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NEW APPROACHES IN ROLL TESTING TECHNOLOGY OF SPIRAL BEVEL AND HYPOID GEAR SETS

Introduction The roll testing of bevel gears has existed as long as bevel gearing itself has existed. A device was required to check and confirm functionality, mounting distances and backlash to suit the future assembly condition of the gear set. Single-flank and vibration checking have traditionally been widely accepted testing and checking methods for evaluating the quality of spiral bevel and hypoid gear sets. Mainly due to productivity reasons, the methods were limited to laboratory application, spot checks to monitor production and assembled gear sets. Only the introduction of CNC roll testing equipment combined with PC-based evaluation technology dating back to 1990 enabled the breakthrough of this technology onto workshop floors in mass production applications (Ref. 1). Since then, this process has been automated, so it's now state-of-the-art technology, where the best assembly position for the gear set is evaluated, checking the quality characteristics for different mounting positions. This fulfilled the requirements of the automotive industry regarding the generation , recording and documentation of information about the quality level of its manufactured gear sets. However, the industry later required checking of the gear set characteristics over a wider range of positions. Checking a defined number of positions, though, was jeopardizing productivity. This is where the new continuous approach can be used to provide the required amount of information without compromising productivity. Methods for Checking Spiral Bevel and Hypoid Gears There are many reasons for checking spiral bevel gears and hypoid gear sets in production, such as monitoring production and documenting manufactured quality. However, in the pre-assembly stage, the main reason is to predict noise emissions, once the gear set is mounted in the carrier. The requirements for a testing device in a production environment are reproducibility of results, short setup and testing times, best possible simulation of " real " situation once the gear set is assembled, a straightforward good/reject identification and a reliable detection of components that do not fulfill the requested quality standards. Methods to check individual components. There are numerous ways of checking individual components that will not be listed, as this paper is purely focused on the possible means of detecting