Double flank gear roll inspection machines. The simple functional inspection

Transcription

1 Double flank gear roll inpection machine The imple functional inpection URM-WZ E

2 General Information The baic principle of the double flank gear roll inpection i that a mater gear (nearly perfect gear) and a workpiece gear are mehing free from backlah. One axi of rotation i mounted firmly and the other i mounted in a floating manner. The variation in ditance when rolling the two gear are detected and form the bai for the evaluation of the gear profile with repect to the exiting compoite error caued by production. When ued with modern evaluation olution uch a a PC, hardware and oftware, the double flank gear roll inpection prove to be an efficient mean of controlling the quality in a quick and eay way. Advantage of Frenco double flank gear roll inpection machine: Stable machine for the hop floor ue. Cutomer-pecific deign: The machine are perfectly adjuted to the pecimen to be meaured and to the condition of meaurement. The meauring force i infinitely variable. Rapid lift-off of the meaurement carriage. Uing non-rotating tip and mounting mandrel, the runout deviation i kept low. Special mater gear pair for calibration. With the evaluation oftware 'FGI pro' being in-houe developed, quick upport i available hould any iue arie. The mater gear are manufactured in-houe at FRENCO in Altdorf, Germany. On requet, we can upgrade older double flank gear roll inpection machine with FRENCO meaurement electronic and the FGI evaluation oftware. 2

3 Meaurement of Geometrie pur gear helical gear worm pinion and gear pinion and worm oil pump gear Tooth Thickne Runout Running quality Damage 3

4 Product Overview ZWP 06 ZWP 14/24 ZWP 18 ZWP 30 4

5 Feature ZWP 06 ZWP 14/24* ZWP 18 ZWP 30 ingle end between tip ingle end between tip ingle end between tip ingle end between tip Centre ditance mm mm (280)* mm (430)* mm mm mm mm mm Centre ditance with adapter for mall centre ditance 1 mm 1 mm 15 mm 15 mm 15 mm 15 mm - - Max. diameter of pecimen with teady centre attachment 3 80 mm 80 mm 400 (430)* mm 160 (300)* mm 200 mm 160 mm 310 mm mm Max. diameter of pecimen with extenion adapter mm Centre height ize 1 Centre height ize 2 Centre height ize up to 600, higher on requet Range for height adjutable ingle end mounting poible within limit - on requet teady centre attachment Adjutment of meauring force no ye ye ye 0 5 N poible within limit 0 20 N 0 50 N Optional gla cale ye - ye ye Optional enor for correction of deviation of mater gear on requet ye on requet on requet Range of application mall workpiece and platic gear large workpiece; robut for hop floor ue medium-ized workpiece; uitable for inpection laboratorie large wheel, worm and haft, deigned for heavy weight Motor drive tandard optional tandard optional Manual operation - ye - ye Motor drive with 2. teady centre attachment Manual operation with 2. teady centre attachment - - ye optional - ye - optional *Verion ZWP 24 i identical to ZWP 14, but ha a larger machine bae. 5

6 ZWP 06 The univeral meauring machine for mall yet highly precie gear The double flank gear roll inpection machine i pecially deigned for mall high-preciion gear. It i alo uitable for platic gear. The meauring force can be lowered to 0 N. The ophiticated deign i extraordinarily precie and enitive. The meauring carriage i upported free from backlah on four leaf pring. Thi o-called parallelogram upenion i very enitive and regiter even the mallet change in centre ditance. The meaurement proce i motor driven by default. We recommend the FRENCO Software FGI pro for the evaluation. Thi will enable you to control the quality of your workpiece eaily, efficiently and reliably. An extenive range of acceorie meet all requirement. ZWP 06 with centre fixture ZWP 06 with mounting device for internal gear and pline 6

7 Acceorie teady centre attachment a = mm a = 40 mm adapter for mall centre ditance centre fixture d = 0,6-8 mm a =15-50 mm a = 20 mm fixture for internal gear and pline d d = 8 mm e = 60 mm pivoting fixture a = mm a = 16 mm e 7

8 ZWP 14 Simple, robut, deigned for hop-floor ue The ZWP 14 i the mot robut double flank gear roll inpection machine of thi product family and ideal for ue on the hop-floor. Thi machine can be driven manually or by motor. The centre ditance can be adjuted manually via an adjutable adapter dic. The meaurement reult are diplayed on a dial indicator. An evaluation uing our electronic meauring device MEG 32 i only poible if the machine i motoried. The extenive range of acceorie allow an individual cutomization to your requirement. Individual olution for your meauring tak are alo poible. ZWP 23P Modular deign with pneumatic lide Special ize ZWP 24 8

9 Stroke = 100 mm Acceorie teady centre attachment mall MAX = 370 mm teady centre attachment large MAX = 420 mm a = 80 mm centre fixture to mount the workpiece only MAX = 140 mm a = 45 mm a a a Pivoting upport for worm and worm gear Fixed upport for worm and worm gear (ymmetrical or aymmetrical) MAX = 150 mm w = ±45 MAX = 250 mm a w a Height adjutable adapter to meaure worm Adjutable quill Fine adjutment for accurate meauring force Adapter for mall centre ditance d = 1-16 mm d = 4-22 mm 9

10 ZWP 18 Highet preciion and comfortable handling The high quality ZWP 18 (previou 898) feature a ophiticated etup and allow high preciion meaurement. The centre ditance can be changed eaily and quickly by adjuting the meauring carriage with a hand-wheel. The adjutable mandrel allow imple and convenient adjutment of the height of the gear to be inpected. Many acceory item can eaily be attached to the intrument. The drive motor i integrated in the device. To enure highet preciion, the meauring carriage are mounted on very mooth running guideway. ZWP 18 with wiveling mounting ZWP 18 with teady centre attachment 10

11 Acceorie teady centre attachment MAX = 370 mm Centre fixture to mount the workpiece only MAX = 140 mm a = 45 mm a a Pivoting upport for worm and worm gear Fixed upport for worm and worm gear (ymmetrical or aymmetrical) MAX = 150 mm w = ±45 MAX = 250 mm a w a Mounting for internal gear and pline meaurement Adapter for mall centre ditance e MIN = 16 mm e MIN = 22 mm 11

12 ZWP 30 The pecialit for large gear wheel, haft and worm With ZWP 30 it i poible to meaure gear and pline with a pitch circle diameter of up to 550 mm and haft with a length of up to 600 mm. The deign i table and optimized for the hop-floor ue. The workpiece large dimenion and heavy weight require pecial component to be intalled. A granite machine bed form the bae of the ZWP 30 onto which the meaurement carriage and mounting attachment for the workpiece and mater gear are intalled. Depite heavy weight load, it i important for the meaurement carriage to move moothly, preciely and free from backlah, which i enured by the cro roller guide. The changeover for the inpection of other pecimen i eaily and quickly to handle. Depending on the cutomer requirement, the meaurement are carried out manually or automatically. The evaluation i carried out via a dial indicator or FRENCO FGI pro oftware. 12

13 Software The oftware FGI pro include both, the control of the drive and the evaluation of data. The oftware i in-houe developed and programmed by our pecialit for application oftware. With the actual value being marked in colour, the pecimen can quickly be evaluated a Pa (green) or Fail (red). The oftware determine the following value: - total radial compoite deviation Fi'' - tooth-to-tooth radial compoite deviation fi'' - runout deviation by compoite tet Fr'' - hort-wave component fk'' Additionally, when machine ha been calibrated: - centre ditance Aa'' - dimenion over ball MdK - tooth thickne Sn - pan ize Wk. Polar chart Viualized Fourier pectrum Further oftware propertie: Eay input and amending of inpection option After the inpection, the workpiece will be turned to the poition of maximum deviation (value are electable) Language feature: - German, Englih, Spanih, French, Portuguee, Polih, Hungarian and Chinee are available - Language of the program and output language can be elected freely (Unicode upport) - Eay data exchange when corporate language are different Archiving function: every ingle meaurement data i aved Central, tatitical analyi due to interface (q-stat, CASQ-it 9000 and internal Ethernet-ytem) 13

14 Retrofit FRENCO retrofit earlier double flank gear roll inpection teter with the powerful meauring electronic MEG32 and the evaluation oftware FGI. The upgrade i ideal for device with manual evaluation, pen recorder or earlier electronic. For retrofitting, pleae end the machine to FRENCO GmbH. The device will be dimantled, cleaned and maller repair will be carried out. Furthermore, probe and motor will be replaced and an emergency-top button will be intalled (unle one i already intalled). The double flank gear roll teter will be completely refurbihed! The following device can be retrofitted: Hommel ZWG 8305 after retrofitting - Mahr 894B, 896B, 898B, 898C - Hommel ZWG8305, ZWG Hoefler ZW300 - other type on requet Höfler ZW300 before retrofitting Höfler ZW300 after retrofitting 14

15 Calibration If the actual centre ditance i to be meaured, it i neceary to calibrate the machine with known centre ditance. The eaiet way to do that i by uing haft, dic and gauge block. Centre ditance It i alo poible to ue 2 mater gear. Calibration haft - gauge block - haft tatic Calibration with dic on haft tatic or dynamic Calibration dic - dic tatic or dynamic Calibration haft - dic tatic or dynamic 15

16 Traceability The Phyikalich-Techniche Bundeantalt (PTB, the national metrology intitute in Germany) doe not offer traceability for double flank gear rolling inpection parameter. Thi mean that the PTB doe not calibrate Fi, fi, Fr or fk. The principle for determining the calibration value and meaurement uncertaintie Limit calibration et MPE FRENCO i probably the only company worldwide that i able to calibrate the gear and double flank gear rolling teter parameter Fi, fi, Fr and fk. To thi end, a highly precie limit calibration et MPE, coniting of 5 mater gear, wa meaured under calibration condition approximately 2,000 time on 75 different double flank gear rolling teter from around the world. F i f i, fe, fk... Calibration of numerou double flank gear rolling teter Statitical analyi F i f i All meaurement reult were analyed uing tatitical method, rogue reult eliminated and arithmetic mean value and intervention limit calculated. Finally, the calibration value Fi, fi, Fr, fk and the meaurement uncertaintie UFi, Ufi, UFr and Ufk can now be calculated uing thee value.... Calibration value and meaurement uncertaintie... There are 12 uch limit calibration et MPE worldwide, five of which, with variou geometrie, are held by FRENCO. What i it ued for? - Calibration of Double Flank Gear Rolling Teter (ZWP) - Evaluation of ZWP - Determination of meaurement uncertainty of ZWP - Conformity aement (Fail/Pa) 16

17 Calibration et MPE A complete calibration of double flank gear roll inpection machine i only poible with a limit calibration et MPE. Such a et conit of 5 mater gear. Fr - mater for long wave portion fi - mater for hort wave portion The reference mater gear i the reference gear. It ha got no modification. Tooth No. 1 i marked. The four other mater gear are rolled, meaured and logged againt tooth 1. reference mater The Fr - mater ha got a radial run-out which preent itelf a a long-wave inuoidal Fr deviation. The fi - mater ha got variation in tooth thickne, which caue a hort-wave Fi deviation. The centre ditance i calibrated with the etting mater centre ditance. The check mater ha got a differing tooth thickne from that of the etting mater centre ditance. The deviation of the centre ditance thereby caued ha got a nominal ize, which hould preent itelf a the actual ize during calibration. Deviation in the cale and linearity can thu be detected. etting mater centre ditance check mater linearity After every final inpection, maintenance and ervice a calibration certificate i iued containing all deviation. Thi certificate can be ued a the bai for wear inpection, audit and certification. 17

18 Meaurement Uncertainty U MS The meaurement uncertainty of a double flank gear rolling teter can be determined uing the calibrated limit calibration et MPE. The tandardied method U MS in accordance to VDA-5 i applied. Parameter and tolerance that are ued a the bai will be agreed with the cutomer. The following parameter: diametral dimenion over/between ball tooth thickne centre ditance are directly traced, and the determined meaurement uncertaintie are directly baed on the dimenion of the Phyikalich- Techniche Bundeantalt (the national metrology intitute). The following parameter: radial compoite error Fi" tooth-to-tooth compoite deviation fi" compoite runout deviation Fr" are indirectly traced. The determined meaurement uncertaintie are baed on table mean value of large volume ample inpection. By knowing the meaurement uncertainty, the inpection planner know if the inpection equipment i uitable for the meaurement tak or not. Thi i the reaon why quality management ytem require the determination of the meaurement uncertainty, which ha to be proved during quality audit. Fr mater etting mater ref. mater fi - mater check mater 18

19 Meunicherheit Correction of deviation of mater gear Mater gear are manufactured with the ame preciion a gauge, they are high-preciion item. However mall form variation cannot be avoided. Epecially the runout deviation caue a deviation in the double flank gear roll inpection which cannot be diregarded. The actual runout deviation of the mater gear i conidered in the meauring uncertainty with twice it value, becaue the deviation of the mater gear and the workpiece uperimpoe each other poitively or negatively depending on the angular poition. If the runout deviation of the mater gear i mm, the meauring uncertainty increae by mm. Thi influence can be minimized by an increaed accuracy of the mater gear (e.g. uing quality A according to the DIN 3970 (FRENCO QF)). By applying the correction of deviation of mater gear thi influence can be nearly completely avoided. runout pecimen Rundlauf Prüfling + = Rundlauf runout Lehrzahnrad mater gear coincidental concurrence out-of-phae Zufällige Zuammentreffen phaenverchoben + = Rundlauf runout mater Lehrzahnrad gear runout pecimen Rundlauf Prüfling coincidental concurrence in phae Zufällige Zuammentreffen phaengleich Correction of deviation of mater gear: The mater gear or the driver ha got a marking for the angular poition which i read by a enor. With a check mater fitting to the mater gear (number of teeth of the check mater and number of teeth of the pecimen mut not have a common divior) a correction run with multiple rotation i carried out. During thi proce the correction value are calculated and aved in the meauring electronic. With thee calculated value the following meauring reult are fully automatically corrected. 19

20 Frenco Product Range High Preciion Gear and Spline Gear and Spline Gauge Mater gear, Mater wheel Artefact, Mater Punche, Die & Electrode Profiled Clamping Sytem Gear and pline manufacture Intrument for Size Inpection Serie V VRK Meauring Pin and Ball VA Gauge, Rocking Type VP Gauge with Face Stop VM Gauge, Gear & Spline Profile VD Circumferential Backlah Meauring Intrument VS Cutomied olution Rotation Meauring Sytem URM URM - K with Ball and Pin URM - R with Mater Wheel EWP Single flank gear roll inpection ZWP Double flank gear roll inpection WS Gear roll can Gear & Spline Inpection DAkkS - Calibration Monitoring of Inpection Equipment Workpiece Inpection Analyi of Deviation Know-how Tranfer Software Training, Seminar, Workhop Conulting and Calculation Literature and Documentation National and International Standard Frenco GmbH gear + pline technology Jakob-Baier-Straße 3 D Altdorf, Germany Phone: +49 (0) Fax: +49 (0) Mail: frenco@frenco.de Internet: 20