Structure-Borne Sound Gear Testing Before Gearbox Assembly
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Solution Overview
Problem
Existing gear testing methods are not cost-effective, fast, or simple, and do not adequately address manufacturing quality verification before installation in a gearbox.
Innovation Solution
A testing device with rotatably mounted shafts driven by an electric motor, sensors for detecting structure-borne sound, and a soundproof housing for optimal signal-to-noise ratio, allowing for quick and easy verification of gear quality under load, with features like braking torque adjustment and RFID/NFC tag reading for gear identification.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If traditional gear testing methods are used, then manufacturing quality can be verified, but the testing process is not cost-effective, fast, or simple
Solution Approach 1:
The patent replaces complex mechanical measurement systems with an acoustic sensing system. A sensor detects structure-borne sound waves generated by gear meshing, and an evaluation unit analyzes these signals to determine gear quality parameters. This substitution of mechanical measurement with acoustic field measurement enables faster, simpler testing while maintaining manufacturing precision verification
Solution Approach 2:
The patent introduces structure-borne sound waves as an intermediary to transfer information about gear quality. The sound waves generated during gear meshing carry information about manufacturing defects, which are then detected by the sensor and evaluated to assess gear quality. This intermediary approach enables indirect but efficient quality verification
2Reliability
If gears are tested after installation in a gearbox, then comprehensive system performance can be evaluated, but cost-effective and fast verification before installation is lost
Solution Approach 1:
The patent enables preliminary testing of individual gears before they are installed in the gearbox. By mounting gears on test shafts and simulating meshing conditions, the system performs quality verification in advance, allowing defective gears to be identified and replaced before final assembly. This preliminary action ensures reliability while improving ease of manufacture
3Productivity
If a sensor for detecting structure-borne sound is used, then rapid defect detection is possible, but achieving optimal signal-to-noise ratio requires soundproof housing
Solution Approach 1:
The patent merges the sensor, evaluation unit, and soundproof housing into an integrated testing system. The sensor is positioned within the soundproof housing to detect structure-borne sound, while the evaluation unit processes the signals. This merging of components achieves optimal signal-to-noise ratio for rapid defect detection while consolidating the device into a cohesive unit
4Object-affected harmful factors
If braking torque is applied under load, then rattling noises are reduced, but additional loading devices and complexity are required
Solution Approach 1:
The patent extracts the function of applying braking torque from a separate loading device and integrates it into the existing shaft and gear system. By mounting the sensor on the shaft and applying braking torque through the gear meshing itself, the system reduces rattling noises without requiring additional complex loading devices
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 rapid, cost-effective verification of gear manufacturing quality by detecting defects through structure-borne noise, reducing rattling noises, and ensuring accurate gear pairing, thus improving manufacturing efficiency and quality assurance.
Implementation Method 1
the testing device has a sensor for detecting structure-borne sound
Implementation Method 2
a first, rotatably mounted shaft driven by an electric motor
Implementation Method 3
a braking torque can be applied from a respective loading device to a respective second shaft
Data Source
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AI summary
The invention relates to a testing device for testing gears, characterised in that the testing device has a first, rotatably mounted shaft driven by an electric motor and second, rotatably mounted shafts, the first shaft being oriented parallel to the second shafts, the testing device having a sensor for detecting structure-borne noise, it being possible for a first gear to be mounted on the first shaft and connected thereto for conjoint rotation therewith, and it being possible for a second gear to be mounted on each second shaft and connected to said second shaft for conjoint rotation therewith such that the first gear is engaged with each second gear.