Patent ID: 7251542

Claim:
A method for manufacturing a complex spiral gear from a blank, said method comprising the steps of: using a first computer program to create a first data set that identifies the contours of said gear; using said first data set to set the operating parameters of a gear-cutting machine; cutting a gear from said blank with said gear-cutting machine; using a second computer program to generate a second data set for the purpose of measuring and inspecting said gear; measuring and inspecting said gear by a gear-inspection machine operated by said second computer program; mounting said gear to a rotatable, indexable chuck; using a third computer program to generate a computer model of the contours of said gear, said third computer program adapted to operate said indexable chuck and a robotic work arm; mounting a first selected machining tool on said robotic work arm; using said third computer program to operate said work arm to bring said first machining tool into contact with a first selected portion of said gear contours; conducting a first machining operation upon said first gear contour portion; operating said indexable chuck to bring a second selected portion of said gear contour into position to be machined; using said third computer program to operate said work arm to bring said first machining tool into contact with said second selected portion of said gear contours; conducting said first machining operation upon said second gear contour portion; and continuing to reindex and machine said gear until all contours desired to be machined have been machined.