Spur Gear Rolling Test Tolerance Setup Using Order Analysis
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Solution Overview
Problem
The setup of a rolling test for spur gears in series production is complex due to unknown tolerances, requiring experienced personnel and is not reliably repeatable or reproducible.
Innovation Solution
A method involving a rolling test rig for spur gears, followed by statistical evaluation for repeatability and reproducibility, hard finishing, and an end-of-line test to determine order-specific tolerance limits, ensuring a robust and reliable rolling test setup.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a rolling test is performed for spur gears in series production, then the dynamic behavior and noise behavior can be checked, but the tolerances are not known in advance making the setup complex and requiring experienced personnel
Solution Approach 1:
The patent applies preliminary action by conducting a preliminary rolling test on a sample of spur gears to determine the standard deviation and establish tolerance limits before the actual series production testing. This preliminary phase involves statistical evaluation (calculating standard deviation from test results) and hard finishing of spur gears, allowing the tolerance limits to be defined in advance based on real test data rather than assumptions, thereby simplifying the setup for subsequent production testing
Solution Approach 2:
The patent implements feedback by using the results of the preliminary rolling test and end-of-line test to define and adjust tolerance limits for the rolling test. The standard deviation calculated from initial test results provides feedback that informs the tolerance limit settings, creating a closed loop where test results directly influence the testing criteria for future production batches
2Manufacturing precision
If the rolling test setup is made robust and reliable with known tolerances, then the testing can be standardized, but the initial setup effort and time increase
Solution Approach 1:
The patent performs all necessary preliminary actions including statistical evaluation of test results, determination of standard deviation, and definition of tolerance limits before the actual series production testing begins. This preliminary setup, though time-consuming initially, establishes a standardized framework that can be reused for subsequent production batches, reducing setup time for future testing
Solution Approach 2:
The patent changes the parameter of tolerance definition from unknown or assumed values to statistically determined values based on actual test results. By calculating standard deviation from preliminary test data and using end-of-line test results to define tolerance limits, the system transforms vague testing criteria into precise, data-driven parameters that can be consistently applied
3Reliability
If experienced or specially trained employees are used to setup the rolling test, then the test can be performed reliably, but the labor cost and complexity increase
Solution Approach 1:
The patent enables the rolling test system to be self-sufficient by automatically determining tolerance limits based on statistical evaluation of test results. The system performs its own calibration and setup using preliminary tests and end-of-line test data, eliminating the need for highly skilled personnel to manually determine appropriate tolerances. The standardized procedure with built-in statistical analysis allows less experienced employees to conduct reliable tests
Data Source
AI summary
A method includes rolling test of spur gears with a rolling test rig, wherein test results are statistically checked for repeatability, reproducibility, and determination of a standard deviation for the test results; hard finishing of spur gears, wherein a respective gearing of a respective spur gear is hard-finished; rolling test of hard-finished spur gears by the rolling test rig for which standard deviation has been determined; end-of-line testing of the hard-finished spur gears by a gear test rig; evaluation of the end-of-line test results of the hard-finished spur gears, wherein spur gears are declared as good or bad parts based on at least one quality criterion; evaluating test results of hard-finished spur gears, wherein results are evaluated which have been declared as good parts according to end-of-line test, wherein the rolling test results include an order analysis, and a tolerance limit is determined for one or more orders per case.