Worm Gear Surface Profile Analysis for Quality Pre-Selection
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Solution Overview
Problem
Existing methods for checking worm gears are lengthy, cumbersome, unreliable, and do not guarantee quality, as they require mounting screws in an assembly line and traditional instruments for analysis, which are not efficient or reliable.
Innovation Solution
A method using an electronic measuring system with a feeler to scan the involute and helix profiles of worm gears, filtering data to obtain accurate surface analysis, allowing for pre-selection before assembly and ensuring compliance with preset tolerance limits to minimize noise and optimize production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional mounting and testing methods are used to check worm gears, then the engagement quality can be assessed, but the process becomes lengthy, cumbersome, and complicated
Solution Approach 1:
The patent performs surface analysis of the worm gear screw before it is mounted in the assembly line. By scanning the involute and helix profiles and analyzing surface characteristics in advance, the method determines whether the screw meets tolerance limits before assembly, eliminating the need for time-consuming post-assembly testing while ensuring engagement quality
Solution Approach 2:
The patent extracts the checking process from the assembly line by performing surface analysis independently before mounting. The electronic measuring system with feeler scans the screw surfaces separately, and the controller analyzes the data to determine compliance with tolerance limits, separating the inspection function from the assembly process to reduce overall time
2Reliability
If traditional instruments are used to analyze screw performance and noise level, then engagement assessment is possible, but the methods are not very reliable and do not guarantee good quality
Solution Approach 1:
The patent replaces traditional mechanical testing instruments with an electronic measuring system. The system uses a feeler to scan the screw surfaces and an electronic controller to analyze surface characteristics, substituting mechanical performance testing with precise electronic surface measurement to achieve more reliable and accurate quality assessment
Solution Approach 2:
By performing surface analysis before assembly, the method identifies and rejects non-compliant screws in advance, ensuring that only screws meeting preset tolerance limits are mounted. This preliminary filtering guarantees quality by preventing defective components from entering the assembly process
3Reliability
If screws are mounted in the assembling line for testing, then performance can be evaluated, but the production cycle is extended and efficiency is reduced
Solution Approach 1:
The patent performs surface analysis of all screws before they are mounted in the assembly line. The electronic measuring system scans the involute and helix profiles, and the controller analyzes surface characteristics to determine compliance with tolerance limits in advance, enabling pre-selection of quality screws and eliminating post-assembly testing delays
Solution Approach 2:
The patent extracts the performance evaluation function from the assembly line by performing surface analysis independently beforehand. This separation allows the assembly line to operate continuously with pre-qualified screws, improving productivity while maintaining reliable performance evaluation through electronic surface measurement
Data Source
AI summary
A check method of worm gears includes the following steps: identification of a real profile (PR) of a worm gear to be checked; scanning of the real profile (PR) in such a way to obtain a measured profile (PM), filtering of the measured profile (PM) with a low pass filter in such a way to obtain a primary profile (PP), filtering of the primary profile (PP) with a high pass filter in such a way to obtain a surface analysis profile (SA), calculation of three parameters (SAa; SAq; SAp) from said surface analysis profile (SA) and comparison of the three parameters (SAa; SAq; SAp) with preset threshold values (TSa; TSq; TSp) in such a way to reject the worm gear when at least one of the parameters exceeds the corresponding threshold value.