中文网站 | English
ZF Series Full-Automatic Gear Sorting Machine
ZF20A Full-Automatic Gear Sorting Machine
I Instrument Overview
     ZF20A full-automatic gear sorting machine is used in automatic sorting of ring gears. It contains a double-flank gear roll tester as its main part. Gantry robots and belt conveyors are used for automatic loading, unloadingandmarking ofworkpieces. It is a novel and intelligent integrated gear tester for automatically sorting workpiece gears into qualified and defect products.
The instrument is mainly composed of a measuring machine, gantry robots and belt conveyors for loading and unloading. The measuring machinecontains a vertical structure facilitating automatic ring gearloading. The workpiece gear and measuring gear are installed on the instrumental axis, thereby guaranteeingthe instrument’s long-term stability; Japan PANASONICfull-digital AC servo motor is adopted as the drive motor, which is characterized by its small volume, light weight and good work performance. The measurement control isrealized through the combination of a computer and a motion controller; The deviations are measured through a Britain RENISHAW high precision encoder system. Quick measurements as well as automatic advancement and retreating are controlled by motors, which is consistent with the characteristics of modern measuring instruments, namely high efficiency, high precision and high reliability.
During operation, the operator only needs to place the workpieces to be testedon the loadingstation in sequence. Eachworkpieceis then transported to the cleaning and drying station by a gantry robot. After cleaning and drying, the workpieceis further transported to the measuring station. After the completion of the automatic measurement, the workpiece is automatically markedaccording to the measuring result. Finally, the workpiece istransported into one ofthreedifferent unloadingstations according to thestatus of its measuring result: qualified, repairable or waste.
II Overall Layout
The instrument overall layout is shown in Figure 1, 2 and 3.
 
                                        Figure 1 Front view
 
                        Figure 2 Top view
 
                    Figure 3 Side view
1. industrial indicator light   2. aluminium profile frame 3. protective net
4. display 5. gantry robot 2 6. gantry robot 1
7. ground pin   8. foma wheel 9. measuring station       
10. cleaning and drying station 11. electric cabinet    12. unloadingstation (qualified)
13. unloading station (qualified) 14. unloading station (waste) 15.unloading  station (repairable)
16. loadingstation 17. loadingstation  
III Measurement Items
1.   Total radialcomposite deviation: Fi″
2.   Tooth-to-tooth radial composite error: fi″
3.   Upper and lower deviations of center distance variation: Eas, Eai
4.   Runout: Fr″
5.   Two-ball measurement: M
6.   Base tangent length: Wk
7.   Automatic search of burrs
IV Measurement Parameters
1.   Min. module of the measured gear --------------------------- 0.5 mm
2.   Max. outer diameter of the measuredgear (measuring machine) ---------- 200mm
3.   Max. outer diameter of the measured gear (conveyor belt, customizable) --- 160mm
4.   Max. outer diameter of the master gear ------------------------------- 200mm
5.   Distance between meshing gear centers ------------------------- 55 to 200mm
6.   Min. resolution of the indication system --------------------------- 0.0001mm
7.   Max. indication error of the instrument------------------------------ 0.004 mm
8.   Max. measurement repeatability error ------------------------------ 0.004 mm
9.   Measurement rhythm (cycle time) ------------------------------------- ≤60s
10. Max. number ofworkpieces allowed at the stations (assume each workpiece has an outer diameter of 160mm.Customizable according to demands)
Loadingstation (2 sets)-------------------------------------------------- 10 pieces each
Unloadingstation (qualified: 2 sets, repairable: 1 set, waste: 1 set ) -------------- 10 pieces each
11. Supply voltage / frequency ------------------------------ AC 210 to 230V/ 50Hz
V Reference Dimensions
The reference dimensionsof the instrument are shown in Figure 4 (mm).
 
               Figure 4 Reference dimensionsof the instrument
VI Instrument Workflow
Figure 5 shows a reference workflow of the instrument. The position of the automatic marking process in the workflow and its marking rules can be customized according to users’ needs.
Figure 5 Instrument referenceworkflow

VII MainPrecision Indices (see attached Table 1)
VIII Instrument Main Characteristics
1. Unique design: A special structural layout is adopted to realize automatic measuring and sorting of ring gears.The structure can be customized according to user’s needs;
2. High-end configuration: Computerized digital control, precision shaft, measurement control driven by AC servo motors, error indication by high precision encodersystem and Windows 7 software;
3. Precise positioning and rapid response: Gantry robots are adopted, which have minimum repetitive positioning error of up to 0.1 mm. The positioning precision of gantry robots reaches 0.05 mm.Besides,they respond quickly when grabbing workpieces;
4. High automation: Robot 1 transports workpieces to be tested in sequence to the cleaning and drying station. After cleaning and drying, robot 2 transports the workpiece to the measuring station. Following the measurement, in the presence of defect teeth, the defect teeth are automatically marked. After the completion of the marking process, robot 2 transports the workpiece to the corresponding unloading station according to its measuring result.The operator only needs to place workpiece gears on the loading stationin sequence. The whole measuring and sorting process can be started with one touch, during which the operator only needs to regularly load and collect workpieces, thereby greatly reducing the dependence on personnel.
5. High measuring efficiency: The unique loading and unloading station designs enablethe placement of workpieces in large numbers at a time. The rhythm (cycle time) including automatic feeding, cleaning and drying, blowing,measuring, marking and final discharging is within 60 s.
6. Simple tooling:For measuring different workpiece models, it is only necessary to replace some tooling of the robots and the measuring machine.Due to the high universality of the tooling, in some cases, no tooling needs to be replaced at all;
7. Accurate sorting: Measured workpieces are respectively sorted into different unloading stations according to the three status of their measuring results: qualified, repairable and waste;
8. Automatic blowing: During the measuring process, the workpiece gear and master gear are automatic blown, thereby reducing the influence of oil or other impurities on the measuring result;
9. Automatic marking: The defect teeth are automatically marked according to the measuring results, offering convenience for the manual deburring process by the operator;
10. Multi-functionality: With a simple and intuitive software user interface, the instrument can realize many functions such as comprehensive acceptance, statistical analysis, quality classification, comprehensive error analysis of batchgears etc.
11. Complete guarantee: The full depth and face width of every tooth of every gear aremeasured, thereby providing users with comprehensive guarantee. Furthermore, the error distribution of batch gears is statistically analyzed, and the analysis results are automatically saved, thereby comprehensively controlling the product quality.
Attached Table 1: Main precision indices of ZF20A full-automatic gear sorting machine
No. Item Verification Requirements Remark
1 Radial and axial circular runout of the measuring mandrel Radial runout: 3 μm
Axialrunout: 3 μm
 
2 Parallelism between the workpiece mandreland the measuringmandrel Vertical: 5μm/50mm
Horizontal: 5μm/50mm
 
3 Max. indication error of the instrument No more than 4μm  
4 Max. measurement repeatability error of the instrument (20measurements) No more than 4μm All measurements should startwith the same tooth.
 
 
 
 
 
 
ZF15B型全自动齿轮分选机
ZF15B Full-Automatic Gear Sorting Machine
I Instrument Overview
        ZF15B full-automatic gear sorting machine is used in automatic sorting of gear shafts. It contains a double-flank gear roll tester as its main body. Gantry robots and belt conveyors are used for automatic loading, unloading and marking of workpieces. It is a novel and intelligent integrated gear tester for automatically sorting workpiece gears into qualified and defect products.
The instrument is mainly composed of a measuring machine, gantry robots and belt conveyors for loading and unloading. The measuring machine contains a horizontal structure facilitating automatic gear shaft loading.The middle axis of the workpiece gear and master gearare kept parallel, thereby guaranteeing the instrument’s long-term stability;Japan PANASONIC full-digital AC servo motor is adopted as the drive motor, which is characterized by its small volume, light weight and good work performance. The measurement control is realized through the combination of a computer and a motion controller; The deviations are measured through a Britain RENISHAW high precision encoder system. Quick measurements as well as automatic advancement and retreating are controlled by motors, which is consistent with the characteristics of modern measuring instruments, namely high efficiency, high precision and high reliability.
During operation, the operator only needs to place the workpieces to be tested in thegridsof the loading station in sequence. Each workpiece is then transported to the measuring station bya picking robot and a gantry robot.After the measurement, the workpiece is automatically marked according to the measuring result.Finally, the workpiece is transported into one of the three different unloading stations according to the status of its measuring result: qualified (grouping supported), repairable or waste.
II Overall Layout
The instrument overall layout is shown in Figure 1, 2 and 3.
                                                    Figure 1  Front view
                                           Figure 2  Top view
 
                             Figure 3  Side view

1. industrial indicator light   2. aluminium profile frame    3. gantry robot 1
4. gantry robot 2 5. protective net    6. industrial PC
7. ground pin   8. picking station    9. foma wheel
10. measuring station 11. automatic marking station    12. electric cabinet   
13. loading station 14.unloadingstation (repairable)    15. unloading station (qualified)
16. waste container    
III Measurement Items
1.   Total radialcomposite deviation: Fi″
2.   Tooth-to-tooth radial composite error: fi″
3.   Upper and lower deviations of center distance variation: Eas, Eai
4.   Runout: Fr″
5.   Two-ball measurement: M
6.   Base tangent length: Wk
7.   Automatic search of burrs
IV Measurement Parameters
1.   Min. module of the measured gear -------------------------------- 0.5mm
2.   Max. outer diameter of the measured gear (measuring machine)---- 200mm
3.   Max. outer diameter of the measured gear (conveyor belt, customizable) ---- 30mm
4.   Max. length of the workpiece gear shaft (measuring machine---- 280mm
5.   Max. length of the workpiece gear shaft (conveyor belt, customizable) ------- 180mm
6.   Max. outer diameter of the master gear -------------------------------- 200mm
7.   Distance between meshing gear centers-------------------------- 80 to 150mm
8.   Min. resolution of the indication system --------------------------- 0.0001mm
9.   Max. indication error of the instrument ----------------------------- 0.004 mm
10. Max. measurement repeatability error -------------------------------- 0.004 mm
11. Measurement rhythm (cycle time) --------------------------------------- ≤25s
12. Max. number of workpieces allowed at the stations (assume each workpiece has an outer diameter of 30 mm. Customizable according to demands)
Loading station ----------------------------------------30 pieces in total (1 columns)
Unloading station (qualified, repairable) ------------------------------ 30 pieces each(2 columns)
Waste container -------------------------------------------------- 30 pieces in total
13. Supply voltage / frequency ----------------------------- AC 210 to 230V/ 50Hz
V Reference Dimensions
The reference dimensions of the instrument are shown in Figure 4 (mm).
Figure 4 Reference dimensions of the instrument
VI  Instrument Workflow
Figure 5 shows a reference workflow of the instrument. The position of the automatic marking process in the workflow and its marking rules can be customized according to users’needs.
Figure 5 Instrument reference workflow
 
VII Instrument Main Characteristics
1. Unique design: A special structural layout is adopted to realize automatic measuring and sorting of ring gears. The structure can be customized according to user’s needs;
2. High-end configuration: Computerized digital control, precision shaft, measurement control driven by AC servo motors, error indication by high precision encoder system and Windows 7 software;
3. Precise positioning and rapid response: Gantry robots are adopted, which have minimum repetitive positioning error of up to 0.1 mm. The positioning precision of gantry robots reaches 0.05 mm. Besides, they respond quickly when grabbing workpieces;
4. High automation: The picking robot and gantry robot 1 transport workpieces to the measuring station in sequence. After the measurement, gantry robot 2 transports the measured workpiece to the marking station for automatic marking. Subsequently, robot 2 transports the workpiece to the unloading station. The operator only needs to place workpiece gears in the grids of the loading station in sequence. The whole measuring and sorting process can be started with one touch, during which the operator only needs to regularly load and collect workpieces, thereby greatly reducing the dependence on personnel.
5. High measuring efficiency: The unique loading and unloading station designs enable the placement of workpieces in large numbers at a time. The rhythm (cycle time) including automatic feeding, blowing, measuring, marking and final discharging is within 25 s.
6. Simple tooling: Equipped with a fixed picking station, gantry robot 1 only needs to pick-off workpieces from the fixed picking station, whereas the special picking robot at the picking station transports workpieces from the loading station to the fixed picking station.For measuring different workpiece models, it is only necessary to replace some tooling of the robots and the measuring machine. Due to the high universality of the tooling, in some cases, no tooling needs to be replaced at all;
7. Accurate sorting: Measured workpieces are respectively sorted into different unloading stations according to the three status of their measuring results: qualified (grouping supported), repairable and waste;
8. Automatic blowing: During the measuring process, the workpiece gear and master gear are automatic blown, thereby reducing the influence of oil or other impurities on the measuring result;
9. Automatic marking: The qualified gears are automatically laser-markedas well asthree-color markedaccording to the grouping result based on the two-ball measurement (M).
10. Multi-functionality: With a simple and intuitive software user interface, the instrument can realize many functions such as comprehensive acceptance, statistical analysis, quality classification, comprehensive error analysis of batch gears etc.
11. Complete guarantee: The full depth and face width of every tooth of every gear are measured, thereby providing users with comprehensive guarantee. Furthermore, the error distribution of batch gears is statistically analyzed, and the analysis results are automatically saved, thereby comprehensively controlling the product quality.