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ZD series Gear Measuring Center Technical Introduction
I. Product introduction
ZD series measuring center utilizes full-closed-loop control technology, new hierarchical controlling and data acquisition principles, 2.5D Digital Probe, advanced probe management system with magnetic sucking disk. It utilizes precise cast iron base, steel rolling guide, ball screw technology, high precision optical grating, servo motors for linear axes, direct drive rotary motor (DDR) for rotary axis. The maximum outer diameter of measurable workpieces is 350 mm. It can measure involute cylindrical gear, gear cutters (hob, shaper cutter, shaving cutter etc.) automatically, fast and with high precision. It can also be extended to measure bevel gear, worm gear and worm wheel, camshaft, etc.
1. Main technical parameters
  ZD20 ZD30 ZD40 ZD50 ZD60 ZD80 ZD100
Gear module range(mm) (0.1)0.3-10 (0.1)0.3-12 0.5-15 0.5-15 0.5-20 1-20 1-20
The maximum outer diameter of gear being measured (mm) 250 350  
450
550 650 850 1050
Max vertical measuring distance (mm) 280 330  
350
380 450 600 600
Distances between centers (mm) 10-500 10-650 10-
1000
10-
1000
10-
1000
10-
1200
10-
1200
Lead angle measuring range(°) 0-90 0-90 0-90 0-90 0-90 0-90 0-90
Max. permissible workpiece weight (kg) 100 150  
300
500 600 800 2000
Supply voltage(V) 220V50Hz 380V50Hz
Power of supply(KVA) 2.0 3.0
 
2. Instrument measuring functions
1) Cylindrical gear
1.1  Measuring types
l spur gear, helical gear, external gear
1.2  Measuring items
l Tooth profile (involute): Fα, ffα, fHα, Cα; Lead (helix): Fβ, ffβ, fHβ, Cβ;
l Pitch (circular pitch): Fp, Fpk, fpt, fu, Rp; Runout: Fr
1.3  Measuring functions
² The workpiece clamping error compensation function
² Tooth root scanning measurement, whole teeth measurement, torsion measurement, topography measurement, gear shaft measurement, comparison between before heat treatment measurement and after heat treatment measurement of the gear
² Missing teeth or block teeth, crowning gear evaluation, tip and root reliefs (profile), top and bottom reliefs (helix), K-Chart design (linear, round, parabola)
² Batch test statistics analysis function
² Base tangent length, distance over balls, tooth thickness change quantity
1.4  Evaluation standard
² GB10095, ISO1328, DIN3962, AGMA2000, JISB1702-1976, GB2363, B18-1155
² Free tolerance
2) Hob (standard configuration)
2.1  Measuring types
² gear hob, worm gear hob
2.2  Measuring items
² Helix, profile (over cutting edge, behind cutting edge), meshing line, axial pitch, hub face runout, side clearance angle, tooth thickness
² Gash lead, gash pitch, form and position of cutting face, tip circle runout, hub radial runout
² Tooth profile type: ZA, ZN, ZI
² Hob with modification: The thickness of the convex Angle
2.3  Evaluation standards
² GB6084, DIN3962, GOST9324
² Free tolerance
3) Shaper cutter (Standard configuration)
3.1  Measuring types
l Spur shaper cutter, helical shaper cutter
3.2  Measuring items
l Tooth profile (involute): Fα, ffα, fHα, Cα; Lead (helix): Fβ, ffβ, fHβ, Cβ
l Pitch (circular pitch): Fp, Fpk, fpt, fu, Rp; Runout: Fr
l Rake angle at head, draft angle at head, lead of cutting face, runout of cutting face
3.3  Measuring functions
l Missing teeth or block teeth
l Crowning teeth
3.4  Evaluation standards
l DIN1829, GOST10059-80, GB/T6082, JB/T 3095
l Free tolerance
4) Shaving cutter (standard configuration)
4.1  Grooving types
l Ring-shaped, spiral
4.2  Measuring items
l Tooth profile (involute): Fα, ffα, fHα, Cα; Lead (helix): Fβ, ffβ, fHβ, Cβ;
l Pitch (circular pitch): Fp, Fpk, fpt, fu, Rp; Runout: Fr
4.3  Evaluation standards
l DIN3962, GB/T 14333-93, small module standard
l Free tolerance
5) Worm (optional configuration)
5.1  Measuring types
l Single lead worm, double lead worm
5.2  Measuring items
l Tooth profile: Fα, ffα, fHα, Cα; Lead (helix): Fβ, ffβ, fHβ, Cβ, fpz
l Pitch: fpx, Fpx
l Shaft radial runout, shaft face runout: frp
l Tooth thickness change quantity Rs
l Tooth profile types: ZA, ZN1, ZN2, ZN3, ZI
5.3  Measuring functions
l Crowning setting, multi-start worm set
5.4  Evaluation standards
l DIN3974, AGMA2011, GB10089
l Free tolerance
6) Worm gear (optional configuration)
6.1  Measuring types
l Single module worm gear, double module worm gear
6.2  Measuring items
l Tooth profile: Fα, ffα, fHα, Cα
l Pitch (circular pitch): Fp, Fpk, fpt, fu, Rp; Runout: Fr
l Tooth thickness Sn
l Tooth profile types: ZA, ZN1, ZN2, ZN3, ZI
6.3  Measuring functions
l Block of missed teeth, crowning setting
6.4  Evaluation standards
l DIN3974, AGMA2011, GB10089
l Free tolerance
7) Bevel gear (optional configuration)
7.1  Measuring types
l Optional configuration
² Straight bevel gear, helical bevel gear
² Straight bevel gear mold
² Spiral bevel gear
² Cycloidal bevel gear
7.2  Measuring items
l Tooth surface topology, pitch (circular pitch), runout Fr, tooth thickness
7.3  Measuring functions
l Machine tool strong-arm function
l Manual measuring pitch, tooth surface scan of spiral bevel gear with unknown parameters, etc.
3. Main precision index
1) Single accuracy requirements (see Schedule 1)
2) Composite accuracy requirements
i)  Profile error value: 2 um; Repeatability (five times): 1 um
Lead error value: 2 um; Repeatability (five times): 1 um
ii)  Gear pitch in sample measurement:
Pitch value for stability (five times repeatability): 2 um
4. Composition and characteristics of the instrument
1) Stable host system: Mechanical host includes the following parts: a natural granite (or precise cast iron) base; a high-precision ball bearing shafting CNC rotary table (C) driven by a direct drive rotary motor with a high-resolution optical scale for position feedback; three linear axes (X, Y, Z) composed of AC servo drive and ball screw, THK guide, roll steel guide rail and high precision linear optical scale; a vertical workpiece guide with high-accuracy linear helix rail. The top center of the vertical workpiece guide uses ball bearings shafting and is driven by AC servo motor. It automatically stops when reaching the measuring position.
2) Advanced 2.5D Digital Probe System: Measuring sensor (patented) uses specially designed 2.5D Digital Probe system. It uses high-precision optical grating (RENISHAW) in 2D measuring directions, which has a stable signal without interfering. Apart from the 2D measuring directions, the sensor can rotate 90° (0.5D) and switch the measuring direction between vertical and tangential. The stylus has a structure of 3-point magnetic fixation, which makes it very easy to change and guarantees high precision of repeated positioning. The Probe system has protection for “out of limit” and mechanical limit protection in the vertical/tangential and radial directions. This probe system satisfies different requirements of gear measuring and cutter measuring.
3) International Probe Management System: The system is used worldwide in high-end gear measuring centers. Every probe and measuring bar are pre-calibrated for variation correction, saving tangential, vertical and radial calibration data without re-calibrate for a long time. A probe can be changed through a 3-point fix magnetic force disk. This system is integrated and gives precautionary information.
4) Reliable raster for datum reference: HEIDENHAIN (Germany) and RENISHAW (UK) encoders with high accuracy and stability are used for reference datum, which guarantee high precision, stability and reliability of the machine.
5) Precise control and data acquisition system: The controlling system is full-close-loop, with IMAC (USA) as controller. All linear axes utilize imported AC servo motors. The rotary motion utilizes direct drive rotary motor. Together with the coordination of IMAC controller, they enable the full-close-loop controlling and complete data acquisition of measuring positions. All measuring actions can be completed automatically.
6) New generation of hierarchical controlling concept: This generation of gear measuring centers uses hierarchical controlling technology. All movements with high real-time requirements are accomplished in the lower controlling layer, while data acquisition, calculation, processing, display and printing are accomplished with the computer in the upper controlling layer. Such work division enhances the reliability, efficiency and measuring speed of the machine, offering possibilities for any measuring methods.
5. Software introduction
The new generation of gear measuring software has the following features:
1) Fully automatic measurement: After parameter input, all measurements, data acquisition, error compensation (eccentricity error by loading and guide error), data evaluation and result output are completed automatically.
2) High-density uniform sampling: All continuous curve measurements of ZD series have a uniform sampling interval of 0.02 mm. Data processing, display and printing are all based on this sampling technique, so that real conditions of tooth surfaces are fully detected.
3) User-friendly interfaces: Zhida software can complete many operations through functional buttons, such as parameter input, measuring mode setting, error evaluation selection, parameter storing and parameter loading, measuring result display, etc. With clearly annotated functional keys on the keyboard, the system is simple and convenient to operate.
4) Automatic calculation: The software automatically calculates measuring length and evaluation length according to basic gear parameters (number of teeth, modules, pressure angle, helix angle, modification coefficient, etc.). Length scale and error scale can be set automatically or manually. The measuring range of the gear can be determined accurately. The computer automatically determines start measuring position, start evaluation position, end evaluation position and end measuring position. The measuring position of the tooth profile is determined according to tip and root circle diameter, the matched gear, or standard rack mesh. The range of evaluation position can also be adjusted manually.
5) Compensation of eccentricity error from workpiece loading: When loading workpieces, the datum axis of the workpiece usually coincides with the rotation axis of the machine. Our software can detect the eccentric and the deflection error caused by that and add compensations accordingly. This technology is especially important for the measuring of internal gears and other workpieces without center holes for fixation. Zhida is the first company in China that has mastered this technology, which greatly improves measuring accuracy and efficiency.
6) Multiple evaluation standards:The software offers 4-division / 3-division / all-teeth and left-sided / right-sided / both-sided gear measuring modes. The profile, helix and pitch error can be evaluated according to GB, ISO, DIN, AGMA, JIS or GOST standards.
7) Multiple output formats:Measuring results (measuring curves and evaluation results) can be printed by the attached laser / ink-jet printer. Several international formats (such as Klingenberg, Gleason, Osaka, etc.) are selectable for printing apart from the ZD-Format.
8) Custom requirements possible:We offer customized software and printing formats if needed.
II. Standard configuration
The standard configuration includes the following parts. The actual configuration might differ from the standard configuration due to custom requirements. The actual configuration is specified in the technical agreement.
1. Measuring machine ------------------------------------------------1 set
2. Workbench ----------------------------------------------------------1 piece
3. Computer ------------------------------------------------------------1 set
4. Laser printer ---------------------------------------------------------1 piece
5. Printing paper -------------------------------------------------------1 package
6. Operation instruction -----------------------------------------------1 set
7. Standard accessorie
1.2 
2.2 s
7.1  Drive device -----------------------------------------------------1 set
7.2  Standard spindle ----------------------------------------------- 1 piece
7.3  Mikrokator -------------------------------------------------------1 piece
7.4  Allen wrench ----------------------------------------------------1 piece
7.5  Packing list ------------------------------------------------------1 piece
7.6  Accessory case ------------------------------------------------ 1 piece
8. Digital probe components:
8.1  Replaceable probe Φ0.5 ----------------------------------- 2 pieces
8.2                   Φ1 ------------------------------------2 piece        
8.3                   Φ1.5 ----------------------------------2 pieces
8.4                   Φ2 ------------------------------------2 pieces
8.5                   Φ3 -------------------------------------2 pieces
8.6  Magnetic sucking disk -------------------------------------3 sets
8.7  Extension rod and linking parts --------------------------1 set
8.8  Probe component box --------------------------------------1 piece
9. Measuring software
9.1  Cylindrical gear measuring software -----------------1 set
9.2  Shaper cutter measuring software ---------------------1 set
9.3  Shaving cutter measuring software --------------------1 set
9.4  Hob measuring software ---------------------------------1 set
III. Optional hardware and software
1. Involute helicoid standard sample plate       
2. Three jaw chuck and base 
3. Internal gear measuring software   
4. Straight spline measuring software
5. Circular spline measuring software
6. Worm measuring software
7. Worm gear measuring software
8. Straight bevel gear measuring software
9. Straight bevel gear mold measuring software
10. Spiral bevel gear measuring software
11. Worm milling cutter measuring software
12. Rack hob (ring) measuring software
13. Spiral bevel gear milling cutter measuring software
14. Cylinder equiangular graduated measuring software
15. Rack measuring software
16. RV reducer measuring software
16.1 Cycloid gear measuring software
16.2 Eccentric shaft measuring software
16.3 Pin wheel housing measuring software
16.4 Planet carrier and planet wheel measuring software        
17. Special workpiece measuring software
IV. Requirements on the machine installation and environment
1. The installation foundation should be firm, flat and away from vibration source;
2. The power supply of the machine should be 220V/50HZ (±5%) single-phase AC power supply with stabilized voltage. (A single-phase uninterruptible power supply of 2KW is required.)
3. There must not be electrical interference around the machine. The machine must be grounded.
4. The machine should be used in metrology rooms. The environment should be kept at a constant temperature of 22 ± 0.5℃; The environment humidity should be kept between 35%-65%.

Schedule 1: Main precision index of ZD series gear measuring center
Order Item Accuracy requirement Verification tool
1 Circular runout of top center and bottom center 0.002 mm a. 1 um indicator
a. magnetic stand
2 Parallelism between probe and
ligature of two centers
front surface:
0.004 mm / 300 mm
side surface:
0.003mm/ 300 mm
a. 1 um indicator
b. magnetic stand
c. precision spindle
(150, 300 mm)
3 Concentricity between two
centers
0.005 mm a. 1 um indicator
b. magnetic stand
c. precision spindle
(150, 300 mm)
4 Indication error of profile, helix Profile: 0.002 mm
Helix: 0.002 mm
sample plate
5 Indication variation of profile, helix Profile: 0.001 mm
Helix: 0.001 mm
sample plate
6 Indication variation of pitch error 0.002 mm standard gear