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Technical Introduction of ZSX10 Intelligent Double-Flank Small Module Gear Roll Testers
I Instrument Description 
    ZSX10 intelligent double-flank small module gearroll tester is developed by Harbin Zhida Measurement and Control Technology Co., Ltd. for small gears on the basis of previous products. This double-flank instrument is developed aiming at the technical characteristic that small center distance and measuring force are required during double-flank measurements of small gears (minimum gear module of 0.15 mm), especially non-metallic gears such as plastic gears etc.
    It adopts the computerized numerical control (CNC) technology and is capable of automatic 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 deviations of the center distance variation (Eas, Eai) which affects the gear backlash, thereby intelligently evaluating the quality of the gear. Besides, it can quickly obtain the location and magnitude of burrs, enabling online deburring processes. Additionally, new measurement requirements proposed by users can be satisfied upon negotiation.
Furthermore, the instrument can be used for calculating the two-ball measurement (M) and the base tangent length (W) of a gear on the basis of the double-flank measurement. It is proved in theory and practice that the measurement realized on the automatic double-flank instrument is more stable and accurate than manual measurement, since M and W measured according to center distancesare more consistent with their principles and definitions.
1. Main Technical Parameters
· Module range of the measured gear ----------------------0.15 to 2 mm
· Max. outer diameter of the measured gear --------------120 mm
· Distance between meshinggear centers ------------------10 to 100 mm
· Distance between top and bottom centers ---------------20 to 100 mm
· Min. resolution of the indication system -----------------0.0001mm
· Max. indication error of the instrument ------------------0.004 mm
2. Main Precision Indices
Instrument single precisions see attached Table 1.
3. MeasuringFunctions
1) Radial composite deviation: (Fi'', fi'')
2) Runout: (Fr'')
3) Two-ball measurement: (M)
4) Base tangent length: (W)
4. Structure Characteristics
1) The micro motion mechanism with parallel spring structure and specially designed workpiece loading method are especially suitable for measurements of small module and nonmetallic gears.
2) The rotation axis of the master gear adopts the mature precision ball bearing structure and is driven by a Japan PANASONIC A5 series full-digital AC servo unit (or similar products). The measurement control is realized through the combination of a computer and a MPC08 motion controller (Beijing Lechuang). The deviations are measured through a high precision digital encoder (USA Microe 195-00607). All measurements are fully automatic.
5. Hardware Configuration (see attached Table 2)
6. Software Functions
The intelligentdouble-flank small gear roll tester software mainly has the following characteristics:
1) A measuring software under Windows 7 is adopted. Basic parameters (tooth number, module, pressure angle and addendum modification factor) of the measured gear and the 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 is provided with a special function of grouping according to the center distance deviations, which is visualized by indicator lights on the screen;
5) Measurement data are automatically saved. Quality indicators (Cp and Cpk values) can be automatically calculated with respect to product models and measuring dates. The saving format is 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.  Operation manuals ---------------------------------1 share
5.  Packing list ------------------------------------------1 share
III Optional Accessories
1. Mandrel for ring gears
2. Non-standard gear tooling
IVInstallation, 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 acceptance according to the technical agreement. A Final Acceptance Report should 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, the manufacturer should send technicians to the site to solve the problems within three working days. 
VQuality Assurance
1. The warranty period of the instrument is one year. If any quality problem is discovered 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 by the 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.
Table1: Main precision indices of ZSX intelligent double-flank small gear roll tester


No. Item Verification Requirements Verification Tools
1 Radial and axial circular runoutof the measuring carriage mandrel Radial runout: 3μm
Axialrunout: 3μm
a. Dial indicator
b. Magnetic stand
2 Repeatability No more than 4μm Level 1 gauge block