Gear Shape Measurement Potential of Laser Triangulation and Confocal-Chromatic Distance Sensors

Area of Science:

• Metrology
• Optical Measurement
• Gear Metrology

Background:

• Growing demand for high-precision gear shape measurements with single-digit micrometer uncertainty.
• Limitations of traditional tactile gear testing in terms of speed.
• Emerging optical systems present faster alternatives but face challenges like surface properties and sensor angles.

Purpose of the Study:

• To investigate the potential of optical gear shape measurement systems.
• To evaluate laser triangulation and confocal-chromatic sensors for gear metrology.
• To identify factors influencing measurement uncertainty in optical gear measurements.

Main Methods:

• Utilized laser triangulation and confocal-chromatic sensors for gear shape measurements.
• Employed a lateral scanning position measurement approach.
• Conducted standard measurements on tooth flanks and spur gears.

Main Results:

• Identified surface properties as the primary source of random effects and uncertainty.
• Laser triangulation yielded uncertainties greater than 10 µm.
• Confocal-chromatic sensor achieved standard uncertainties below 6.5 µm.
• Multiple reflections did not impact uncertainty with the lateral scanning method.

Conclusions:

• Confocal-chromatic sensors demonstrate potential for achieving sub-10 µm uncertainty in optical gear shape measurements.
• Optical systems, even commercial ones not specifically designed for gears, can meet stringent metrology requirements.
• Further development in optical metrology can enhance the speed and precision of gear inspection.