Reducer Transmission Error Testing With Laser Tracker Alignment
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Solution Overview
Problem
Existing methods for testing transmission error in reducers are complex, requiring high-precision instruments and skilled operators, leading to low efficiency and limited practical application.
Innovation Solution
A test apparatus and method using a laser tracker, target balls, and a motor-driven encoder system to measure the rotation angles of the input and output ends of a reducer, eliminating assembly errors through coordinate conversion and simplifying the process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If a conventional test apparatus with separate motor and load machines is used, then the structure is simple, but the measurement precision of transmission error is insufficient
Solution Approach 1:
The patent combines the motor machine, load machine, and test subject into a single integrated test apparatus structure. The motor machine and load machine are coupled through the test subject (speed reducer) within a unified framework, allowing simultaneous measurement of multiple parameters (rotation angles, torques, speeds) with high precision sensors while maintaining structural coherence.
Solution Approach 2:
The test apparatus is designed as a multi-functional system that can simultaneously perform multiple measurement functions: measuring rotation angles of input and output shafts, measuring torques on both shafts, measuring rotational speeds, and calculating transmission errors. This universal design enables comprehensive transmission error characterization without requiring separate test setups.
2Measurement precision
If high-precision sensors are installed on both input and output shafts, then the measurement precision improves, but the device complexity increases
Solution Approach 1:
The patent integrates multiple sensors (encoders for rotation angle, torque sensors for torque measurement, speed sensors for rotational speed) into a coordinated measurement system where sensors on both input and output shafts work together to provide comprehensive data for transmission error calculation, rather than treating them as separate independent systems.
Solution Approach 2:
The control unit serves as an intermediary that receives data from all sensors, processes the signals, coordinates the measurements, and calculates the transmission errors. This central processing approach simplifies the overall system architecture by providing a single point of data integration and analysis.
3Reliability
If the test apparatus can operate at actual driving speeds, then the reliability of test results improves, but the ease of operation becomes more difficult
Solution Approach 1:
The test apparatus is designed to dynamically operate across a range of speeds including actual driving speeds of the speed reducer. The motor machine can vary its rotational speed to match real-world operating conditions, and the load machine can adjust accordingly, enabling reliable transmission error measurement under dynamic conditions that reflect actual service environments.
Solution Approach 2:
The control unit implements feedback control by continuously monitoring measurements from sensors and adjusting motor and load machine operations to maintain synchronized testing conditions. This feedback mechanism automates the complex coordination required for high-speed operation, reducing the manual operational difficulty while ensuring test reliability.
Data Source
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AI summary
A speed reducer transmission error test method and apparatus. The test apparatus comprises: a base (1); a test workpiece (2), wherein the test workpiece (2) is provided on the output end of a speed reducer (6) to be tested, and the speed reducer (6) is fixed on the base (1); a driving assembly (3), wherein the output end of the driving assembly (3) is connected to the input end of the speed reducer (6), so that the driving assembly is used for driving the input end of the speed reducer (6) to rotate and determining the rotation angle information of the input end of the speed reducer (6); a detection assembly (4), comprising a laser tracker (42) located at one side of the output end of the speed reducer (6), and target balls (41) provided on the test workpiece (2), wherein the target balls (41) cooperate with the laser tracker (42) so as to be used for determining the motion trajectory information of the target balls (41); and a receiving assembly (5) for determining the transmission error of the speed reducer (6) according to the rotation angle information of the input end of the speed reducer (6) and the motion trajectory information of the target balls (41). The speed reducer transmission error test method can be widely used in practical application.