There is a wide assortment of instruments for testing of gears, designed and manufactured by Gearspect Company. By its assortment the instruments of type DO cover the spectrum of gear testing methods. There are instruments with classic method with a dial gauge measuring or modern instrument controlled by a computer.

ZLK 500 PC

Besides of above mentioned instruments of our own construction and manufacturing, our company also offers complete modernisation - retrofiting of classic instruments SP 60, PH 100 etc., MAAG company.

The test by single flank method

The test by single flank method shows inaccuracy (uneven) of transmission of rotary motion of bevel gearing in the same conditions as in operation. The test is made separately on right and left teeth sides. When the uneven transmission of rotary motion is lower then the gear (gearing) is more accurate. Individual deviations which are received by this test are described in standard DIN 3965 and in this leaflet.

General characteristic

The gear tester ZLK 500 PC, produced by Modul-company was originally designed for bevel gearing. The tester was modernizated especially it was redesign in mechanical construction under observation for geometric accuracy principles and following modernization with completion by high accuracy linear and rotation scanners from Heidenhain - company.

After provided modernization is the instrument ZLK 500 PC designed for testing of deviations of bevel gearing by the single flank method with evaluation by a computer according to DIN 3965 standard.

The tester is utilized for measuring of noise by subjective listening within maximum revolutions of pinion 2000 1/r.p.m. and maximum braking torque crown wheel 15 Nm.

It is possible also to test gear carrier zone ("mirror") on gear flank by printing of scraping colour. Gear tester is driven by a electrical motor with possibility change revolutions in steps and controlling from computer directly.

Method of testing

Gear Tester ZLK 500 PC allows testing of deviations of single flank generating Bevel gears. The principle of this method is that a pair of bevel gears in mesh is in the same position correspond with the assembly distances of pinion and crown wheel.

With respect that for bevel gearing is very difficult to produce ?master gears? it is tested meshing pinion with wheel as a complete. It is applicable principle so called ?coupling? of gearing. During rotation of gearing is alternated mesh of various teeth of pinion and wheel. If mesh the concrete tooth of pinion starts with the concrete tooth of wheel (we can imagine that these teeth are designated) the mesh of the same teeth is repeated after specific revolutions of pinion and related number of wheel revolutions. It is so called full mesh cycle which is still repeated. The test by single flank method must evaluate for definition property of gearing (for the reason of repeated processing) and just this mesh cycle (the cycle duration i.e. the correspond numbers of revolutions of pinion and wheel) it is selected by operator.

In the stated cycle are evaluated the deviations of angle position of crown wheel (recalculated on arc outside pitch circle of wheel and define in mm) from its theoretical angle position defined angle position of pinion and gear ratio.

These deviations are displayed on monitor and from such record are evaluated:

F_i´ - step of single flank generating per mesh cycle

f_i´ - step of single flank generating per pitch

F_l?(respF_p´ according DIN 3971 - deviation of single flank generating per mesh cycle

By filter off deviation f_l´ we recieve further display of course with characteristic errors in mesh individual meshing pairs of teeth:

F_k´(respF_p´ according DIN 3971) - deviation of single flank generating per pitch

In case of negative result or if we request the best mesh of gearing and subject to exist possibility for starting gearing assembly (i.e. marked tooth of pinion change into mesh with another tooth of wheel) the tester notice this possibility. (For information: larger number possibilities of composition of pinion and wheel exist subject to the numbers of teeth z1, z2 are divisible. In case of no-divisible numbers z1, z2 is the starting position arbitrary because each tooth of pinion is in mesh with all teeth of wheel).

Measuring and control programs use WINDOWS ´ 98.

The main control program allows:

• use in shop environment
• in short time to process and display measured values
• by means of a special SW classifies tested bevel gearing
• blocking of individual tester functions by password
• adjustment of angle measure in base mode (XX° XX´ XX?) or decimal mode (XX, XXXX° )

• the program allows to display tolerance and regulate limits by means of colour lights:

• red - out of tolerance limit
• yellow - out of regulate limit
• green - O.K.

Such evaluation is valid for all deviations and serve for quick orientation of operator

• testing of gearing: by the obtained deviations of single flank gearing according to chapter ? Method of testing? and according to their evaluation into accuracy classes according to DIN 3965 standard; it is respected the fact that we request to receive pair of gears (not the relation between the measured and master gears) and it respects the dependence of numerical values allowed deviations in relation to further parameters (coefficient of mesh duration) as stated in DIN standard. Before test starting it is possible to select the class accuracy as limit of testing. The wheel is tested with respect to pre-selected limit and exceed is announced on monitor by colour lights and by red larger letters, on protocols by larger letters.
• to recall parameters of measured gearing from stored data incl. results and graphs of measuring
• setting of communication language version on monitor for testing and print of protocols:standard language versions: Czech, German or English, the others are delivered as a special equipment
• setting of protocols print in various sizes - black and white, colour versions
• FFT analysis
• look-out for measure data tooth by tooth
• data storage in a way, that can be further processed by program SPC for quality control (optional accessories)