Automatic Geometrical Dimension Determination for Worm Thread Grinding Tools
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Solution Overview
Problem
Current gear cutting processes require manual or semi-automatic determination of geometrical parameters for tools with worm thread forms, leading to increased dressing times and potential errors due to the lack of fully automated and precise measurement methods.
Innovation Solution
A method for automatically determining the geometrical dimensions of a tool with a machining region in worm thread form using a measurement element that detects distance values during tool rotation, allowing for precise calculation of parameters like outer diameter, lead angle, and thread number, with the option of using a dresser for impact sound detection and motor parameter evaluation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If manual or semi-automatic methods are used to determine geometrical parameters of the tool, then the process can be performed with simple equipment, but the dressing time increases and measurement precision decreases
Solution Approach 1:
The patent replaces manual mechanical measurement methods with an automated optical measurement system. A measurement element optically detects distance values to tool surfaces during rotation, eliminating the need for manual mechanical contact and calculation, thereby achieving both high precision and reduced measurement time
Solution Approach 2:
The measurement system automatically determines geometrical parameters by optically detecting distance values during tool rotation and calculating parameters such as outer diameter, lead angle, and thread number without requiring manual intervention or hand-performed worksteps
2Reliability
If manual operations are performed to position the tool and record measurements, then the equipment complexity remains low, but the reliability of the settings decreases due to potential human errors
Solution Approach 1:
The patent replaces manual positioning and recording operations with an automated optical measurement system that continuously tracks distance values during tool rotation. The control unit automatically calculates geometrical parameters and stores them, eliminating human error while maintaining systematic control
Solution Approach 2:
The measurement element continuously detects distance values during tool rotation and feeds this information back to the control unit, which processes the data to determine accurate geometrical parameters. This closed-loop feedback system ensures reliable and repeatable measurements
3Productivity
If fully automatic measurement is implemented, then productivity increases and manual errors are reduced, but the device complexity and initial setup requirements increase
Solution Approach 1:
The measurement element is designed to perform multiple functions: it optically detects distance values to various tool surfaces, tracks tool rotation, and enables determination of multiple geometrical parameters including outer diameter, lead angle, and thread number. This multi-functional approach increases productivity without proportionally increasing device complexity
Solution Approach 2:
The patent employs an optical measurement system that replaces complex mechanical contact measurement methods. The optical system non-contactly detects surface positions during rotation, simplifying the mechanical requirements while enabling fully automatic determination of multiple geometrical parameters
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 fully automatic, precise, and efficient determination of process-relevant geometrical parameters, reducing manual errors and dressing times, and allowing for the use of the method with unknown grinding worms.
Implementation Method 1
a measurement element for optically measuring a distance to a surface of the tool
Implementation Method 2
a dresser (1) having an impact sound device for detecting a contact of the dresser (1) with the tool (2)
Data Source
AI summary
The present disclosure relates to a method for the automatic determination of the geometrical dimensions of a tool having a machining region in worm thread form, in particular of a grinding worm, wherein in the method: a measurement element is directed to the tool for the detection of a distance, the tool is set into rotation with respect to the measurement element, and a conclusion is drawn on the geometry of the tool on the basis of distance values that were detected by the measurement element during the rotation of the tool.