Measuring instruments

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Measuring instruments

DO-0 - Instrument for double flank testing of small diameter gears

DO-1 - Instrument for double flank testing of gears

DO-1V - Instrument for double flank testing of spur and helical internal gears

DO-2 - Instrument with special support for single flank testing of bevel gears

DO-2S - Instrument for single flank testing of worm gears

DO-2K - Instrument with special support for single flank testing of bevel gears

DO-3 - Instrument for complete analytical testing of Helix, Profile, and Tooth Spacing Deviations

DO-0

DO0-PC

DO 0 - Instrument for double flank testing of small diameter gears utilizing a dial indicator.

DO 0 PC - Instrument for double flank testing of small diameter gears utilizing a PC Control.

Wide assortment of instruments for gear testing, produced by GEARSPECT. By its assortment the instruments of type DO cover the whole spectrum of gear testing methods. We manufacture classical manual versions with dial gauge reed-out, or computer controlled version with printed record of measuring.

DO-0

manual instrument for testing up to 120mm/4,7 inch dia. gears, by the double flank rolling method

DO-0 PC

computerized instrument for testing up to 120 mm/4,7 inch dia. gears by the double flank rolling method

Double flank testing

Measures the centre distance variation when master gear and testing gear are in mesh.

You can test such deviations:

F_i'' - deviation of double flank rolling per revolution

f_i'' - deviation of double flank rolling per pitch

F_r'' - medium deviation of double flank rolling per revolution

f_a'' - deviation of value of axes distance related to theoretical value

Operation software

Measuring and control programs use WINDOWS ´ 98.

The main control program allows:

use of the instrument in shop enviroment
quick measure and display tested deviations
direct input of the deviations in mm instead of accuracy class
precisely find the place of respective mechanical damage of actual class
to move gear into exact selected position for marking the place of damage
by means of a special SW to select the measured gears according to deviations, respectively according to select tolerance of axis distances
by means of a special SW to control automatic marker for marking (optional accessory)
blocking of instrument functions by password
adjustment of length dimensions for measuring in millimetres (mm) or inches ('')
adjustment of angles measure in basic form (XX° XX´ XX'') or decimal form (XX, XXXX° )

gear testing in:

MODULE
DIAMETRAL PITCH (DP)
CIRCULAR PITCH (CP)

recalls from databank data of tested gear including the results and test graphs
selectable language communication version from English, German, French, Italian
adjustment of print of testing protocol in various sizes, black and white or colour
FFT analysis
look-out for measure data tooth by tooth
data storage in a way, that can be further processed by program SPC for quality control (optional accessories)

Double flank gear tester DO-0 and DO-0 PC

Technical data	DO-0 PC
Max. gear diameter clamping by calibrated bore Max. gear diameter between centres bracket	120 mm 100 mm
Center distance Center distance with reduction	35 - 85 mm 10 - 75 mm
Module / DP	0,1 - 2
Measuring accuracy.	0,001 mm
Max. weight of workpiece	1 kg

DO 1

DO 1 - Instrument for double flank testing of gears utilizing a dial indicator.

DO 1 PC -Instrument for double flank testing of spur and helical gears utilizing a PC Control.

DO-1

manual instrument for testing up to 320mm/12,5 inch dia. gears, by the double flank rolling method

DO-1 PC

computerized instrument for testing up to 320mm/12,5 inch dia. gears by the double flank rolling method

Double flank testing

Measures the centre distance variation when master gear and testing gear are in mesh.

You can test such deviations:

F_i'' - deviation of double flank rolling per revolution

f_i'' - deviation of double flank rolling per pitch

F_r'' - medium deviation of double flank rolling per revolution

f_a'' - deviation of value of axes distance related to theoretical value

Operation software

Measuring and control programs use WINDOWS ´ 98.

The main control program allows:

use of the instrument in shop enviroment
quick measure and display tested deviations
direct input of the deviations in mm instead of accuracy class
precisely find the place of respective mechanical damage of actual class
to move gear into exact selected position for marking the place of damage
by means of a special SW to select the measured gears according to deviations, respectively according to select tolerance of axis distances
by means of a special SW to control automatic marker for marking (optional accessory)
blocking of instrument functions by password
adjustment of length dimensions for measuring in millimetres (mm) or inches ('')
adjustment of angles measure in basic form (XX° XX´ XX'') or decimal form (XX, XXXX° )

gear testing in:

MODULE
DIAMETRAL PITCH (DP)
CIRCULAR PITCH (CP)

recalls from databank data of tested gear including the results and test graphs
selectable language communication version from English, German, French, Italian
adjustment of print of testing protocol in various sizes, black and white or colour
FFT analysis
look-out for measure data tooth by tooth
data storage in a way, that can be further processed by program SPC for quality control (optional accessories)

Double flank gear testerDO-1 and DO-1 PC

Technical data	DO-1 PC
Max. gear diameter clamping by calibrated bore Max. gear diameter between centres bracket	320 mm 180 mm
Center distance Center distance with reduction	65 - 250 mm 30 - 220 mm
Module / DP	1 - 8
Measuring accuracy.	0,001 mm
Max. weight of workpiece	30 kg

DO 1V PC

DO 1V PC - Instrument for double flank testing of spur and helical internal gears utilizing a PC Control.

DO 2 PC

DO 2 PC - Instrument for single and double flank testing of spur and helical gears utilizing a PC Control.

Single flank testing

When you drive a workpiece with the master gear at operating center distance (with backlash between the teeth). The instrument measures the difference of the synchronous motion between the two gears.

The single flank gear test may help to determine the ideal position for mating two gears. A software program is included for this purpose.

The accuracy of the center distance adjustment is 2m.

Double flank testing

This checks the center distance variation when rolling a master gear against a work piece.

Program equipment

The control program is written down by a language C++ Builder and follows the all standards and usage valid for WINDOWS ´95. The instrument is controlled by symbols.

The main controlling program makes possible:

to use the instrument in usual workshop operation and it is adapted for instrument operator
in a real time to scanner and display tested deviations of a single and double flank rolling method,
when evaluating to select among ESN, DIN, ISO, AGMA standards and ~ . Marking ~ allows the direct command the deviations in m m instead accuracy class
besides course of kinematics error is calculated and displayed the course of speed and acceleration,
mutually combination of the gears for noise reduction
measuring of teeth backlash in pair of gears during generating,
by means of a special SW to determine from measured deviations of single of double flank method precisely the place of respectively mechanical damaged of concrete teeth
turning into exact selected position for marking the place of damage. Such turning it is possible to realize according to own selection of damage tooth or automatically by means of program when deviation of single or double flank rolling per pitch.
by means of a special SW to select the measured gear according to deviations of single or double flank rolling
by means of a special SW to control automatic marker for marking of gears (optical accessory)
blocking of instrument functions by password as prevention for unskilled operation
adjustment of length dimensions for measuring in millimeters (mm) or inches ('')
adjustment of angle measure in basic form (XX° XX´ XX'') or decimal form (XX, XXXX° )
gear testing: module gearing

diametral pitch (DP)
gearing
circular pitch (CP) gearing

recall from databank the parameters of tested gear earlier including the results and test graphs
adjustment of communication version on tube for testing and print of protocols:

standard languages: Czech, German and English - the other versions are delivered as optional accessories

adjustment of print of testing protocol in various sizes - black and white, color, standard or shortening version
reversed scanning of a tested signal by so-called FFT analysis to a spectrum of single harmonical units including spectrum of speed and acceleration which is suitable especially for noise and passive resistance
out pot and saving the results in a form for further working out by program SPC for quality control according to ISO 9000 (optional accessories)

An auxiliary program for elimination of master gear own errors allows for single and double flank method:

for each master gear resp. course its radial runout and sum deviations to find the best function for steps course of radial runout and sum deviations.
calculated course of sum deviations and radial runout to save into data bank of master gears
during measuring rolling process to realize the correction of results in respect the inaccuracy of master gear

You can test such deviations:

F_i´ - deviation of single flank rolling per revolution

f_i´ - deviation of single flank rolling per pitch

F_s´ - medium deviation of single flank rolling per revolution

Stated deviations are known as slow or quick error.

Besides of deviations for single flank rolling the instrument measure the deviations of double flank rolling also:

F_i'' - deviation of double flank rolling per revolution

f_i'' - deviation of double flank rolling per pitch

F_r'' - medium deviation of double flank rolling per revolution

f_a'' - deviation of value of axes distance related to theory value

For the concrete class of accuracy are the gear wheels classifying and over crossing is recorded in protocol.

Technical Data of the instrument DO 2 PC in a basic execution

Technical data	DO-2 PC
Max. gear diameter	400 mm (without support stand)
Max. diameter of measured gear clamped into centres	180 mm ( 280 mm )
Center distance with reduction	65 - 375 mm (without support stand) 65 - 315 mm (with support stand)
Measuring accuracy	0,001°
Max. weight of workpiece	20 kg

DO 2K PC

DO 2K PC -Instrument with special support for single flank testing of bevel gears utilizing a PC Control.

The test of bevel gearing by single flank method

The test by single flank method determines inaccuracy (uneven) of transmission of rotary motion of bevel gearing in the same conditions as in practise. The test is made separately on right and left teeth sides. The sides of teeth which are not in mesh are separated by side clearance. When the uneven transmission of rotary motion is lower then the gear (gearing) is more accurate. Individual deviations which are received by this test are described in DIN 3965 standard and in this leaflet.

General characteristic of instrument

The gear tester DO 2 K PC is determined for deviations measuring of bevel gearing by single flank rolling method with PC evaluation according to DIN 3965 standard. Using of precision linear and rotation encoders guarantee high precise scanning of measuring value. Testing with colour it is possible also.

We use MICROCON electric drive for this instrument which have possibility change revolutions in steps and controlling from computer directly.
Measuring method

Pair of bevel gear let mesh together, mutual position will be determined according to pinion and crown gear assembly distance.
As for bevel gears it is very difficult to produce of master gears, we will test both meshing gears which will be used as pairing gears (coupling).
In this cycle are evaluated the deviations of angle of crown wheel (recalculated on arc outside pitch circle of wheel and define in mm) from its theoretical angle position define angle position of pinion and gear ration.

F_i´ - step of single flank generating per mesh cycle

f_i´ - step of single flank generating per pitch

F_p´ - (resp F_p´

according to DIN 3971) deviations of single flank generating per mesh cycle.

By filter of deviation f_l´

we receive further display of course with characteristic errors in mesh individual meshing pairs of teeth:

f_k´ (resp. f_p´ according to DIN 3971) - deviations of single flank generating per pitch.

In same case of mesh cycle each teeth of pinion mesh with all teeth of crown gear. In such case the start positioning is not important. It happened if the number of pinion teeth and crown gear is no-divisible.

In the other cases (if the numbers of teeth are divisible) during mesh cycle the determined teeth of pinion is not in mesh with all teeth of crown gear. In such case exist more numbers of meshing cycles e.i. more numbers of possible starting mutual teeth positioning. The instrument will inform you and determine the further possibilities of positioning.

The important part is regressive analysis of measured signal by means of so called FFT analysis into spectrum of individual elements. After measuring will known "correct" gearing, which is verified in processing, it is possible to store such gearing into program as so called limit curve and determine and compare the quality further gearing accordingly.

Software equipment

Measuring and control program use WINDOWS^?.

The main control program allows:

using in current workshop and it is adapted for operator also
in short time to process and display measured data of single flank generating
by means of a special SW classify tested bevel gearing according to deviations single flank generating
blocking of individual tester functions by password for preventation of no-quality action
selection of angle measured in base mode (xx°xx´xx?) or in decimal mode (xx.xxxx°),
program allows display of tolerance and regulation limits by means of colour lights:
- red - out of tolerance
- yellow - out of regulation limit
- green - OK
Such presentation is valid for all deviations and it serve for quick orientation of operator.
measuring of gearing: for receiving of deviations of single flank rolling according to chapter. "Principle of measuring" and according to values to classification into class of accuracy according to DIN 3965 it is respected the fact that it is measured of gearing and dependence of numerical values in allowed limits.
Before starting of measuring it is possible to select the class accuracy for measured gearing. With respect to preselected values the gearing is evaluated - over crossing tolerance is signalized by colour lights on monitor and by special red text on protocol.
recall from databank the parameters of measured gearing including the result and graph
adjustment of communication version of monitor for testing and print of protocols:
standard language: Czech, German and English, the other version are delivered as optional equipment
adjustment of print of testing protocol in various sizes - black and white, colour version
reversed scanning of tested signal by so-called FFT analysis to a spectrum of individual harmonic units - the data can be compared with before measured spectrum of selected gearing by means of inserting so caller limit curve.
to look thought a testing record tooth by tooth
to exit and storage of test results in a form for further working by means of program SPC for quality control (special equipment) to reserve measured data on external medium

Technical parameters:

Maximum outside diameter of measured pinion	200 mm
Assembly distance	100 mm
Shaft angle of measured bevel gearing	90°
Scanning accuracy	0,001°
Maximum weight of measured gear	15 kg

DO 2S PC

DO 2S PC - Instrument for single flank testing of worm gears utilizing a PC Control.

Worm gearing test by single flank rolling method

Test with single flank rolling determine inaccuracy of rotating movement of worm gearing as during working condition. The test will be made separate on the right and left tooth face. When inaccuracy of rotating movement will be smaller, the gearing will be precise. Single deviations which we get from this testing are describe in DIN 3975 standard and this leaflet.

General characteristic of instrument DO 2 S PC

The gear tester is designed for workshop and laboratory use. Gearing accuracy is evaluate by single flank rolling method with PC data processing (results on the screen, printing protocol).
Results of measuring are classified to accuracy class, according to DIN 3974-2. Results can be transferred to the own standard by writing directly numerical deviations value to PC. You have also possibility mark individual tooth with color. Worm drive electromotor can change revolution by step directly from PC.

Method of testing measured data (deviations)

For single flank rolling test is worm with worm wheel located in nominal mutual position i.e. in specified distances of axes, axis of worm must be in middle plane of worm wheel which guarantee tooth backlash. The worm is driven by low revolution (approx.1 rev./1sec.) and worm wheel is slightly braking for maintain of meshing on one (or second) side of tooth. The degree of precision is determined as per no-uniform revolutions of worm wheel with no-uniform revolutions of worm.

In principle it is possible to measure by the Gear Tester deviations of individual parts of gearing i.e. worm and worm wheel in mesh with master worm wheel and master worm. Usually is measured meshing worm and worm wheel i.e. the general practice of principle so called ?coupling? of gearing is applied.

Possibility of deviations measuring according DIN 3975 standard.

F_i´ - step of single flank rolling per mesh cycle

f_i´ - step of single flank rolling per pitch

F_p´ - deviation of single flank rolling per mesh cycle
By filter off deviation F_p´we receive further display of course with characteristic errors in mesh individual meshing pairs of teeth.

f_p´ - deviation of single flank rolling per mesh cycle

In case of inconvenient result or if we request the best gearing mesh and if exists possibility of another gearing positioning (i.e. marked thread of worm give in mesh with another then original marked tooth of worm wheel) the instrument will signalize such possibility. (For information: large number of possible positioning of worm and worm wheel exists subject to numbers of teeth z1, z2 are divisible. In case of no-divisible constellation z1, z2 the starting position is arbitrary because each worm thread to mesh with all teeth of worm wheel. The same gearing constellation is for on-thread worm.).

Software equipment
Measuring and control program use WINDOWS 98´.

The main control program allows:

use in shop environment
in short time to process and display measured data
by means of a special SW classify tested worm gearing
blocking of individual tester functions by password
selection of angle measure in base mode (XX?XX´XX?) or in decimal mode (XX, XXXX°)
program allows display of tolerance and regulation limits by means of colour lights:
- red - out of tolerance
- yellow - out of regulation limit
- green - OK

measuring of gearing: for receiving of deviations of single flank rolling according to chapter. ?Principle of measuring? and according to values to classification into class of accuracy according to DIN 3974-2, it is respected the fact that it is measured of gearing and dependence of numerical values in allowed limits.

instead of class accuracy it is possible to determine the own deviations values
recall from databank the parameters of measured gearing including the result and graph
adjustment of communication version on monitor for testing and print of protocols
standard language: Czech, German and English, the other versions are delivered as optional equipment
adjustment of print of testing protocol in various sizes - black and white, colour version
reversed scanning of tested signal by so-called FFT analysis to a spectrum of individual harmonic units - the data can be compared with before measured spectrum of selected gearing by means of inserting so caller limit curve
to look thought a testing record tooth by tooth
to exit and storage of test results in a form for further working by means of program SPC for quality control (special equipment)

Technical parameters:

Technical data	DO-2S PC
Max axis distance	310 mm
Min axis distance	20 mm
Max diameter of measuring worm	110 mm
Min diameter of measuring worm	10 mm
Max length of worm between centre	700 mm
Max weight of worm wheel	20 kg
Max weight of worm	10 kg
Axis angle between worm and worm wheel	90°
Measuring accuracy	0,001°

DO 3 PC

DO 3 PC - Instrument for complete analytical testing of Helix, Profile, and Tooth Spacing Deviations. Scanning and evaluation by a PC Control.

Principle

Accuracy of gear geometrical shape is detected by movement of measuring probe on tooth surface during turning cycle of measured gear at the same time.

When profile (involute) is measured, the probe move radially against the gear, for inclination (helix angle) parallel with gear axis.

Measuring of run-out and pitch is done by probe contact with teeth sides in teeth spaces. Geometrical correct model of teeth sides calculated mathematically.

Program

The control program is made and written under the Borland C++ in WINDOWS´95 including all standards and usage valid for WINDOWS´95. The instrument activity is controlled by symbols.

The main controlling program in the basic execution makes possible:

use in machine shop environment
scanning of involute form of tooth, scanning of tooth surface in axial direction
by means of a special processing methods to count deviations of profile, tooth side inclination pitches and radial run-out,
setting-up in metric (mm) or inches (˛) dimension
n setting-up of angle measure in basic form (XX° XX´ XX?) or in decimal form (XX,XXX° )
measuring of gearing:

module gearing
DP gearing
CP gearing

execute calibration of measuring instrument and positioning of reference point for measuring in automatic cycle
parameters of measured gear display again from databank incl. graphs measuring
select for measuring-tooth or tooth space measuring
measuring control with adjustment of different parameters in accordance with customer wish :

measuring of tooth inclination:

number of measuring teeth eligible (1 - 4)
it is possible to measure left or right tooth flank or both tooth flanks
evaluation: Standard, Barrel

measuring of tooth form (profile)

number of measuring tooth eligible (1 - 4)
it is possible measure left or right tooth flank or both tooth flanks
evaluation: Standard, Barrel

measuring of pitch and radial run-out incl. run-out of root diameter

possibility measuring of root diameter
across teeth dimension (min/max)
across balls dimension (min/max)

choice of speed and sensitivity of measuring

It is possible to direct setting-up of deviations in mm instead of class accuracy

The program makes possible display toleration and regulation limits by means of colour light

This evaluation is valid for all deviations and serve for quick orientation of operator

The program has possibility block individual functions for prevention of damage
To display the measured deviations on monitor
To display graphic individual measuring test results on monitor

deviation of profile
deviation of tooth inclination
deviation of radial run-out
deviation of individual tooth pitch (left or right flank)
deviation of adjacent tooth pitch (left or right flank)
deviation of total tooth pitch (left or right flank)

Setting-up language version on monitor for measuring and print the protocol (record):

standard: Czech, German, English, the others versions are available as optional equipment

Setting-up language version on monitor for measuring and print the protocol (record):
standard: Czech, German, English, the others versions are available as optional equipment
Setting-up print of protocol in the different size - black and white or colour versions
Save the results into databank with a possibility to display again tested values and graphs at any later time incl. reservation measured values on special medium
Output and data saving in a form suitable for further processing by program SPC for quality control (special accessories)

Tested deviations

The instrument model DO-3 PC is selected for testing of gearing deviations so that during evaluation it is possible to choose accuracy classification according to original DIN 3962 or direct instruction for evaluation in mm.

Name of a deviation	designation DIN
Adjacent pitch error	f_p
Difference between adjacent pitches	f_u
Cumulative pitch error	F_p
Radial run-out	F_r
Total profile error	F_f
Profile angle error	f_Ha
Profile form error	f_f
Total alignment error	F_b
Tooth alignment error	f_Hb
Longitudinal form error	f_bf
Size of root dia D_f	D_f
Dimension across teeth	W/z
Dimension across balls	M_dk

Before beginning of testing you can choose accuracy of class tested gear. According to the chosen value the gear is tested, overcrossing is recorded by marked printing.

As concern the form of gearing it is possible to measure spur gears, internal gears, including longitudinal and modification of gearing. In a special execution it is possible to measure shaping cutters, hobs and involute grooving.

Technical Data of the instrument DO-3 PC in a basic execution

Max. gear diameter with centre bracket	180 (280 mm)
Max. module of gear	8,0 mm
Min. module for involute testing for tooth inclination- and pitch testing	0,7 mm 0,5 mm
Max. helix angle, right and left hand	50°
Max. weight	20 kg
Min. pitch circle diameter	10 mm
Measuring accuracy	comply with class accuracy II. according to VDI 2612