Oriented Internal and External Gear Teeth Manufacturing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current gear manufacturing systems are unable to produce internal ring gears with specific orientation between outer diameter spline teeth and inner diameter gear teeth, failing to meet high volume demands for accurately aligned gear components.
Innovation Solution
A system and method that utilize a sensor to detect the position of features on the gear, a cutting tool to form features on the inner surface, and a controller to determine and achieve the desired angular orientation of the cutting tool relative to the gear, ensuring precise alignment of inner and outer surface features during the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If both spline teeth and gear teeth are broached on a cutting machine to meet high volume demands, then productivity is improved, but the ability to produce gear teeth with specific orientation relative to spline teeth is lost
Solution Approach 1:
The patent applies preliminary action by first broaching the spline teeth on the outer diameter of the ring gear, then using a sensor to detect the actual position of these spline teeth. Based on this detection, the system calculates the required rotation angle and rotates the gear or cutting tool before broaching the inner diameter gear teeth. This ensures the gear teeth are oriented at the correct angle relative to the spline teeth, resolving the contradiction between high-volume production and precise angular orientation.
2Manufacturing precision
If a sensor and rotation control system are added to orient gear teeth, then manufacturing precision is improved, but device complexity increases
Solution Approach 1:
The patent implements feedback by using a sensor to detect the actual position of the spline teeth on the outer diameter of the ring gear. The detected position information is fed back to a controller, which calculates the deviation from the desired orientation and determines the required rotation angle. This feedback mechanism enables precise angular orientation of the gear teeth relative to the spline teeth, resolving the contradiction between manufacturing precision and device complexity.
3Manufacturing precision
If the gear or cutting tool is rotated to achieve desired orientation, then manufacturing precision is improved, but the manufacturing process time increases
Solution Approach 1:
The patent replaces complex mechanical alignment systems with a sensor-based detection and electronic control system. Instead of using elaborate mechanical fixtures or manual alignment procedures, the system uses a sensor to detect spline tooth positions, electronically calculates the required rotation angle, and actuates a rotation mechanism. This substitution reduces the time required for orientation adjustments while maintaining high manufacturing precision, resolving the contradiction between manufacturing precision and production time.
Data Source
AI summary
A system and method for forming a feature on an inner surface of a gear includes a sensor for sensing the position of a feature on the gear, a cutting station having a cutting tool for forming the feature on the inner surface of the gear, and a controller. The controller is operable to determine an amount of rotation necessary to rotate either the gear or the cutting tool such that the feature on the inner surface of the gear is formed at a desired orientation relative to the feature on the outer surface of the gear.