Measuring Sensors Calibration in Worm Gear Rolling Testers.

Marcos Pueo,Raquel Acero,Ángel Gracia,Jorge Santolaria

doi:10.3390/s20113148

Marcos Pueo, Raquel Acero + Show 2 more

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https://doi.org/10.3390/s20113148

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Abstract

The ISO standard regulating gear-rolling measurement does not specify in detail the calibration and verification procedures for this type of equipment. This may be one of the reasons for the lack of reproducibility in these rolling tests. The uncertainty budget method, which is the most appropriate way to know the accuracy of this dynamic measurement, shows that the measuring sensors’ accuracy is only a part of the total measurement process uncertainty. In this work, a new calibration and verification procedure for a worm gear rolling tester is presented, based on machine tool, coordinate measuring machine and gear measuring instruments’ calibration techniques. After compensating numerically for the measuring instruments, it has been evaluated how the error components of each movement affect the meshing point, a fundamental factor to ensure a good gear transmission. The study shows that there are unintentional position variations, not detected by the measuring sensors, that have to be identified and quantified in the calibration for their later inclusion in the uncertainty budget. In this way, the measurement uncertainty could be reduced, and thus improve the reproducibility of these testers, as a preliminary stage to the development of optimized rolling measurement equipment to solve current limitations.

Highlights

Rolling tests are functional tests where the quality grade of a gear unit is determined by rolling it against a higher quality master gear
We present the calibration and evaluation procedure of a single and double-flank rolling worm gear tester, analysing in detail the influence of the measurement sensors used on the accuracy of the equipment
We present a new calibration and evaluation procedure of a single and double-flank rolling worm gear tester, analysing in detail the influence of the measurement sensors used on the accuracy of the equipment

Summary

Introduction

Rolling tests are functional tests where the quality grade of a gear unit is determined by rolling it against a higher quality (precision) master gear. These tests are presented as the fastest and most complete way to check the behaviour of a gear or a transmission since it is not limited to checking the geometry of a few randomly selected teeth but of the complete set From its results, both geometric errors (profile, pitch, cumulative pitch and eccentricity errors) and manufacturing problems (misalignments in the axes, poor clamping, handling shocks, etc.) can be identified. Both geometric errors (profile, pitch, cumulative pitch and eccentricity errors) and manufacturing problems (misalignments in the axes, poor clamping, handling shocks, etc.) can be identified They allow for the verification of parallel, bevel and worm gears. There is a growing interest in studies and developments of new gear measurement techniques and instruments, based on rolling principles, due to its potential in industry [7,8,9]

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