DE102018122041A1 - METHOD FOR PRODUCING A BEVEL WHEEL BY MEANS OF A CNC-CONTROLLED MULTI-AXIS MACHINE AND PRODUCTION SYSTEM - Google Patents

Abstract

Process for manufacturing a bevel gear using a CNC-controlled multi-axis machine, with the process steps:
A) Design of a bevel gear geometry and calculation of a target geometry for the bevel gear to be manufactured;
B) providing measurement data for tool geometry, such as measurement data for a dressed grinding wheel geometry, measurement data for a cutter head or the like;
C) Provision of a kinematic model of the multi-axis machine, with measurement data for recurring mechanical excitations, such as bearing rollover, meshing, gear ratios in the drive train or the like;
D) Manufacturing the bevel gear
- correcting the flank shape deviations caused by the machine kinematics and tool geometry,
- Measurement data of the machine kinematics and the machine control, such as actual position values of the machine axes, axis speeds, the current consumption of the axis drives or the like, are recorded during production;
E) Calculation of the actual geometry of the bevel gear to be produced based on
- the target geometry calculated in step A),
- the measurement data provided in step B),
- The kinematic model provided in step C) and
- The measurement data recorded in step D).

Description

The present invention relates to a method for manufacturing a bevel gear using a CNC-controlled multi-axis machine and a manufacturing system.

In modern motor vehicles with hybrid or electric drive, the transmission noise is no longer masked or only to a lesser extent by the engine noise or the running noise of the wheels. The transmission noise can be perceived by the vehicle occupants and perceived as disturbing. Current vehicle transmissions should therefore be compact and lightweight, and the drive power transmitted reliably over the entire specified mileage of the motor vehicle in question - with the lowest possible noise emission.

The noise emission of a gearbox is largely due to the meshing of the teeth that roll within a gearbox housing. In this case, deviations of the tooth geometry from the nominal geometry, such as surface ripples of the tooth flanks or the like, can in particular lead to higher harmonic noise excitations when rolling a tooth, which contribute to a conspicuous noise behavior of a tooth.

Deviations of finely machined bevel gear teeth from their specified target geometry result, for example, from deviations of the machine geometry from the target machine geometry, deviations of the machine kinematics from the target kinematics, the resilience of the machine structure or deviations of the tool geometry from the target tool geometry.

The quality of a manufactured bevel gear toothing with regard to its noise behavior can currently only be determined at the end of the production chain using a noise test bench. As far as manufactured gears are noticeable, there is an extensive search for the cause, which is often carried out based on empirical values and the above-described factors influencing the gearing deviation are checked, e.g. the axis drives of the machine tool, the tool geometry or the workpiece clamping.

Against this background, the present invention is based on the technical problem of specifying a method and a production system for producing a bevel gear, which enable early detection of process and / or machine-technical deviations, in particular to map those process and / or machine-technical deviations to the Recognizing toothing geometry and / or at least partially or completely avoiding it, which lead to higher harmonic noise excitations when rolling off bevel gear sets.

The technical problem described above is solved in each case by a method according to claim 1 and a manufacturing system according to claim 8. Further refinements of the invention result from the dependent claims and the description below.

1. A) Auslegung einer Kegelradgeometrie und Berechnung einer Sollgeometrie für das zu fertigende Kegelrad;
2. B) Bereitstellen von Messdaten zur Werkzeuggeometrie, wie Messdaten zu einer abgerichteten Schleifscheibengeometrie, Messdaten zu einem Messerkopf oder dergleichen;
3. C) Bereitstellen eines Kinematik-Modells der Mehrachsmaschine, mit Messdaten zu wiederkehrenden mechanischen Anregungen, wie Lagerüberrollung, Zahneingriffe, Übersetzungen im Antriebsstrang oder dergleichen;
4. D) Fertigung des Kegelrads
   • - unter Korrektur der maschinenkinematisch und werkzeuggeometrisch bedingten Flankenformabweichungen,
   • - wobei während der Fertigung Messdaten der Maschinenkinematik und der Maschinensteuerung, wie Positionsistwerte der Maschinenachsen, Achsgeschwindigkeiten, der Stromaufnahme der Achsantriebe oder dergleichen, erfasst werden;
5. E) Berechnung der Ist-Geometrie des zu fertigenden Kegelrads anhand
   • - der im Schritt A) berechneten Sollgeometrie,
   • - der im Schritt B) bereitgestellten Messdaten,
   • - des im Schritt C) bereitgestellten Kinematik-Modells und
   • - der im Verfahrensschritt D) aufgezeichneten Messdaten.

According to a first aspect, the invention relates to a method for producing a bevel gear using a CNC-controlled multi-axis machine, with the method steps:

1. A) Design of a bevel gear geometry and calculation of a target geometry for the bevel gear to be manufactured;
2. B) providing measurement data for tool geometry, such as measurement data for a dressed grinding wheel geometry, measurement data for a cutter head or the like;
3. C) Provision of a kinematic model of the multi-axis machine, with measurement data for recurring mechanical excitations, such as bearing rollover, meshing, gear ratios in the drive train or the like;
4. D) Manufacturing the bevel gear
   • - correcting the flank shape deviations caused by the machine kinematics and tool geometry,
   • - Measurement data of the machine kinematics and the machine control, such as actual position values of the machine axes, axis speeds, the current consumption of the axis drives or the like, are recorded during production;
5. E) Calculation of the actual geometry of the bevel gear to be produced based on
   • - the crotch A ) calculated target geometry,
   • - the crotch B ) provided measurement data,
   • - the step C. ) provided kinematics model and
   • - The one in the process step D ) recorded measurement data.

The above-described calculation of the actual geometry thus creates a “virtual twin” of the component, which depicts the deviations of the toothing from the target geometry or the actually produced toothing geometry as realistically as possible.

On the basis of this virtual twin, a software-supported analysis of the expected noise excitation can be carried out (forward analysis), in particular by simulated rolling of the virtual twin using appropriate software. Thus, a first assessment of the noise behavior can be carried out before the manufactured component is examined using a noise test bench. Alternatively, the software-supported analysis of the expected noise excitation using the virtual twin can completely replace the test of the manufactured component on a noise test bench.

It goes without saying that the description and order of the individual process steps does not imply a mandatory order of the process steps. For example, process step C. ) also before or simultaneously to the process steps A ) and B ) be performed.

• - in einem Verfahrensschritt F1) die zu erwartende Geräuschanregung des gefertigten Kegelrads berechnet wird, durch:
  • - Bestimmung von Abweichungen der Flankenform der im Schritt E) berechneten Ist-Geometrie zu der im Schritt A) berechneten Sollgeometrie, wie Oberflächenwelligkeiten oder dergleichen;
  • - Berechnung des zu erwartenden Geräuschverhaltens des gefertigten Kegelrads durch Ordnungsanalyse der bestimmten Abweichungen.

According to a further embodiment of the method, it is therefore provided that

• - in one process step F1 ) the expected noise excitation of the manufactured bevel gear is calculated by:
  • - Determination of deviations in the flank shape of the step E ) calculated actual geometry to that in step A ) calculated target geometry, such as surface ripples or the like;
  • - Calculation of the expected noise behavior of the manufactured bevel gear by order analysis of the determined deviations.

Surface ripples on the tooth flanks of the manufactured bevel gear make a significant contribution to noise excitation during rolling and are often the cause of a striking noise behavior. With the help of the order analysis described above, a potentially noisy toothing can be detected at an early stage and one or more dominant orders can be assigned as the cause of the noticeable noise behavior.

• - in einem Verfahrensschritt F2) eine Ursache für eine Geräuschanregung des gefertigten Kegelrads bestimmt wird, durch:
  • - Analyse des Geräuschverhaltens des gefertigten Kegelrads, wobei ein Ordnungsspektrum bestimmt wird;
  • - Vergleich des Ordnungsspektrums mit dem Kinematikmodell der Mehrachsmaschine.

According to a further embodiment of the method, it is provided that

• - in one process step F2 ) a cause for noise excitation of the manufactured bevel gear is determined by:
  • - Analysis of the noise behavior of the manufactured bevel gear, whereby an order spectrum is determined;
  • - Comparison of the order spectrum with the kinematic model of the multi-axis machine.

Correlates, for example, a conspicuous order of noise with a known, recurring mechanical excitation of the multi-axis machine, e.g. a bearing rollover, a spindle speed, a transmission ratio in the drive train or the like, the cause of the deviation of the toothing from its nominal geometry can be e.g. can be traced back to an imbalance of the spindle or the like (backward analysis).

The analysis of the noise behavior can be carried out by a test bench test on the gearing, for example by a rotational error measurement and / or a structure-borne noise analysis, and / or on the basis of an analysis of the method step E ) calculated actual geometry. In addition to the software-based prediction of the noise behavior, the in the process step E ) the calculated actual geometry (virtual twin) can thus be used alternatively or additionally to identify process and / or machine-related causes for toothing deviations that impair noise behavior.

According to a further embodiment of the method, it is provided that on the basis of the step F1 ) calculated noise excitation and / or in step F2 ) the cause of the noise excitation is corrected for the process parameters. In this way, the calculated, expected toothing deviations can be corrected for a toothing to be manufactured, particularly during the machining of this toothing.

If a toothing is ground within a bevel gear grinding machine, for example, a deviation of the "virtual twin" calculated as part of a first infeed of the tool, which will lead to conspicuous noise excitation, can be corrected in a second infeed of the grinding tool, in which the process parameters are corrected of the predicted deviations. A machine-specific or machine-internal control loop can be specified (machine-internal "closed loop") in order to improve the quality of the gears produced and to avoid rejects.

The expected noise excitation can be calculated using a computer on the multi-axis machine itself or using a server connected to the machine wirelessly or by cable. If the calculations take place on a server, the method according to the invention can be carried out in a simple manner with already existing machine tools which have a network interface.

Alternatively or additionally, it is provided that on the basis of the step F1 ) calculated noise excitation and / or in step F2 ) certain cause of noise excitation Maintenance of the multi-axis machine is carried out. Insofar as a certain dominant noise order can be directly assigned based on the kinematic model of the multi-axis machine, e.g. a shape and / or position deviation of a machine component, such as a bearing, a spindle or the like, the component quality is improved by replacement, calibration and / or Repair of the component in question.

A further embodiment of the method is characterized by providing the step D ) and E ) recorded and calculated data in a central database for quality control.

The recorded data can be collected, analyzed and used to improve the calculation of the actual geometry, in particular measurements on the manufactured components being compared to the respectively calculated actual geometry.

According to a further embodiment of the method, it is provided that the CNC-controlled multi-axis machine is a bevel gear grinding machine and the method is a bevel gear grinding method.

According to a further embodiment of the method, it is provided that the CNC-controlled multi-axis machine is a bevel gear milling machine and the method is a bevel gear milling method.

• - auf Grundlage der im Schritt F1) berechneten Geräuschanregung und/oder im Schritt F2) bestimmten Ursache der Geräuschanregung eine Bestimmung
• - einer zu erwartenden Lebensdauer und/oder eines Verschleißzustands einer Komponente der Mehrachsmaschine erfolgt.

It can be provided that

• - based on the step F1 ) calculated noise excitation and / or in step F2 ) a certain cause of the noise excitation
• - An expected service life and / or a state of wear of a component of the multi-axis machine takes place.

For example, the calculated expected noise excitation can still be within the tolerable range, but the calculated orders of a ripple analysis, e.g. indicate impending bearing damage to a spindle bearing. The analysis of the virtual twin can therefore also be used to determine the machine condition or the wear condition of individual machine components.

According to a second aspect, the invention relates to a production system for producing a bevel gear, set up for carrying out the method according to the invention, with a CNC-controlled multi-axis machine for carrying out the method step D ) and with a simulation computer to carry out one or more of the process steps A ), B ), C. ) and E ).

It can be provided that the simulation computer is a server and the CNC-controlled multi-axis machine for data exchange is networked wirelessly and / or wired to the server. Computing-intensive processes can thus be outsourced to the server.

It can be provided that the simulation computer is an integral part of the CNC-controlled multi-axis machine. For example, a powerful multi-core processor can be installed within the machine tool, in particular for one or more of the steps E ), F1 ), F2 ), G1 ) of the process to be carried out autonomously within the machine.

Figure list

• 1 ein Ablaufdiagramm eines erfindungsgemäßen Verfahrens;
• 2 ein erfindungsgemäßes Fertigungssystem.

The invention is described in more detail below with the aid of a drawing showing exemplary embodiments, each of which shows schematically:

• 1 a flow diagram of a method according to the invention;
• 2nd a manufacturing system according to the invention.

In one step A ) First, a bevel gear geometry is designed and a target geometry is calculated for the bevel gear to be manufactured. A software tool for bevel gear design, such as the software KIMoS5 (Klingelnberg Integrated Manufacturing of Spiral Bevel Gears) can be used for this purpose. During the design of the wheelset, for example, the contact pattern position and size of the contact pattern as well as the load-free rolling deviation are analyzed.

1 describes the sequence of a bevel gear grinding method according to the invention.

In one step B ) Providing measurement data for the geometry of a dressed grinding wheel, which is provided for grinding the tooth flanks of the bevel gear to be manufactured. The grinding wheel geometry can be determined by a measurement, in particular an optical measurement, and / or can be calculated from a relative kinematics of the dressing roller with respect to the grinding wheel.

In one step C. ) a kinematic model of the multi-axis machine is provided, with measurement data for recurring mechanical excitations, such as bearing rollover, meshing, gear ratios in the drive train, rotational speeds of the grinding spindle, rotational speed and geometry of the dressing roller and the like.

In one step D ) the bevel gear is manufactured with correction of the flank shape deviations caused by the machine kinematics and tool geometry, measurement data of the machine kinematics and the machine control, such as actual position values of the machine axes, axis speeds, the current consumption of the axle drives or the like, being recorded during manufacture.

In one step E ) the actual geometry (virtual twin) of the bevel gear to be manufactured is calculated on the basis of the in step A ) calculated target geometry, in step B ) provided measurement data, the one in step C. ) provided kinematic model and that in the process step D ) recorded measurement data.

The step D ) and E ) recorded and calculated data are made available in a central database for quality control.

In one step F1 ) the expected noise excitation of the manufactured bevel gear is calculated by determining deviations in the flank shape of the step E ) calculated actual geometry to that in step A ) calculated target geometry, such as surface ripples or the like and by calculating the expected noise behavior of the manufactured bevel gear by order analysis of the determined deviations.

In one step F2 ) a cause for a noise excitation of the manufactured bevel gear is determined by analyzing the noise behavior of the manufactured bevel gear, whereby an order spectrum is determined and by comparing the order spectrum with the kinematics model of the multi-axis machine.

Based on the step F1 ) calculated noise excitation and / or in step F2 ) certain cause of the noise excitation take place in one step G1 ) a correction of the process parameters and, if necessary, in one step G2 ) maintenance of the multi-axis machine.

2nd shows a manufacturing system 2nd for producing a bevel gear, set up to carry out the method according to 1 . The manufacturing system 2nd has a CNC controlled multi-axis machine 4th to carry out the process step D ) and a simulation computer 6 to carry out one or more of the process steps A ), B ), C. ) and E ).

The simulation computer 6 is a server 6 . The CNC-controlled multi-axis machine 4th is wireless and / or wired to the server for data exchange 6 networked.

Claims (10)

Process for manufacturing a bevel gear using a CNC-controlled multi-axis machine, with the process steps: A) Design of a bevel gear geometry and calculation of a target geometry for the bevel gear to be manufactured; B) providing measurement data for tool geometry, such as measurement data for a dressed grinding wheel geometry, measurement data for a cutter head or the like; C) Provision of a kinematic model of the multi-axis machine, with measurement data for recurring mechanical excitations, such as bearing rollover, meshing, gear ratios in the drive train or the like; D) Manufacturing the bevel gear - correcting the flank shape deviations caused by the machine kinematics and tool geometry, - Measurement data of the machine kinematics and the machine control, such as actual position values of the machine axes, axis speeds, the current consumption of the axis drives or the like, are recorded during production; E) Calculation of the actual geometry of the bevel gear to be produced based on - the target geometry calculated in step A), - the measurement data provided in step B), - The kinematic model provided in step C) and - The measurement data recorded in step D). Procedure according to Claim 1 , characterized in that - in a process step F1) the expected noise excitation of the manufactured bevel gear is calculated by: - determining deviations of the flank shape of the actual geometry calculated in step E) from the target geometry calculated in step A), such as surface ripples or the like; - Calculation of the expected noise behavior of the manufactured bevel gear by order analysis of the determined deviations. Procedure according to Claim 1 or Claim 2 , characterized in that - in a method step F2) a cause for a noise excitation of the manufactured bevel gear is determined by: - analyzing the noise behavior of the manufactured bevel gear, an order spectrum being determined; - Comparison of the order spectrum with the kinematic model of the multi-axis machine. Method according to one of claims 2 or 3, characterized in that - on the basis of the noise excitation calculated in step F1) and / or the cause of the noise excitation determined in step F2) - a correction of the process parameters (G1), in particular within the machine, and / or - the multi-axis machine (G2) is serviced. Method according to one of the preceding claims, characterized by - providing the data recorded and calculated in steps D) and E) in a central database for quality control. Method according to one of the preceding claims, - The CNC-controlled multi-axis machine is a bevel gear grinding machine and the method is a bevel gear grinding method or - The CNC-controlled multi-axis machine is a bevel gear milling machine and the method is a bevel gear milling method. Method according to one of the preceding claims, - a determination is made on the basis of the noise excitation calculated in step F1) and / or the cause of the noise excitation determined in step F2) - An expected service life and / or a state of wear of a component of the multi-axis machine takes place. Manufacturing system for manufacturing a bevel gear, - set up to carry out the method according to one of claims 1 to 7, - With a CNC-controlled multi-axis machine to carry out process step D) and - With a simulation computer to carry out one or more of the process steps A), B), C) and E). Manufacturing system according to Claim 8 , characterized in that - the simulation computer is a server and - the CNC-controlled multi-axis machine for data exchange is networked wirelessly and / or wired with the server. Manufacturing system according to Claim 8 or Claim 9 , characterized in that - the simulation computer is an integral part of the CNC-controlled multi-axis machine.

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