Rapid Spur Gear Profile Inspection Using Chromatic Confocal Sensors

Gears, as critical power-transmission components in most power equipment, have a particularly urgent need for in situ inspection systems. Traditional gear inspection methods rely on contact inspection instruments, which are not only time-consuming, but also potentially damage the gear surface due to contact. This study delves into the detection requirements in the gear manufacturing process and establishes a rapid, non-contact detection mechanism and model using a CHCS. This model employs a CHCS to achieve high-speed, non-contact measurement on various surfaces with extremely high accuracy, enabling real-time monitoring of production process details, thereby improving production efficiency and ensuring product quality. Through actual inspection and comparison with a standard involute spur gear tooth profile model, this study implements a complete inspection system in a prototype. The results of gear inspection using a CHCS with an accuracy of 1 μm showed that the interquartile range of qualified gears under test (GUTs) was within 2.5 μm, and the beard line value was within 10 μm. The experiment demonstrated a layout equipped with a CHCS where the rotating axis represents the hobbing machine spindle. This method can be completed without moving the gear, enabling subsequent finishing processes.