Determination of the mean base circle radius of gears by optical multi-distance measurements
Determination of the mean base circle radius of gears by optical multi-distance measurements
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DOI：
10.5194/jsss-9-273-2020
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发表时间：
2020-08-20
影响因子：
1
通讯作者：
Fischer, Andreas
中科院分区：
文献类型：
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作者：
Pillarz, Marc;von Freyberg, Axel;Fischer, Andreas
风力涡轮机齿轮箱所需的可靠性提高了对大型齿轮测量的要求。需要进行广泛的测量来可靠地评估单微米范围内的大型齿轮的几何形状。由于单独固定的测量体积，坐标测量仪和齿轮测量仪等标准方法对于直径 > 1 m 的大型齿轮达到了极限。因此，提出了一种可扩展的光学测量方法，该方法由单个传感器与转台相结合，用于多距离测量，并随后对齿轮形状参数进行基于模型的评估。在进一步的工作中，可扩展的测量方法将扩展到多感官系统。以正齿轮为例，确定平均基圆半径作为基本形状参数。使用基圆半径是由于与其他形状参数（例如轮廓斜率偏差）的几何关系。对于小齿轮和大齿轮，由于传感器噪声而导致的平均基圆半径理论上可实现的测量不确定度估计小于 5 μ m (k=2)，这验证了传感器系统的可扩展性。为了展示原理的一般证明，对直径为 0.105m 的齿轮进行了两组光学测量，并通过触觉测量进行参考。结果，确定了k=2时1.2μm的随机误差。与参考值的剩余系统偏差分别为 4.3 和 1.6 μm。因此，总测量不确定度目前受到系统效应的限制，总不确定度小于 5 μm (k=2) 的既定目标与 1.5 μm 相差甚远。然而，1.2 μ m (k=2) 的随机误差表明，实现了足够的测量精度，并且多距离测量方法有可能通过适当的策略来补偿系统影响，从而达到目标测量不确定度。实验和理论结果证明了所提出的单传感器多距离方法对齿轮精确检测的原则适用性。
The required reliability of wind turbine gearboxes increases the requirements for large gear measurements. Extensive measurements to reliably assess the geometry of large gears in the single micrometer range are necessary. Due to an individually fixed measuring volume, standard methods like coordinate and gear measuring instruments reach their limits for large gears with diameters > 1 m. Therefore, a scalable optical measurement approach consisting of a single sensor in combination with a rotary table for multi-distance measurements with subsequent model-based evaluation of shape parameters of gears is presented. The scalable measurement approach is to be extended to a multisensory system in further work. As a fundamental shape parameter the mean base circle radius using the example of spur gears is determined. The base circle radius is used due to the geometric relationship to further shape parameters for example to the profile slope deviation. The theoretically achievable measurement uncertainty of the mean base circle radius due to sensor noise is estimated to less than 5 mu m (k=2) for a small and a large gear, which verifies the scalability of the sensor system. In order to show a general proof of principle, two series of optical measurements on a gear with a diameter of 0.105m are performed and referenced with a tactile measurement. As a result, random errors of 1.2 mu m for k=2 are determined. The remaining systematic deviations to the reference value amount to 4.3 and 1.6 mu m, respectively. Hence, the total measurement uncertainty is currently limited by systematic effects, and the defined aim of a total uncertainty of less than 5 mu m (k=2) is narrowly missed by 1.5 mu m. The random errors of 1.2 mu m (k=2) show, however, that an adequate measurement precision is achieved and that the multi-distance measurement approach has the potential to reach the aimed measurement uncertainty with appropriate strategies to compensate for the systematic influences. The experimental and theoretical results prove the principle applicability of the proposed single sensor multi-distance approach for the precise inspection of gears.