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Technical Introduction of ZS Series Intelligent Double-Flank                                     Gear Roll Testers
I Instrument Description
    ZS series intelligent double-flank gear roll tester (hereinafter referred to as 'instrument') is a double-flank instrument for external cylindrical gears. It is developedaccording to user requirements on the basis of our JS series products. It adopts the computerized numerical control (CNC) technology and is capable ofautomatic acquisitions and intelligent processing of measuring data. It automatically measures the total radial composite deviation Fi”, tooth-to-tooth radial composite deviation fi” and runout Fr”. Meanwhile, given the theoretical center distance, it can measure the upper and lower deviationsof the center distance variation (Eas, Eai), which affects the gear backlash. Additionally, it canquickly obtain the location and magnitude of burrs, enablingonlinedeburring processes.Furthermore, the instrument is able to calculate the two-ball measurement (M) and the base tangent length (W) of a gear. Compared with similar products on the market, the instrument has the following four additional auxiliary functions:
1. Automatic feeding:Motor-controlled reciprocating motions of the micro-motion carriage realize the automatic feeding and fast reversion, which greatly savesmeasuring time;
2. Automatic blowing:Automatically blow the master and workpiece gear before each measurement to reduce the influence of oil or other impurities on the measurement result;
3. Automatic brushing:Automatically brush the master and workpiece gear before each measurement toimprove the measurement accuracy (optional function);
4. Industrial workbench:The specially designed industrial workbench integrates domestic and foreign workbench design concepts and valuable user requirements.It is equipped with industrial indicator lights, enabling easyinstrument monitoring and operations. With such a workbench, the instrument operates as a complete station without the need of extra space for loading / unloading.
1. Main Technical Parameters


Model ZS20A ZS20B ZS30A ZS30B ZS40A
Module range of the measured gear(mm) 0.5 to 8 0.5 to 8 0.5 to 8 0.5 to 8 0.5 to 8
Max. outer diameter of the measured gear (mm) 300 300 400 customized customized
Distance between meshinggear centers (mm) 55 to 200 55 to 200 65 to 300 customized customized
Shaft length of themeasured gear (mm)   20-380   customized  
Min. resolution of the indication system (mm) 0.0001
Overall dimension of the instrument
(length*width*height, mm)
1290 * 650 * 1960
Supply voltage / frequency AC 210 to 230V/ 50Hz
 
2. Main Precision Indices: See attached Table 1
3. Measuring Functions     
1) Radial composite deviation: (Fi'', fi'')
2) Upper and lower deviations of center distance variation: (Eas, Eai)
3) Runout: (Fr'')
4) Two-ball measurement: (M)
5) Base tangent length: (W)
4. Instrument Structure
     1) The natural granite baseis stable and reliable. Precision cross roller guidesare adopted in the radial micro motion partto offer high accuracy;
2) Master gear and workpiece gear are arranged along the instrument central axis, thereby guaranteeing the long-term stability of the instrument;
3) For A-Type double-flank ring gearroll testers, the ring gear is installed on theworkpiece mandrelor the reduction sleeve on the left side of the instrument.The workpiece mandrelcannot be rotated. The workpiece gear rotates on the workpiece mandrelorreduction sleeve through sliding friction;
4) For B-Type double-flank gear shaft roll testers, the gear shaft is installed between the top and bottom centerson the left side of the instrument.The top and bottomcenters are bothrotatable;
5) For A-Type double-flank ring gearroll testers, the master gear is installed on the master gear shaft on the right side of the instrument. The master gear shaft utilizes a dense ball bearing shaft structure, thereby providing a high rotation accuracy.
6) For B-Type double-flank gear shaft roll testers, the master gear is installed on the right side of instrument between the top and bottomcenters with the help of a mandreland special tooling. The master gear can be moved verticallyon the mandrel, thereby enabling the measurement of workpiece gears at different heights.
7) The master gear can be fed manually and automatically. The manual feeding of the master gear is realized through a fast retreating handle. The automatic feeding is realized through a radial adjustment motor after an integrated proximity switch detects the presence of the workpiece gear.
8) The center distance is obtained through a long linear encoder, which is capable of acquisitions of center distances throughout the complete range of the instrument.
9) The rotation axisof the master gear is driven by a Japan PANASONIC digital AC servo unit. The measurement control is realized through the combination of a computer and a DMC3400 motion controller (Shenzhen Raiser). The acquisition of center distances and the indication of deviations are completed by a Britain high precision encoder system (Renishaw RGH24). All data processingis fully automatic.
5. Software Functions
1) A measuring software under Windows7 is adopted. Basic parameters (tooth number, module, pressure angle and addendum modification factor) of the measured gear and master gear as well as the precision grade or free tolerance parameters can be input for error evaluation. There are two measuring modes to choose from: the normal double-flank mode and the center distance deviation mode.
2) The measuring speed and meshing rotation direction can be adjusted in the software;
3) Measurement results can be output through a laser printer. Various common international formats can be applied to the measurement reports.
4) The software can be used for grouping according to center distance deviations, two-ball measurements etc. Grouping results are visualized by indicator lights on the screen;
5) Measurement data are automatically saved. Quality indicators (Cp andCpk values) can be counted automaticallywith respect toproduct models and measuring dates.Saving formatsare compatible with Microsoft Office.
II Standard Configuration
The standard configuration includes the following contents:
1. Measuring machine --------------------------------- 1 set
2. Special workbench ---------------------------------- 1 piece
3. Computer --------------------------------------------- 1 suite
4. Master gear tooling ---------------------------------- 1 suite
5. Operation manuals ----------------------------------- 1 share
 6. Packing list --------------------------------------------1 share
III Optional Accessories and Functions
1. Reduction sleeve                  
2. Master gear
3. Capsfor the lower center
4. Automatic brushing function
5. Automatic fast lifting of the top tailstock
IV Requirements on Instrument Installation Environment
1. The instrument installation foundation should be solid and flat;
2. Two-phase AC power supply 220V/50HZ (±5%) is used for the instrument. The voltage should be stable;
3. The environment should be free fromelectromagnetic interference.
V Installation, Acceptance and After-Sales Service
1. Instrument packing box can only be opened under the supervision and approval of the technical personnel of the manufacturer;
2. After the completion of the instrument installation and adjustment, both parties should be jointly responsible for the on-site acceptanceaccording to the technical agreement.AFinal Acceptance Reportshould be signed by both parties upon completion of the acceptance;
3. In order to ensure normal operations of the instrument, in case of problems in the use of the instrument, the manufacturer should propose solutions to the user within eight hours after receiving a notice hereof. If the problems are not eliminated, themanufacturer should send technicians to the site to solve the problems within three working days.
VI Quality Assurance
1. The warranty period of the instrument is one year. If any quality problem isdiscovered in the instrument itself within the warranty period, the manufacturer should provide maintenance service for the instrument for free;If the quality problem is caused bythe user’s improper use, costs of maintenance shall be charged from the user;
2. An after-sales service system including regular return visits and telephone consultations is adopted to timely discover and solve problems and difficulties in the use of the instrument;
3. Original software functions of the instrument can be upgraded for free over the lifetime of the instrument.
Attached Table 1: Main Precision Indices
No. Item VerificationRequirements Verification Tools
1 Parallelism between the measuring carriage mandreland workpiece carriage mandrel 0.005 mm / 50 mm a. Dial indicator
b. Magnetic stand
c. Level 1 gauge block
2 Parallelism between the measuring carriage top-bottom center ligatureand the workpiece carriage   top-bottom center ligature 0.005 mm / 50 mm
 
a. Dial indicator
b. Magnetic stand
c. Level 1 gauge block
3 Concentricitybetween two centers Short pole: 0.005mm
Long pole: 0.015mm
a. Dial indicator
b. Magnetic stand
c. Precision mandrel
4 Circular runout of themotor-driven center of the measuring carriage Runout: 0.003mm a. Dial indicator
b. Magnetic stand
5 Repeatability 0.003mm Level 1 gauge block