Precision control and compensation of helical gear hobbing via electronic gearbox Cross-Coupling controller

The gear generation process is strongly dependent on the accuracy of the multi-axis relative motion, which is controlled by the electronic gearbox (EGB). This research mainly focuses on helical gear hobbing and on EGB control error analysis, estimation and compensation in the generation process of a gear hobbing machine. First, a simple approach for estimation of the helical gear pitch error and the spiral line contour error is proposed. Then, in conjunction with this estimation method, an EGB cross-coupling controller (ECCC) architecture, which is connected by the EGB and the cross-coupling controller, is presented. Simulation results show that the proposed ECCC has higher control accuracy than an uncoupled controller, and its control accuracy can be further improved using friction compensation. Finally, experiments are conducted on an YS3118 six-axis hobbing machine. The helical gears machined using this machine have high precision. In addition, the proposed ECCC architecture can be implemented easily on most motion systems that are in current use.

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