Measuring gears: Gear measurement technology with Q-Tech

Table of contents:

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

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For companies that depend on reliable gear measurements, there is a solution: Q-Tech, a leader in precision gear measurement technology. As a family-run business, Q-Tech offers first-class measurement services for gear analysis, gear measurement and gear testing. They are experts in gear quality control and ensure that your gears meet the highest standards.

Key findings:

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Precise gear measurement technology is crucial for the quality of gears.
More than 80% of the gears deviate from the specific requirements.
If manufacturers rely on professional surveying technology, they can drastically reduce machine downtime, costly repairs, excessive wear and tear and inadequate results
Q-Tech is a leading company in precision gear measurement technology and offers first-class measurement services.
Q-Tech's range of services includes gear analysis, gear measurement and gear testing.
Q-Tech, in collaboration with ZEISS, uses the latest measurement technology equipment to ensure accurate results.

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How do gears work?

Gear wheels are mechanical components that are used to transmit rotary movements and

-torques can be used. They are fitted with circular teeth that engage with the teeth of another wheel. This interaction enables a continuous and even transfer of energy.

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In industry, gears are indispensable for transferring rotary motion from one shaft to another, varying the rotational speed and torque and changing the direction of rotation. They are essential components of machines and gearboxes.

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Gear wheels work by transferring rotational movements and forces from one gear wheel to another. The teeth of one gearwheel mesh with the teeth of another gearwheel, so that when the first is turned, the second is also moved. This allows both the speed and the direction of rotation to be changed.

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Where are gears used?

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Gear wheels are widely used in industry. One of the best-known areas is the automotive sector. There, gears are installed in transmissions to convert the engine speed into a suitable wheel torque. Gears are also indispensable in mechanical engineering. In toolmaking, for example, the quality of the results depends largely on the accuracy of the gears in the production machine. In aerospace engineering, gears in gearboxes, accumulators and control systems must be extremely precise in order to withstand extreme external conditions.

Other areas of application include the energy sector (wind turbines,

water turbines) and medical technology. There, gear wheels in MRI scanners or dental drills ensure precise motion control.

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What gear shapes are there?

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Different shapes of gears are used in industry depending on the application. Each shape is characterized by specific advantages and disadvantages and must be specifically and precisely integrated into an overall system.

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In summary, the following gear wheel shapes are used in the industry:

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Spur gears: This is the most common type of gear in mechanical engineering. The teeth are arranged on the (circumference) of the wheel (rolling cylinder). When two gears mesh, the respective axes of rotation are always parallel to each other. A distinction is also made between external gearing and internal gearing. If spur gears are mounted on a so-called rack, they can also generate a linear movement in addition to rotating movements. A special form is helical spur gears, which can have both helical and paired teeth.

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Bevel gears: Bevel gears are gears that, unlike spur gears, can be arranged at several angles to each other. Bevel gears can be used to control the direction of energy as required. A subtype of bevel gear is the hypoid gear, which is used to generate screw movements.

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Worm gears: Worm gears are special cases of spur gears. Due to its shape, this gear is also known as a worm. Here, the shaft winds around the tooth in a linear fashion like a screw and thus generates a greater torque.

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Production of gear wheels

The manufacture of gears requires maximum precision and accuracy. Slight deviations from the requirement 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.

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What materials are gears made from?

The number of materials that play a role in the manufacture of gears is large. In earlier times, for example, the components were still largely made of wood.

The most common materials used in production today are:

Iron
Steel
Plastics
Cast iron
Bronze

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

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Different gear manufacturing processes

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Various processes are available for the production of gears, including machining, forging, sintering and precision casting. Each of these processes has its own characteristics and areas of application.

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During machining, the gear cutting pattern is created by using tools that are guided over the workpiece. This process is well suited to the precise production of individual parts and small series. In forging, the gears are formed from a pre-formed workpiece through pressure and temperature treatment. This process offers high strength, but is less precise than machining.

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Sintering is a process in which the gear cutting pattern is produced from powdered material that 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 hollow chamber.

This process offers high precision and enables the production of complicated geometries.

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Depending on the area of application, different manufacturing processes and focal points are used in production.

Gear manufacturing process according to area of application:

Procedure	Properties	Areas of application
Machining	Precise, suitable for individual parts and small batches	Mechanical engineering, automotive industry
Forging	High strength, less precise	Heavy industry, gear production
Sintering	Complex geometries, large quantities	Electronics industry, medical technology
Precision casting	High precision, complex geometries	Aerospace, precision mechanics
Laughing Bacchus Winecellars	Yoshi Tannamuri	Canada

These are just a few examples of gear manufacturing processes. The selection of the right process depends on the requirements for precision, strength, costs and production volume.

Measurement of gears and toothing

When manufacturing gears, it is important to record gear geometries correctly in order to avoid expensive machine failures, high wear and insufficient performance. A range of measurement data must be recorded and evaluated in order to detect the smallest deviations and correct them during the manufacturing process.

Gear drives are used in a variety of individual applications and are often characterized by unique special geometries. Q-Tech impresses with a qualified team of experts for carrying out, interpreting and advising on precise gear measurements.

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State-of-the-art machines and highly developed software are used to measure gears and splines. International and national standards must be adhered to, which manufacturers can use as a guide during the production process. In the case of high tolerance requirements, Q-Tech specialists help to provide reliable information about the condition and quality of the gears. Areas of application include not only the production of gears, but also the field of tool correction, for example

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How do gear measuring machines work?

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

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These machines use advanced measuring technologies such as air bearings, precision rotary tables and special measuring software to perform precise measurements. Due to their high accuracy, gear measuring machines enable an exact assessment of gear quality and the identification of deviations from specific requirements.

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Gear measuring machines are used in various industries such as the automotive industry, aviation and mechanical engineering. They are used to check the quality of gears and ensure that they meet strict requirements. With Q-Tech and ZEISS machines, you get first-class measuring services and the certainty that your gears meet the highest quality standards.

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The precision and quality of gears is crucial for the performance and reliability of machines and devices. To ensure that these standards are met, many companies rely on equipment and software from ZEISS.

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Basics and standards of gear measurement and testing

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Gear measurement is based on certain principles and standards that define the measurement methods and requirements. International standards such as the ISO standards and national standards such as the DIN standards are widely used in gear measurement technology. These standards ensure uniform and standardized procedures for measuring and testing gears.

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Some important standards that are used in gear measurement technology are:

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DIN ISO 1328 is a standard that contains guidelines for the design and manufacture of gears. It is an internationally recognized standard that ensures the quality and compatibility of gears used in various industries such as automotive, aerospace and mechanical engineering. The standard covers various aspects of gear design, including tooth profile, accuracy and measurement methods.
AGMA 2015: The AGMA standard describes the measurement of gears on gearboxes. It defines the gear parameters to be measured and specifies the test conditions.
DIN standards: DIN standards are widely used in Germany and serve as a guideline for gear measurement. They include various standards for the measurement and testing of gears.

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Compliance with these standards ensures the precision and reproducibility of gear measurements. By applying these standards, manufacturers and users can be sure that their products meet the specified quality standards.

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With a sound understanding of the principles and standards of gear measurement, companies are able to carry out accurate and reliable measurements and ensure the quality of their gears.

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Measurement of gears and workpieces using the example of gear production

Measuring gears is an important step in gear production and other areas in which gears are used.

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Various methods are used for this. One of the most common methods is tooth flank measurement. The tooth flanks are analyzed to determine deviations from the specific requirements. This enables a precise assessment of the gear quality and the identification of possible deviations or defects.

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Another important measuring method is the testing of gear parameters. Various parameters such as module, number of teeth, profile shift and flank pitch are measured and compared with the specified tolerances. This allows the quality of the gears to be assessed objectively.

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Gear measurement with ZEISS GEAR PRO

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Zeiss Gear Pro is a 3D gear model and an extension of the

Zeiss Calypso metrology software. The program not only provides information on the exact dimensions and tolerance deviations of gears, but also visually prepares the condition.

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If used correctly, the program guarantees accurate measurement results and the functions can be flexibly adjusted to the respective system.

Some of the advantages of GEAR PRO are

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Graphical support for data entry
The software creates a CAD simulation of the gearing based on the geometry definition, allowing the input to be quickly and visually checked
The software enables the use of both active and passive sensors
Accurate measurement results can be achieved with or without a turntable, depending on requirements
The evaluation is carried out automatically and in accordance with applicable standards
Protocols are drawn up with regard to recommended measures and applications, which can be used to make any necessary adjustments

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CMM in gear measuring technology

The GEAR PRO extension from Calypso supports and optimizes coordinate measuring machines (CMMs) in gear measurement. The CMM measures the spatial coordinates of the gear system. GEAR PRO enables the measurement with a graphics-supported input field and creates a 3D gear model that provides information about calculated deviations and necessary corrections. All desired evaluation and measurement ranges can be quickly set via the input field.

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The combination of Zeiss coordinate measuring machines with the GEAR PRO software enables accurate measurement of all gear shapes and up to a size of 3 meters outer diameter and 16 tons weight.

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By integrating GEAR PRO into ZEISS CALYPSO, coordinate measuring machines can be specifically extended for gear measurement. The analytical

GEAR PRO's 3D gear model and graphics-supported input dialogs help to make gear measurement extremely efficient.

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Q-Tech are your experts for gear measurement

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Tight tolerances are crucial to the quality, wear, efficiency and reliability of your gearing technology. Our measurement experts have the latest measuring equipment from Zeiss and use the state-of-the-art GEAR PRO software to ensure the quality of your gears and geometry definitions.

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Our expertise coupled with the accurate use of state-of-the-art measuring technology ensures reliable inspection of all types of gearing. We use ZEISS GEAR to measure cylindrical gears, bevel gears, rotors, hobs and worms and adapt to individual customer requirements. With plastic gears, a computer tomograph can also be used to produce an informative target/actual comparison from the deviations.

In addition to carrying out gear measurements, we are also available to support you with your measuring equipment. We accompany you from the planning stage through to the implementation of the ISO GPS standard. With our measurement technology training courses, seminars, individual training and coaching, we pass on our knowledge to your employees and ensure higher production quality, better customer satisfaction and early detection of possible failures due to deviating measurement data.

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Conclusion:

Gear measurement technology is crucial for the quality assurance of gears and prevents malfunctions and increased wear. With modern measuring technologies from Q-Tech and ZEISS, the smallest deviations can be precisely detected and corrected, resulting in reduced downtimes and costs.

Q-Tech offers leading services in precision gear measurement technology, supported by international and national standards, and ensures that gears meet the highest quality standards. Investments in this technology optimize production processes and increase the service life and efficiency of machines.

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FAQ

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What is gear measurement technology?

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Gear metrology deals with the measurement and inspection of gear geometries and features in order to ensure the quality of gears.

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Why is gear measurement important?

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Gear measurement is an important step in the production of gears and other applications where gears are used to check quality and ensure compliance with specific requirements.

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What gear manufacturing processes are there?

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There are various methods for manufacturing gears, such as machining, forging, sintering and precision casting. Each process has its own characteristics and areas of application.

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What principles and standards apply to gear measurement?

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Which measuring methods are used for gear measurement?

There are various measurement methods for checking the quality of gears, such as tooth flank measurement and testing the gearing parameters. These methods enable an accurate assessment of gear quality and the identification of deviations from specific requirements.

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How do gear measuring machines work?

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Gear measuring machines are specially developed machines for the accurate and reliable measurement of gears and other toothed workpieces. They use advanced measuring technologies such as air bearings, precision rotary tables and special measuring software to perform accurate measurements.

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How does Q-Tech help with gear measurement?

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Q-Tech is a team of metrology specialists who help mechanical engineering companies and gear manufacturers to identify deviations from standards in measurements in order to ensure the quality of the design. When it comes to gear measurement

Q-Tech to carry out the measurement using the GEAR PRO CMM extension. The services include gear analysis, gear measurement and gear testing. In addition, our experts pass on their know-how via training courses, seminars and consultations on your measuring equipment.

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