When electric drives are used in vehicles, the masking effect of an internal combustion engine disappears, allowing the noise behavior of the transmission to take center stage. At the same time, peak power and torque increase, engine speeds increase, and power must be transferred optimally in both directions due to the regenerative braking system. Conventional design parameters remain important, however: The build space is limited, durability must not be compromised, and the product must still be cost-efficient. Optical metrology as part of a hybrid measurement concept helps to overcome all these challenges.
Tactile or contact probes are the most common metrology technique in the coordinate measurement world, including the more specialized gear measurement community. Tactile probes can be active or passive, scanning or touch only, and may vary in cost and performance depending on the system itself. They are offered by multiple industrial companies as standalone OEM products (e.g., Renishaw) or only included in their coordinate measuring machines (e.g., Zeiss, Klingelnberg, and Hexagon). Their overall performance, especially their robustness and flexibility, have led to a gold standard for most metrology tasks.
Gears are characterized by a rather complex geometry and tight tolerances, especially compared to other mechanical components. Looking into noise performance of gears, form tolerances are in the single micrometer range to ensure a quiet running behavior. Combined with the geometrical complexity, this is a major challenge for any new metrology standard to be established. For all features and their tolerances, the measuring system must be statistically capable to
ensure appropriate accuracy and repeatability. With today’s tactile measuring system, there are measuring devices available that meet nearly all the requirements. Tactile metrology is characterized by a high accuracy and repeatability as well as a high flexibility. However, for some applications measuring times are rather high, particularly if compared to production cycling times.