Patent Application
20180104754
This application claims priority under 35 U.S.C. §§ 119(a)-(d) to German patent application no. DE102016119717.3 filed Oct. 17, 2016, which is hereby expressly incorporated by reference as part of the present disclosure.
The present invention relates to the retractability of bevel gears in a bevel gear transmission. In addition, it relates to a device, which comprises a gear cutting machine and a correspondingly equipped development environment. In addition, it relates to a correspondingly modified bevel gear transmission.
There are various types of bevel gear transmissions. Each of these bevel gear transmissions comprises at least two bevel gears, which are mutually engaged with one another. Bevel gear transmissions are also referred to as angular transmissions, since the rotational axes of the two bevel gears are at an angle to one another.
The removal is typically performed in the reverse sequence of the steps mentioned by way of example.
Both during the installation and during the removal, a collision of the teeth of the two bevel gears can occur. Such a collision occurs above all in the case of helical-toothed and spiral-toothed bevel gears. In practice, a hammer is sometimes used when inserting the first bevel gear 20, in order to overcome the mechanical resistance which can result due to such a collision, even if this procedure is not technically correct. Using an angle grinder is also known, for example, to remove parts of the tooth flanks on one or two teeth of the first bevel gear 20, so that they no longer collide and jam during the insertion.
It is obvious that such approaches have disadvantages. Flexing or grinding away parts of a tooth flank results in weakening of this tooth. The possibility for load transmission from one to the other bevel gear is thus reduced. Cracking and failure of the affected tooth can occur here. Furthermore, the removal of material on one or two teeth results in an imbalance, which can in turn have an influence on the quiet running.
Even if no further problems should occur after the flexing or grinding away during the insertion of the first bevel gear 20, since it can be ensured during the insertion that the first bevel gear 20 having the modified tooth/teeth is exactly engaged with the tooth gaps of the second bevel gear 30 in a suitable angle position, the separation (also called pulling) of the two bevel gears 20, 30 can nonetheless be difficult or even impossible, if one does not find the same angle position again.
To avoid the mentioned problems during the installation or during the pulling of bevel gears of a bevel gear transmission, the retractability can be taken into consideration from the outset in the design of the transmission. It is sometimes possible to avoid the jamming from the outset by way of a small adaptation of the macro-geometry of the two bevel gears of the bevel gear transmission. If, for example, the tooth flanks extending in a spiral should have an excessively small radius of curvature, a gear cutting tool having a larger tool nominal radius can thus be used during the gear cutting. The larger nominal radius results in a less strongly curved profile of the tooth flanks and therefore also in a lesser tendency toward jamming. In the case of large-module bevel gears, as are used in stone mills and the like, however, gear cutting tools having a sufficiently large tool nominal radius are not available. In addition, such changes of the macro-geometry often have to be “traded off” against a reduced degree of overlap and, because of this, also a reduced carrying capacity.
Situations therefore occur again and again in which the retractability does not enable an adaptation of the macro-geometry or in which the adaptation of the macro-geometry determined by computer is undesirable.
It is an object of the invention therefore to find a way which reliably enables the retractability of two bevel gears during the separation thereof, without having to depend on manual re-machining.
According to at least some embodiments, a method enables or improves the retractability of a first bevel gear, which is configured to form a transmission together with at least a second bevel gear, wherein the transmission is installed in a housing in such a way that a rotational movement of the first bevel gear can be transferred into a rotational movement of the second bevel gear, or vice versa.
According to at least some embodiments, the method comprises the following steps:
The finish machining in the bevel gear cutting machine can be performed as continuous indexing finish machining or discontinuous indexing finish machining (also called the single indexing method).
Design data for the first or the second bevel gear may be provided in a preparatory method step, which is performed before an ascertainment of the first machine data, wherein the first machine data are then derived from these design data.
The preparatory method step may be carried out in a development environment, which is equipped with software for designing a transmission.
The development environment may comprise a computer which is equipped with software for designing transmissions.
In some at least embodiments, a (total) device comprises a CNC-controllable gear cutting machine and a development environment, wherein the development environment can be brought into a communication connection with the gear cutting machine. The gear cutting machine comprises a CNC controller and multiple CNC-controlled axes, and is configured to manufacture a bevel gear with gear teeth on the basis of machine data with a continuous gear cutting procedure. The (total) device may comprise the following features:
At least some embodiments enable partially automated machining of at least one bevel gear of a bevel gear transmission, to improve or enable the retractability thereof.
According to at least some embodiments, the penetration region is removed in a targeted and highly accurate manner by a cutting finish machining procedure by means of modified machine (setting) data (called second machine data here). In at least some such embodiments, a continuously running milling or grinding procedure may be used as the cutting finish machining procedure.
The finish machining which is used for the flank modification can be used, for example, on the thrust flanks of crown wheels, if the transmission is only to be used in traction operation.
An advantage of at least some embodiments is that they supply reproducible and reliable results. A bevel gear transmission which was improved/optimized using embodiments of the invention with respect to the retractability on all teeth of one of the bevel gears does not display any imbalance, as is the case in bevel gear transmissions in which one of the bevel gears to be paired was manually finish machined.
It is an advantage of at least some embodiments that reproducible finish machining results, because it is measurable.
Since the finish machining was applied to all right and/or all left flanks of one of the two bevel gears, the retractability is provided in any arbitrary engagement position of the wheel set.
At least some embodiments have the advantage that when carrying out the retractability analysis, the carrying capacity of the teeth can be taken into consideration, to thus avoid excessively strong local weakening of the teeth.
At least some embodiments have the advantage that even in the case of large and heavy bevel gear transmissions, the bevel gear pinion can be axially pulled during a removal, without an axial (lowering) movement of the crown wheel being necessary.
At least some embodiments are usable both in the continuous and also in the discontinuous indexing method on CNC-controlled gear cutting machines. Bevel gear milling machines and bevel gear grinding machines, which have at least five CNC-controlled axes, are particularly suitable.
The finish machining for the purpose of flank modification can be carried out according to at least some embodiments on the soft bevel gear (i.e., before the hardening) or on the hardened bevel gear.
At least some embodiments are suitable for industrial transmissions and for transmissions which are distinguished by a high carrying capacity and for transmissions which have a module >10.
The figures will be described in a connected and comprehensive manner. Exemplary embodiments will be described in greater detail hereafter with reference to the drawings.
Terms are used in conjunction with the present disclosure which are also used in relevant publications and patents. However, it is to be noted that the use of these terms is only to serve for better understanding. The inventive concepts and the scope of protection of the patent claims are not to be restricted in the interpretation by the specific selection of the terms. The invention may be readily transferred to other term systems and/or technical fields. The terms are to be applied accordingly in other technical fields.
A superposition of rotational and traction movement is referred to as an axial traction movement. The term “axial traction movement” is to indicate that the traction movement comprises a clear axially oriented component. An “axial insertion movement” is a superposition of rotational and thrust movements.
A rectangular housing 11 is used, in which the two bevel gears 20, 30 are installed (paired with one another) so that they are engaged. An installation/inspection opening can be provided laterally on the housing 11, which is closed oil-tight here using a plate 12 and a suitable seal (not shown). During a removal, firstly, the installation/inspection opening on the housing 11 is opened and the oil is (partially or entirely) drained. The first bevel gear 20 can then be pulled in the axial direction, i.e., parallel to the rotational axis R1 of the first shaft 21, out of the housing 11 through the installation/inspection opening. The pulling is shown in each of
If the second bevel gear 30 has to be repaired or replaced, this second bevel gear 30 can thus be unscrewed and removed through the installation/inspection opening on the housing 11. The second bevel gear 30 can also be removed through another opening of the housing 11, for example, by axial lowering, which is often only feasible in the case of extremely heavy crown wheels with great effort. The installation situation also often does not enable lowering of the second bevel gear 30, i.e., the first bevel gear 20 also has to be removed by pulling in the axial direction in these cases.
If one of the bevel gears 20 or 30 was modified according to certain embodiments the invention, the pulling Z1 can thus be carried out without problems and without jamming of the teeth 22, 32 of the two bevel gears 20, 30.
To enable or simplify the installation and removal, which was explained on the basis of multiple figures to be understood as examples, a method is described hereafter with reference to the flowcharts of
First machine data MD1 may be provided in a first step S1. These data MD1 can be loaded from a memory region 51 or provided by software SW1, for example. The machine data MD1 are used for the CNC-managed control of a bevel gear cutting machine 100 (see, for example,
The machine data MD1 can be transferred in an (intermediate) step to the bevel gear cutting machine 100, as indicated in
A retractability analysis ZV is now carried out. The method step ZV uses either the machine data MD1, or it uses design data AD of the transmission 10. The retractability analysis ZV can also use a combination of the machine data MD1 and the design data AD, however. It is therefore indicated by a node 52 in
In
The machine data MD2, or possibly the modified first machine data MD1, can be transferred in an (intermediate) step to the bevel gear cutting machine 100, as indicated in
The retractability analysis ZV can comprise the following partial steps, for example:
In step TS1, a computer determines whether, during the installation in the housing 11, the first bevel gear 20 can be engaged by an axial insertion movement with the second bevel gear 30 and/or whether the first bevel gear 20 can be separated by an axial traction movement from the engagement with the second bevel gear 30. To be able to ascertain a collision of the two bevel gears 20, 30 during the installation or removal, the design data AD of the transmission 10 may be computer analyzed. In particular, the precise flank geometry and installation location have to be known to be able to ascertain a collision of the two bevel gears 20, 30. This means the design data AD, which are used here, should particularly contain items of information on the flank geometry and installation location. The design data AD can be loaded from a memory region 53, for example, as shown in
If the computer determines in step TS1 a possible collision during the engagement or during the separation between a tooth 22 of the first bevel gear 20 and a tooth 32 of the second bevel gear 30, the steps TS2 i. and TS2 ii. follow:
The step TS2 i. can proceed from a computation approach in which, for example, the outlines of the second bevel gear 30 are statically defined in a coordinate system and in which, for example, the outlines of the first bevel gear 20 are moved relative to the second bevel gear 30 (for example, by a successive coordinate transformation). In most cases, both bevel gears 20, 30 have to be rotated, while the first bevel gear 20, for example, is axially displaced. The relative movement comprises a superposition of rotational and linear movements in these cases. A type of collision region in the three-dimensional coordinate system results due to this relative movement (which takes place by computer in a virtual sense here). This collision region may correspond to the penetration region of the volume body of the first bevel gear 20 with the volume body of the second bevel gear 30.
A flank modification FM of the tooth flanks of the teeth 22 of the first bevel gear 20 or the teeth 32 of the second bevel gear 30 can now be ascertained by computer on the basis of this penetration region.
The step TS2 ii. can establish the second machine data MD2 so that during the execution of the corresponding CNC-controlled movements in the bevel gear cutting machine 100, the required flank modification FM can be performed on the tooth flanks of the teeth 22 of the first bevel gear 20 or on the tooth flanks of the teeth 32 of the second bevel gear 30 by cutting machining.
If the computer determination in the step TS1 does not predict a collision, the retractability analysis ZV thus branches via an interface SS1 of
Before or during the method, a continuous indexing or discontinuous indexing gear cutting machining may be carried out in the bevel gear cutting machine 100, to provide the first bevel gear 20 or the second bevel gear 30 with gear teeth according to the first machine data MD1. It is not essential as to when this gear cutting machining is carried out.
As part of the some embodiments, a continuous indexing or a discontinuous indexing finish machining is carried out in the bevel gear cutting machine 100 to perform the flank modification FM according to the second machine data MD2 on the already provided teeth 22 of the first bevel gear 20 or on the already provided teeth 32 of the second bevel gear 30. This step of finish machining is carried out in any case after the original gear cutting of the corresponding bevel gear 20 or 30. This means the bevel gear 20 or 30 to be finish machined was already (previously) cut.
The (total) device 200 comprises at least one CNC-controllable gear cutting machine 100 and a development environment 50, wherein the development environment 50 can have a communication connection 54 established with the gear cutting machine 100. This communication connection 54 is shown by a block arrow in
The gear cutting machine 100 comprises a CNC-controller 101 and multiple CNC-controlled axes X, Y, Z, B, R1, R2 (the number of these CNC-controlled axes and the axis titles thereof are only to be understood as an example). In
The gear cutting machine 101 can comprise an internal and/or external memory 102, as indicated in
In order to be able to provide the first bevel gear 20 or the second bevel gear 30 with gear teeth on the basis of the first machine data MD1 in the scope of a continuous gear cutting procedure, the first machine data MD1 are loaded, for example, from the memory 102 via the communication connection 103 into the CNC controller 101, so that the CNC controller 101 can perform the cutting, continuous gear cutting machining on the corresponding bevel gear 20, 30 step-by-step. Such methods for gear cutting machining are well-known and will therefore not be explained in greater detail here.
The development environment 50 may be equipped with software SW1, which is designed for designing a transmission 10 having a first bevel gear 20 and a second bevel gear 30 to be paired therewith.
The development environment 50 can be equipped with means 55 for (manual) input of data D1. The data D1 can comprise, for example, the basic specifications required for a design method, which are required for the definition of a transmission 10.
From these data D1, the software SW1 can compute and provide design data AD1 for the first bevel gear 20 in the scope of a design procedure. These design data AD1 can either be converted in the development environment 50 into machine-specific machine data MD1, or this conversion is performed in the gear cutting machine 100 itself (by means of a software module SW2 therein, for example).
The development environment 50 may be designed for carrying out a retractability analysis ZV. For this purpose, the development environment 50 can comprise, for example, a software module ZV1, as indicated in
The machine data MD1 and/or MD2 can be transferred by the software module SW2 to the memory 102, as schematically indicated by the communication connection 105, and/or the machine data MD1 and/or MD2 can be transferred directly (for example, by the development environment 50) to the CNC controller 101, or they can be transferred by the software module SW2 to the CNC controller 101, as schematically indicated by the communication connection 106.
The software module ZV1 can also be situated in a computer of the gear cutting machine 100. In this case, the mentioned development environment 50 is part of the machine 100.
The software module ZV1 may be designed for the purpose, in the scope of the above-mentioned retractability analysis ZV, to ascertain by computer a flank modification FM on teeth 22 of the first bevel gear 20 or the second bevel gear 30. This flank modification FM is ascertained so that a collision of the teeth 22 of the first bevel gear 20 with teeth 32 of the second bevel gear 30 during the installation or removal is avoided.
After the computer-based carrying out of the retractability analysis ZV, the second machine data MD2 (or in an alternative embodiment the modified design data AD1*) are provided directly or indirectly. These second machine data MD2 are defined so that they are usable in the gear cutting machine 100 for the CNC-controlled finish machining of the teeth 22 of the first bevel gear 20 or the teeth 32 of the second bevel gear 30.
The retractability analysis ZV may also consider information on the counter flank play during the ascertainment of the flank modification FM.
In
The software module ZV1 can associate these line trains with a material removal. If one removes material, for example, on the tooth flanks 23 in accordance with the computed material removal in the scope of the finish machining, collision or jamming is then avoided during the axially oriented installation or removal.
To illustrate this on the basis of a concrete example,
As can be seen in
The simplest form of the finish machining results from a superposition of a crown wheel geometry previously generated in the plunging method with the original setpoint geometry of the tooth gaps. By suitable selection of the plunging position in conjunction with a workpiece wheel rotation adapted to the penetration depth, the “interfering” material component can be removed very exactly from the flanks 33 of the bevel gear 30.
Alternatively, a modified rolled geometry of the original geometry of the bevel gear can also be superimposed for the finish machining.
As may be recognized by those of ordinary skill in the pertinent art based on the teachings herein, numerous changes and modifications may be made to the above described and other embodiments of the present invention without departing from the spirit of the invention as defined in the claims. Accordingly, this detailed description of embodiments is to be taken in an illustrative, as opposed to a limiting sense.
| Number | Date | Country | Kind |
|---|---|---|---|
| 102016119717.3 | Oct 2016 | DE | national |
