1、Cylindrical and Bevel Gear Inspection - A Simple Task Using Dedicated CNC-Controlled Gear Inspection Machines by: G. Mikoleizig, Klingelnberg Soehne GmbH TECHNICAL PAPER COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesCylindrical and Bevel Task Using D
2、edicated Inspection Machines Gear Inspection - A Simple CNC-Controlled Gear Guenter Mikoleizig, Klingelnberg Soehne GmbH The statements and opinions contained herein are those of the author and should not be construed as an official action or opinion of the American Gear Manufacturers Association. A
3、bstract Within the past few years, production conditions have changed considerably in many industrial enterprises. Increasingly small batch sizes must be produced to a high standard of quality in shorter time intervals. Consequently, the production equipment must be as flexible and simple to use as
4、possible. The condition also applies for the production of gears. In this case, the function of the gear inspection technology is to check a wide range of gears, comparing them with tolerances predetermined in company standards or in national and international standards. This task, very ambitious in
5、 itself, must frequently be performed under highly accurate production conditions. Suitable checking equipment is now available in the form of special CNC-controlled gear measuring machines, which have already been established in the industry for many years. This presentation will describe the desig
6、n and functioning of appropriate inspection machines. The conceptual design is explained in reference to the individual tasks, and the most important components of the testing machine, such as drive systems, probe systems, control and computer systems, are described. The second part of the presentat
7、ion deals with software, as well as practical measurement examples in the areas of software management, operator guidance, evaluation and documentation of measuring results, examples of measurement times, measurement accuracy and the introduction of new software for the analytical evaluation of acyl
8、indrical gear set. By means of the tooth contact analysisof agear set, the combined effect of gear and pinion is simulated on the computer on the basis of individual profile and alignment measurements. A particular challenge for gear inspection machines is checking of the flank form of spiral bevel
9、gears. With these geometrically very complex shapes, different coordinates and a different master direction have to be taken into consideration for each measuring point. In conjunction with a special 3D-probe system, a special control function and the related evaluation, it is possible to achieve co
10、ntinuous recording of measured values with high measuring accuracy and short measuring times also on such workpieces. The preparations for performing a measurement are supported by graphicoperator guidance and can be carried out by the operator in just a few minutes. When evaluating the measuring re
11、sults, there is the requirement to derive the necessary condition of the bevel gear manufacturing system directly from this evaluation. In this connection, the presentation will discuss a new, fully-automatic correction system. The presentation will illustrate the status and the potential of current
12、 gear inspection machines with practical examples. Copyright O 2000 American Gear Manufacturers Association 1500 King Street, Suite 201 Alexandria, Virginia, 22314 October, 2000 ISBN: 1-55589-770-3 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Servicesa a e
13、a CYLINDRICAL- AND BEVEL GEAR INSPECTION - A SIMPLE TASK USING DEDICATED CNC-CONTROLLED GEAR INSPECTION MACHINES - Guenter Mikoleizig, Dipl-lng. Technical Management Inspection Machinery - Klingelnberg Soehne GmbH, Hueckeswagen, Germany 1 .O Introduction As in many areas of industry, the prevailing
14、condi- tions have changed in gear manufacture as well. Higher quality requirements and frequently changing batch sizes must be dealt with in production on a daily basis. In this regard, the gear measuring technology un- dertakes the important task of checking and docu- menting the gears, which are a
15、s a rule modified and optimized, and specifying any necessary setting cor- rection to production. In many cases, national, inter- national and also company-specific standards must be complied with in this context. Consequently, gear measuring technology is of great importance in achieving and subseq
16、uently maintain- ing a required quality standard. The relevant gear inspection machines required to determine individual deviations on profile, lead, pitch and runout are dealt with below. 2.0 Basic design and function of gear measur- ing machines CNC-controlled gear inspection machines have al- rea
17、dy been successfully used in the industry for many years. Starting from the known measuring tasks of profile, lead, pitch and runout on cylindrical gears, these machines offer a very much greater diversity of application on the basis of their technol- ogy. Ultimately, an extended software package is
18、 all that is required to also be able to inspect worms and wormgears, bevel gears or even gear cutting tools such as hobs, shaving and shaper cutters. Basically, CNC-inspection machines consist of the following components: Basic bed with rotational axis and linear measuring axes CNC-control for exec
19、uting measuring movements and forming measured value Evaluation computer system for programming measuring runs and evaluating measurement results, including documentation via printer of gear-related workpieces, suited to the evaluation computer system Evaluation software for inspecting a diverse ran
20、ge Figure 1 shows an overall view of a CNC-controlled inspection machine of medium structural size for workpieces up to 650 mm diameter. Nr. i KS f mo 1 DOC.l nirator: Lucht L)*CCI: 06.03.1999 15:l NO. Of CPL1.1, 12 FOICC Width 2 o1 VMIUJ m 2 .45m -“ E. ,.a 71 PrcPsIIcc drlqlc +190000“ Lengfh E-. Ei
21、lz/8 500:l Tooth to tooth spacing fp right + 4CL.valuv Oua. Nm.VaIUC Qua. ACt.valiie pua. Som.valuc Oua. 4.0 5 3.5 4 2.8 4 3.5 4 4.5 4 2.1 2 4.5 4 6.8 5.5 11.5 5 11.0 4 9.6 4 11.0 4 6.2 4 7.0 4 5.5 4 7.0 4 1.8 2 Tooth to tooth total accumulative Fp right Pitch iiic RUI)DYI PI I 9.4 5 I 8.0 4 + Nomin
22、al 44.53 44.49 1 I 500:l PariilLiOl, if tuoth thickness R+ tu1 44.516 44.516 44.515 + Example 02: Measuring sheet Gear Spacing DIN 3962 18 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Servicesh Y e Gear Profile/Lead PD.No.: CTI04 071113 O P 26 operator: Luc
23、ht nite: 02.05.2000 14 : 2C 12 Face Width: 2 om TYP: DrdVlng NO.: Gear 12 m=dille rn 2.39mm BV. a 8.5mn Order NO. : KS-Hckeswaqen pressure angle 20 Length 6“. Ii 16na LDC. OE check: KLINGELNBERG Base cii.-0 ab 3 O . 03 Lmm EZI-O lmm Gear No. if teeth Cuzt./Uach. NO.: P 26 Hcllx angle 28“ hppr. Lengt
24、h M1 3.3m 0 Example 03: Measuring sheet Prof/e/Lead AGMA 2000 19 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesPrOq.NO.: STI 040711130 P 26 Type: Gear Gear 12 DI-ivlng NO.: Order No. : KC-Hckeswaqen CusC./MCh. NO.: P 26 operator- Lucht Date: 02.05.20
25、00 14 : 20 NO. Of Leech 12 pressure angle 209 Madule m 2 . 3 9lIUl Helix angle 280 Loc. O check: KTJNGELNBERG Example 04: Measuring sheet Gear Spacing AGMA 2000 20 WA Max. T.S. Index Ermr Wax. Tooth Spaoinq Error U mx Range of Pitch Error T.S. Tocal Index Error T.S.fmal Index Error over m %z/e RP FP
26、 ACt.value Vual. Nm.+u Qual. AOC value Qual. Nom.value Qial. 2.0 14 4.0 12 1.6 14 4.0 12 1.3 4.5 3.1 4.5 3.6 3.2 5.1 14.0 6.3 14. O 3.0 9.0 3.1 9.0 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Servicese TIP OUTSIDE concave 2.3 GFEOC BA I H ROOT ?arameter 1o
27、rm.chor.thickness Pressure Angle concave Pressure Angle convex Spiral Angle concave Spiral Angle convex .-_-_-_ (E4; R=75.865; Z=23.170) Nominal I Actual I Dev. I 1.Tol. 1 u.Tol. Unit _-_- 4.5241 4.4951 -0.0291 I I I mm I DEGREE I DEGREI I DEGREI I DEGREI l I I 1 -0.0051 I I -0.0011 I I 0.0031 I I 0
28、.0011 I I I I I I flaunting distance I 48.50001 48.50001 0.00001 I I mm -0.8 -0.1 0.2 -0.1 0.0 -0.9 -0.1 0.6 0.51 -1.2 -0.4 -0.4 -0.4 0.7 -0.3 0.4 0.5 -0.7 2 -0.7 0.2 0.4 0.0 0.6 -0.1 0.1 0.0 -0.2 3 0.1 -0.2 0.2 0.2 0.0 0.1 -0.2 -0.4 -0.54 0.4 0.0 0.5 0.3 0.5 0.2 0.5 0.7 0.2 5 0.8 0.3 0.2 -0.1 -0.2
29、0.2 0.2 -0.2 -1.4 6 0.7 0.4 0.4 0.1 0.0 0.3 -0.2 -1.0 -2.1 7 I I _ _ I INSIDE TIP OUTS I DE I I- -_-.-I / Concave / Convex / 3.7 1.4 1.2 0.8 0.8 1.7 1.8 3.6 4.9 / 7 / 3.0 0.0 -0.1 -0.1 -0.9 0.7 0.6 2.0 3.7/6 / 3.3 0.7 0.1 0.1 0.5 1.1 1.6 2.8 4.0 / 5 / 2.8 0.2 0.3 0.4 0.0 1.1 1.7 3.4 4.6/4 / 2.5 0.5
30、0.2 0.4 0.7 0.8 1.4 2.2 3.3 / 3 / 4.2 1.4 0.6 1.0 -0.3 0.7 2.1 3.0 3.1 / 2 2.3 0.0 -0.9 0.3 0.0 0.7 1.5 1.8 1.9/1 Example 05: Evaluation Flank form measurement 21 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling ServicesTooth to Tooth Measurement No 23 I Type:
31、Operator H Lucht Date 23.02 1999 09.27 Part Name Me s t-ei-r-g d No of Teeth 33 Press. Angle Part No Meisterrad Module mm spiral Angle35.0000 Order No Number of rows/columns : 7/9 Tooth to Tooth ACCJmUlative Fpi. Left Side (Convex) - Tooth to Toorh Spacing fpi. Rignt Side (Concave1 + I Runout Test K
32、 I Actual Qual .I Perm. IQuafl Example 06: Evaluation Tooth to Tooth spacing 22 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Services., Tooth to Tooth Measurement No 23 I Type: Operator: H. Lucht Date 23.02.1999 09: 27 Part Name: Meisterrad EN0 .: Order No.
33、: Number of rows/colurnns : 7/9 Cust./Mach. No.: EM0 Pitch point row/column : E4 N-of Teeth 33 Press. Angle Meisterrad Module mm Spiral Angle 35.0000 Tooth to Tooth Accumulative Fpi Variation of Tooth Thickness Rs Runout Test I ActuallQua1.i Perm. I0ual.I KLINGELNBEI Example 07: Evaluation Tooth to
34、Tooth spacing 23 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Services3 6 steps to perform a cylindrical gear measurement 1 2 3 4 Adoption of workpiece position Workpiece mounting between centers ur in chuck Call-up of measuring program via data catalog Use
35、 of appropriate probe arrangement if required (vertical starting position) Start of automatic measuring run Conclusion of measurement with output of documentation 5 6 Total time required for steps 1-6 for typical automobiie cylindricai gear approx. 5 minutes Appendix 01: Cylindrical Measurement 6 st
36、eps to perform a bevel gear measurement Workpiece mounting by means of chuck Nominal data specified by floppy disk, online or by calling up a data catalog Use of suitable probe arrangement if required Adoption of workpiece reference surface position Specification of mounting distance Start of automa
37、tic measuring run Conclusion of measurement with output of documentation and automatic calculation of corrected machine setting data via the KOMI3 program Total time required for steps 1-6 for typical automobile ring gear approx. 10 minutes 1 2 3 4 5 6 I I Appendix 02: Bevel Gear Measurement 24 COPY
38、RIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Services Master gear measurement Suitable for straight- and spiral bevel gears without nominal data Flank form compared to master gear data with grid selection 15 x 15 measuring points Index and runout according DIN
39、3965 / AGMA Measuring sequence for automated master flank data generating Compensation of clamping errors up to 2 mm Nominal data measuring Suitable for spiral bevel gears method Klingelnberg-Oerlikon and Gleason according to nominal data Flank form compared to nominal data with grid selection 15 x
40、15 measuring points Calculation of pressure- and spiral angle deviation as well as tooth thickness based on flank form measurements Index and runout according DIN 3965 / AGMA 0 Interface to KIMOS, KOMET, CDSTM, G-AGETM, Super G-AGETM Compensation of clamping errors up to 2 mm Appendix 03: Design and Function Bevel Gear Software+. 25 COPYRIGHT American Gear Manufacturers Association, Inc.Licensed by Information Handling Services
