Measuring Sensors Calibration in Worm Gear Rolling Testers

Area of Science:

• Mechanical Engineering
• Metrology

Background:

• Existing ISO standards lack detailed calibration procedures for gear-rolling measurement equipment.
• This deficiency contributes to poor reproducibility in gear rolling tests.
• Measurement uncertainty analysis reveals sensor accuracy is only one component of total uncertainty.

Purpose of the Study:

• To develop and present a novel calibration and verification procedure for worm gear rolling testers.
• To enhance the accuracy and reproducibility of gear rolling measurements.
• To address limitations in current gear measurement equipment.

Main Methods:

• Adapted calibration techniques from machine tools, coordinate measuring machines, and gear metrology instruments.
• Numerically compensated for measuring instrument errors.
• Evaluated the impact of movement error components on the gear meshing point.

Main Results:

• Identified unintentional position variations not detected by standard sensors.
• Quantified the influence of these variations on the meshing point.
• Demonstrated that including these variations in calibration reduces measurement uncertainty.

Conclusions:

• The proposed calibration procedure improves the accuracy of worm gear rolling testers.
• Addressing unintentional position variations is crucial for reducing measurement uncertainty.
• This work is a step towards developing optimized equipment for more reliable gear measurements.