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IMEKO2009 Lisbon
Background
Requirements: reduction of noise The noise and vibration form the gears
and vibration are caused by the form deviation in
micro meter level of gears.
Therefore, the requirement of the gear
form deviation is “sub micrometer” level.
Capabilities of GMIs
are mostly evaluated by measuring
Test for the gear profile, lead, a calibrated gear artifact
pitch, etc.
Difficult to manufacture
with high accuracy
We propose
new concept artifacts
used simple geometries
Gear measuring instrument (GMI)
IMEKO2009 Lisbon
Introduction
Gear artifacts Proposed artifacts
NMIJ: U95 Simple geometries U95 Profile: 0.3 µm
Profile: 0.6 µm
Helix artifact
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Contents
Introduction
DBA used for evaluation of GMIs on the gear profile
measurement capability
Two types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
Characteristics
Calibration method
IMEKO2009 Lisbon
Double Ball Artifact (DBA)
Use for evaluating GMI’s capability of a profile
measurement
Reference axis is used as a center axis of gear
Form checking ball is used as a tooth form
Cross-section of the DBA Started from 2002 fy
Form checking ball Centering ball
Datum plane
Spring
Reference axis
Prototype of DBA
IMEKO2009 Lisbon
Principle of profile evaluation
X
Involute curve
Involute curve
stylus
M’ M’’
Base circle rb
M’’’
Y O
DBA measurement
Involute curve:
can be expressed mathematically.
IMEKO2009 Lisbon
Pitch artifact using balls
Expand the DBA method to pitch evaluation
IMEKO2009 Lisbon
How to assume as a gear
The centering ball is used to set the reference axis assumed as
the center axis of a gear
The reference axis is perpendicular to the datum plane and
passes through the center of the centering ball
The pitch balls are used instead of gear teeth
Spring
Reference axis
IMEKO2009 Lisbon
Pitch artifacts (Multi Ball Artifacts)
Combination type
Combinations
Combination type MBA
Spheres are fixed by magnetic force.
It is impossible to
assemble a MBA with
perfect pitch angle. disadvantage:
not apply for steel stylus
Making a gap
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Stabilities of combination type MBA
0.2
Repeatability of single
pitch deviation[m]
0.1
-0.1
-0.2
1 2 3 4 5 6 7 8
Number
Repeatability of single pitch deviation
0.2
Repeatability of cumilative
Reproducibility of 5 times assemblies
pitch deviation[m]
0.1
-0.1
-0.2
1 2 3 4 5 6 7 8 9
Number
Repeatability of cumulative pitch deviation
IMEKO2009 Lisbon
Separation type
Centering ball
Datum plane Pitch angles are defined by a curvic coupling.
Pitch ball Advantages:
Inexpensive
Easy to manufacture
Calibration is not necessary (pitch angles
are defined by those of a curvic coupling)
Disadvantages:
Curvic coupling
Low cost type Stability ? (Balls are fixed by glue)
Datum plane Base plane is made of a zero expansion
Pitch ball
ceramics (NEXCERA).
Advantage:
Environment robust
Disadvantage:
Centering ball Calibration is necessary
Environment robust type Expensive
IMEKO2009 Lisbon
Contents
Introduction
DBA used for evaluation of GMIs on the gear profile
measurement capability
Three types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
Characteristics
Calibration method
IMEKO2009 Lisbon
Pitch angle calibration
Probing system Probing system
MBA MBA of GMI
of CMM
Index table
IMEKO2009 Lisbon
Multiple-orientation technique
This method eliminate the systematic errors of an instrument
Geometrical error, probing error, etc.
13 15
13
11 15
11 1
fj = 2
9 1
・・・
9 3
7 3
5 7 5
[µm]
0,4
Difference [mm]
Difference [mm]
0,2 0,4
0,0 0,0
-0,2 -0,4
-0,4
-0,8
-0,6
-0,8 -1,2
-1,0 -1,6
0 1 2 3 4 5 6 7 8 9 1011121314151617 0 1 2 3 4 5 6 7 8 9 1011121314151617
Tooth number Tooth number
IMEKO2009 Lisbon
Contents
Introduction
DBA used for evaluation of GMIs on the gear profile
measurement capability
Three types of MBAs for evaluation of GMIs on the gear pitch
measurement capability
Characteristics
Calibration method
IMEKO2009 Lisbon
Measurement setup
Gear measuring instrument:MGL-26A
Manufactured by Osaka Seimitsu Kikai
IMEKO2009 Lisbon
Repeatability and reproducibility of GMI
2 2
Repeatability [m]
Repeatability [m]
1 1
0 0
-1 -1
-2 -2
1 3 5 7 9 11 13 15 1 3 5 7 9 11 13 15
Pitch number Pitch number
Reproducibility [m]
1 1
0 0
-1 -1
-2 -2
1 3 5 7 9 11 13 15 1 3 5 7 9 11 13 15
Pitch number Pitch number
OSK-NMIJ 0.4
0 0
uw: standard uncertainty of calibration value
-2 -0.2
NMIJ ur: standard uncertainty of repeatability
-4 -0.4
OSK
-6 -0.6 up: standard uncertainty of reproducibility
1 2 3 4 5 6 7 8 9 10111213141516
Pitch number us: standard uncertainty of systematic error
6 0.6 k: coverage factor set to k = 2
pitch deviation [m]
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Thank you for your attention !!
IMEKO2009 Lisbon
Angular pitch deviation
If the pitch balls are arranged at Y
equal intervals, we define the Reference circle
Centering ball
nominal angular position as the
center of the ith pitch ball by
2
i 1 i 1,2,, n
r
qi
n X
where O
i: pitch ball number in the clockwise direction
n: the total number of pitch balls T(qi)
where
T(qi): the true angular position in the actual MBA
IMEKO2009 Lisbon
Calibration parameter
The single pitch deviation for a
virtual gear is calculated by
Y
f pli r Pqi Pqi 1 Ωi Ωi 1
Reference circle
Centering ball
f pri r Pqi Pqi 1 Ωi Ωi 1
where r
r: reference circle radius X
Wi: angle between the measurement point
O
and the center of the ith pitch ball
T(qi)
r 2
C 2
r 2
Ωi cos1 i ci
2 r C
i
where Wi
rci: radius of ith pitch ball i-1th pitch ball
Center of ith pitch ball
Ci: ball center distance between the
centering ball and the ith pitch ball
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Measurement value
Measurement value
15
M qi , j Pqi E qi j Erand
M(qi , fj) and (qi) [arcsec]
10
E(qi): Systematic error
5
Erand: Non systematic error
0
Mean value
-5 1 m
q i M q i , j
-10 m j 1
-15
1 m
Pq i E q i j Erand
0 60 120 180 240 300 360
Nominal angular position qi [deg]
m j 1
Pq E m q
i i
Law of the Fourier series
When m-number of curve with a phase shift of 2/m at a time are
averaged, the averaged curve shows the sum of an integral multiple of
mth-order Fourier components of the original curve.
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Example of law of Fourier series
15 Original curve 6
Amplitude [arcsec]
Shifted curve
deviation [arcsec]
10
Angular pitch
5 4
0
-5 2
-10
Phase shift of
-15 0
0 60 120 180 240 300 360 1 2 3 4 5 6 7 8
Nominal angular position qi [deg] Fourier component
15 6
Mean curve
Average curve
Amplitude [arcsec]
10
Average [arcsec]
5 4
0
-5 2
-10
-15
0 60 120 180 240 300 360 0
Nominal angular position qi [deg] 1 2 3 4 5 6 7 8
Fourier component
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How to set virtual gear dimension
rb rc sin cos cos C 2 rc 2 cos2
rb Oc Pitch ball
r rc
C
α X
O B
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Measurement value
Measurement value
M qi , j Pqi E qi j Erand
15
P(qi): Angular pitch deviation
-5
1 m
Pqi E qi j Erand -10
m j 1
-15
Pqi E m
qi Expected value 0 60 120 180 240 300 360
Nominal angular position qi [deg]
is zero
By law of Fourier series
the sum of an integral multiple of mth-order
Fourier components of the systematic error
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To obtain the systematic error: 1st step
15
1 m
P q i j E q i Erand 3
at each orientation 0
E qi j -1
-2
0 60 120 180 240 300 360
Nominal angular position qi [deg]
IMEKO2009 Lisbon
Calibration value
Pq i
Dispersion [arcsec]
2
s =0.24 arcsec
1
0
Measurement -1
uncertainty
-2
-3
0 60 120 180 240 300 360
Nominal angular position qi [deg]
IMEKO2009 Lisbon
Calibration for length
(k=2)
IMEKO2009 Lisbon 37