JP7824513B2 - Gear cutting machine and phase alignment method thereof - Google Patents

Description

The present invention relates to a gear cutting machine that cuts gears by rotating a tool and workpiece synchronously, and a phase alignment method for the same.

In gear cutting machines, when a tool, such as a cutter, and a workpiece are rotated synchronously to cut a gear, it is necessary to align the phase of the cutter and the workpiece. For example, Patent Document 1 discloses a phase alignment method for a gear cutting machine, which "uses a gear cutting machine equipped with a tool spindle that drives the cutter, a workpiece spindle that drives the workpiece, a cutter phase measurement unit that detects the phase of the cutter, and a workpiece phase measurement unit that detects the phase of the workpiece, attaches a dummy cutter that is tougher and less hard than the cutter and measures the phase, meshes the dummy cutter with the workpiece to align them, replaces the dummy cutter with the cutter and measures the phase, and corrects the phase of the cutter based on the phase of the dummy cutter."

Patent Application No. 2021-146366

However, the technology in Patent Document 1 required dedicated sensors and drive units for detecting the phase of the workpiece and the tool, respectively, and also required a dummy cutter. Another technique used for phasing gear cutting machines is to attach a laser sensor to the tool spindle to detect the phase of the workpiece. With this method, a tool whose phase has been adjusted in advance outside the machine is mounted on the actual machine. However, with this method, manual labor is required when the operator mounts the tool, whose phase has been adjusted in advance, on the actual machine, which can lead to installation errors, setup mistakes, and installation errors.

In light of the above, the present invention aims to provide a gear cutting machine and a phase alignment method that can adjust the phase of both the workpiece and the tool while minimizing the number of additional parts used for phase detection and preventing errors caused by manual work.

To solve the above problems, a typical configuration of the gear cutting machine of the present invention includes a work spindle that rotates the attached workpiece, a tool spindle that rotates the attached tool, a laser sensor attached to the side of the tool spindle, a sensor rotation device that rotates the laser sensor along the axial direction of the tool spindle, an angle control unit that controls the rotation angle of the sensor rotation device, and a phase detection unit that detects the phase of the workpiece and tool.

The phase detection unit preferably detects the phase of the tool by detecting peaks while rotating the laser sensor along the axial direction of the tool using a sensor rotation device.

To solve the above problems, a typical configuration of the phase alignment method for a gear cutting machine of the present invention is a method for aligning the phase of a gear cutting machine that includes a work spindle that rotates the workpiece, a tool spindle that rotates the tool, a laser sensor attached to the side of the tool spindle, a sensor rotation device that rotates the laser sensor in the axial direction of the tool spindle, and an angle control unit that controls the rotation angle of the sensor rotation device. The angle control unit controls the rotation angle to point the laser sensor toward the workpiece to detect the phase of the workpiece, and the angle control unit controls the rotation angle to point the laser sensor toward the tool to detect the phase of the tool, thereby aligning the phase of the workpiece and the tool.

The present invention provides a gear cutting machine and a phase alignment method that can adjust the phase of both the workpiece and the tool while minimizing the addition of parts used for phase detection and preventing errors caused by manual work.

FIG. 1 is a diagram illustrating a gear cutting machine according to an embodiment of the present invention. FIG. 2 is a diagram illustrating a state in which a laser sensor of the gear cutting machine of FIG. 1 is moved from an initial position to a rotated position. 3 is a diagram illustrating a rotational position of a laser sensor different from that of FIG. 2 in the gear cutting machine of FIG. 1 . FIG. FIG. 2 is a diagram illustrating a state in which a laser sensor is placed at a standby position in the gear cutting machine of FIG. 1 . FIG. 2 is a diagram illustrating a tool attached to a tool spindle in the gear cutting machine of FIG. 1 . 4 is a flowchart illustrating a phase alignment method for a gear cutting machine according to the present embodiment. 6 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of FIG. 1 is the skiving cutter of FIG. 5( a ). 6 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of FIG. 1 is the hob cutter of FIG. 5( b ).

Preferred embodiments of the present invention will be described in detail below with reference to the accompanying drawings. Dimensions, materials, and other specific values shown in these embodiments are merely examples intended to facilitate understanding of the invention and, unless otherwise specified, do not limit the present invention. Furthermore, in this specification and drawings, elements having substantially the same function and configuration are designated by the same reference numerals to avoid redundant explanation, and elements not directly related to the present invention are not shown.

Figure 1 is a diagram illustrating a gear cutting machine according to this embodiment, illustrating a state in which the laser sensor 130 is positioned at the initial position P0. Figure 2 is a diagram illustrating a state in which the laser sensor of the gear cutting machine of Figure 1 is moved from the initial position P0 to a rotation position P1. Figure 3 is a diagram illustrating a rotation position P2 of the laser sensor in the gear cutting machine of Figure 1, which is different from that in Figure 2. Figure 4 is a diagram illustrating a state in which the laser sensor is positioned at a standby position P3 in the gear cutting machine of Figure 1.

The gear cutting machine of this embodiment shown in Figures 1 to 4 is a device that cuts gears by synchronously rotating a workpiece 102 and a tool 104. The gear cutting machine 100 has a workpiece spindle 110 that rotates the workpiece 102, and a tool spindle 120 that rotates the tool 104. The workpiece 102 is attached to the workpiece spindle 110, and the tool 104 is attached to the tool spindle 120, both of which are interchangeable.

Figure 5 is a diagram illustrating the tools attached to the tool spindle of the gear cutting machine of Figure 1. Examples of tools 104 attached to the tool spindle 120 (see Figures 1-4) include a skiving cutter 104a shown in Figure 5(a) and a hob cutter 104b shown in Figure 5(b).

The skiving cutter 104a shown in Figure 5(a) has multiple blades 106a arranged in a gear-like pattern in the rotational direction of the tool spindle 120. The hob cutter 104b shown in Figure 5(b) has blades 106b arranged in a screw-like pattern in the tool length direction. The hob cutter 104b also has grooves 108 formed to allow chips and powder generated during machining to escape to the outside.

A feature of this embodiment is that the gear cutting machine 100 is equipped with a laser sensor 130, a sensor rotation device 140, and a control unit 150 that controls the operation of the gear cutting machine 100. The laser sensor 130 is a distance measurement sensor that is attached to the side of the tool spindle 120 for phase detection. The sensor rotation device 140 rotates the laser sensor 130 along the axial direction of the tool spindle 120.

In this embodiment, the control unit 150 functions as an angle control unit 152 and a phase detection unit 154. The angle control unit 152 controls the rotation angle of the sensor rotation device 140. The phase detection unit 154 detects the phase of the workpiece 102 and the tool 104 by directing the laser sensor 130 toward the workpiece 102 and the tool 104 through rotation angle control by the angle control unit 152.

Figure 6 is a flowchart illustrating the phase alignment method for a gear cutting machine according to this embodiment. In the alignment method for a gear cutting machine according to this embodiment, as shown in Figure 6, the control unit 150 first functions as a phase detection unit, and controls the rotation angle of the laser sensor 130 using the angle control unit 152, causing the laser sensor 130 to emit a laser beam toward the workpiece 102 (S202). For example, if the laser sensor 130 is at the initial position P0 in Figure 1, the angle control unit 152 controls the rotation angle drive of the sensor rotation device 140, and rotates the laser sensor 130 along the axial direction of the tool spindle 120 to the rotation position P1 in Figure 2.

Then, the control unit 150 rotates the workpiece 102 while the laser is being irradiated (S204), and the phase detection unit 154 detects the phase of the workpiece 102 (S206). Then, the phase detection unit 154 detects the phase of the tool 104 (S208).

(Tool phase detection: when the tool 104 is the skiving cutter 104a)
Fig. 7 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of Fig. 1 is the skiving cutter of Fig. 5(a). When detecting the tool phase, first, as shown in Fig. 7, the phase detection unit 154 rotates the laser sensor 130 using the sensor rotating device 140 (S222).

For example, if the laser sensor 130 is at the initial position P0 in Figure 1, the angle control unit 152 controls the rotation angle of the sensor rotation device 140, and the sensor rotation device 140 rotates the laser sensor 130 along the axial direction of the tool spindle 120 to rotation position P2 in Figure 3. The control unit 150 then controls the laser sensor 130 to emit a laser beam toward a predetermined position (the position of the blade 106a) based on the tool specifications of the tool 104 (skiving cutter 104a) (S224). That is, if the tool 104 is the skiving cutter 104a, the laser is emitted in one direction D1 (the direction of the predetermined position (the position of the blade 106a)) as shown in Figure 5(a).

The control unit 150 then rotates the tool 104 (skiving cutter 104a) while the laser is being irradiated (S226). If a predetermined peak is detected by the laser irradiation (YES in S228), the phase detection unit 154 detects the phase of the tool 104 (S230). If a predetermined peak is not detected by the laser irradiation (NO in S228), the phase detection unit 154 detects an abnormality, such as the predetermined tool not being attached to the tool spindle 120 (S232).

(Tool phase detection: when the tool 104 is the hob cutter 104b)
Fig. 8 is a flowchart illustrating a method for detecting the phase of a tool when the tool used in the gear cutting machine of Fig. 1 is the hob cutter of Fig. 5(b). In Fig. 8, operations common to those in Fig. 7 are denoted by the same reference numerals and will not be described again.

As shown in FIG. 8, the laser sensor 130 is rotated (S222), and a laser is emitted toward a predetermined position on the side of the hob cutter 104b (S224). The predetermined position may be anywhere within the range where the blade 106b is located. The hob cutter 104b is rotated (S226), and when a predetermined peak is detected (YES in S228), the phase detection unit 154 detects the phase of the tool 104 (S230).

If the specified peak is not detected by irradiating the laser (NO in S228), it is possible that the peak position overlaps the position of the groove 108. Therefore, the angle control unit 152 controls the rotation angle of the sensor rotation device 140, which then rotates the laser sensor 130 along the axial direction of the tool. Then, the phase detection unit 154 irradiates the tool 104 (hob cutter 104b) with a laser while the laser sensor 130 is rotating (S242).

That is, in the phase alignment method for the gear cutting machine 100 of this embodiment, in S242, peaks are detected while changing the irradiation direction of the laser sensor 130 in the tool length direction of the tool 104 (hob cutter 104b) (laser scanning). Specifically, the irradiation direction of the laser sensor 130 is changed to directions D2, D3, and D4 as shown in Figure 5(b). Note that the hob cutter 104b does not rotate while laser scanning is being performed in the tool length direction.

If a peak is detected in the laser scan (YES in S244), the control unit 150 returns to the operation of S224 and rotates the hob cutter 104b to detect the phase of the tool (S230). If a peak is not detected in the laser scan (NO in S244), the phase detection unit 154 detects an abnormality, such as the specified tool not being attached to the tool spindle 120 (S246).

When scanning the laser in the tool length direction, there is a possibility that the laser may scan the groove 108 of the hob cutter 104b. Therefore, even if no peak is detected (NO in S244), rather than immediately detecting an abnormality (S246), the angle of the hob cutter 104b may be changed and the laser may be scanned again in the tool length direction (S242).

As explained using Figures 7 and 8, once the phase of the tool 104 (skiving cutter 104a or hob cutter 104b) has been detected, the control unit 150 aligns the phase of the workpiece 102 with that of the tool 104. When subsequently machining the workpiece 102 using the tool 104, the laser sensor 130 is moved to the standby position P3 (which may be the same as the initial position P0) in Figure 4.

As described above, the gear cutting machine 100 and phase alignment method of this embodiment are provided with one laser sensor 130 and one sensor rotation device 140 that rotates the laser sensor 130, and the laser sensor 130 is rotated by the sensor rotation device 140. This makes it possible to detect the phases of both the workpiece 102 and the tool 104 and align their phases.

The above configuration minimizes the need for additional components used for phase detection, preventing increases in equipment costs while still achieving the above-mentioned effects. Furthermore, since no manual work is required when detecting the phases of the workpiece 102 and tool 104, it is possible to prevent errors caused by manual work.

Furthermore, with the gear cutting machine 100 of this embodiment, the phase of the hob cutter 104b in addition to the skiving cutter 104a can be detected by irradiating the tool with a laser while rotating the laser sensor 130 in the tool length direction. This broadens the range of application of phase detection, allowing for the use of standardized parts and reducing equipment costs.

While the preferred embodiments of the present invention have been described above with reference to the accompanying drawings, it goes without saying that the present invention is not limited to such examples. It is clear that a person skilled in the art could conceive of various modifications or alterations within the scope of the claims, and it is understood that these also naturally fall within the technical scope of the present invention.

The present invention can be used as a gear cutting machine that processes gears by rotating a tool and workpiece synchronously, and as a phase alignment method for the same.

100... gear cutting machine, 102... workpiece, 104... tool, 104a... skiving cutter, 104b... hob cutter, 106a... blade, 106b... blade, 108... groove, 110... work spindle, 120... tool spindle, 130... laser sensor, 140... sensor rotation device, 150... control unit, 152... angle control unit, 154... phase detection unit

Claims (2)

a work spindle that rotates the attached workpiece;
a tool spindle for rotating an attached tool;
a laser sensor attached to a side of the tool spindle;
a sensor rotating device that rotates the laser sensor along the axial direction of the tool spindle;
an angle control unit that controls a rotation angle of the sensor rotation device;
a phase detection unit that detects the phases of the workpiece and the tool;
Equipped with
a gear cutting machine , characterized in that the phase detection unit detects peaks while rotating the laser sensor along the axial direction of the tool using the sensor rotation device, thereby detecting the phase of the tool . A phase alignment method for a gear cutting machine including a work spindle that rotates a workpiece, a tool spindle that rotates a tool, a laser sensor attached to a side surface of the tool spindle, a sensor rotating device that rotates the laser sensor along an axial direction of the tool spindle, and an angle control unit that controls a rotation angle of the sensor rotating device,
The angle control unit controls the rotation angle to direct the laser sensor toward the workpiece, thereby detecting the phase of the workpiece;
detecting a peak while rotating the laser sensor along the axial direction of the tool by rotation angle control by the angle control unit, and detecting a phase of the tool;
A phase alignment method for a gear cutting machine, comprising: aligning the phases of the workpiece and the tool.