齿轮双啮单项偏差测量仪的测控软件

在生产现场测量齿轮各单项偏差(齿距、齿廓、螺旋线)是个难题。目前应用在生产现场的齿轮测量大多采用双面啮合测量原理,而传统的齿轮双面啮合测量主要测量齿轮径向综合偏差。为此,研制了基于双啮齿条测头的齿轮单项偏差测量仪,可同时获得左右齿面单项偏差。主要介绍了该测量仪的系统框架、测量流程和测控软件。该测控软件的主要功能包括伺服控制、数据采集、数据处理和测量结果报表打印等,经反复测试,运行稳定。     

锥齿轮齿距及齿形偏差测量与分析方法

研究了基于齿轮测量中心的锥齿轮齿距偏差和齿形偏差测量与分析方法及其实现技术。该方法应用齿轮啮合理论,根据锥齿轮齿面成形方法,建立了齿面几何参数计算模型;在齿面上建立测量网格,控制齿轮测量中心四轴运动使齿面和测头于测量网格点接触,采集实际坐标轴及测头读数;应用B样条法构造实际齿面,计算其齿形偏差。在此基础上,开发了基于哈量集团公司制造的390X系列齿轮测量中心的实现软件系统。30家锥齿轮制造企业实际应用表明,该软件系统为提高锥齿轮精度、减小齿形偏差提供了先进的测量与分析手段。     

基于直母线族误差的大齿轮在机测量原理

根据大齿轮的特点及渐开线螺旋面的线族特征,提出基于直母线误差的测量原理。采用齿条刃边测头与齿轮廓面相啮合,获得其直母线族误差,进而通过误差理论分析模型分离出齿廓总偏差和螺旋线总偏差。     

未知参数小模数齿轮齿距和齿廓偏差视觉测量

小模数齿轮齿槽间隙小,接触式测量难度高,且易损坏测头,本文主要研究基于视觉的未知参数小模数齿轮的齿距偏差和齿廓偏差测量。基于亚像素数字图像处理技术定位齿轮测量基准,即齿轮几何中心,并测量得到齿数、模数、齿顶圆直径和齿根圆直径;依据齿轮精度标准ISO1328-1:2013中偏差项目定义,给出了基于视觉测量的齿轮齿距偏差和齿廓偏差评定方法,开发了小模数齿轮视觉测量数据处理软件。对模数为0.5 mm的渐开线圆柱直齿轮进行了齿距和齿廓偏差视觉测量试验,并与齿轮测量中心的测量结果对比,左右齿面测量结果的绝对误差最大为4μm,最小为1μm,评定齿轮精度等级均为8级。本文给出的未知参数小模数齿轮视觉测量系统和偏差评定方法可在一定范围内用于小模数齿轮测量。     

大齿轮误差测量数学模型的建立和仿真分析

基于齿轮啮合理论,采用了刃边齿条形测头在位综合测量直母线偏差的方案。通过测量轮齿廓面上直母线族的各个偏差,确定测量网格,建立了在获得直母线偏差后分离出齿廓偏差和螺旋线偏差的数学模型,并对其进行了仿真分析。文中的数学模型和仿真研究结果为研制直母线测量仪和在线测量系统提供了理论依据。     

三坐标图像测量在渐开线圆柱齿轮齿距与齿廓偏差中的应用

针对小模数齿轮传统方法测量难,费时费力等缺点,提出了一种基于三坐标测量机CCD测头在齿轮偏差测量中的新方法。该方法可以实现在齿廓有效工作范围内自动快速扫描齿廓坐标,并直接进行数据存储与处理,通过渐开线拟合的方法得到各偏差,实现在线测量。理论分析和实验表明,本方法对小模数齿轮的测量具有简便、无接触和效率高的优点。     

基于激光跟踪仪的特大型直齿轮齿距偏差测量新方法

为了测量特大型齿轮齿距偏差,提出了基于激光跟踪仪的特大型直齿轮齿距测量新方法。利用激光跟踪仪的大空间测量能力测量齿轮齿槽,分别获得被测特大型直齿轮相邻两条齿距误差曲线。由于被测齿轮直径超过6 000 mm,可以根据点到直线距离公式近似计算单个齿距误差。首先,分析了传统方法下基于激光跟踪仪构建齿轮工件坐标系后的齿距测量模型,并根据特大型直齿轮的特点,提出了基于激光跟踪仪的无坐标系特大型直齿轮齿距误差测量模型。测量模型回避了特大型齿轮工件坐标系的建立,直接对齿槽进行双面接触测量;通过对两条齿槽测量直线进行误差评定即可获得单个齿距最大误差与单个齿距平均误差,通过转站测量实现齿距累积总偏差的测量;最后,采用蒙特卡罗法对不同测量方法的测量不确定度进行仿真分析,得出系统测量不确定度。实验结果表明,提出的基于激光跟踪仪的特大型直齿轮齿距偏差测量方法满足直径6 000 mm以上的8级精度特大型齿轮的单个齿距偏差测量要求,满足直径6 000 mm以上的10级精度特大型齿轮的齿距累积总偏差测量要求。     

基于投影法的摆线齿轮齿廓偏差检测及分析

摆线齿轮齿廓偏差与其传动平稳性、运动精度等有直接联系。针对目前摆线齿轮检测过程中存在检测效率低、检测样本不足等问题,提出了以影像测量技术为平台的摆线齿轮齿廓偏差检测的一种非接触检测方法。基于光学影像测量系统和Sobel边缘检测算法,得到了被测摆线齿轮全齿廓图像和实际齿廓边缘点坐标;基于摆线齿轮齿廓方程和分割逼近法,得到了沿测量点处法线方向上的理论坐标值,建立了齿廓偏差求解模型,实现了摆线齿轮全部轮齿齿廓偏差的测量,并对引起摆线齿轮齿廓偏差的因素进行了分析,为摆线齿轮齿形设计与制造提供依据。     

椭圆弧齿线圆柱齿轮激光非接触测量方法

针对目前椭圆弧齿线圆柱齿轮测量方法的缺乏,设计了一种基于激光位移传感器的椭圆弧齿线圆柱齿轮精密测量装置。阐述了椭圆弧齿线圆柱齿轮的几何形状特征,介绍了激光非接触式测量装置的构成与测量原理,通过对该齿轮多个径向截面轮廓的激光测量,建立齿轮测量截面的轮廓数据模型;对截面轮廓数据模型进行坐标转换,计算出齿轮中间截面的齿距偏差;分析同一轮齿不同截面的齿廓测量数据,计算不同截面分度圆与齿廓交点坐标值,计算出椭圆弧齿线的整体偏差值。该方法能够有效填补曲线齿线圆柱齿轮的测量技术空白,且具有较高的测量精度和效率;其同样也适用于其他圆柱齿轮测量。     

基于端面滚切法加工的锥齿轮齿面测量研究

针对端面滚切法加工的锥齿轮齿形精度问题,在国产齿轮测量中心上对齿面偏差测量方法进行了研究.分析了测量原理,规划了测量区域和测量路径,建立了锥齿轮端面滚切法切齿数学模型,计算出了理论齿面.对测头半径和测杆变形进行了坐标补偿,通过齿轮与浏量机坐标转换,得到了控制测量动作的测头中心理论位置,根据实际测量值建立了齿面偏差方程....     

一种新型齿轮综合偏差测量齿轮及测量原理

传统渐开线齿轮综合偏差的检测常采用齿轮单面啮合法和齿轮双面啮合法。由于2种方法的测量原理及测量参数等不同,需采用齿轮单啮仪和齿轮双啮仪2种仪器分别进行测量,从而分别获得被测齿轮的切向综合偏差和径向综合偏差,2种偏差无法通过一次啮合检测得到。针对传统齿轮综合检测的不足,设计了一种由2个特殊半齿测量齿轮组成的新型测量齿轮,提出了一种新的齿轮综合偏差测量原理,并给出了其综合偏差结果的评定方法。该测量齿轮与被测齿轮通过一次类单面啮合测量,获得产品齿轮两侧齿面的切向综合偏差和径向综合偏差,明显提高了渐开线齿轮综合偏差的检测效率,降低了在测量设备上的投资。     

齿轮齿向位置偏差的双面啮合综合检测

简要介绍了国外开发的新型齿轮双啮仪的结构特点,分析了影响齿向位置偏差的工艺因素,初步探讨了齿轮齿向位置误差的双面啮合综合测量原理。带二维测量机构的新型双啮仪可从齿轮双面啮合滚动检测中获取更多的齿轮精度及加工工艺系统信息,在汽车、摩托车齿轮制造业具有广阔的应用前景。     

对角修形斜齿轮设计与数控磨齿研究

为了减小齿面振动,降低磨削误差,提出对角修形斜齿轮数控磨齿加工方法：通过设计对角修形曲线,经过3次B样条拟合为对角修形曲面;根据齿条展成渐开线齿面原理,建立平面砂轮磨削斜齿轮6轴联动Free-Form型数控磨齿模型,通过齿条与砂轮位矢等效转换,推导各轴运动关系;建立基于CNC机床各轴运动敏感性分析的齿面修正模型,各轴运动用6阶多项式表示,通过判断砂轮与齿面的接触状态,确定磨削齿面的误差,并分析各系数扰动对齿面误差的影响;以齿面误差平方和最小为目标函数,通过粒子群优化方法,得到机床各轴运动参数,该方法计算结果稳定且精度较高。通过算例表明：沿齿向方向压力角、螺旋角、展成角的微调可分别实现一定的对角修形加工;微调6轴联动机床各轴运动参数,可有效减小对角修形斜齿轮的磨削误差,通过机床运动敏感性分析验证理论和算法的正确性。     

3D measurement of gears based on a line structured light sensor

Gears are core components of transmission systems. The current trend of gear measurements is the rapid and full digitization. To rapidly obtain information on the three-dimensional (3D) shape of the gear tooth flank, a 3D point cloud measurement system based on a line structure light sensor and high precision air floating rotary table is proposed. The system can acquire more than 1.5 million 3D data points on one side of the gear tooth flank within less than 5 s. In this study, the measured 3D point cloud data is used to calculate the profile error, pitch error, then compared to those obtained from traditional contact measurements. In addition, tooth flank error was evaluated. The results show that the 3D point cloud measurement system can perform fast and accurately in 3D measurements of gears and it is a novel system for gear measurement and error calculation.     

基于全齿廓信息的齿距偏差快速测量方法

齿距偏差直接影响齿轮传动的性能,一直是最受重视的齿轮精度指标之一。如何快速、准确地获取中等精度齿轮的齿距偏差是汽车齿轮行业亟待解决的关键问题,但传统方法存在测量效率低、重复性差等不足。所提方法采用齿廓偏差曲线的全部信息作为齿距偏差的评价依据,采用统计分析方法定义和计算齿距评价新指标,克服了传统方法使用小样本和极值法进行齿距偏差评价的不足。所提方法可充分利用齿轮测量数据,具有评价指标值对随机误差不敏感、重复测量结果一致性好、评价结果与齿轮实际使用性能之间相关性更加紧密的特点。在汽车齿轮快速测量机上通过实际测量实验验证了新方法的使用效果,齿距测量速度高达0.3 s/齿面时仍具有很高的重复测量精度。     

Pitch deviation measurement and analysis of curve-face gear pair

The curve-face gear pair is proposed as a new type of gear pair which was put forward in recent years. It can achieve variable ratio transmission of motion and power between the intersection axes. In the matter of the inspection of the pitch deviations of this gear pair, there is no practical possibility for a reliable metrological traceability to national or international measurement standards can be provided. Hence, a new method was proposed in this article, which was based on the CNC gear measuring center, aimed at the gear artefacts processed by the five-axis machining center. With the coordinate data which were obtained by the gear measuring center, the pitch deviations of the gear pair were obtained. In addition, based on the values of the pitch deviations, the angular deviations of curve-face gear pair can be worked out, and the results turn out that the measurement method is feasible.     

Pitch deviation measurement of an involute spur gear by a rotary profiling system

This paper presents surface-profiling based gear pitch deviation measurement for an involute spur gear. A rotary profiling system, which consists of an air-bearing spindle and a displacement sensor with a diamond stylus, is employed to measure gear pitch deviation. In measurement of gear pitch deviation, an eccentric error between a gear axis and a motion axis of the rotary stage in the profiling system would affect accuracy of gear profile measurement. In this paper, at first, the influence of the eccentric error on measurement of gear pitch deviation is estimated in computer simulation based on a geometric model of the profiling system. After that, a new scanning method named “opposite-direction dual scanning method” is proposed so that a steep profile of gear flank surface with a local slope of up to 90° can be measured by the developed rotary profiling system. For compensating distortions in the measured gear tooth profile, which are induced not only by the eccentric error but also by a probe offset introduced by the proposed scanning method, a self-calibration and compensation method is applied. To verify the feasibility of the proposed method, measurement of gear pitch deviation of a master involute spur gear with a certificate data is carried out. Measurement uncertainty of the proposed method is also analyzed.     

螺旋锥齿轮齿面扫描式测量法及其应用研究

螺旋锥齿轮的实际齿面形状是影响其动力学性能的一个非常重要的因素。本文介绍了采用虚拟共轭基准面的螺旋锥齿轮齿面的扫描式测量、数据处理及应用方法，即大齿轮的基准面采用的是由机床设定参数计算出的理论齿面，而小齿轮的基准面采用的是与大齿轮共轭的假想小齿轮齿面。由于采用了二维测头进行齿面测量，有效地避免了测头与齿面间摩擦力的影响，既能保持高精度，又能进行快速测量。同时，该种测量采用连续扫描的方法，信息量大、速度快，适合于大批量生产中的螺旋锥齿轮的齿面质量管理与控制。由于扫描式测量采用了虚拟共轭基准齿面，所以从测量数据本身就可以判断齿面的接触斑点位置与形状，因而可以直观、有效地对齿面质量进行管理与控制。     

CAD齿轮齿形生成及应用

以插入算法实现齿廓的电脑图形生成熏进一步设计成菜单命令。通过对输出齿形进行编辑分析熏为齿轮、滚刀设计提供直观的分析手段。     

Laser tracker performance quantification for the measurement of involute profile and helix measurements

Standard-conforming measurements for a large involute gear were performed with a manually operated laser tracker system and the corresponding task-specific measurement uncertainties were estimated. Especially, readers using laser trackers for inspecting large involute gears will get information of a taskspecific measurement performance for the first time, which significantly differs from the laser tracker machine specification. To ensure unambiguous and repeatable measurement results, user-friendly auxiliary tools are used, which allows the operator to probe the measurement points according to existing guidelines and standards. Measurements were taken on a robust and highly accurate large involute gear measurement standard of the Physikalisch-Technische Bundesanstalt (PTB) under laboratory conditions. The size of this gear measurement standard complies with those gears used in wind power plants. The external gear materializes a left and a right hand gear as well as a spur gear. The obtained results of profile, helix and surface measurements are presented. These research activities were carried out at the PTB in the department of coordinate metrology.