Measurement precisionVSObject-affected harmful factors

Solution Approach 1:

The patent eliminates the vulnerable mechanical stylus tip by substituting it with an optical scanning system. This replacement removes the source of vulnerability while preserving the ability to detect fine surface roughness details through optical means rather than mechanical contact.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical 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

Enables quick and accurate roughness measurements on small-module gears and 3-dimensional structures, improving measurement precision and extending the probe's usability to areas previously inaccessible, such as tooth flanks, with enhanced durability and reduced risk of damage.

Implementation Method 1

an optical scanning device (30), in particular a chromatic confocal sensor device or a triangulation sensor device, for non-contact optical scanning

Methodology Applied

Scientific EffectLight reflection: Reflection

Implementation Method 2

a chromatic confocal sensor device or a triangulation sensor device

Methodology Applied

Scientific EffectChromatic confocal effect: Dispersion (of waves)

Implementation Method 3

a chromatic confocal sensor device or a triangulation sensor device

Methodology Applied

Scientific EffectTriangulation: Parallax

Data Source

PatentEP3569976B1Roughness probe, apparatus with said roughness probe and respective use

Publication Date: 2023.07.05 KLINGELNBERG GMBH

Figure 1~2B
Figure 2C~2D
Figure 3~4

AI summary

Roughness measuring probe (15) for scanning a surface (F) comprising an integrating device (20) and an optical scanning device (30), wherein the optical scanning device (30) is arranged directly on or in the integrating device (20), wherein the integrating device (20) is designed to specify an average distance between the roughness measuring probe (15) and a larger area of the surface (F) when scanning the surface (F), and wherein the optical scanning device (30) is designed to optically scan a smaller area of the surface (F) without contact.