Measuring Gears: Gear Measurement Technology with Q-Tech

Did you know that precise gear measurement technology is essential for the quality of gears? A study has shown that more than 80% of gears used in machines and transmissions exhibit deviations from specific requirements. These deviations can lead to malfunctions, increased wear, and even machine failures.

For companies that rely on reliable gear measurements, there is a solution: Q-Tech, a DAkkS-accredited measurement service provider with dual accreditation for CT and CMM (D-PL-19600-01-00). Q-Tech offers first-class measurement services for gear analysis, gear measurement, and gear inspection. Q-Tech's measurement experts use state-of-the-art ZEISS coordinate measuring machines with the GEAR PRO extension and are specialists in the quality control of gearing.

Key Insights

• Precise gear measurement technology is crucial for the quality of gears.
• More than 80% of gears show deviations from specific requirements.
• By relying on professional measurement technology, manufacturers can drastically reduce machine failures, costly repairs, and excessive wear.
• Q-Tech is DAkkS-accredited for CT and CMM according to DIN EN ISO/IEC 17025 (Accreditation number D-PL-19600-01-00).
• The services offered include gear analysis, gear measurement, gear inspection, and tool correction.
• Q-Tech uses ZEISS coordinate measuring machines with GEAR PRO and the ZEISS METROTOM 800 and 1500 CT scanners.

How Do Gears Work?

Gears are mechanical components used to transmit rotational movements and torques. They are circular with teeth that mesh with the teeth of another gear. This interaction enables continuous and uniform energy transmission.

In industry, gears are indispensable for transmitting rotational movements from one shaft to another, varying rotational speed and torque, and changing the direction of rotation. They are essential components of machines and transmissions.

Gears function by transmitting rotational movements and forces from one gear to another. The teeth of one gear mesh with the teeth of another gear, so that when the first rotates, the second is also moved. This allows both speed and direction of rotation to be changed.

Where Are Gears Used?

Gears are widely used in industry. One of the most well-known areas is the automotive sector. There, gears are installed in transmissions to convert engine speed into an appropriate wheel speed. In mechanical engineering, gears are also indispensable. In tool manufacturing, for example, the quality of the results largely depends on the precision of the gearing in the production machine. In aerospace technology, gears in transmissions, actuators, and control systems must exhibit the highest precision to withstand extreme external conditions.

Other application areas include the energy sector (wind turbines, water turbines) and medical technology. There, gears in MRI scanners or dental drills ensure precise motion control.

What types of gears are there?

Depending on the application, various types of gears are used in industry. Each type is characterized by specific advantages and disadvantages and must be precisely and purposefully integrated into an overall system.

Spur Gears: This is the most common gear type in mechanical engineering. The teeth are arranged around the circumference of the wheel (pitch cylinder). When two gears mesh, their respective axes of rotation are always parallel to each other. Furthermore, a distinction is made between external and internal gearing. If spur gears are mounted on a rack, they can generate linear motion in addition to rotational movements. A special form is helical gears, which can be both helically cut and paired.

Bevel Gears: Bevel gears are gears that, unlike spur gears, can be arranged at various angles to each other. With bevel gears, the direction of power can be controlled as desired. A sub-form of bevel gears is the hypoid gear, which is used to generate screw movements.

Worm Gears: Worm gear drives are special cases of spur gears. Due to its shape, this wheel is also simply called a worm. Here, the shaft winds linearly like a screw around the tooth, thereby generating greater torque.

Gear Manufacturing

The manufacturing of gears requires the highest precision and accuracy. Small deviations from requirements can make a big difference in terms of wear, quality, and efficiency of the systems. Depending on the application, individual solutions and concepts must be considered during the manufacturing process.

What materials are gears made from?

The number of materials that play a role in gear manufacturing is large. In earlier times, components were still largely made of wood.

The most common materials used in manufacturing today are:

• Iron
• Steel
• Plastics
• Cast Iron
• Bronze

For precise manufacturing, the corresponding materials must be both soft enough for machining and hard enough to prevent excessive wear. The gear teeth are in constant contact during operation, which is why regular maintenance and inspection of the material is essential. A precise gear measurement ensures accurate quality control by revealing even the smallest deviations and visually displaying the condition of gears through optical measurement methods.

Different Gear Manufacturing Processes

Various methods are available for manufacturing gears, including machining, forging, sintering, and precision casting. Each of these processes has its own characteristics and applications.

With Machining , the gear profile is created by using tools guided over the workpiece. This method is well-suited for the precise production of individual parts and small series. With Forging , gears are formed from a pre-shaped workpiece through pressure and temperature treatment. This process offers high strength but is less precise than machining.

The Sintering process produces the gear profile from powdered material, which is formed into a solid workpiece under high pressure and temperature. This method is ideal for complex geometries and the production of gears in large quantities. Finally, Precision Casting enables the production of gears by pouring liquid metal into a shaping cavity. This process offers high precision and allows for the creation of intricate geometries.

Depending on the application, different manufacturing processes are used:

Measurement of Gears and Gear Teeth

Even during gear manufacturing, it is crucial to accurately capture gear geometries to avoid expensive machine failures, high wear, and insufficient performance. For this, a range of measurement data must be collected and evaluated to detect even the smallest deviations and correct them during the manufacturing process.

Gear drives are used in diverse and customized applications and often feature unique special geometries. Q-Tech provides support with a qualified team of experts for the execution, interpretation, and consultation of precise gear measurements.

For the measurement of gears and gear teeth, state-of-the-art machines and highly developed software are used. This requires international and national standards are adhered to, which manufacturers can use as a guide during the production process. For high tolerance requirements, Q-Tech's measurement experts reliably provide information on the condition and quality of the gearings. Applications include not only the production of gears but also, for example, the field of tool correction.

How do gear measuring machines work?

Gear measuring machines are specially developed machines for the precise and reliable measurement of gears and other toothed workpieces. With their advanced measurement technology, they ensure that the quality of gears meets the highest standards.

These machines utilize advanced measurement technologies such as air bearings, precision rotary tables, and specialized measurement software to perform precise measurements. Thanks to their high accuracy, gear measuring machines enable an exact assessment of gear quality and the identification of deviations.

Gear measuring machines are used in various industries such as the automotive industry, aerospace, and mechanical engineering. With Q-Tech and ZEISS machines, you receive first-class measurement services and the assurance that your gears meet the highest quality standards. The precision and quality of gears are crucial for the performance and reliability of machines and equipment.

Fundamentals and Standards of Gear Measurement and Inspection

The gear measurement is based on specific fundamentals and standards that define the measurement methods and requirements. International standards such as ISO standards and national standards such as DIN standards are widely used in gear metrology. These standards ensure uniform and standardized procedures for measuring and inspecting gears.

Some important standards:

• DIN ISO 1328 – international standard with guidelines for the design and manufacture of gears, covering tooth profile, accuracy, and measurement procedures.
• AGMA 2015 – describes the measurement of gearings on transmissions, defines the gear parameters to be recorded, and specifies the test conditions.
• DIN 3960 et seq. – German series of standards as a guide for gear definitions, gear tolerances, and measurement procedures.
• DIN EN ISO/IEC 17025 – Basis for the DAkkS accreditation of Q-Tech (Accreditation number D-PL-19600-01-00) for tactile CMM measurements and CT-based 3D coordinate metrology.

Gear measurement using the example of gearbox production

Gear measurement is an important step in gearbox production and other areas where gears are used.

Various methods are used for this. One of the most common methods is Flank measurement. The tooth flanks are analyzed to identify deviations from specific requirements.

Another important measurement method is the Inspection of gear parameters. Here, various parameters such as module, number of teeth, profile shift, and flank angle are measured and compared with the specified tolerances.

Gear measurement with ZEISS GEAR PRO

ZEISS GEAR PRO is a 3D gear module and an extension of the metrology software ZEISS CALYPSO. The program not only provides information about the exact dimensions and tolerance deviations of gears but also visually presents their characteristics.

When used correctly, the program delivers accurate measurement results, and its functions can be flexibly adjusted to the respective system. Some advantages of GEAR PRO include:

• Graphical support for data entry
• CAD simulation of the gearing based on the geometry definition
• Use of both active and passive sensors possible
• Accurate measurement results with or without a rotary table
• Automatic evaluation according to applicable standards
• Reports with recommended measures and applications

CMM in Gear Metrology

The GEAR PRO extension for CALYPSO supports and optimizes coordinate measuring machines (CMMs) in gear measurement. The CMM measures the spatial coordinates of the gear system. GEAR PRO enables measurement using a graphically supported input field and creates a 3D gear model, providing insights into calculated deviations and necessary corrections.

The combination of ZEISS coordinate measuring machines with GEAR PRO software enables precise measurement of all gear forms, up to 3 meters in outer diameter and 16 tons in weight. Integrating GEAR PRO into ZEISS CALYPSO specifically enhances CMMs for gear measurement.

Q-Tech's Measurement Experts for Gear Metrology

Tight tolerances are crucial for the quality, wear, efficiency, and reliability of your gearing technology. Q-Tech's measurement experts utilize the latest ZEISS measuring devices and state-of-the-art GEAR PRO software to ensure the quality of your gears and geometric definitions.

This expertise, combined with the accurate application of state-of-the-art measurement technology, ensures reliable inspection of all gear types. Q-Tech uses ZEISS GEAR for measuring cylindrical gears, bevel gears, rotors, hob cutters, and worms. For plastic gears, a ZEISS METROTOM computed tomograph can also provide insightful nominal-actual comparison to be presented.

In addition to performing gear measurements , Q-Tech's measurement experts are available to support you with your measuring devices. Q-Tech supports you from planning to the implementation of the ISO-GPS standard. With the metrology training courses, seminars, individual training, and coaching from the Q-Tech Expert Academy, the measurement experts pass on their knowledge to your employees.

Conclusion

Gear metrology is crucial for the quality assurance of gears, preventing malfunctions and increased wear. With modern measurement technologies from Q-Tech and ZEISS, even the smallest deviations can be precisely detected and corrected, leading to reduced downtime and costs. Q-Tech provides leading services in precision gear metrology, supported by international and national standards, ensuring that gears meet the highest quality standards.

FAQ: Frequently Asked Questions about Gear Metrology

What is Gear Metrology?

Gear metrology involves the measurement and inspection of gear geometries and features to ensure gear quality. Measured parameters include module, number of teeth, profile shift, helix angle, as well as tooth flank and pitch deviations according to DIN 3960 et seq. and ISO 1328.

Why is gear measurement important?

Gear measurement is a crucial step in the production of gears, transmissions, and drive-relevant components to ensure functionality, smooth running, and service life, and to demonstrate compliance with specific requirements. Measurements according to DIN EN ISO/IEC 17025 provide internationally recognized test results.

What gear manufacturing processes are there?

Machining (precise, single parts/small series), forging (high strength), sintering (complex geometries, high volume), and precision casting (high precision). Each process has specific advantages and disadvantages regarding tolerance, surface quality, and cost-effectiveness.

Does Q-Tech offer DAkkS-accredited gear measurements?

Yes. Q-Tech is DAkkS-accredited according to DIN EN ISO/IEC 17025 (Accreditation number D-PL-19600-01-00) – for both tactile CMM measurements and CT-based 3D coordinate metrology. You can find the full scope of accreditation at /akkreditierung.

What measurement methods are used for gear measurement?

Tooth flank measurement, inspection of gear parameters (module, number of teeth, profile shift, helix angle), runout measurement, as well as combined tactile and CT-supported analyses. Q-Tech also provides an Initial Sample Inspection Report according to VDA Volume 2 if required.

How do Q-Tech's measurement experts help with gear measurement?

Q-Tech's measurement experts perform gear measurements using the ZEISS GEAR PRO CMM extension. Services include gear analysis, gear measurement, gear inspection, and tool correction. For new customers, also as part of a free initial scan.

How does the measurement process at Q-Tech work?

Briefing on the measurement task, fixturing on ZEISS CMM with rotary table, measurement with GEAR PRO, automatic standard-compliant evaluation, creation of a measurement report (optional as DAkkS test report). Secure data transfer via Q-T·SEC.

Contact

Q-Tech Roding GmbH
Weiherhausstraße 2a, 93426 Roding
Phone: +49 9461 914 93-0
Email: info@q-tech-roding.de
Online Appointment: q-tech-roding.de/online-termin