基准级渐开线测试理论与技术研究
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摘要
齿轮是机械制造领域中重要的基础件与传动元件,它被广泛应用于现代工业中的各个方面。齿轮制造质量的提高取决于诸多方面,其中齿轮测试技术与仪器的精度是一个重要的因素。在渐开线圆柱齿轮若干精度指标中,齿形检验难度较大。当前渐开线齿形量仪的测量原理主要有标准曲线法、标准轨迹法、坐标法及基于激光测量技术的齿形测量方法等。上述方法目前最高只能测量GB/T1009.1-2001标准中的2级精度渐开线圆柱齿轮的齿形误差,无法胜任1级精度渐开线齿形的测量。
本文针对1级精度渐开线齿形的测量展开研究。通过论证超精密渐开线齿形的最佳测量方法,认为基准级渐开线测量仪在现有渐开线量仪中具有最少的测量误差源,测量精度最高。文中设计制作了基准级渐开线测量仪测量支架机构,分析了无回差微位移传递杠杆的位移传递精度,并进行实验验证;采用机械补偿法对基圆盘、齿轮与芯轴组件进行配位安装,使组件偏心引起的测量误差最小;在分析测头位置偏差对渐开线齿形测量影响的基础上,提出了齿形角比较法与测点偏差试值补偿法用于基准级渐开线测量仪的测头位置调整,调整精度能满足1级精度渐开线齿形的测量要求;文中还对基圆盘与基准导尺间的弹性蠕滑问题进行了探讨,计算出基圆盘与基准导尺间的弹性蠕滑率。
通过分析基准级渐开线测量仪所有测量误差源对渐开线齿形测量的影响,采用《测量不确定度评定与表示指南》(GUM)对仪器的测量不确定度进行评价,并与1级精度渐歼线齿廓总公差进行比较,得知仪器的测量精度能完全满足1级精度渐开线齿形的测量要求。由于GUM法评价仪器测量不确定度时,无法体现仪器部分作用误差间可能具有的相互抵消与补偿的关系,采用蒙特卡罗法对仪器的测量不确定度进行了分析,使评价结果更加接近真实值。
本文还研制了测量数据采集与处理系统,并对齿形误差评价区间的选择、测量异常值处理,以及采样间隔的确定等问题进行了分析。
根据对仪器测量误差源的分析,建立了相应的误差补偿模型,并对基圆盘直径偏差、基圆盘与齿轮组件的残余偏心补偿模型进行了验证。对部分误差源进行补偿后,基准级渐开线测量仪的测量精度有较大提高。
最后,对1级精度渐开线圆柱齿轮齿形进行测量实验,并与中国计量院KlingelnbergP65齿轮测量中心进行量值比对。经比较当前各国家级计量单位齿形测量仪的测量不确定度,认为本文研制的基准级渐开线测量仪在现有渐开线齿形量仪中的测量精度最高。
Gears are important basic parts and transmission components in machinery manufacture field, which are used in many aspects of modern industry. Improvement of gear manufacturing quality is based on many factors, and accuracy of instrument for measuring gear is one of important factors. In accuracy indexs of involute gears, tooth profile error is difficult to measure. The available methods for measuring involute tooth profile include specification curve mode, generation mode and coordinate mode, etc. The methods above can measure involute teeth profile of level 2 (GB/T10095.1-2001) gears at most, and cannot be used to measure level 1 gear.
Measuring technology of level 1 involute is researched in this paper, and accuracy of the instrument for measuring reference level involute is highest in all instruments for measuring involute. This paper designed measuring support, and analyzed and verified the accuracy of minimal displacement transfer level. Manufacture compensation method was used to assembly base discs, gear and core shaft, and measuring error caused by component's eccentricity is reduced. By analyzing measurement error made by deviation of stylus, tooth profile angle comparison method and error compensation method are used to adjust situation of stylus, and adjustment accuracy are 10μm and 15μm, which accords with measuring specification of level 1 gear. Elastic creep between base discs and guide is analyzed, and creep rate is computed.
All the measuring errors in the instrument are analyzed, and measurement uncertainty is evaluated by GUM. By comparing the instrument's measuring uncertainty and tolerance of level 1 involute, the instrument accords with measuring specification of level 1 gear. Because compensation relation of some measuring errors cannot be embodied when GUM evalutes measuring uncertainty of instrument, mont carlo method is used to evaluate the instrument's measuring uncertainty, which makes evalution result close to true value.
In the paper, data acquisition and processing system is developed, and evalution interval of tooth profile, outlier's processing and acquisition interval are analyzed.
By analyzing measuring error of the instrument, error compensation model is established, and diameter's error of base disc and eccentricity of components are compensated. Measuring accuracy of the instrument for measuring reference level involute is increased greatly after compensation.
Finally, level 1 gear's tooth profile is measured, and measuring result is compared with gear measuring center's (Klingelnberg P65) measuring result in national metering institute. By comparing accuracies of instruments in national institutes, the instrument for measuring reference level involute is regard as the highest accuracy instrument.
本文针对1级精度渐开线齿形的测量展开研究。通过论证超精密渐开线齿形的最佳测量方法,认为基准级渐开线测量仪在现有渐开线量仪中具有最少的测量误差源,测量精度最高。文中设计制作了基准级渐开线测量仪测量支架机构,分析了无回差微位移传递杠杆的位移传递精度,并进行实验验证;采用机械补偿法对基圆盘、齿轮与芯轴组件进行配位安装,使组件偏心引起的测量误差最小;在分析测头位置偏差对渐开线齿形测量影响的基础上,提出了齿形角比较法与测点偏差试值补偿法用于基准级渐开线测量仪的测头位置调整,调整精度能满足1级精度渐开线齿形的测量要求;文中还对基圆盘与基准导尺间的弹性蠕滑问题进行了探讨,计算出基圆盘与基准导尺间的弹性蠕滑率。
通过分析基准级渐开线测量仪所有测量误差源对渐开线齿形测量的影响,采用《测量不确定度评定与表示指南》(GUM)对仪器的测量不确定度进行评价,并与1级精度渐歼线齿廓总公差进行比较,得知仪器的测量精度能完全满足1级精度渐开线齿形的测量要求。由于GUM法评价仪器测量不确定度时,无法体现仪器部分作用误差间可能具有的相互抵消与补偿的关系,采用蒙特卡罗法对仪器的测量不确定度进行了分析,使评价结果更加接近真实值。
本文还研制了测量数据采集与处理系统,并对齿形误差评价区间的选择、测量异常值处理,以及采样间隔的确定等问题进行了分析。
根据对仪器测量误差源的分析,建立了相应的误差补偿模型,并对基圆盘直径偏差、基圆盘与齿轮组件的残余偏心补偿模型进行了验证。对部分误差源进行补偿后,基准级渐开线测量仪的测量精度有较大提高。
最后,对1级精度渐开线圆柱齿轮齿形进行测量实验,并与中国计量院KlingelnbergP65齿轮测量中心进行量值比对。经比较当前各国家级计量单位齿形测量仪的测量不确定度,认为本文研制的基准级渐开线测量仪在现有渐开线齿形量仪中的测量精度最高。
Gears are important basic parts and transmission components in machinery manufacture field, which are used in many aspects of modern industry. Improvement of gear manufacturing quality is based on many factors, and accuracy of instrument for measuring gear is one of important factors. In accuracy indexs of involute gears, tooth profile error is difficult to measure. The available methods for measuring involute tooth profile include specification curve mode, generation mode and coordinate mode, etc. The methods above can measure involute teeth profile of level 2 (GB/T10095.1-2001) gears at most, and cannot be used to measure level 1 gear.
Measuring technology of level 1 involute is researched in this paper, and accuracy of the instrument for measuring reference level involute is highest in all instruments for measuring involute. This paper designed measuring support, and analyzed and verified the accuracy of minimal displacement transfer level. Manufacture compensation method was used to assembly base discs, gear and core shaft, and measuring error caused by component's eccentricity is reduced. By analyzing measurement error made by deviation of stylus, tooth profile angle comparison method and error compensation method are used to adjust situation of stylus, and adjustment accuracy are 10μm and 15μm, which accords with measuring specification of level 1 gear. Elastic creep between base discs and guide is analyzed, and creep rate is computed.
All the measuring errors in the instrument are analyzed, and measurement uncertainty is evaluated by GUM. By comparing the instrument's measuring uncertainty and tolerance of level 1 involute, the instrument accords with measuring specification of level 1 gear. Because compensation relation of some measuring errors cannot be embodied when GUM evalutes measuring uncertainty of instrument, mont carlo method is used to evaluate the instrument's measuring uncertainty, which makes evalution result close to true value.
In the paper, data acquisition and processing system is developed, and evalution interval of tooth profile, outlier's processing and acquisition interval are analyzed.
By analyzing measuring error of the instrument, error compensation model is established, and diameter's error of base disc and eccentricity of components are compensated. Measuring accuracy of the instrument for measuring reference level involute is increased greatly after compensation.
Finally, level 1 gear's tooth profile is measured, and measuring result is compared with gear measuring center's (Klingelnberg P65) measuring result in national metering institute. By comparing accuracies of instruments in national institutes, the instrument for measuring reference level involute is regard as the highest accuracy instrument.
引文
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