A manufacturing error of a cycloidal gear is the key factor affecting the transmission accuracy of a robot rotary vector (RV) reducer. A methodology is proposed to realize the digitized measurement and data processing of the cycloidal gear manufacturing error based on the gear measuring center, which can quickly and accurately measure and evaluate the manufacturing error of the cycloidal gear by using both the whole tooth profile measurement and a single tooth profile measurement. By analyzing the particularity of the cycloidal profile and its effect on the actual meshing characteristics of the RV transmission, the cycloid profile measurement strategy is planned, and the theoretical profile model and error measurement model of cycloid-pin gear transmission are established. Through the digital processing technology, the theoretical trajectory of the probe and the normal vector of the measured point are calculated. By means of precision measurement principle and error compensation theory, a mathematical model for the accurate calculation and data processing of manufacturing error is constructed, and the actual manufacturing error of the cycloidal gear is obtained by the optimization iterative solution. Finally, the measurement experiment of the cycloidal gear tooth profile is carried out on the gear measuring center and the HEXAGON coordinate measuring machine, respectively. The measurement results verify the correctness and validity of the measurement theory and method. This methodology will provide the basis for the accurate evaluation and the effective control of manufacturing precision of the cycloidal gear in a robot RV reducer.
In order to improve the tooth surface geometric accuracy and transmission quality of hypoid gears, a new digitized reverse correction method is proposed based on the measurement data from a one-dimensional probe. The minimization of tooth surface geometrical deviations is realized from the perspective of mathematical analysis and reverse engineering. Combining the analysis of complex tooth surface generation principles and the measurement mechanism of one-dimensional probes, the mathematical relationship between the theoretical designed tooth surface, the actual machined tooth surface and the deviation tooth surface is established, the mapping relation between machine-tool settings and tooth surface deviations is derived, and the essential connection between the accurate calculation of tooth surface deviations and the reverse correction method of machine-tool settings is revealed. Furthermore, a reverse correction model of machine-tool settings is built, a reverse correction strategy is planned, and the minimization of tooth surface deviations is achieved by means of the method of numerical iterative reverse solution. On this basis, a digitized reverse correction system for hypoid gears is developed by the organic combination of numerical control generation, accurate measurement, computer numerical processing, and digitized correction. Finally, the correctness and practicability of the digitized reverse correction method are proved through a reverse correction experiment. The experimental results show that the tooth surface geometric deviations meet the engineering requirements after two trial cuts and one correction.
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