电动汽车（电动汽车）不仅在道路上更加普遍，而且许多汽车公司都在宣布电动汽车计划在其产品组合中占据主导地位。随着从内燃烧（IC）转移到电动的转移，传动系统组件的数量将大大减少。那么，这如何影响将高强度扭矩从电动机转换为车轮的RPM所需的齿轮组件？在这里，我们探索一些制造选择。
从根部到尖端上的一个齿轮侧面的非平面缝合的示例。
车辆操作的两个因素与用于电动汽车的新齿轮包有关 - 效率或“距离”和齿轮噪声。为了吸引消费者，电动汽车将需要达到与内燃机相似的行驶里程。实现这一目标将需要具有较低表面纹理的齿轮，其中表面摩擦减少，从而增加了车辆的整体范围。其次，来自IC发动机的声音通常掩盖了传动系统的噪音。在车架和乘客舱室中设计了降低乘客舱中声音的努力。然而，随着向电动发动机的转移，如果齿轮噪声不变为新的制造工艺，齿轮噪声可能再次变得突出。随着最近的处理开发和EV齿轮的更严格规格，精度计量学可以发挥基本作用。
齿轮可以采取多种的设计和制造paths, leading product design engineers to evaluate different methods to achieve stringent surface texture and waviness specifications and high production volume demands. Contingent on the production method, fabricating accurate gear tooth form and flank texture can be a balancing act. But when achieved, specific techniques can produce gears in high quantities while attaining the required form and surface texture demands. One such method is continuous generating grinding which uses threaded wheels, which remain in constant contact with the developing gear tooth structure (see figure 1). This method, among others, has been proven to produce the essential gear texture and waviness specifications to improve gear tooth interaction while reducing contingent noise.
Processing of data for waviness allows engineers to visualize small fluctuations which may occur in part processing.
To ensure the surfaces on the gears are optimized, it is essential to use metrology tools to analyze, understand, and characterize. With high-value gears, it is highly preferable that non-contact metrology solutions are used, which will not compromise or damage the post-processed gears. As gear surfaces become smoother, tactile and other analysis methods will become more challenging to use. They may result in surface scoring or might not reach the critical inspection areas. This creates a need for a suite of 3D non-contact optical profilers. At the heart of ZYGO’s optical metrology solutions is its coherence scanning interferometry (CSI), which uses specialized optical microscope objectives that provide the imaging and magnification of a surface and measure the 3D topography of the surface.
CSI分析完全是非接触的，与其他基于显微镜的3D地形技术相反，在所有大型上，测量的高度分辨率是一致的，无论放大倍数是1x还是100x。这为基于CSI的系统提供了独特的机会，因为齿轮的形状和尺寸可能会限制能够进入感兴趣领域的目标的类型。
With other technologies, the use of a long working distance objective may limit the vertical resolution of the measurement. ZYGO’s internally developed objectives lose neither vertical resolution nor measurement precision. Additionally, the extreme stability of the measurement, ease of gaining access to the measurement area, and the assortment of objectives are required for meeting on-the-floor production metrology.
齿轮侧粗糙度在润滑膜保留中起着至关重要的作用，并且使表面更耐用。
重点的另一个关键领域是现场缝制。与全景摄影相似，用户可以设置一个测量值以捕获比安装目标更多的区域。这创建了一个重叠测量的矩阵，这些矩阵被“缝合”在一起以形成更大的总体测量。在齿轮计量学方面，这是有利的，是从齿轮侧面（从边缘到边缘）获得表面纹理，或从齿轮根到尖端缝制，从而越过柔和的形状。应强调在非平面表面上执行这些缝合测量的能力，例如肌状形表面。通过对测量顺序的开始和终点进行编程，用户可以以连续的高精度重新衡量Abledoid Gear。
将缝线和测量方法与长期和长时间的工作距离目标，软件易用性和内部Python脚本相结合，为用户提供了一个完整的解决方案，用于测量许多不同的齿轮类型。
The growth of the EV market is inevitable. It places significant challenges in front of manufacturers as they wrestle with the need for technological advances in the real nuts and bolts of vehicle engineering. Top of the list at the moment is the requirement for advanced finishing and grinding technologies that are used to produce extremely complex and precise surface features in gear teeth to enhance efficiency and reduce noise, thereby improving customer satisfaction.
As is often the case in advanced design and manufacturing, metrology’s role moves from a necessary evil to enabling technology when pursuing innovative technological advancements. In the area of gear manufacturing for EVs, it is vital to accurately, quickly, and easily characterize the precision surface features.
光学计量学是一种多功能检查方法，在验证齿轮质量和设计意图实现方面具有至关重要的作用。如今，它已成为“首选”计量解决方案，从无接触，无损，快速，高度敏感的事实中受益，并且具有出色的分辨率和准确性。
Zygo
zygo.com
提交以下：Gears • gearheads • speed reducers
