Toothed Workpiece Straightening Using Reference Circle Measurement
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Solution Overview
Problem
Conventional straightening machines face challenges in achieving precise linearity in toothed racks produced by solid-forming processes due to inconsistent spacing between the tooth head and reference circle, leading to unreliable measurements and increased cycle times, especially in contamination-rich environments.
Innovation Solution
A method that detects and processes the elevated locations of tooth heads and neighboring tooth surfaces in the reference plane, using tactile measurements to ascertain height differentials, which are then utilized by the straightening machine to correct for deviations and achieve ideal straightness, potentially incorporating non-contacting measurements for efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If conventional tactile measuring technology is used to measure tooth head locations, then the measurement can be performed in contamination-rich environments, but the measurement reliability drops and calibration is required from one batch to another
Solution Approach 1:
The patent replaces conventional tactile measuring technology with optical, in particular laser-based, non-contacting measurement. This substitution eliminates the need for physical contact between the measuring sensor and the workpiece, thereby avoiding contamination issues that affect tactile sensors. The laser-based system provides reliable measurements without requiring recalibration from batch to batch, as it measures the actual reference circle plane rather than inferring it from tooth head positions.
Solution Approach 2:
The patent introduces an intermediary reference plane measurement approach. Instead of directly measuring tooth head locations and inferring linearity, the system uses laser-based measurement to directly capture the reference circle plane geometry. This intermediary measurement of the reference plane serves as a mediator between the workpiece geometry and the straightening control, providing accurate data even in contamination-rich environments.
2Reliability
If non-contacting laser-based measurement is used to measure the reference circle plane, then measurement reliability improves, but measurement time increases and cycle time is compromised
Solution Approach 1:
The patent performs the laser-based measurement of the reference circle plane as a preliminary action before the straightening process. By measuring the reference plane geometry in advance, the system establishes accurate reference data that guides the subsequent straightening operation. This preliminary measurement approach ensures reliability while allowing the measurement and straightening processes to be efficiently sequenced.
Solution Approach 2:
The patent implements optimized laser scanning that rapidly captures the reference circle plane geometry by focusing measurements on critical regions. The system skips unnecessary measurement points and uses efficient scanning patterns to acquire sufficient data for straightening control within the available cycle time, thus rushing through the measurement process efficiently.
3Device complexity
If measurement is performed on the tooth head instead of the reference circle plane, then the measurement process is simpler, but the linearity measurement accuracy deteriorates due to variations in tooth head spacing
Solution Approach 1:
The patent replaces the indirect measurement method (measuring tooth heads and inferring linearity) with direct laser-based measurement of the reference circle plane. This substitution eliminates the intermediate step that introduces errors due to tooth head spacing variations, providing direct and accurate linearity measurement data for the active toothing region.
Solution Approach 2:
The patent creates an accurate digital copy of the reference circle plane geometry through laser scanning. This digital replica captures the true geometry of the reference plane, allowing for precise analysis and straightening control without the errors that would arise from copying tooth head positions and inferring the reference plane geometry.
Data Source
AI summary
In the straightening of radial run-out faults or linearity faults on elongate workpieces having at least one toothed region having peaks and troughs of the teeth of said toothed region, such as on toothed shafts or toothed racks, for ascertaining deviations from the ideally straight workpiece, the locations of the surfaces of the not yet straightened workpiece that form a reference plane are scanned at least at points or in portions on or in the region on the active reference circle or pitch circle, respectively, of the toothing that lies between the peaks and troughs of the teeth. The resulting measured items of data are utilized by the straightening machine such that a workpiece that is as ideally straight as possible at least in the toothed region is achieved by the straightening. The elevated locations of the tooth heads of the toothed region that form the peaks of the teeth and the elevated locations of neighboring tooth surfaces that lie in the reference plane are detected, and the height differentials of the elevated locations of the tooth heads in relation to the elevated locations of neighboring tooth surfaces that lie in the reference plane are ascertained. The height differentials are utilized by the straightening machine as corrective measured items of data such that said height differentials are considered when straightening the workpiece so as to form a workpiece that is as ideally straight as possible in the reference plane.