These new features have been added to assess the quality of gears and transmissions. The systems analyze the rolling noise and carry out a single-flank and double-flank rolling test / rotation fault diagnosis, in which the speed (up to nominal speed) and load torque can be variably adjusted. In addition, the backlash is determined and the concentricity error in the double flank contact is determined. Defective teeth are detected and marked with a special marking system (laser, color, inkjet markings) for reworking. Rework can be done directly on the test system and the part can then be automatically returned to the test. Other test methods - such as Diameter monitoring, center distance control, etc. - can be integrated. The test systems are either designed for interlinked fully automatic operation or for manual loading and unloading and it uses the same clamping devices as upstream processing machines. An extension can therefore be implemented quickly and inexpensively.

A number of well-known automobile manufacturers and suppliers around the world, major mechanical engineering companies and electrical groups are successfully and reliably using our systems and diagnostic systems. With the determined data of the different processes, statements are made about the quality. Interference sources or causes of errors (acoustic errors, design-related weak points, assembly, functional or manufacturing errors and damage) are identified and quality certificates are created. Statistical evaluations allow changes and trends in the manufacturing process to be recognized, controlled, sorted and corrected with reworking and smoothing machines. Tooth-precise errors can be recorded, marked and dealt with. By returning this information, industrial manufacturing processes with regard to product quality, manufacturing security and cost efficiency are optimized in a timely and goal-oriented manner. Time-consuming and expensive failures are avoided in good time with the help of the LiTW systems.

A gear test can be done in a variety of ways, e.g. by analyzing the noise behavior or mechanically, e.g. by means of a center distance measurement, determination of the rotational acceleration, or by a target / actual comparison of the theoretical and actual position of a gear pair) or by a combination of acoustic and mechanical test methods. The gear testing is based on single-flank and double-flank rolling.

This deflection is recorded for the geometry test with a linear displacement sensor. A vibration sensor is mounted on the testing slide for the noise test. In the double-flank test, single gears as well as whole entire shafts can be tested.

The specimen and the master gear have a fixed center distance, in which the two components are in one-flank contact. The specimen is driven again and the master gear is braked by another drive in order to apply the desired torque / speed ratio.

The TAC-Sensor is mounted on the spindle shaft of the specimen or of the Master Gear for the test. This sensor measures the non-uniformity of rotation. This irregularity can be caused by various errors in the toothing.

e.g.: radial run-out, whobble, any kind of mistakes in contact pattern, etc.

The TE test (Transmission Error test) is a test method according to DIN 3960 or VDI 2608 described single-flank rolling test. Here, the set of gears rolling with one another, as it is later paired in the gearbox. Geometric deviations that affect the function of the wheel pairs can be efficiently recorded. The deviations lead to gear ratio fluctuations or rotational irregularities, which lead to vibration and noise excitation.

The gear ratio fluctuation is referred to as a rotation error or single-flank pitch deviation. High-resolution incremental angle encoders are installed on the axes to record the measurement parameters. This enables an exact replication of individual tooth meshes and the curve of the total error, the long-wave and short-wave components, diameter deviation and the pitch jump can be quickly and precisely calculated and graphically displayed.

With the optical surface inspection, the measurement data are recorded and output to a system controller via an interface. In addition, the sensor has a trigger input where automatic measurements can be started and assigned. This enables to detect chatter marks and roundness defects and assess the surface quality. The surface inspection works quickly, requires little maintenance, is robust and precise.

Optical surface inspection for checking surface quality and chatter marks

Optical surface inspection for checking roundness error

In order to increase the degree of automation and improve handling, we offer marking and labeling systems. These are used to mark and classify certain areas of the toothing on gear wheels and gear shafts. A total of 4 systems (laser, inkjet, needle embossing and color marking system) are offered. During the test, good and bad parts can be optically marked and the location of the greatest damage is marked tooth-precise. Impregnation of a tiny data matrix code is also possible. With the help of a camera check, all information (geometry, component properties, as well as component and batch numbers), test properties and unevenness of the parts can be read out again.

To complete the degree of automation, the parts can be moved, checked and divided using conveyor belts, reversible grippers and interlinking.