Fig. 1 Schematic diagram of a traditional gear processing machine chain
Fig. 2 Schematic diagram of the transmission chain of non-full-function CNC gear machining
Fig. 3 Based on software interpolation gear machine CNC system structure
Traditional gear machining systems involve complex motion relationships. For instance, in gear hobbing machines or worm grinding machines, multiple chains such as the speed chain, differential chain, and feed chain are involved, as shown in Figure 1. These systems require careful adjustments for rapid approach, cutting, and retraction, which can be time-consuming and often necessitate additional components.
Since the 1980s, both domestic and international companies have started to modernize these machines by implementing numerical control (NC) systems, leading to the development of CNC gear processing tools. With advancements in microelectronics and high-precision AC servo systems based on modern control theory, this transformation has become more feasible and efficient.
CNC gear systems are typically divided into two categories: full-function and non-full-function. The non-full-function type uses NC axes for feed motion and often relies on traditional mechanical transmissions for other chains. For example, models like the YKS3120 from Nanjing No. 2 Machine Tool Plant or the YKX3132 from Chongqing Machine Tool Works are 2- to 3-axis CNC machines. These systems offer improved convenience over mechanical ones, allowing multi-axis linkage for tooth shaping without the need for special fixtures, thus enhancing productivity and precision. However, their accuracy still depends heavily on the mechanical transmission system.
In recent years, full-function CNC systems have gained popularity due to advances in computer technology and high-speed, precise servo systems. Full-function systems not only control feed axes but also generate and differential motions. Two main methods exist: software-based interpolation and hardware-controlled systems. Software interpolation allows greater flexibility, enabling the processing of non-circular and modified gears with high precision. For example, the STAR-930E system developed by Hefei University of Technology successfully performs high-speed, high-precision non-circular gear hobbing.
On the other hand, hardware-controlled systems use phase-locked servo technology to achieve high accuracy and fast response, making them ideal for high-precision grinding applications. However, they are less flexible and cannot easily adjust parameters in real-time, limiting their use for non-circular gears.
Looking ahead, the future of CNC gear systems lies in combining the strengths of both software and hardware—allowing real-time modification of electronic gear ratios while maintaining high precision and speed. This hybrid approach will likely become the next major development in the field, offering both flexibility and performance.
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