Non-Contact Gear Chamfering Contour Measurement System

Gear transmission is one of the most important components in automobile gearbox. The machining quality and machining precision of chamfer directly impact on the performance of automobile gearbox and the whole transmission system. So it is necessary to detect the machining precision of gear chamfering. The main methods of detecting gear chamfering outline in many factories are mostly based on probe-contact measurement that has a high measurement accuracy, but it is complicated to locate. Besides the probe will easily scratch the gear surface and be worn during the measurement. In this paper, based on the two stages of non-contact measurement composed by visual orientation and laser measurement technology, it realizes the fast, precise and efficient measurement of gear chamfering outline.Machine vision in the manufacturing industry is mainly used to detect the size of the workpiece geometry. The precision of monocular vision measurement mainly depends on the CCD chip sizes and optical lens, positioning and measuring with a CCD in plane, however it cannot obtain angle parameters of chamfering profile on height direction. Laser measurement technology mainly adopts laser triangulation theory, carrying out non-contact measurement on the surface. The precision of Keyence laser sensor can reach 0.1 μm, at the height direction to realize high precision measurement. Combining with advantages of rapid positioning based on visual inspection, the laser displacement sensor is guided to move to the area to be detected, so that system realizes the automatic and intelligent test.The main contents of the research include the flowing:1) The introduction of research background and the research status at home and abroad;2) According to the requirements of gear chamfering detection requirements, elaborate chamfer profile measurement plan that contains visual positioning, and a high precision laser displacement sensor;3) According to the demands of system scheme and measurement demanding, the measurement of non-contact gear chamfering, hardware structure design, calculation and selection are included;4) According to the principle of measurement, the software interface of non-contact chamfering contour measurement system is designed and programmed, mainly including gear image edge extraction, gear center localization, measurement path planning, and results display;5) Measurement system is studied through the experiments of the accuracy of each component, the errors of system, the stability and adaptability of the measurement system, to analyze the sources of error and put forward methods to minimize measurement errors.