Abstract:
A universal dynamic gear quality and consistency verification inspection system and method is provided. The system and method provides a dynamic gear verification inspection station including a Double Flank master gear and a probe for inspecting gear features and an electronic plug having pre-reference pads and mechanical rests for supporting and locating the part to be inspected. The probes are provided to verify all angles and functional parameters relayed to appropriate software for evaluation and record maintenance. A probe may also be provided for face checking.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates generally to a system and method for inspecting mechanical articles. More particularly, the present invention relates to a system and method for dynamically inspecting gears to verify quality and consistency. 
       BACKGROUND OF THE INVENTION 
       [0002]    It is necessary in almost every application of gears in various systems that the gears be of good quality and consistent configuration. It is not possible, nor is it necessarily desirable, for these gears be individually and manually inspected by workers. Rather, it is more desirable to provide an automated machine capable of making the appropriate inspection consistently and quickly. 
         [0003]    The gear inspection must of necessity involve the verification of a variety of parameters. These parameters include the so-called “Double Flank” functional parameters (Fi″, fi″, Fr″, Aa″, Nick) that indicate a total radial composite deviation, and other parameters indicative of angular deviations, more specifically lead angle, lead angle variation, taper, and taper variation. As is known in the art, a dynamic inspection station for making all such verifications includes an expanding arbor or a post for supporting and measuring the gear to be checked, and two masters, i.e. a master roller gear on one side of the expanding arbor and a ‘gimbal’ master on the other side. The master roller gear meshes with the gear to be checked without backlash in a double flank arrangement, and is used to check the radial deviations, while the gimbal master have specially shaped teeth and allows to detect angular deviations. Systems exist today which attempt to achieve a comprehensive system of quality and consistency verification. 
         [0004]    However, having both master roller gears and gimbal masters, further to expanding arbors is costly, more specifically where different masters and arbor sizes are required to support the inspection of different gear manufacturing requirements. Additionally, the gimbal assembly must overcome inertia to follow the variation of the lead and taper angle of a gear, thus slowing down the inspection cycle. 
         [0005]    Accordingly, a need exists today for an improved system and method for verifying quality and consistency of gears on a relatively high-speed basis. 
       SUMMARY OF THE INVENTION 
       [0006]    Two preferred embodiments of a dynamic gear quality and consistency verification inspection station are provided. The system and method, regardless of the embodiment, provides a dynamic gear verification inspection station and method which overcomes the inadequacies and costs associated with prior art systems. The system of the present invention provides a dynamic gear verification inspection station that eliminates multiple parts and one master thereby eliminating excessive time and cost for inspections. 
         [0007]    According to one embodiment of the disclosed invention, the dynamic gear inspection station includes only one master, more specifically a spring-loaded so-called “Double Flank” master gear. This station includes a probe for inspecting gear features and an electronic plug having pre-reference pads and mechanical rests for supporting and locating the part to be inspected. The probes are provided to verify all angles and functional parameters relayed to appropriate software for evaluation and record maintenance. One or more probes may also be provided for face checking. 
         [0008]    According to another embodiment of the disclosed invention, the dynamic gear inspection station includes only one master, more specifically a Double Flank master gear. In this case, too, the station includes a probe for inspecting gear features, while the master gear is set within a master locating assembly, for example with a gimbal station, having probes for checking lead and taper angles. The part to be checked is located on an expanding arbor and drives the master gear. The expanding arbor station may also include a probe for face checking. Probes are provided to check all angles and functional parameters relayed to the appropriate software for evaluation and record maintenance. The expanding arbor and master locating assembly having probes provide a more accurate means to measure small parts, large and flat rings and parts with internal splines. 
         [0009]    Other features of the invention will become apparent when viewed in light of the detailed description of the preferred embodiment when taken in conjunction with the attached drawings and the appended claims. 
     
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    For a more complete understanding of this invention, reference should now be made to the embodiment illustrated in greater detail in the accompanying drawings and described below by way of examples of the invention wherein: 
           [0011]      FIG. 1  illustrates a side elevational view of an embodiment of the inspection station for checking all angles and functional parameters of a gear according to the disclosed invention; 
           [0012]      FIG. 2  illustrates a top view of the part locating assembly of the inspection station of  FIG. 1 , showing some details laying in lower planes; and 
           [0013]      FIG. 3  illustrates a side elevational view of an alternate embodiment of the inspection station for checking all angles and functional parameters of a gear according to the disclosed invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0014]    In the following figures, the same reference numerals will be used to refer to the same components. In the following description, various operating parameters and components are described for one constructed embodiment. These specific parameters and components are included as examples and are not meant to be limiting. 
         [0015]    Referring to the drawings and in particular to  FIG. 1 , an embodiment of the disclosed invention is shown. Particularly, an elevated side view of an inspection station, generally illustrated as  10 , is shown. The inspection station  10  has utility in verifying the parameters of a part  12  such as a gear defining a rotation axis. The part  12  includes an axial through opening and may be of a variety of materials, including both ferrous and non-ferrous metals as well as non-metal materials such as polymers or fibers. 
         [0016]    The inspection station  10  includes a locating assembly, generally illustrated as  16 , with a frame  22  rotatably and slidably supporting a spring-loaded roller master  14 . 
         [0017]    The locating assembly  16  includes a plug supporting structure  20 , coupled to the frame  22 , that includes a supporting ring  30  and carries a substantial vertical plug  18  with a substantially cylindrical central body defining a rotation axis of the plug. 
         [0018]    As is also visible in  FIG. 2 , provided on the plug  18  are a plurality of contact points or probes which measure certain desired parameters of the part  12 . The probes are part of a part-inspecting system and may be mechanical probes contacting the part to be checked, or non-contact (e.g. optical) probes. While a variety of positions and numbers of probes may be used, preferably there is an upper layer of probes  24 ,  24 ′ and  24 ″ and a lower layer of probes of which only one, probe  26 , is visible in  FIG. 1  (preferably three probes define the lower layer of probes). The probes  24 ,  24 ′,  24 ″ and  26  check at least one parameter of the part  12  when the roller master  14  engages the part  12 . While a total of six probes in two layers are preferred, it is possible that a greater or lesser number of probes may be provided on a greater or lesser number of layers. 
         [0019]    The locating assembly  16  further includes pre-reference surfaces, e.g. with pads  28 ,  28 ′ positioned on the supporting ring  30 . One or more optional probes, indicated with reference number  31  in  FIG. 1 , is/are provided on the supporting ring  30  for checking a lower face of the part  12 . The pads  28 ,  28 ′ are provided to allow a place whereupon a first location of said lower face of the part  12  leans before the roller master  14  engages the part  12 . 
         [0020]    The roller master  14  is loaded by a spring  15  and dictates the position, against the plug  18 , of the part  12 . Since the part ordinarily is a gear, the position is dictated by making reference to the gear teeth. To provide appropriate support for the part  12 , the locating assembly  16  includes mechanical rests for seating the part  12 . These mechanical rests can be of a variety of configurations, but it is preferred that they are one or more rollers or balls and most preferably include a couple of balls  32 ,  32 ′ positioned in appropriate cavities defined in the exterior circumference of said central body of the plug  18  for providing lateral support to the part  12  and a ball  34  for providing lower support to the part  12 . The ball  34  is provided in an appropriate cavity defined in the upper surface of the supporting ring  30 . 
         [0021]    A radial probe  29  detects movement of the spring-loaded roller master and provides a signal for Double Flank checks. 
         [0022]    In use, an inner cylindrical surface of the part  12  at the axial through opening is pushed by the spring-loaded roller master  14  against the balls  32 ,  32 ′. The pads  28 ,  28 ′ and the ball  34  are dimensioned and arranged in such a way that when the part  12  is free its lower face leans upon both the pads  28 ,  28 ′ and the ball  34 , while when the roller master  14  engages and pushes the part  12 , the part  12  slightly tilts, and its lower surface detaches from the pads  28 ,  28 ′ and is thereafter vertically supported solely by the ball  34 . The balls  32 ,  32 ′ and  34  do not affect the movement of the part  12  during rotation. The plug  18  detects the position of the axis of the part  12  during its rotation. 
         [0023]    According to the described system, the probes of the above-mentioned two layers ( 24 ,  24 ′,  24 ″ and  26 ) allow to check the teeth of the part  12  as regards lead and taper angle, in absolute values and variations. The clearance between the plug  18  and the part  12  is large enough to accommodate a slight diametrical difference in parts such as the same part taken from different stages of the part-forming operation. 
         [0024]    The data collected by the probes  24 ,  24 ′,  24 ″, and  26  are provided to a computer for comparative analysis against an ideal profile for a given part. If the actual data compares favorably with the ideal or model parameters, the part is deemed to have passed inspection. Non-compliance results in a rejected part. 
         [0025]    The inspection station  10  eliminates the need for a gimbal station and a gimbal master, which optimizes costs and inspection time. The probes associated with the gimbal station are also eliminated by the present invention and are replaced by a more simple and compact plug. Further, the need for a costly expanding arbor is also eliminated by the present invention. Thus, the cycle time is shortened by eliminating the gimbal station, especially when measuring gears, where the lead and taper variation is difficult for a gimbal to follow. 
         [0026]    It was mentioned above that a greater or lesser number of probes may be provided. Specifically, additional probes may be provided to measure face defects of the gear where, instead, along with the diameter, taper and bore shape are detectable without requiring any additional gauges. 
         [0027]    As noted above, the couple of balls  32 ,  32 ′ can be replaced by different mechanical rests, e.g. a single ball or at least one properly shaped surface allowing pivotal movements between the axes of the part  12  and the plug  18 . 
         [0028]    Pads  28 ,  28 ′ can also be replaced by one or more different pre-reference surfaces having the same functional features described above. 
         [0029]      FIG. 3  illustrates a side elevational view of an alternate variation of the dynamic gear inspection system of the present invention. According to this view, an inspection station, generally illustrated as  100 , is provided. The inspection station  100  includes an expanding arbor or drive  110  for locating a part  112 , such as a gear, to be checked. A Double Flank roller master  114  located within a master locating assembly with a gimbal station  116  is driven by the expanding arbor  110 . The Double Flank roller master  114  is rotatable along a first axis A. The part  112  is located parallel to the roller master  114 . A probe  117  is provided for checking the face of the part  112  to detect misplacement of the face of the part with respect to its inner diameter. 
         [0030]    The gimbal station  116  includes a pivotable assembly  118 , for measuring lead and taper angles of the part  112 , which is pivotably attached to the gimbal station  116  along a second axis B. One or more probes for checking lead and taper angles of the part  112  is provided in operative association with the pivotable assembly  118 . Preferably three such probes are provided, of which two probes,  120 ,  120 ′, are illustrated. The probes  117 ,  120  and  120 ′ are of the type illustrated in  FIGS. 1 and 2  and discussed above with respect thereto. In general, the probes  117 ,  120  and  120 ′ function to measure all angular parameters of the part  112 . In conjunction with these probes, the expanding arbor  110  in combination with the gimbal station  116  provides accurate measurement of small parts, large and flat rings, and parts with internal splines, including double flank checking and interior diameters. 
         [0031]    The inspection station  100  may accurately measure parts  112  that are too small to fit on the plug  18  of the inspection station  10  shown in  FIGS. 1 and 2  and described in conjunction therewith. The gimbal station  116  is used with the roller master  114  for measuring Double Flank features. A rotatable slide  122 , holding the gimbal station  116 , is provided. A radial probe  129  detects movement of the rotatable slide  122  along a C axis. This provides a signal for Double Flank checks. This arrangement eliminates the need for a specially shaped gimbal master. 
         [0032]    The data collected by the probes  117 ,  120  and  120 ′ are provided to a computer for comparative analysis against an ideal profile for a given part. If the actual data compares favorably with the ideal or model parameters, the part is deemed to have passed inspection. Non-compliance results in a rejected part. 
         [0033]    As a variation to the invention disclosed with reference to  FIG. 3 , the roller master  114  can be located on the expanding arbor  110 , while the part to be checked  112  is located in the master locating assembly with the gimbal station  116 . Moreover, one or the other of roller master  114  and part  112  may be put into rotation by proper means and drive the other. 
         [0034]    The inspection system according to both the described embodiments and possibly featuring other variations advantageously allow to perform a complete inspection of a gear with only one master, and does not need any specially shaped gear master. The inspection station according to the embodiment of  FIGS. 1 and 2  has the additional advantage of a very simple structure, with neither a gimbal station nor an expanding arbor. 
         [0035]    While the invention has been described in connection with one or more embodiments, it is to be understood that the specific mechanisms and techniques which have been described are merely illustrative of the principles of the invention, numerous modifications may be made to the methods and apparatus described without departing from the spirit and scope of the invention as defined by the appended claims.